2005 Polaris ATP 330&500 SERVICE MANUAL

GENERAL INFORMATION
Specs
2004-2005 330/500 ATP

Model Identification . . . . . . . . . . . . . . . . . . . . . . . 1.2
Serial Number Location . . . . . . . . . . . . . . . . . . . 1.2
Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . 1.3
2004 ATP General Specifications . . . . . . . . . . . 1.4
Specifications - 2004 ATP 330 . . . . . . . . . . . . . 1.5
2005 ATP General Specifications . . . . . . . . . . . 1.7
Publication Numbers . . . . . . . . . . . . . . . . . . . . . 1.10
Accessory Springs . . . . . . . . . . . . . . . . . . . . . . . 1.10
Standard Torque Specifications . . . . . . . . . . . . 1.10
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11--1.15
Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . 1.16
Unit of Measure Conversion Table . . . . . . . . . . 1.17
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . 1.18
1.1
GENERAL INFORMATION
MODEL IDENTIFICATION
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification

A 05 JD 32 AA
Emissions &
Year Designation Basic Chassis Model Option
Designation Engine Designation
ENGINE DESIGNATION NUMBERS

ES320PFE101 . . . . . . . . . . . . . . Single, Oil/Air Cooled, SOHC 4 Stroke, Electric Start
EH500PLE201 . . . . . . . . . . . . . . Single, Water Cooled, SOHC 4 Stroke, Electric Start
VIN IDENTIFICATION
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 J D 3 2 A * 5 P 0 0 0 0 0 0
Body Style Emissions Model * This could be either

Engine Year Individual Serial No. a number or a letter
Powertrain Check Digit Plant No.
ENGINE SERIAL NUMBER LOCATION

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 recoil housing on the right side of engine.(A) An additional
number is stamped on the center top of crankcase beneath the cylinder.
UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION

The machine model number and serial number are
important for vehicle identification. The machine
serial number is stamped on the lower left side of
the frame tube.(B)
Front
A B
1.2
GENERAL INFORMATION
TRANSMISSION I.D. NUMBER-

LOCATION
The transmission I.D. number is located on
the right side of machine.
COLD WEATHER KITS FOR 4 CYCLE ATVS

Engine Heater -- (PN 2871507)
ACCESSORY ENGINE HEATER
REPLACEMENT KEYS
Replacement keys can be made from the original
key. To identify which series the key is, take the
first two digits on the original key and refer to the
chart to the right for the proper part number.
Series # Part Number

20 4010278
21 4010278
22 4010321
31XX
23 4010321
Key Series 27 4010321
Number
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
1.3
GENERAL INFORMATION
MODEL: . . . . . . . . . . 2004 ATP 330 4x4

MODEL NUMBER: . A04JD32AA
ENGINE MODEL: . . ES32PFE101
Category Dimension / Capacity

Length 91 in./231 cm
Width 46 in./116.8 cm
Height 46 in./116.8 cm
Wheel Base 56 in./142 cm
Dry Weight 719 lbs./326 kg
Gross Vehicle Weight 1300 Lbs. / 590 kg
Front Rack Capacity 90 lbs./40.8 kg
Rear Box Capacity 250 lbs./113 kg
Side Pocket Capacity 20 lbs./9 kg
Towing Capacity 1000 lbs./454 kg
Hitch Tongue Capacity 100 lbs./45.4 kg
(Rear box capacity and
tongue weight not to ex-
ceed 250 lbs/113 kg)
MODEL: . . . . . . . . . . 2004 ATP 500 4x4

MODEL NUMBER: . A04JD50AA, A04JD50CA
ENGINE MODEL: . . EH50PLE200, EH50PLE201

Hitch Tongue Capacity 120 lbs./54 kg
1.4
GENERAL INFORMATION
MODEL: . . . . . . . . . . 2004 ATP 330 4x4

ENGINE MODEL: . . ES32PFE101
Engine Drivetrain
Platform Fuji 4 stroke, Single Cylinder Transmission Type Drumshift -- H/L/N/Rev/Park
Engine Model Number ES32PFE101 Transmission Capacity 13.5 oz. / 400ml
Engine Displacement 329cc Rear Gearcase Capacity 18 oz. / 532ml
Number of Cylinders 1 Front Gearcase Capacity 5 oz. / 150ml
Bore & Stroke (mm) 78.5 x 68 mm Gear Ratio : Low 11.57:1
Compression Ratio 9.2:1 Rev 6.84:1
Compression Pressure 70--90 psi w/ decompressor High 4.41:1

Front Drive 3.7:1
Engine Idle Speed 1300 ± 200 RPM
Rear Drive 3.08:1
Engine Max Operating Rpm 6950 RPM
Clutch Type PVT Non--EBS
Cooling System Oil / Air w/ fan assist
Belt 3211077
Overheat Warning HOT on Instrument Cluster
Steering / Suspension
Lubrication Wet Sump
Front Suspension / Shock A--arm / MacPherson Strut
Oil Requirements / Capacity Polaris 0W--40 1.9 qt. / 1.8 ltr
Front Travel 6.7 in. / 17.02 cm
Exhaust System USFS Approved
Rear Suspension / Shock Swing Arm w/ Sachs Shocks
Carburetion
Rear Travel 7.1 in. / 18.03 cm
Carburetor model Mikuni BST 34mm
Ground Clearance 6.5 in. / 11.43 cm
Main Jet 122.5
Shock Preload Adjustment Front --Non Adjustable.
Pilot Jet 42.5 Front / Rear Rear -- Ratchet Style-- Std.
Pilot Air Jet 160 Turning Radius 75 in. / 190.5 cm unlocked
Jet Needle -- Clip Position 4HB48--2 Toe Out 1/8--1/4-- in / .0 -- .159 mm
Needle Jet P--0 (829)
Wheels / Brakes
Pilot Screw 2 Turns Out
Wheel Size / Pattern -- Front Steel 24x8--12 / 4--156
(Initial starting point, settings
may vary for each ATP) Wheel Size / Pattern -- Rear Steel 24x11--12 / 4--156
Float Height 13 ± 1 mm / 0.51 ± 0.40“ Front Tire Model / Size Titan 24x8--12
Fuel Delivery Fuel Pump Rear Tire Model / Size Titan 24x11--12
Fuel Capacity / Requirement 3.25 gal US / 12.3 ltr Recommended Air Pressure Front & Rear -- 5 psi
87 Octane (minimum)
89 Oxygenated Brake -- Front Dual Hydraulic Disc
Brake -- Rear Dual Hydraulic Disc
Electrical
Alternator Output 200 w @ 5000 RPM
Voltage Regulator 3--Phase -- LR--390
JETTING CHART
AMBIENT TEMPERATURE
Lights : High Beam 30 watts Altitude Below 40°F +40°F to +80°F
Low Beam 30 watts Below 5°C +5°C to +28°C
Brake Two 12V/1.7 watts Meters 0--1800
(0--6000) 127.5 122.5
(Feet)
Tail Two 12V/8.26 watts above 1800 120 115
(above 6000)
Ignition System DC/CDI Ignition
Ignition Timing 30° ± 2° BTDC @ 5000 RPM CLUTCH CHART Standard helix spring position is 2 -- 2
Shift Drive Driven Driven
Spark plug / Gap NGK BKR6E/ .036 in. / 0.9 mm Altitude Weight Spring Spring Helix
Battery / Model / Amp Hr Low Maintenance 41--35
Yuasa YTX12 14 Amp Hr 0--1800 20--40 Blu/Grey Black
(5133701)
Meters (0--6000) (5631356) (7042202) (7041782)
2--2
Circuit Breakers Fan 10 amp / Harness 20 amp (Feet)
1800--3700 20--38 Blu/Grey Black 41--35
Starting Electric / Recoil Backup (5133701)
(6000--12000) (5631357) (7042202) (7041782)
2--2
Instrument Cluster Analog Speedo w/ LCD
1.5
GENERAL INFORMATION
MODEL: . . . . . . . . . . 2004 ATP 500 4x4

ENGINE MODEL: . . EH50PLE200, EH50PLE201
Engine Drivetrain
Engine Model Number EH50PLE200, EH50PLE201 Transmission Capacity 13.5 oz. / 400ml
Bore & Stroke (mm) 92 x 75 mm Gear Ratio : Low 8.66:1

Front Drive 3.7:1
Rear Drive 3.08:1
Clutch Type PVT w/EBS
Cooling System / Capacity Liquid -- 3.2 qt. / 3.02 ltr
Belt 3211069
Lubrication Pressurized Dry Sump
Oil Requirements / Capacity Polaris 0W--40 2 qt. / 1.9 ltr
Carburetion
Carburetor model Mikuni BST 40 mm
Main Jet 155
Pilot Jet 40 Front / Rear Rear -- Ratchet Style-- Std.
Jet Needle -- Clip Position 6H25--94--3 Toe Out 0 -- 1/16 in / .0 -- .159 mm
Needle Jet Y--0M (896)
Wheels / Brakes
Float Height 14.7 ± 1 mm / 0.58 ± 0.40“ Front Tire Model / Size Titan 25x8--12
87 Octane (minimum)
Electrical
Alternator Output 250 w @ 5000 RPM
Voltage Regulator 3--Phase -- LR--390
JETTING CHART
AMBIENT TEMPERATURE
Lights : Pod 60 watts Altitude Below 40°F +40°F to +80°F
Grill Two x 27 watts Below 5°C +5°C to +28°C
Brake Two 12V/1.7 watts Meters 0--1800
(0--6000) 160 155
(Feet)
Tail Two 12V/8.26 watts above 1800 152.5 147.5
(above 6000)
Ignition System DC/CDI Ignition
Ignition Timing 30° ± 2° BTDC @ 5000 RPM CLUTCH CHART EBS models have no helix/spring adjustment
Shift Drive Driven Driven
Spark plug / Gap NGK BKR6E/ .028 in. / 0.7 mm Altitude Weight Spring Spring Helix
Battery / Model / Amp Hr Low Maintenance
Yuasa YTX12 14 Amp Hr 0--1800 10 BH Blu/Grn Wht/Yel EBS
Meters (0--6000) (5630711) (7041157) (7041635) (5132751)
Circuit Breakers Fan 10 amp / Harness 20 amp (Feet)
1800--3700 10 RH Blu/Grn Wht/Yel EBS
Starting Electric / Recoil Backup (6000--12000) (5630709) (7041157) (7041635) (5132751)
Instrument Cluster Analog Speedo w/ LCD
1.6
GENERAL INFORMATION
MODEL: . . . . . . . . . . 2005 ATP 330 4x4

ENGINE MODEL: . . ES32PFE

Hitch Tongue Capacity 100 lbs./45.4 kg
MODEL: . . . . . . . . . . 2005 ATP 500 4x4

ENGINE MODEL: . . EH50PLE

Hitch Tongue Capacity 120 lbs./54 kg
1.7
GENERAL INFORMATION
MODEL: . . . . . . . . . . 2005 ATP 330 4x4

ENGINE MODEL: . . ES32PFE
Engine Drivetrain
Engine Model Number ES32PFE103 Transmission Capacity 13.5 oz. / 400ml
Bore & Stroke (mm) 78.5 x 68 mm Gear Ratio : Low 11.57:1

Front Drive 3.7:1
Rear Drive 3.08:1
Clutch Type PVT Non--EBS
Cooling System Oil / Air w/ fan assist
Belt 3211077
Lubrication Wet Sump
Oil Requirements / Capacity Polaris 0W--40 1.9 qt. / 1.8 ltr
Carburetion
Carburetor model Mikuni BST 34mm
Main Jet 122.5
Pilot Jet 42.5 Front / Rear Rear -- Ratchet Style-- Std.
Jet Needle -- Clip Position 48B48--3 (3rd clip position) Toe Out 1/8--1/4-- in / .0 -- .159 mm
Needle Jet P--4M (829)
Wheels / Brakes
Pilot Screw 2.25 Turns Out
Float Height 13 ± 1 mm / 0.51 ± 0.40“ Front Tire Model / Size Titan 24x8--12
87 Octane (minimum)
Electrical
Alternator Output 200 w @ 5000 RPM JETTING CHART
Voltage Regulator 3--Phase -- LR--390 AMBIENT TEMPERATURE
Altitude Below 40°F
Lights : High Beam 30 watts +40°F to +80°F
Below 5°C +5°C to +28°C
Low Beam 30 watts Meters 0--1800
(0--6000) 127.5 122.5
Brake Two 12V/1.7 watts (Feet)
above 1800 120 115
Tail Two 12V/8.26 watts (above 6000)
Ignition System DC/CDI Ignition CLUTCH CHART Standard helix spring position is 2 -- 2
Ignition Timing 30° ± 2° BTDC @ 5000 RPM Shift Drive Driven Driven
Altitude Weight Spring Spring Helix
Spark plug / Gap NGK BKR6E/ .036 in. / 0.9 mm
0--1800 Blu/Grey Black 41--35
20--40
Battery / Model / Amp Hr Low Maintenance --14 Amp Hr Meters (0--6000) (5631356) (7042202)
(5133701)
(7041782)
2--2
Starting Electric / Recoil Backup (Feet) 41--35
1800--3700 20--38 Blu/Grey Black
(5133701)
Instrument Cluster Analog Speedo w/ LCD (6000--12000) (5631357) (7042202) (7041782)
2--2
1.8
GENERAL INFORMATION
MODEL: . . . . . . . . . . 2005 ATP 500 4x4

MODEL NUMBER: . A05JD50AA, AB, AC
ENGINE MODEL: . . EH50PLE
Engine Drivetrain
Engine Model Number EH50PLE203,204 Transmission Capacity 13.5 oz. / 400ml
Engine Displacement 499cc Rear Gearcase Capacity 18 oz. / 532 ml
Bore & Stroke (mm) 92 x 75 mm Gear Ratio : Low 8.66:1

Front Drive 3.7:1
Rear Drive 3.08:1
Clutch Type PVT w/EBS
Cooling System / Capacity Liquid -- 3.2 qt. / 3.02 ltr
Belt 3211069
Lubrication Pressurized Dry Sump
Oil Requirements / Capacity Polaris 0W--40 2 qt. / 1.9 ltr
Carburetion
Carburetor model Mikuni BST 40 mm
Main Jet 155
Pilot Jet 40 Front / Rear Rear -- Ratchet Style-- Std.
Jet Needle -- Clip Position 6H25--94--3 Toe Out 0 -- 1/16 in / .0 -- .159 mm
Needle Jet Y--0M (896)
Wheels / Brakes
Wheel Size / Pattern -- Front 25x8--12 / 4--156
may vary for each ATP) Wheel Size / Pattern -- Rear 25x11--12 / 4--156
Float Height 14.7 ± 1 mm / 0.58 ± 0.40“ Front Tire Model / Size Titan 25x8--12
87 Octane (minimum)
Electrical
Alternator Output 250 w @ 5000 RPM JETTING CHART
Voltage Regulator 3--Phase -- LR--390 AMBIENT TEMPERATURE
Altitude Below 40°F
Lights : Pod 60 watts +40°F to +80°F
Below 5°C +5°C to +28°C
Grill Two x 27 watts Meters 0--1800
(0--6000) 160 155
Brake Two 12V/1.7 watts (Feet)
above 1800 152.5 147.5
Tail Two 12V/8.26 watts (above 6000)
Ignition System DC/CDI Ignition CLUTCH CHART EBS models have no helix/spring adjustment
Ignition Timing 30° ± 1.5° BTDC @ 3500 RPM Shift Drive Driven Driven
Altitude Weight Spring Spring Helix
Spark plug / Gap NGK BKR6E/ .028 in. / 0.7 mm
0--1800 10 BH Blu/Grn Wht/Yel EBS
Battery / Model / Amp Hr Low Maintenance -- 14 Amp Hr
Meters (0--6000) (5630711) (7041157) (7041635) (5132751)
Starting Electric / Recoil Backup (Feet)
1800--3700 10 RH Blu/Grn Wht/Yel EBS
Instrument Cluster Analog Speedo w/ LCD (6000--12000) (5630709) (7041157) (7041635) (5132751)
1.9
GENERAL INFORMATION
PUBLICATION NUMBERS
Year Model Model No. Owner’s Parts Parts
Manual PN Manual PN Micro Fiche PN
2004 ATP 330 4x4 A04JD32AA 9917747 9917748 9917749
A04JD50AA,
2004 ATP 500 4x4 9917747 9918593 9918594
A04JD50AC
2005 ATP 330 4x4 A05JD32AA 9919515 9919516 9919517
A05JD50AA,
2005 ATP 500 4x4 A05JD50AB, 9919515 9919518 9919519
A05JD50AC
NOTE: When ordering service parts be sure to use the correct parts manual.
NOTE: Other publications can be downloaded from www.polarisindustries.com or ordered from www.pure-
polaris.com.
ACCESSORY HEAVY DUTY SPRINGS

7042324--385 Heavy Duty Spring
*Available Grey Only
ATP 330 & 500

*Order Through Your Polaris Dealer
STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF
FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering,
suspension, and engine sections.
Bolt Size Threads/In Grade 2 Grade 5 Grade 8

Torque in. lbs. (Nm)
#10 - 24 . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . . . . . . . . 43 (5.0) . . . . . . . . . . . . . . 60 (6.9)
#10 - 32 . . . . . . . . . . . . . . 31 (3.6) . . . . . . . . . . . . . . . . 49 (5.6) . . . . . . . . . . . . . . 68 (7.8)
Torque ft. lbs. (Nm)*
1/4 - 20 . . . . . . . . . . . . . . 5 (7) . . . . . . . . . . . . . . . . . . 8 (11) . . . . . . . . . . . . . . . . 12 (16)
1/4 - 28 . . . . . . . . . . . . . . 6 (8) . . . . . . . . . . . . . . . . . . 10 (14) . . . . . . . . . . . . . . 14 (19)
5/16 - 18 . . . . . . . . . . . . . . 11 (15) . . . . . . . . . . . . . . . . 17 (23) . . . . . . . . . . . . . . 25 (35)
5/16 - 24 . . . . . . . . . . . . . . 12 (16) . . . . . . . . . . . . . . . . 19 (26) . . . . . . . . . . . . . . 29 (40)
3/8 - 16 . . . . . . . . . . . . . . 20 (27) . . . . . . . . . . . . . . . . 30 (40) . . . . . . . . . . . . . . 45 (62)
3/8 - 24 . . . . . . . . . . . . . . 23 (32) . . . . . . . . . . . . . . . . 35 (48) . . . . . . . . . . . . . . 50 (69)
7/16 - 14 . . . . . . . . . . . . . . 30 (40) . . . . . . . . . . . . . . . . 50 (69) . . . . . . . . . . . . . . 70 (97)
7/16 - 20 . . . . . . . . . . . . . . 35 (48) . . . . . . . . . . . . . . . . 55 (76) . . . . . . . . . . . . . . 80 (110)
1/2 - 13 . . . . . . . . . . . . . . 50 (69) . . . . . . . . . . . . . . . . 75 (104) . . . . . . . . . . . . . 110 (152)
1/2 - 20 . . . . . . . . . . . . . . 55 (76) . . . . . . . . . . . . . . . . 90 (124) . . . . . . . . . . . . . 120 (166)
Metric / Torque 6 x 1.0. 72-78 In. lbs. 8 x 1.25 14-18 ft. lbs 10 x 1.25 26-30 ft. lbs.
1.10
GENERAL INFORMATION
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION CHAPTER TOOL
USED IN
2870872 Shock Spanner Wrench 2, 7
PA--44689 Valve/Clutch Adjuster 2,3
2871043 Flywheel Puller 3
2872105 Water Pump Mechanical Seal Puller 3
2870773 C--Clip Installation Tool 3
2870569 Crankshaft Truing Tool 3
2200634 Valve Seat Reconditioning Kit 3
8700229 Flywheel Holding Wrench 3
2870386 Piston Pin Puller 3
2871445 Piston Pin Puller Adapter 3
2870967 Slotted Nut Socket 3
2870968 Counter Balance Puller 3
2872314 Carburetor Float 4
Adjustment Tool
2870975 Mity Vact 3, 4, 9
2870506 Clutch Puller 6
9314177 Clutch Holding Wrench 6
2871358 Clutch Holding Fixture 6
2870341 Drive Clutch Spider Removal and Install 6
Tool
28970338 Spider Nut Socket 6
2870654 Clutch Offset Alignment Tool 6
2872292 EBS Clutch Offset Alignment Tool 6
2870913 Driven Clutch Puller 6
2870910 Roller Pin Tool 6
2871226 Clutch Bushing Replacement Tool Kit 6
2201379 EBS Bushing Replacement Kit 6
2870386 Piston Pin Puller 6
8700220 Clutch Compression Tool 6
2870871 Ball Joint Replacement Tool 7
8700226 CV Boot Clamp Pliers 7
2871071 Foxt Body Holding Tool 5, 7
2870623 Shock Absorber Spring Compression Tool 5, 7
2871573 LH Strut Spring Compressor 5, 7
2871574 RH Strut Spring Compressor 5, 7
2872608 Roller Pin Removal Tool 7,8
2871710 10” Center Distance Tool 8
PV--43568 Fluket77 Digital Multimeter 10
2870836 Battery Hydrometer 10
2870630 Timing Light 10
8712100 or 8712500 Tachometer 10
2870761 Hall Sensor Probe Harness 10
2871745 Static Timing Light Harness
NOTE: Polaris dealers can order the tools listed above through their Polaris Special Service Tools catalog.
1.11
GENERAL INFORMATION
SPECIAL TOOLS
Special Tools maybe required while servicing your
machine. Some of the tools listed are mandatory and Standard Tools and Engine Tools
other tools maybe substituted with a similar tool, if
available. Polaris reccommends the use of Polaris
special tools when servicing any Polaris product.
Standard Tools and Engine Tools
2870569 -- Crankshaft True Kit

PU--45432 -- Caliper or
A Basic Caliper
2870386 -- Piston Pin Puller
Basic Micrometer
2871445 -- Piston Pin Puller Adapter
2870968 -- Counter Balance Puller

2871043 -- Flywheel Puller
PV--43527 Oil Filter Wrench

2870773 -- C--Clip Install Tool
2870967 -- Slotted Nut Socket PA--44689 -- Valve/Clutch Adjuster
2870390 -- Piston Support Block

8700229 -- Flywheel Holder & Adapter
1.12
GENERAL INFORMATION
Standard Tools and Engine Tools
2870303 -- Hone Kit 2871283 -- Crank/Water Pump Seal

Install Kit
Clutch (PVT) Tools
2870305 -- Stone Replacement Kit

2870506 -- Drive Clutch Puller
2870588 -- Hone Oil (12 oz.)

2870913 -- Driven Clutch Puller
2200634 -- Valve Seat

Reconditioning Kit
2870654 -- ATV Clutch Align Tool
2872292 -- EBS Clutch Align Tool

2870459 -- Dial Indicator
PV--35667--A -- Cylinder Leak 9914177--A -- Drive Clutch Holding Tool

down Tester
8700220 -- Clutch Compression Tool
1.13
GENERAL INFORMATION
Clutch (PVT) Tools Suspension Tools
2870871 -- ATV Ball Joint Tool Kit

2870341 -- Drive Clutch Spider
Removal Tool
2871351 -- Shock IFP Depth Tool

2870910 -- Roll Pin Tool
2871071 -- Shock Body Holding Tool
2871226 -- Clutch Bushing

Replacement Kit
2870623 -- Shock Spring Compressor
2201379 -- EBS Bushing

Replacement Kit
2871573 & 2871574 -- Strut

2870338 -- Spider Nut Socket Spring Compressor
2871358 -- Clutch Holding Fixture

8700225 & 8700226 -- CV Boot
Clamp Pliers
1.14
GENERAL INFORMATION
Suspension & Transmission Tools Electrical Tools
2870872 -- Shock Spanner Wrench
2870630 -- Timing Light
2871710 -- Center Distance Tool
2872608 -- Roll Pin Removal Tool

2871745 --Static Timing Light Harness
Electrical Tools
2460761 -- Hall Sensor Probe Harness
PV--43568 --Fluke 77 Multimeter
PV--39991 -- Peak Reading Adapter
PV--39617 -- Current Clamp

PV--37453 -- Christie Se--Sulfating
Multi--Battery Charger
2870836 -- Battery Hydrometer PV--63070 -- Christie Multi--Battery

Charger
Fuel & Brake Systems
RPM
8712500 -- PV--39951--A --
Tachometer Tachometer
2870975 -- Mity Vac
1.15
GENERAL INFORMATION
SAE TAP DRILL SIZES DECIMAL EQUIVALENTS

Thread Size/Drill Size Thread Size/Drill Size 1/64 . . . . . . . . . . . . . . . . .0156
1/32 . . . . . . . . . . . .0312 . . . 1 mm = .0394″
#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″
#2-56 51 3/32 . . . . . . . . . . . .0938
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 9/64 . . . . . . . . . . . . . . . . .1406
5/8-18 37/64
#3-56 45 5/32 . . . . . . . . . . . .1563 . . . 4 mm = .1575″
#4-40 43 3/4-10 21/32 11/64 . . . . . . . . . . . . . . . .1719
#4-48 42 3/4-16 11/16 3/16 . . . . . . . . . . . .1875 . . . 5 mm = .1969″
#5-40 38 7/8-9 49/64 13/64 . . . . . . . . . . . . . . . .2031
7/8-14 13/16 7/32 . . . . . . . . . . . .2188
#5-44 37
15/64 . . . . . . . . . . . . . . . .2344 . . . 6 mm = .2362″
#6-32 36 1-8 7/8 1/4 . . . . .25
#6-40 33 1-12 59/64 17/64 . . . . . . . . . . . . . . . .2656 . . . 7 mm = .2756″
#8-32 29 1 1/8-7 63/64 9/32 . . . . . . . . . . . .2813
#8-36 29 19/64 . . . . . . . . . . . . . . . .2969
1 1/8-12 1 3/64 5/16 . . . . . . . . . . . .3125 . . . 8 mm = .3150″
#10-24 24 1 1/4-7 1 7/64 21/64 . . . . . . . . . . . . . . . .3281
#10-32 21
1 1/4-12 1 11/64 11/32 . . . . . . . . . . .3438 . . . 9 mm = .3543″
#12-24 17 23/64 . . . . . . . . . . . . . . . .3594
#12-28 4.6mm 1 1/2-6 1 11/32
3/8 . . . . .375
1/4-20 7 1 1/2-12 1 27/64 25/64 . . . . . . . . . . . . . . . .3906 . . . 10 mm = .3937″
1/4-28 3 1 3/4-5 1 9/16 13/32 . . . . . . . . . .4063
5/16-18 F 1 3/4-12 1 43/64 27/64 . . . . . . . . . . . . . . . .4219 . . . 11 mm = .4331″
7/16 . . . . . . . . . . . .4375
5/16-24 I 2-4 1/2 1 25/32 29/64 . . . . . . . . . . . . . . . .4531
3/8-16 O 2-12 1 59/64 15/32 . . . . . . . . . .4688 . . . 12 mm = .4724″
3/8-24 Q 2 1/4-4 1/2 2 1/32 31/64 . . . . . . . . . . . . . . . .4844
7/16-14 U 2 1/2-4 2 1/4 1/2 . . . . .5 . . . . . . . . . . . . . . 13 mm = .5118
7/16-20 25/64 33/64 . . . . . . . . . . . . . . . .5156
2 3/4-4 2 1/2 17/32 . . . . . . . . . .5313
3-4 2 3/4 35/64 . . . . . . . . . . . . . . . .5469 . . . 14 mm = .5512″
9/16 . . . . . . . . . . . .5625
37/64 . . . . . . . . . . . . . . . .5781 . . . 15 mm = .5906″
19/32 . . . . . . . . . .5938
39/64 . . . . . . . . . . . . . . . .6094
METRIC TAP DRILL SIZES 5/8 . . . . .625 . . . . . . . . . . . . 16 mm = .6299″
41/64 . . . . . . . . . . . . . . . .6406
Tap Size Drill Size Decimal Nearest 21/32 . . . . . . . . . .6563 . . . 17 mm = .6693″
Equiva- Fraction 43/64 . . . . . . . . . . . . . . .6719
11/16 . . . . . . . . . . .6875
lent 45/64 . . . . . . . . . . . . . . . .7031 . . . 18 mm = .7087″
3 x .50 #39 0.0995 3/32 23/32 . . . . . . . . . .7188
3 x .60 3/32 0.0937 3/32 47/64 . . . . . . . . . . . . . . . .7344 . . . 19 mm = .7480″
4 x .70 #30 0.1285 1/8 3/4 . . . . .75
4 x .75 1/8 0.125 1/8 49/64 . . . . . . . . . . . . . . . .7656
25/32 . . . . . . . . . .7813 . . . 20 mm = .7874″
5 x .80 #19 0.166 11/64
51/64 . . . . . . . . . . . . . . . .7969
5 x .90 #20 0.161 5/32 13/16 . . . . . . . . . .8125 . . . 21 mm = .8268″
6 x 1.00 #9 0.196 13/64 53/64 . . . . . . . . . . . . . . . .8281
7 x 1.00 16/64 0.234 15/64 27/32 . . . . . . . . . .8438
8 x 1.00 J 0.277 9/32 55/64 . . . . . . . . . . . . . . . .8594 . . . 22 mm = .8661″
8 x 1.25 17/64 0.265 17/64 7/8 . . . . .875
9 x 1.00 5/16 0.3125 5/16 57/64 . . . . . . . . . . . . . . . .8906 . . . 23 mm = .9055″
9 x 1.25 5/16 0.3125 5/16 29/32 . . . . . . . . . .9063
10 x 1.25 11/32 0.3437 11/32 59/64 . . . . . . . . . . . . . . .9219
10 x 1.50 R 0.339 11/32 15/16 . . . . . . . . . .9375 . . . 24 mm = .9449″
11 x 1.50 3/8 0.375 3/8 61/64 . . . . . . . . . . . . . . . .9531
31/32 . . . . . . . . . .9688 . . . 25 mm = .9843
12 x 1.50 13/32 0.406 13/32 63/64 . . . . . . . . . . . . . . . .9844
12 x 1.75 13/32 0.406 13/32 1 . . . . . 1.0
1.16
GENERAL INFORMATION
UNIT OF MEASURE 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 9.807 = 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) x R2 x H (height) = Cylinder Volume
°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F

°F to °C: 5 (°F + 40) ÷ 9 - 40 = °C
1.17
GENERAL INFORMATION
GLOSSARY OF TERMS
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8″ or 1 cm). Polaris measures chain length in number of pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive
clutch to close and grip the drive belt.
Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported
between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and
out-of-round in the cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn’t complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load.
(i.e. a bare wire touching the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
2
kg/cm : Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
2
lbs/in : Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the
windings. Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040″.
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch System)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston’s most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
1.18
MAINTENANCE
Periodic Maintenance Chart . . . . . . . . . . . . . . . 2.2-2.5

Lubricand and Maintenance Products . . . . . . . 2.6--2.7
ATP Component Locations . . . . . . . . . . . . . . . . 2.8
Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . 2.9
Recommended Lubricants . . . . . . . . . . . . . . . . . 2.9
Lubrication Charts . . . . . . . . . . . . . . . . . . . . . . . . 2.10--2.11
Front Gearcase Lubrication . . . . . . . . . . . . . . . . 2.12
Rear Gearcase Lubrication . . . . . . . . . . . . . . . . 2.13
Transmission Lubrication . . . . . . . . . . . . . . . . . 2.14
Carburetor Adjustments . . . . . . . . . . . . . . . . . . . 2.15--2.17
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17--2.18
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . 2.19--2.20
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20--2.21
Coolant System Maintenance (ATP 500) . . . . 2.21--2.22
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . 2.23--2.24
Air Box Sediment Tube Service . . . . . . . . . . . . 2.24
Breather Filter (ATP 500) . . . . . . . . . . . . . . . . . . 2.25--2.25
Recoil Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
Oil Level Check / Change Filter . . . . . . . . . . . . 2.25--2.30
Oil Pump Priming Procedure . . . . . . . . . . . . . . . 2.30
Valve Clearance / Adjustment . . . . . . . . . . . . . . 2.30--2.32
Steering and Toe Alignment . . . . . . . . . . . . . . . 2.32--2.34
Exhaust System Inspection . . . . . . . . . . . . . . . . 2.34--2.35
Brake System Inspection . . . . . . . . . . . . . . . . . . 2.35--2.37
Suspension Service . . . . . . . . . . . . . . . . . . . . . . 2.37
Wheel Removal/Installation . . . . . . . . . . . . . . . . 2.38--2.39
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39
Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . 2.40--2.41
2.1
MAINTENANCE
PERIODIC MAINTENANCE CHART

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection,
adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for
replacement parts, use genuine Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle
speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more
frequently.
Severe Use Definition
G Frequent immersion in mud, water or sand
G Racing or race-style high RPM use
G Prolonged low speed, heavy load operation
G Extended idle
G 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:
H= 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, chain 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 immediately 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 J could result in component failure and lead
to serious injury or death. Have an authorized Polaris dealer perform these services.
2.2
MAINTENANCE
MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart
Item Maintenance Interval Remarks
(whichever comes first)
Hours Calendar Miles
(Km)
J Steering -- Pre-Ride -- Make adjustments
j as needed. See Pre-Ride
" Front suspension -- Pre-Ride -- Ch kli t
Checklist.
" Rear suspension -- Pre-Ride --
Tires -- Pre-Ride --
" Brake fluid level -- Pre-Ride --
" Brake lever travel -- Pre-Ride --
Brake systems -- Pre-Ride --
Wheels/fasteners -- Pre-Ride --
Frame fasteners -- Pre-Ride --

" Engine oil level -- Pre-Ride --
E
" Air filter, pre-filter -- Daily -- Inspect; clean often
E
" Air box sediment -- Daily -- Drain deposits when visible
E tube
Coolant -- Daily -- Check level daily, change coolant every 2 years
(if applicable)
Headlamp/tail -- Daily -- Check operation; apply dielectric grease if re-
lamp placing
" Air filter, -- Weekly -- Inspect; replace as needed
E main element
Recoil housing -- Weekly -- Drain water as needed, check often if operating
in wet conditions
" Brake pad wear 10 H Monthly 60 (100) Inspect periodically
J
Battery 20 H Monthly 125 (200) Check terminals; clean; test
" Front gearcase oil 25 H Monthly 155 (250) Inspect level; change yearly
(if equipped)
" Middle gearcase 25 H Monthly 155 (250) Inspect level; change yearly
oil (if equipped)
" Rear gearcase oil 25 H Monthly 155 (250) Inspect level; change yearly
(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)
J Have an authorized Polaris dealer perform these
services.
2.3
MAINTENANCE

(Km)
" Engine breather 25 H Monthly 155 (250) Inspect; replace if necessary
E filter (if equipped)
" Engine oil change 25 H 1M 155 (250) Perform a break-in oil change at one month
E (break-in)
" General 50 H 3M 310 (500) Lubricate all grease fittings, pivots, cables, etc.
lubrication
Shift Linkage 50 H 6M 310 (500) Inspect, lubricate, adjust
J Steering 50 H 6M 310 (500) Lubricate
" Front suspension 50 H 6M 310 (500) Lubricate
" Rear suspension 50 H 6M 310 (500) Lubricate
Carburetor float 50 H 6M 310 (500) Drain bowl periodically and prior to storage
bowl
J Throttle Cable/ 50 H 6M 310 (500) Inspect; adjust; lubricate; replace if necessary
E ETC Switch
J Choke cable 50 H 6M 310 (500) Inspect; adjust; lubricate; replace if necessary
E
E Carburetor air 50 H 6M 310 (500) Inspect ducts for proper sealing/air leaks
intake ducts/
flange
Drive belt 50 H 6M 310 (500) Inspect; adjust; replace as needed
Cooling system 50 H 6M 310 (500) Inspect coolant strength
(if applicable) seasonally; pressure test
system yearly
" Engine oil change 100 H 6M 620 Perform a break-in oil change at 25 hours/one
E (1000) month
" Oil filter change 100 H 6M 620 Replace with oil change
E (1000)
" Oil tank vent hose 100 H 12 M 620 Inspect routing, condition
E (1000)
J Valve clearance 100 H 12 M 620 Inspect; adjust
E (1000)
services.
2.4
MAINTENANCE

(Km)
J Fuel system 100 H 12 M 620 Check for leaks at tank cap, lines, fuel valve, fil-
E (1000) ter, pump, carburetor; replace lines every two
years
J Fuel filter 100 H 12 M 620 Replace yearly
E (1000)
" Radiator 100 H 12 M 620 Inspect; clean external
(if applicable) (1000) surfaces
" Cooling hoses 100 H 12 M 620 Inspect for leaks
(if applicable) (1000)
" Engine mounts 100 H 12 M 620 Inspect
(1000)
Exhaust muffler/ 100 H 12 M 620 Inspect
pipe (1000)
J Spark plug 100 H 12 M 620 Inspect; replace as needed
E (1000)
J Ignition Timing 100 H 12 M 620 Inspect
E (1000)
" Wiring 100 H 12 M 620 Inspect for wear, routing,
(1000) security; apply dielectric grease to connectors
subjected to water, mud, etc.
J Clutches (drive 100 H 12 M 620 Inspect; clean; replace worn parts
and driven) (1000)
J Front wheel 100 H 12 M 1000 Inspect; replace as needed
bearings (1600)
J Brake fluid 200 H 24 M 1240 Change every two years
(2000)
Spark arrestor 300 H 36 M 1860 Clean out
(3000)
E Idle speed -- Adjust as needed
J Toe adjustment -- Inspect periodically; adjust when parts are re-
placed
" Auxiliary brake -- Inspect daily; adjust as needed
J
Headlight aim -- Adjust as needed
services.
2.5
MAINTENANCE
POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS

Part No. Description Additives / Sealants / Thread Locking Agents /
Engine Lubricant Misc.
2870791 Fogging Oil (12 oz. Aerosol) 2870585 Loctitet Primer N, Aerosol, 25 g
2871098 Premium 2 Cycle Engine Oil (Quart) (12 2871956 Loctitet Thread Sealant 565
Count) (50 ml.) (6 Count)
2871281 Engine Oil (Quart) Premium 4 Synthetic 2871949 Loctitet Threadlock 242
0W--40 (4--Cycle) (12 Count) (50 ml.) (10 Count)
2871844 Engine Oil (Gallon) Premium 4 Synthetic 2871950 Loctitet Threadlock 242
0W--40 (4--Cycle) (4 Count) (6 ml.) (12 Count)
2871567 Engine Oil (16 Gallon) Premium 4 2871951 Loctitet Threadlock 262
Synthetic 0W--40 (4--Cycle) (50 ml.) (10 Count)
Gearcase / Transmission Lubricants 2871952 Loctitet Threadlock 262
2873602 Premium Synthetic AGL Gearcase Lube (6 ml.) (12 Count)
(12 oz. bottle) (12 Count) 2871953 Loctitet Threadlock 271
2873603 Premium Synthetic AGL Gearcase Lube (6 ml.) (12 Count)
(1 Gal.) (4 Count)
2871954 Loctitet Threadlock 271
2871653 Premium ATV Angle Drive Fluid (36 ml.) (6 Count)
(8 oz.) (12 Count)
2870584 Loctitet 680-Retaining Compound
2872276 Premium ATV Angle Drive Fluid (10 ml.)
(2.5 Gal) (2 Count)
2870587 Loctitet 518 Gasket Eliminator /
2870465 Oil Pump for 1 Gallon Jug
Flange Sealant (50 ml.) (10 Count)
Part No. Description
2871326 Premium Carbon Clean
2871654 Premium Demand Drive Hub Fluid (12 oz.) (12 Count)
(8 oz.) (12 Count) 2870652 Fuel Stabilizer (16 oz.) (12 Count)
2872277 Premium Demand Drive Hub Fluid 2871957 Black RTV Silicone Sealer
(2.5 gal.) (2 Count) (3 oz. tube) (12 Count)
Grease / Specialized Lubricants 2871958 Black RTV Silicone Sealer
2871322 Premium All Season Grease (3 oz. (11 oz. cartridge) (12 Count)
cartridge) (24 Count)
2870990 DOT3 Brake Fluid (12 Count)
2871423 Premium All Season Grease (14 oz.
cartridge) (10 Count) 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
2871460 Starter Drive Grease (12 Count) 2872893 Engine Degreaser (12oz.) (12 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count)
NOTE: The number count indicated by each part
2871551 Premium U-Joint Lube (14 oz.) (10 Count) number in the table above indicates the number of
2871312 Grease Gun Kit units that are shipped with each order.
2871329 Dielectric Grease (Nyogelt)
Coolant NOTE: Each item can be purchased separately at a
2871323 60/40 Coolant (Gallon) (6 Count)
local Polaris dealer.
2871534 60/40 Coolant (Quart) (12 Count)
2.6
MAINTENANCE
POLARIS LUBRICANTS/FLUIDS FOR ATP MODELS

Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer.
ATV Angle Drive Fluid
2873554 -- ATV Oil Change Kit

-- Oil Filter & 3 Qts. of 0W--40 oil
-- Reservoir Gasket
-- Drain Plug Gasket
-- Instruction Sheet
2.7
MAINTENANCE
ATP COMPONENT LOCATIONS

Instrument Cluster
(Speedometer) AWD/Turf Switch
Brake Fluid Reservoir
Brake Lever
Light Control
& Run Switch
Reverse
Override Throttle
Choke Ignition/Key
Front Storage Box
Box Dump Lever
Side Storage
PVT Cover
Fuel Valve
RES
OFF
Front Gearcase
(Behind Radiator) ON
Gas Cap Engine (Front of Transmission)
Rear Gearcase
Gear Shifter
Rear Prop Shaft

(Between Rear Gearcase
and Transmission)
Right Side View
Front Prop Shaft

(Between Transmission Front Drive Shafts
and Front Gearcase)
Transmission Engine Auxiliary Brake

Recoil
2.8
MAINTENANCE
PRE-RIDE / DAILY INSPECTION

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
G Tires - check condition and pressures
G Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
G Engine coolant - check for proper level at the recovery bottle
G All brakes - check operation and adjustment (includes auxiliary brake)
G Throttle - check for free operation
G Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
G Engine stop switch - check for proper function
G Wheels - check for loose wheel nuts
G Air cleaner element - check for dirt or water; clean or replace
G Steering - check for free operation, noting any unusual looseness in any area
G Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
RECOMMENDED LUBRICANTS - QUICK REFERENCE

Item Type Notes
Engine Oil Polaris Premium 4 Add to proper level on dipstick.
Synthetic, 0W--40
Transmission Polaris AGL Gearcase Lu- Refer to procedures outlined later in this
bricant chapter.
Front Gearcase Premium Front Gearcase Refer to procedures outlined later in this
Fluid chapter.
Rear Gearcase Premium ATV Angle Drive Add to proper level on accessory dipstick
Fluid or drain and refill with proper amount.
Coolant Level Polaris Premium 60/40 Fill reservoir tank to full line. Add if neces-
(ATP 500) Pre-mixed Antifreeze/ sary. If reservoir was empty or extremely
Coolant or a 50/50 mixture low, allow engine and cooling system to
high quality antifreeze/ cool completely and check level in radia-
coolant and distilled water tor. Fill to top of filler neck and bleed sys-
tem.
Brake Fluid Polaris DOT 3 Brake Fluid Fill to indicated level inside reservoir.
POLARIS LUBRICANT SYMBOL I.D. CHART
AGL 0W/40 DHF ADF
Polaris DOT 3 Polaris Sythetic Polaris Sythetic Polaris Demand Polaris ATV
Brake Fluid Gearcase Lube OW--40 Oil Drive Hub Fluid Angle Drive Fluid
AGL
U--Joint
Polaris U--Joint Lube Polaris All Season Grease
2.9
MAINTENANCE
LUBRICATION
NOTE: Refer to Page 2.8 for general component locations.
Ill. Item Lube Required Method Frequency*

#
1 Engine Oil Polaris 0W--40 Add oil to proper level. Change after 1st month, 6 months or 100
Synthetic hours thereafter; Change more often (25-50
hours) in extremely dirty conditions, or short
trip cold weather operation.
2 Transmission Polaris AGL Gear- Add lube to bottom of fill hole Change annually
case Lubricant
3 Brake Fluid Polaris DOT 3 Fill master cylinder reservoir to in- As required. Change fluid every 2 years.
Brake Fluid dicated level inside reservoir.
Dipstick
Dipstick 0W/40
Oil Filter
1. Engine Oil and Filter (500 ) 1. Engine Oil (330)
Parking Brake Lock

Reservoir
AGL Transmission Fill Plug

2. Transmission 3. Brake Fluid
* More often under severe use, such as operated in water or under severe loads.
¡ Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
© Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
¢ Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special
2.10
MAINTENANCE
LUBRICATION
NOTE: Refer to Page 2.8 for general component locations.
Ill. Item Lube Required Method Frequency*

#
4 Front Gearcase Demand Drive Hub Fluid Drain completely. Add lube to Change annually
specified quantity. See Page
2.10.
5 Rear Gearcase Polaris Angle Drive Fluid Drain completely. Add lube to Change annually
specified quantity. See Page
2.11.
6 Front Prop Shaft Premium U-Joint Grease Locate Fittings and Grease Semi-annually¡
7 Rear Prop Shaft Premium U-Joint Grease Locate Fittings and Grease Semi-annually¡
8 Front Strut Ball Premium U-Joint Grease Locate Fittings and Grease Semi-annually¡
Joint
Centralized Hilliard
Fill Plug
DHF ADF
Drain
Plug Drain
Fill Plug Plug
5. Rear Gearcase
4. Front Gearcase
6. Front Prop
Shaft U-Joint
7. Rear Prop Shaft & Yoke 8. Front Strut Ball Joint
* More often under severe use, such as operated in water or under severe loads.
¡ Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)

© Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
¢ Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special
2.11
MAINTENANCE
FRONT GEARCASE LUBRICATION

NOTE: Refer to Page 2.9 for lubricant symbol I.D. To change gearcase lubricant:
The gearcase lubricant level should be checked and
changed in accordance with the maintenance
schedule.
G Be sure vehicle is level before proceeding and in
PARK.
G Check vent hose to be sure it is routed properly
and unobstructed.
G The correct front gearcase lubricant to use is
Polaris Premium Demand Hub Fluid.
B
A
FRONT GEARCASE SPECIFICATIONS 11 ft.lbs (15 Nm)
Specified Lubricant: View Under Front of ATV
Premium Demand Drive Hub Fluid Drain Plug
(PN 2871654)
Capacity: . . . . . . . . .5.0 Oz. (150 ml.) 1. Remove gearcase drain plug (A) (11 mm) located
on the bottom of the gearcase and drain oil. (The
Fill Plug Torque: 8--10 ft.lbs. (11--14 Nm) drain plug is accessible through the skid plate.)
Catch and discard used oil properly.
Drain Plug Torque: 11 ft. lbs. (15 Nm)
2. Clean and reinstall drain plug (A) using a new
sealing washer. Toque to 11 ft.lbs. (15 Nm).
FRONT GEARCASE
Make sure vent is unobstructed
Fill Plug
Fill plug
8--10 ft.lbs.
(11--14 Nm)
Left Side View Front Wheel
3. Remove fill plug (8 mm hex). Check the O--ring.

11 ft.lbs.
Drain plug (15 Nm) 4. Fill with the recommended fluid amount (5 oz.) or
ILL. 1
to the bottom of the fill plug hole threads. (See ILL.
3).
To check the lubricant level:
Front Gearcase
The front and rear gearcase lubricant level cannot be
Plug Threads
checked with a dipstick. The front gearcase must be
drained and re-filled with the proper amount of Fill with 5 oz. lubricant
lubricant or be filled to the bottom of the fill plug hole or bottom of fill plug
threads. Refer to procedures. threads.
ILL. 3
5. Install fill plug and check for leaks.
2.12
MAINTENANCE
REAR CARRIER 3. Reinstall fill plug. Tighten to 40--50 ft. lbs. (54--68
Nm).
LUBRICATION 4. Check for leaks.
NOTE: Refer to Page 2.9 for lubricant symbol I.D.
REAR GEARCASE SPECIFICATIONS
To check the level:
Specified Lubricant:
1. With machine on level ground, remove fill plug
ATV Angle Drive Fluid (PN 2871653)
from rear gearcase.
Capacity: ATP 330/500.......18 oz. (532
ml)
Fill Plug Torque: 40--50 ft. lbs.
(54--68 Nm)
Drain Plug Torque: 30--45 in. lbs.
(3--5 Nm)
To change the lubricant:
5. Remove gearcase drain plug located on the

Fill Plug
40--50 ft. lbs. bottom and drain the oil. Catch and discard used oil
properly.
(54--68 Nm)
6. Clean and reinstall the drain plug with a new
2. The fluid should be level with the fill plug hole. If sealing washer and tighten to 30--45 in. lbs. (3--5
level is low, add ATV Angle Drive Fluid (PN Nm).
2871653) . Fill the rear gearcase to the bottom of 7. Remove fill plug.
the fill plug threads. Refer to ILL. 3.
ADF
Fill Plug
40--50 ft.lbs Drain Plug
(54--68 Nm) 30--45 in. lbs.
(3--5 Nm)
8. Add 18 oz. (532 ml.) of ATV Angle Drive Fluid (PN
2871653) or fill to the bottom of threads of the fill
REAR GEARCASE plug hole as shown in ILL 3.
9. Reinstall fill plug. Tighten to 40--50 ft. lbs (54--68
Nm).
10. Check for leaks.
Fill To Bottom
of Fill Plug
Threads
ILL. 3
2.13
MAINTENANCE
TRANSMISSION
Transmission Oil Measurement
LUBRICATION
NOTE: Refer to Page 2.9 for lubricant symbol I.D.
The transmission lubricant level should be checked
and changed in accordance with the maintenance
schedule.
G Be sure vehicle is level before 1 5/8 “
proceeding. (4.13 cm)
TRANSMISSION SPECIFICATIONS
Specified Lubricant:
Polaris AGL Gearcase Lubricant:
(PN 2873603) (Gallon) (PN 2873602) (12 oz.) To change lubricant:
1. Remove propshaft shield from the right side of the
Capacity: . . . . . 13.5 oz. / 400 ml vehicle, if equipped.
Drain Plug / Fill Plug Torque: 2. Remove transmission drain plug and drain the oil.
The drain plug is located on the front side of the
14 ft. lbs. (19.4 Nm) transmission. Catch and discard used oil
properly.
G Check vent hose to be sure it is not
kinked or obstructed.
G Follow instructions on following
pages to check / change
transmission lubricant.
To check the level:
1. Remove propshaft shield from the right side of the
vehicle, if equipped.
2. Remove fill plug (A) and visually inspect the oil 14 ft.lbs.
level. Level is correct when it reaches the bottom (19 Nm) 1
of the fill hole or 1 5/8” from the top of the fill plug
hole, as shown. 3. Clean and reinstall the drain plug with a new
sealing washer. Torque to 14 ft. lbs. (19.3 Nm).
AGL
AGL
14 ft.lbs.
19 Nm
A
4. Remove fill plug.

5. Add 13.5 oz. (400 ml) of Polaris AGL Gearcase
Lubricant or to proper level as described above.
Clean and reinstall the drain plug with a new
sealing washer. Torque to 14 ft. lbs. (19.3 Nm)
6. Check for leaks.
7. Reinstall propshaft shield, if equipped.
2.14
MAINTENANCE
THROTTLE INSPECTION CHOKE (ENRICHER)

Check for smooth throttle opening and closing in all ADJUSTMENT
handlebar positions. Throttle lever operation should
be smooth and lever must return freely without
binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle
speed increases at any point in the turning range,
inspect throttle cable routing and condition.
Adjust cable tension as needed until lock--to--lock
turning can be accomplished with no rise in
engine rpm.
Boot
5. Replace the throttle cable if worn, kinked, or
damaged. If the choke knob does not stay out when pulled,
adjust the choke tension by tightening (clockwise) the
2 jam nut under the rubber boot between the choke
3 knob and nut. Firmly grasp the rubber boot and
1 tighten until the choke slides freely but stays out when
pulled.
6
5 4 PILOT SCREW ADJUSTMENT
ETC Cover
Ill. 1 Removal Sequence
To remove the ETC cover:

1. Use a medium flat blade screwdriver and insert FRONT
blade into the pocket of the cover starting on the (Engine)
#1 position.
2. Twist screwdriver slightly while lifting on the cover
to release snap. Pilot Screw
3. Repeat procedure at the other five locations as
shown. View -- Right Cover Panel Removed
NOTE: Do not attempt to remove cover until all
latch points are released.
Pilot Screw
2.15
MAINTENANCE
1. Start engine and warm it up to operating IDLE SPEED ADJUSTMENT

temperature (about 10 minutes).
2. Turn pilot screw in (clockwise) until lightly seated.
Turn screw out the specified number of turns. CV Carburetor
NOTE: Do not tighten the pilot screw forcefully
against the seat or the screw and/or seat will be
permanently damaged.
The pilot screw is set at the factory.
Each carburetor will have a slightly differ-
ent pilot screw setting, the adjustments
below are the recommended settings, the
settings may differ from these recommen-
dations.
Idle Screw
Pilot Screw Adjustment:
ATP 330 -- 2 Turns Out 1. Start engine and warm it up thoroughly.
ATP 500 -- 2 Turns Out 2. Adjust idle speed by turning the idle adjustment
screw in (clockwise) to increase or out
3. Connect an accurate tachometer that will read in (counterclockwise) to decrease RPM.
increments of + or -- 50 RPM such as the PET
2100DX (PN 8712100DX) or the PET 2500 (PN NOTE: Adjusting the idle speed affects throttle cable
8712500). freeplay and electronic throttle control (ETC)
adjustment. Always check throttle cable freeplay
4. Set idle speed to 1200 RPM. Always check after adjusting idle speed and adjust if necessary.
throttle cable freeplay after adjusting idle speed
and adjust if necessary.
5. Slowly turn mixture screw clockwise using the Idle Speed:
pilot screw wrench until engine begins to miss.
ATP 330 1300 +/-- 200
6. Slowly turn mixture screw counterclockwise until ATP 500 1200 +/-- 200
idle speed increases to maximum RPM.
Continue turning counterclockwise until idle RPM
begins to drop.
THROTTLE CABLE /
7. Center the pilot screw between the points in Step
5 and 6. ELECTRONIC THROTTLE
8. Re adjust idle speed if not within specification. CONTROL (ETC SWITCH)
IMPORTANT 330 NOTE: Idle speed is specified with
the lights OFF. The idle speed will drop between ADJUSTMENT
100-150 RPM when the lights are turned on.
1. Slide boot off throttle cable adjuster and jam nut.
2. Place shift selector in neutral and set parking
brake.
2.16
MAINTENANCE
3. Start engine and set idle to specified RPM. area where refueling is performed
or where gasoline is stored.
Adjuster
G Do not overfill the tank. Do not fill
Boot Lock- Boot
Sleeve the tank neck.
nut
G If you get gasoline in your eyes or
if you swallow gasoline, seek
medical attention immediately.
G If you spill gasoline on your skin
or clothing, immediately wash it
off with soap and water and
change clothing.
Ill. 1 G Never start the engine or let it run
in an enclosed area. Engine
NOTE: Be sure the engine is at operating exhaust fumes are poisonous and
temperature. See Idle Speed Adjustment. can result loss of consciousness
or death in a short time.
4. Loosen lock nut on in-line cable adjuster (Ill. 1).
G Never drain the float bowl when
5. Turn adjuster until 1/16″ to 1/8″ freeplay is the engine is hot. Severe burns
achieved at thumb lever. (Ill. 2). After making may result.
adjustments, quickly actuate the thumb lever
several times and reverify freeplay.
FUEL LINES
Fuel Pump
Inspect
Fuel Lines
Direction
of travel
1/16″ - 1/8″ Filter
Ill. 2 Freeplay
6. Tighten lock nut securely and slide boot

completely in place to ensure a water-tight seal. 1. Check fuel lines for signs of wear, deterioration,
7. Turn handlebars from left to right through the entire damage or leakage. Replace if necessary.
turning range. If idle speed increases, check for 2. Be sure fuel lines are routed properly and secured
proper cable routing. If cable is routed properly and with cable ties. CAUTION: Make sure lines are
in good condition, repeat adjustment procedure. not kinked or pinched.
3. Replace all fuel lines every two years.
FUEL SYSTEM
WARNING VENT LINES
Gasoline is extremely flammable and explosive Check fuel tank, oil tank, carburetor, battery and
under certain conditions. transmission vent lines for signs of wear,
G Always stop the engine and refuel deterioration, damage or leakage. Replace every two
outdoors or in a well ventilated years.
area. Be sure vent lines are routed properly and secured
G Do not smoke or allow open with cable ties. CAUTION: Make sure lines are not
flames or sparks in or near the kinked or pinched.
2.17
MAINTENANCE
FUEL FILTER
The fuel filter should be replaced in accordance with
the Periodic Maintenance Chart or whenever
sediment is visible in the filter.
Fuel Filter Located Close to Carburetor Drain tube

attached
Arrow Indicates Direction of Flow here
Drain Screw
Ill. 2 To Carburetor Ill. 1
1. Shut off fuel supply at fuel valve. RES

2. Remove line clamps at both ends of the filter.
3. Remove fuel lines from filter.
4. Install new filter and clamps onto fuel lines with
OFF
arrow pointed in direction of fuel flow.
5. Install clamps on fuel line.
6. Turn fuel valve “ON”.
7. Start engine and inspect for leaks.
ON
Ill. 2
CARBURETOR DRAINING
The carburetor float bowl should be drained COMPRESSION TEST
periodically to remove moisture or sediment from the
bowl, or before extended periods of storage. NOTE: 4-Stroke engines are equipped with an
automatic decompressor. Compression readings will
NOTE: The bowl drain screw is located on the bottom vary in proportion to cranking speed during the test.
left side of the float bowl. Average compression for a 500 engine (measured)
1. Turn fuel valve to the off position. is about 70-90 psi during a compression test.
Average compression for a 330 engine (measured)
2. Place a clean container beneath the bowl drain
is about 70--90 psi during a compression test.
spigot or bowl drain hose.
3. Turn drain screw out two turns and allow fuel in Smooth idle generally indicates good compression.
the float bowl and fuel line to drain completely. Low engine compression is rarely a factor in running
condition problems above idle speed. Abnormally
4. Inspect the drained fuel for water or sediment.
high compression can be caused by a decompressor
5. Tighten drain screw. malfunction, or worn or damaged exhaust cam lobes.
6. Turn fuel valve to “ON”. Inspect camshaft and automatic decompression
7. Start machine and check for leaks. mechanism if compression is abnormally high.
NOTE: All tubes attached to the carburetor must be A cylinder leakage test is the best indication of engine
check for pinching or blockage, as this will effect condition on models with automatic decompression.
engine performance. Follow manufacturer’s instructions to perform a cylinder
leakage test. (Never use high pressure leakage testers
as crankshaft seals may dislodge and leak).
2.18
MAINTENANCE
BATTERY MAINTENANCE
Cylinder Leakage
Service Limit 10 %
(Inspect for cause if leakage exceeds 10%)
Average Engine Compression
330 & 500 Engine: 140--160 psi
WARNING
without decompression
Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from
ENGINE MOUNTS contact with skin, eyes or clothing. Anti-
dote:
Inspect rubber engine mounts (A) for cracks or damage. External: Flush with water.
Check engine fasteners and ensure they are tight.
Internal: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten
egg, or vegetable oil. Call physician im-
mediately.
Eyes: Flush with water for 15 minutes and
get prompt medical attention.
A Batteries produce explosive gases. Keep

A sparks, flame, cigarettes, etc. away. Venti-
late when charging or using in an enclosed
space. Always shield eyes when working
near batteries. KEEP OUT OF REACH OF
CHILDREN.
The battery is located under the seat.

A
Battery Location: Under Seat
ENGINE FASTENER TORQUE

Check engine fasteners periodically and verify they
are tight.
NOTE: All ATP batteries are Low Maintenance

design and construction. All Low Maintenance
batteries are fully charged and tested at the
factory before installation. Expected shelf life is
6--8 months depending on storage conditions. As
a general rule before placing the battery into
service, check the battery condition and charge
accordingly.
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
2.19
MAINTENANCE
hours using a variable rate charge. Do not use the Electrolyte Freezing Points
alternator to charge a new battery.
Specific Gravity Freezing
Low Maintenance batteries are permanently of Electrolyte Point
sealed at the time of manufacture. The use of 1.265 -75° F
lead--calcium and AGM technology instead of
lead--antimony allows the battery acid to be fully 1.225 -35° F
absorbed. For this reason, a Low Maintenance 1.200 -17° F
battery case is dark and the cell caps are not 1.150 +5° F
removable, since there is no need to check
electrolyte level. 1.100 +18° F
1.050 +27° F
NEVER attempt to add electrolyte or water to a Low
Maintenance battery. Doing so will damage the
case and shorten the life of the battery. Refer to the
Battery Maintenance Video (PN 9917987) for proper
SPARK PLUG
instruction on servicing Low Maintenance
330 Engine
batteries. A
SEALED LOW MAINTENANCE

BATTERY OFF--SEASON
STORAGE
To prevent battery damage during extended periods
of non-use, the following basic battery maintenance
items must be performed: 1. Remove spark plug high tension lead (A). Clean
plug area so no dirt and debris can fall into engine
G Remove the battery from the
when plug is removed.
machine and wash the case and
battery tray with a mild solution of 2. Remove spark plug.
baking soda and water. Rinse with 3. Inspect electrodes for wear and carbon buildup.
lots of fresh water after cleaning. Look for a sharp outer edge with no rounding or
G Using a wire brush or knife, remove erosion of the electrodes.
any corrosion from the cables and
terminals.
G Charge at a rate no greater than 1/10 Inpsect electrode for
of the battery’s amp/hr capacity until wear and buildup
the voltage reaches 13.0VDC or
greater.
G Store the battery either in the machine
with the cables disconnected, or store
in a cool place.
NOTE: Stored batteries lose their charge at the rate
4. Clean with electrical contact cleaner or a glass
of up to 1% per day. Recharge to full capacity every
bead spark plug cleaner only. CAUTION: A wire
30 to 60 days during a non-use period. If the battery
brush or coated abrasive should not be used.
is stored during the winter months, electrolyte will
freeze at higher temperatures as the battery 5. Measure gap with a wire gauge. Refer to
discharges. The chart provided indicates freezing specifications for proper spark plug type and gap.
points by specific gravity. Adjust gap if necessary by bending the side
electrode carefully. (Ill. 1)
6. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if
the incorrect spark plug is used.
7. Apply a small amount of anti-seize compound to
the spark plug threads.
2.20
MAINTENANCE
8. Install spark plug and torque to specification.
Recommended Spark Plug:
Refer to Specifications
Spark Plug Torque: Antifreeze Hydrometer

14 Ft. Lbs. (19 Nm)
G A 50/50 or 60/40 mixture of antifreeze
and distilled water will provide the
optimum cooling, corrosion protection,
Spark Plug Gap and antifreeze protection.
G Do not use tap water, straight antifreeze,
or straight water in the system. Tap water
contains minerals and impurities which
build up in the system.
G Straight water or antifreeze may cause
.028″ (0.7 mm) the system to freeze, corrode, or
overheat.
Polaris 60/40 Anti-Freeze / Coolant

LIQUID COOLING SYSTEM
(PN 2871323)
OVERVIEW -- ATP 500
The engine coolant level is controlled or maintained
by the recovery system. The recovery system COOLING SYSTEM HOSES --
components are the recovery bottle, radiator filler ATP 500
neck, radiator pressure cap and connecting hose.
As coolant operating temperature increases, the
expanding(heated)excesscoolantisforcedoutofthe
radiator past the pressure cap and into the recovery
bottle. Asenginecoolant temperature decreasesthe
contracting(cooled)coolantisdrawnbackupfromthe
tank past the pressure cap and into the radiator.
Some coolant level drop on new machines is normal
as the system is purging itself of trappedair. Observe
coolant levels often during the break-in period.
Overheating of engine could occur if air is not fully
purged from system.
PolarisPremium60/40isalreadypremixedandready
to use. Do not dilute with water.
1. Inspect all hoses for cracks, deterioration,

COOLANT STRENGTH / TYPE abrasion or leaks. Replace if necessary.
-- ATP 500 2. Check tightness of all hose clamps.
Test the strength of the coolant using an antifreeze CAUTION:

hydrometer.
Do not over-tighten hose clamps at radiator, or
radiator fitting may distort, causing a restriction to
2.21
MAINTENANCE
coolant flow. Radiator hose clamp torque is 36 in. lbs.

(4 Nm).
RADIATOR -- ATP 500 Recovery

Bottle
Accessible
Under Side
A Panel
B
With the engine at operating temperature, the coolant

level should be between the upper and lower marks
on the coolant reservoir. If not:
1. Remove reservoir cap. Inner splash cap vent
hole must be clear and open.
2. Fill reservoir to upper mark with Polaris Premium
60/40 Anti Freeze / Coolant or 50/50 or 60/40
1. Check radiator (A) air passages for restrictions or mixture of antifreeze and distilled water as
damage. Check and clean the brush guard (B) in required for freeze protection in your area.
front of the radiator.
3. Reinstall cap.
2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with compressed air or NOTE: If overheating is evident, allow system to cool
low pressure water. completely and check coolant level in the radiator and
inspect for signs of trapped air in system.
COOLING SYSTEM
PRESSURE TEST -- ATP 500 RADIATOR COOLANT LEVEL
INSPECTION -- ATP 500
Refer to Page 3.48 for pressure test procedure.
NOTE: This procedure is only required if the cooling
system has been drained for maintenance and/or
repair. However, if the recovery bottle has run dry, or
COOLANT LEVEL if overheating is evident, the level in the radiator
should be inspected and coolant added if necessary.
The recovery bottle, located on the left side of the WARNING Never remove the pressure cap
machine, must be maintained between the minimum when the engine is warm or hot. Escaping steam can
andmaximumlevelsindicatedontherecoverybottle. cause severe burns. The engine must be cool before
removing the pressure cap.
NOTE: Use of a non-standard pressure cap will not

allow the recovery system to function properly.
2.22
MAINTENANCE
Front C
Compartment A
Ill.1
To access the radiator pressure cap:
Remove the six screws securing front rack. Turn
handle bars full left or right to provide more clearance. Cleaning:
Remove front cover by placing your fingers under the
5. Slip the pre-filter element (C) off of main element.
front of the cover and pulling upward.
Clean the pre filter with high flash point solvent,
followed by hot soapy water.
6. Rinse and dry thoroughly.
AIR FILTER/PRE-FILTER
7. Inspect element for tears or damage.
SERVICE -- 330 / 500 8. Foam filters only: Apply foam filter oil or clean
engine oil and squeeze until excess oil is
It is recommended that the air filter and pre filter be
removed.
replaced annually. When riding in extremely dusty
conditions, replacement is required more often. 9. Inspect main filter and replace if necessary. If the
filter has been soaked with fuel or oil it must be
The pre filter should be cleaned before each ride using replaced.
the following procedure:
Installation:
1. Lift up on the rear of the seat.
10. Reinstall pre-filter element over main filter. Be
2. Pull the seat back and free of the tabs. NOTE: sure the element covers entire surface of main
When reinstalling seat, make sure the slots in the filter without folds, creases, or gaps.
seat engage the tabs in the fuel tank.
11. Reinstall filter on main filter mount. Place filter
3. Remove clips from air box cover (A) and remove clamp over the assembly and tighten.
cover. Inspect the gasket (E). It should adhere
tightly to the cover and seal all the way around. NOTE: Apply a small amount of general purpose
grease to the sealing edges of the filter before
reinstalling
4. Loosen clamp and remove air filter assembly (B &

C).
2.23
MAINTENANCE
ATP 330 Filter Clamp AIR BOX SEDIMENT TUBE

Periodically check the air box drain tube located
toward the rear of the machine. Drain whenever
deposits are visible in the clear tube.
1. Remove drain plug from end of sediment tube.
2. Drain tube.
3. Reinstall drain plug.
ILL. 2
ATP 500
Filter Clamp
Sediment Tube
Ill.1
NOTE: The sediment tube will require more frequent

service if the vehicle is operated in wet conditions or
at high throttle openings for extended periods.
Ill.3
BREATHER FILTER
Proper Filter Placement
Main Filter ATP 500 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).
Filter Support In-line breather filters should be installed with the arrow
pointing toward the engine (away from the air box).
Air Box
Typical Breather Filter Location
Ill.4 Front
NOTE: The air filter should rest on the filter support.

Proper placement of the air filter is important to
prevent rattles and air leaks. See Illustrations above. In-Line Breather Filter
12. Install air box cover and secure with clips. Location A
2.24
MAINTENANCE
NOTE: In-line breather filter service life is extended 330 ENGINE OIL LEVEL
when the foam air box pre-filter is in place and
maintained properly. Never operate the engine To check the oil level:
without the pre-filter.
1. Set machine on a level surface.
2. Start and run engine for 20-30 seconds. This will
BREATHER HOSE return oil to its true level in the engine sump.
1. Be sure breather line is routed properly and 3. Stop engine, remove dipstick and wipe dry with a
secured in place. CAUTION: Make sure lines are clean cloth.
not kinked or pinched.
RECOIL HOUSING Dipstick Location
0W/40
Recoil Drain
G Drain the housing periodically to remove 4. Reinstall dipstick, screwing into place.
moisture. The plug is located under the
skid plate on the recoil handle side. 5. The dipstick must be screwed completely in to
ensure accurate measurement.
G Drain the recoil housing after operating
the ATV in very wet conditions. This 6. Remove dipstick and check to see that the oil
should also be done before storing the level is in the normal range. The oil should be
ATV. The drain screw is located at the between the top of the bottom crosshatched area
bottom of the recoil housing. Remove the and the bottom of the top crosshatched area. Add
screw with a 10 mm wrench. Reinstall oil as indicated by the level on the dipstick. Do not
screw once housing has been drained. overfill.
G CAUTION: Make sure the manual start
handle is fully seated on the recoil housing Normal Oil Operating
(B), especially when travelling in wet Range is between crosshatch.
areas. If it is not sealed properly, water
may enter the recoil housing and damage
components.
G Water will enter the recoil housing if the
starter handle is disengaged from the rope
guide when under water.
G After travelling in wet areas the recoil
housing and starter should always be
drained completely by removing the Crosshatch Areas of Dipstick
recoil.
G Do not open the crankcase drain unless
the engine has ingested water. Some
engine oil will be lost if crankcase drain is
opened. NOTE: Do not fill the over the normal oil operating
G If recoil handle seal has been damaged, range. Filling over the normal operating range could
the handle should be replaced. cause a mist of oil to enter the air box.
2.25
MAINTENANCE
NOTE: Rising oil level between checks in cool

weather driving, can indicate moisture collecting in the
oil reservoir. If the oil level is over the full mark,
change the oil. Crankcase Drain
Recommended Engine Oil:
Polaris Premium 4 All Season

Synthetic, 0W-40 (PN 2871281)
Ambient Temperature Range:

-40° F to 120° F
Engine Sump Drain Plug - Bottom View

8. The oil filter is located on the right side of the
OIL AND FILTER CHANGE machine. Place shop towels beneath oil filter.
Using an oil filter wrench, turn filter
1. Place vehicle on a level surface. counterclockwise to remove.
2. Clean area around drain plug at bottom of oil pan.
3. Run engine two to three minutes until warm. Stop
engine.
4. Place a drain pan beneath oil pan and remove
drain plug from under the crankcase. CAUTION:
Oil may be hot. Do not allow hot oil to come into
contact with skin as serious burns may result.
5. Allow oil to drain completely.
NOTE: It is not necessary to drain the oil from the oil
cooler, unless contaminants, water, or debris are
found in the crankcase oil. Filter
6. Replace sealing washer (A) on drain plug. NOTE:

The sealing surfaces on drain plug and oil tank 9. Using a clean dry cloth, clean filter sealing surface
should be clean and free of burrs, nicks or on crankcase.
scratches. 10. Lubricate O-ring on new filter with a film of engine
7. Reinstall drain plug and torque to 14 ft. lbs. (19 oil. Check to make sure the O-ring is in good
Nm). condition.
11. Install new filter and turn by hand until filter gasket
contacts the sealing surface, then turn and
additional 1/2 turn.
NOTE: The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks or
scratches.
12. Remove dipstick and fill tank with 2 quarts (1.9 l)
of Polaris Premium 4 Synthetic Oil (PN 2871281).
13. Place gear selector in neutral and set parking
brake.
14. Start the engine and let it idle for one to two
minutes. Stop the engine and inspect for leaks.
15. Re-check the oil level on the dipstick and add oil
as necessary to bring the level to the upper mark
Drain plug located under the engine. on the dipstick.
2.26
MAINTENANCE
2. Start and run engine for 20-30 seconds. This will

Check Oil Level On Dipstick return oil to its true level in the oil tank. About a
cup of oil remains in the crankcase.
3. Stop engine, remove dipstick and wipe dry with a
clean cloth.
4. Reinstall dipstick, screwing into place.
NOTE: The dipstick must be screwed completely in
to ensure accurate measurement.
5. Remove dipstick and verify that the oil level is in
the normal range. Add oil as indicated by the level
on the dipstick. Do not overfill.
ADD 8 OZ. NORMAL FULL
16. Dispose of used filter and oil properly.

Maintain Oil Level In Normal Range
Screw in completely to check

Crankcase Drain Plug Torque:
14 ft. lbs. (19 Nm)
Oil Filter Torque: Recommended Engine Oil:

Turn by hand until filter gasket
contacts sealing surface, then Polaris Premium 4 All Season
turn an additional 1/2 turn Synthetic, 0W--40, (PN 2871281)
Oil Filter Wrench: Ambient Temperature Range:

(PV--43527) -40° F to 120° F
NOTE: Rising oil level between checks in cool

weather driving, can indicate moisture collecting in the
ATP 500 ENGINE OIL LEVEL oil reservoir. If the oil level is over the full mark,
change the oil.
The oil tank is located on the left side of the vehicle.
ATP 500 OIL AND FILTER

CHANGE
WARNING
Personal injury can occur when han-
dling used oil. Hot oil can cause burns
or skin damage.
NOTICE:
A Care must be taken to ensure that fluids are
contained. Be prepared to collect the fluid
0W/40 with suitable containers before opening any
compartment or disassembly any component
containing fluids.
To check the oil level: 1. Place vehicle on a level surface.
1. Set machine on a level surface.
2.27
MAINTENANCE
2. Run engine two to three minutes until warm. Stop

engine.
3. Clean area around drain plug (B) at bottom of oil
tank. Remove drain plug (B). D
4. Place a drain pan beneath oil tank and remove
drain plug. CAUTION: Oil may be hot. Do not
allow hot oil to come into contact with skin as
serious burns may result.
A
B Reference
C Mark on Tank
5. Allow oil to drain completely. C

6. Replace sealing washer (A) on drain plug (B).
NOTE: The sealing surfaces on drain plug and oil
tank should be clean and free of burrs, nicks or
scratches. ILL. 3
7. Reinstall drain plug (B) and torque to 14 ft. lbs. (19 14. Place shop towels beneath oil filter (E) . Use Oil
Nm). Filter Wrench (PV--43527), turn filter
8. Loosen clamp (D). counterclockwise to remove.
9. Remove oil hose from screen fitting (C) on bottom
of oil tank.
10. Remove screen fitting (C) and clean the screen.
11. Apply Loctitet Thread Sealant 565 (PN
2871956) or an equivalent pipe thread sealant or
PTFE sealant tape to clean, oil free threads of
fitting (C).
12. Install screen fitting (C) and rotate a minimum of 2
E
1/2 turns (clockwise) into the tank threads. Then
rotate the screen fitting (C) clockwise until the
nipple of the screen fitting (C) aligns with the
marking on the tank (see Ill. 3). NOTE:
Maximum torque for the screen fitting (C) is 25
ft.lbs. (34 Nm), do not overtighten.
15. Using a clean dry cloth, clean filter sealing surface
13. Install oil hose on fitting (C) and re--install clamp
on crankcase.
(D).
16. Lubricate O-ring on new filter with a film of engine
oil. Check to make sure the O-ring is in good
condition.
17. Install new filter and turn by hand until filter gasket
contacts the sealing surface, then turn and
additional 1/2 turn.
2.28
MAINTENANCE
23. Dispose of used filter and oil properly.
Crankcase Drain
Oil Tank Drain Plug Torque:
14 ft. lbs. (19 Nm)
Crankcase Drain Plug Torque:

14 ft. lbs. (19 Nm)
Oil Filter Torque:

Turn by hand until filter gasket
contacts sealing surface, then
turn an additional 1/2 turn
Engine Sump Drain Plug - Bottom View
Oil Filter Wrench:
18. Approximately 1 cup of engine oil will remain in (PV--43527)
the crankcase. To drain, remove drain plug found
on lower right side of crankcase.
Oil Tank Screen Fitting Torque:
NOTE: The sealing surfaces on the drain plug and See Step 12
crankcase should be clean and free of burrs, nicks or Recommended Engine Oil:
scratches. Polaris Premium 4 All Season
19. Reinstall drain plug. Synthetic, 0W--40, (PN 2871281)
20. Remove dipstick and fill tank with 2 quarts (1.9 L)
Ambient Temperature Range:
of Polaris Premium 4 Synthetic Oil (PN 2871844). -40° F to 120° F
21. Place gear selector in Park and set parking brake.
NOTE: Clamp or pinch off the vent line 2” from the oil
tank as shown below in the Oil Pump Priming
Procedure for the ATP 500 engine (see next page). OIL PUMP PRIMING
22. Re-check the oil level on the dipstick and add oil PROCEDURE (ATP 500 ONLY)
as necessary to bring the level to the upper mark
on the dipstick.
NOTE: This priming procedure must be
performed whenever the oil hose connection
between the oil tank and pump inlet has been
disconnected.
1. Clamp or pinch off vent line (A) approximately 2I

from oil tank to avoid the end of oil tank vent fitting,
and the vent line’s pressure relief slit
2. Run engine for 10--20 seconds.
3. Remove the vent line clamp. A rush of air should
be heard, indicating the oil pump is 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.
2.29
MAINTENANCE
4. ATP 330-- Remove plastic valve plugs.
(A) Vent Hose to Air Box 330 Valve Plugs
Oil Lines
To Engine
To Air Box
Approx. 5. ATP 500-- Remove rocker cover bolts, cover and
2I gasket.
NOTE: It may be necessary to tap cover lightly

with a soft-faced hammer to loosen it from the
cylinder head.
Slit 6. Remove timing inspection plug from recoil
housing. Position engine at Top Dead Center
Oil Tank Pinch Off (TDC).
(A) Vent Hose CAUTION: Failure to position the crankshaft at TDC
on compression stroke will result in improper valve
adjustment.
VALVE CLEARANCE 330/500 7. Rotate engine slowly with recoil rope, watching
ENGINES the intake valve(s) open and close.
NOTE -- 330: Continue to rotate, observing the intake
Inspect and adjust valve clearance while the engine valve closing and then starting to open and the “T”
is cold and the piston positioned at Top Dead Center aligns with the pointer. The camshaft lobes should be
(TDC) on compression stroke. pointing downward at this point.
1. Remove the seat. NOTE -- 500: Watch the camshaft sprocket locating
2. Remove body panels and fuel tank as necessary pin and slowly rotate engine until the locating pin is
to gain access to valve cover. facing upward, directly in line with the crankshaft to
camshaft center line as shown. The camshaft lobes
NOTE: ATP 330 -- Remove front rack, ignition, should be pointing downward at this point.
choke lever, handlebar cover, fuel valve, front cab
and fuel tank (see chapter 5).
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.
2.30
MAINTENANCE
500
Sprocket alignment pin facing up 330 Engine
Crankshaft-to-Camshaft Centerline Valve Adjuster Tool: PA--44689
8. Verify accurate TDC positioning by observing the 3. Hold adjuster screw and tighten adjuster lock nut
“T” mark aligned with the pointer in the timing securely.
inspection hole. In this position there should be 4. Re-check the valve clearance.
clearance on all valves. 5. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.
6. Repeat this step for the second intake valve on
the ATP 500.
EXHAUST VALVE
CLEARANCE ADJUSTMENT
1. Insert .006″ feeler gauge(s) between end of
exhaust valve stem and adjuster screw(s).
9. Check for proper valve clearance. Adjust if 2. Loosen locknut(s) and turn adjuster screw(s) until
needed. there is a slight drag on feeler gauge(s). NOTE:
The feeler gauge(s) should remain inserted
INTAKE VALVE CLEARANCE during adjustment of each valve on the ATP 500 .
330 / 500 Engines NOTE: The exhaust valves on the 500 engines share
.006″ (.15 mm) a common rocker arm, and must be adjusted using
two feeler gauges. The ATP 330 exhaust valve is
adjusted the same as the intake valve. The
Valve/Clutch Adjuster Tool (PN PA--44689) can be
used to adjust the 500 engines valves.
INTAKE VALVE CLEARANCE
ADJUSTMENT 500 Engine
1. Insert a .006″ (.15mm) feeler gauge between end
of intake valve stem and clearance adjuster
screw.
2. Using Valve/Clutch Adjuster Tool (PN
PA--44689), loosen adjuster lock nut and turn
adjusting knob until there is a slight drag on the
feeler gauge.
Feeler Gauge for Both Valves
2.31
MAINTENANCE
WARNING
3. When clearance is correct, hold adjuster screw
and tighten locknut securely Due to the critical nature of the procedures out-
lined in this chapter, Polaris recommends
4. Re-check the valve clearance. steering component repair and adjustment be
5. Repeat adjustment procedure if necessary until performed by an authorized Polaris MSD--certi-
clearance is correct with locknut secured. fied technician when replacing worn or dam-
aged steering parts. Use only genuine Polaris
replacement parts.
330 / 500 Engines One of two methods can be used to measure toe
alignment. The string method and the chalk method.
.006″ (.15 mm)
If adjustment is required, refer to following pages for
procedure.
6. ATP 330: Inspect o-rings on the plastic valve
plugs, replace if damaged. Securely fasten valve
plugs.
TIE ROD END / STEERING
7. Scrape gasket surfaces to remove all traces of
the old gasket. CAUTION: Use care not to INSPECTION
damage the sealing surface of the cover or
cylinder head. (500) G To check for play in the tie rod end,
8. Reinstall the cover using a new gasket. (500) grasp the steering tie rod, pull in all
directions feeling for movement.
9. Torque cover bolts to 72 in. lbs. (8 Nm). (500)
G Repeat inspection for inner tie rod
10. Remove the shop towel from the spark plug end on steering post.
cavity.
11. Install the spark plug. Torque to 14 ft. lbs. (19
Nm).
12. Install the spark plug high tension lead.
13. Install parts removed for access.
(ATP 500)
Cover Bolt Torque: 72 in. lbs. (8Nm)
(ATP 330 and 500)

Spark Plug Torque: 14 ft. lbs. (19 Nm)
STEERING
The steering components should be checked
periodically for loose fasteners, worn tie rod ends, and G Replace any worn steering
damage. Also check to make sure all cotter pins are components. Steering should move
in place. If cotter pins are removed, they must not be freely through entire range of travel
re-used. Always use new cotter pins. without binding.
Replace any worn or damaged steering components. G Elevate front end of machine so front
Steering should move freely through entire range of wheels are off the ground. Check for
travel without binding. Check routing of all cables, any looseness in front hub / wheel
hoses, and wiring to be sure the steering mechanism assembly by grasping the tire firmly
is not restricted or limited. NOTE: Whenever steering at top and bottom first, and then at
components are replaced, check front end alignment. front and rear. Try to move the wheel
Use only genuine Polaris parts. and hub by pushing inward and
pulling outward.
G If abnormal movement is detected,
inspect the hub and wheel assembly
2.32
MAINTENANCE
to determine the cause ( possible Be sure to keep handlebars centered. See notes
loose wheel nuts or loose front hub below.
components).
NOTE: String should just touch side sur-
face of rear tire on each side of machine.
Rear rim
Measure measure-
Check for Loose Wheel or Hub from string ment should
to rim at be 1/16″ to
G Refer to the Body/Steering Chapter
front and 1/8″ (.2 to .3
5 or Final Drive Chapter 7 for service
rear of rim. cm) more
procedures.
than front rim
measure-
CAMBER AND CASTER ment.
The camber and caster are non-adjustable.
WHEEL ALIGNMENT
METHOD 1:
STRAIGHTEDGE OR STRING
NOTE: The steering post arm “frog” can be
used as an indicator of whether the handle-
bars are straight. The frog should always
point straight back from the steering post.
2.33
MAINTENANCE
WHEEL ALIGNMENT Hold

Rod End
METHOD 2: CHALK
1. Place machine on a smooth level surface.
2. Set handlebars in a straight ahead position and
secure handlebars in this position. NOTE: The
steering arm “frog” can be used as an indicator of
whether the handlebars are straight. The frog
Correctly Incorrectly
should always point straight back from the
Tightened Tightened
steering post.
Jam Nut Jam Nut
3. Place a chalk mark on the center line of the front Ill.2
tires approximately 10″ (25.4 cm) from the floor or Ill.2
as close to the hub/axle center line as possible.
NOTE: It is important that the height of both To adjust toe alignment:
marks be equally positioned in order to get an G Hold tie rod end to keep it from rotating.
accurate measurement.
G Loosen jam nuts at both end of the tie rod.
4. Measure the distance between the marks and
record the measurement. Call this measurement G Shorten or lengthen the tie rod until
“A”. alignment is as required to achieve the
proper toe setting as specified in
5. Rotate the tires 180° by moving vehicle forward or Method 1 or Method 2.
backward. Position chalk marks facing rearward,
even with the hub/axle centerline. G IMPORTANT: When tightening the tie
rod end jam nuts, the rod ends must be
6. Again measure the distance between the marks held parallel to prevent rod end damage
and record. Call this measurement “B”. Subtract and premature wear. Damage may not
measurement “B” from measurement “A”. The be immediately apparent if done
difference between measurements “A” and “B” is incorrectly. See illustration 2.
the vehicle toe alignment. The recommended
vehicle toe tolerance is 1/8″ to 1/4″ (.3 to .6 cm) G After alignment is complete, torque jam
toe out. This means the measurement at the front nuts to 12-14 ft. lbs. (16-19 Nm).
of the tire (A) is 1/8″ to 1/4″ (.3 to .6 cm) wider than
the measurement at the rear (B)
EXHAUST PIPE
TOE ALIGNMENT The exhaust pipe must be periodically purged of
ADJUSTMENT accumulated carbon as follows:
1. Remove the clean out plugs located on the
If toe alignment is incorrect, measure the distance bottom of the muffler as shown in illustration 1.
between vehicle center and each wheel. This will tell
you which tie rod needs adjusting. NOTE: Be sure
handlebars are straight ahead before determining
which tie rod(s) need adjustment.
CAUTION: During tie rod adjustment, it is very

important that the following precautions be taken
when tightening tie rod end jam nuts. If the rod end Ill.1 Clean Out Plug
is positioned incorrectly it will not pivot, and may
break. 2. Place the transmission in Park and start the
engine. Purge accumulated carbon from the
system by momentarily revving the engine
several times.
2.34
MAINTENANCE
3. If some carbon is expelled, cover the exhaust 8. Reinstall the clean out plugs.
outlet and lightly tap on the pipe around the clean
out plugs with a rubber mallet while revving the
engine several more times.
WARNING
G Do not perform clean out immediately
after the engine has been run, as the ex-
haust system becomes very hot. Serious
burns could result from contact with ex-
haust components.
G To reduce fire hazard, make sure that
there are no combustible materials in the
area when purging the spark arrestor.
G Wear eye protection.
G Do not stand behind or in front of the ve-
hicle while purging the carbon from the
spark arrestor.
G Never run the engine in an enclosed
4. If particles are still suspected to be in the muffler, area. Exhaust contains poisonous car-
back the machine onto an incline so the rear of the bon monoxide gas.
machine is one foot higher than the front. Set the
hand brake and block the wheels. Make sure the G Do not go under the machine while it is
inclined. Set the hand brake and block
machine is in Park and repeat Steps 2 and 3. SEE the wheels to prevent roll back.
WARNING
5. If particles are still suspected to be in the muffler, Failure to heed these warnings could result in
drive the machine onto the incline so the front of serious personal injury or death.
the machine is one foot higher than the rear. Set
the hand brake and block the wheels. Make sure
the machine is in Park and repeat Steps 2 and 3.
SEE WARNING
BRAKE SYSTEM INSPECTION
The following checks are recommended to keep the
brake system in good operating condition. Service life
of brake system components depends on operating
conditions. Inspect brakes in accordance with the
maintenance schedule and before each ride.
G Keep fluid level in the master cylinder
reservoir to the indicated level inside
reservoir.
G Use Polaris DOT 3 Brake Fluid (PN
1 ft. 2870990).
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.
2.35
MAINTENANCE
Sight Parking Brake HOSE/FITTING INSPECTION

Glass Lock
Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.
AUXILIARY BRAKE TESTING

The auxiliary brake should be checked for proper
function.
Auxiliary Foot Brake Pedal

Rear Master Cylinder Reservoir
Full
Located Under Seat Full Height
Engagement
Max
Min
Floor
Board Surface
G Check brake system for fluid leaks.
G Check brake for excessive travel or
1. Support the rear wheels off the ground.
spongy feel.
2. While turning the rear wheels by hand, apply the
G Check friction pads for wear,
auxiliary foot brake. This brake should not stop
damage or looseness.
the wheels from turning until the lever is half way
G Check surface condition of the disc. between its rest position and bottoming on the
footrest.
BRAKE PAD INSPECTION
Pads should be changed when the friction material is
AUXILIARY BRAKE
worn to 3/64″ (.1 cm), or about the thickness of a dime. ADJUSTMENT (HYDRAULIC)
Auxiliary Brake
3/64″
(.1cm)
Minimum
Thickness
Use the following procedure to inspect the hydraulic

auxiliary (foot) brake system and adjust or bleed if
necessary:
2.36
MAINTENANCE
First, check foot brake effectiveness by applying 50 lb. FRONT SUSPENSION

(approx.) downward force on the pedal. The top of the
pedal should be at least 1 inch, (25.4mm) above the Compress and release front suspension. Damping
surface of the footrest. should be smooth throughout the range of travel.
Check all front suspension components for wear or
1/8, to 1/4, damage.
Free Play Inspect front strut cartridges for leakage.
50 lbs 1″ or greater
CONTROLS
Floorboard
If less than one inch, two things must be examined:

Free Play:
Free play of the brake pedal should be 1/8 - 1/4
inch (3.2 - 6.35 mm).
If free play is excessive, inspect pedal, linkage, and
master cylinder for wear or damage and replace any
parts as needed.
Bleeding:
If free play is correct and brake pedal travel is still
excessive, air may be trapped somewhere in the
system. Bleed the hydraulic auxiliary brake system in Check controls for proper operation, positioning
a conventional manner, following the procedure and adjustment.
outlined in Brake Chapter 9.
Brake control and switch must be positioned to allow
brake lever to travel throughout entire range without
contacting switch body.
SUSPENSION SPRING
PRELOAD ADJUSTMENT Throttle
assembly
clamp
Center Spring
Adjustment Ring
1 2
Align clamp
edge with
Shock Spanner Wrench knurl
(PN 2871095) Align throttle control assembly clamp with knurl on
handlebar
Operator weight and vehicle loading affect

suspensionspringpreloadrequirements. Adjustas WHEELS
necessary, using the spanner wrench (2) supplied
in your ATV tool kit to turn the adjustment cam (1). Inspect all wheels for runout or damage. Check wheel
nuts and ensure they are tight. Do not over tighten the
2.37
MAINTENANCE
wheel nuts. WHEEL REMOVAL FRONT OR

REAR
WARNING
Operating an ATV with worn tires will increase
the possibility of the vehicle skidding and pos-
sible loss of control.
Worn tires can cause an accident.
Always replace tires when the tread depth
measures 1/8″ (.3 cm) or less.
WHEELS Flange Nuts:

Flat side against wheel
Inspect all wheels for runout or damage. Check wheel
nuts and ensure they are tight. Do not over tighten the 1. Stop the engine, place the transmission in park
wheel nuts. and lock the parking brake.
2. Loosen the wheel nuts slightly.

WHEEL, HUB, AND SPINDLE 3. Elevate the side of the vehicle by placing a
suitable stand (A) under the footrest frame.
TORQUE TABLE
Model Item Specification
Front Wheel 27 Ft. Lbs.
ATP 330 4x4 Nuts (37 Nm)
Rear Wheel 27 Ft. Lbs.
Nuts (37 Nm)
ATP 500 4x4
Front Hub 70 Ft. Lbs.
Retaining Nut (95 Nm) A
Rear Hub 80 Ft. Lbs.
Retaining Nut (108 Nm) 4. Remove the wheel nuts (1) and remove the
wheel.
ATP 330 & 500

Front & Rear
Wheel Nuts (4)
27 ft. lbs. (37 Nm)
Front Hub Nut

70 ft. lbs. (95 Nm)
1
Rear Hub Nut

80 ft. lbs. (108 Nm)
WHEEL INSTALLATION
1. With the transmission in park and the parking
brake locked, place the wheel in the correct
position on the wheel hub. Be sure the valve stem
2.38
MAINTENANCE
is toward the outside and rotation arrows on the

tire point toward forward rotation.
Tread
2. Attach the wheel nuts and finger tighten them. Depth 1/8I (3 mm)
The flange side of nut goes against the wheel.
Flange
Side
WARNING
1 Operating an ATV with worn tires will in-
crease the possibility of the vehicle skid-
3. Lower the vehicle to the ground. ding easily with possible loss of control.
4. Securely tighten the wheel nuts to the proper Worn tires can cause an accident.
torque listed in the table.
Always replace tires when the tread
depth measures 1/8″ (.3 cm) or less.
CAUTION:
If wheels are improperly installed it could affect

vehicle handling and tire wear. On vehicles with FRAME, NUTS, BOLTS,
tapered rear wheel nuts, make sure tapered end of nut
goes into taper on wheel. FASTENERS
Periodically inspect the torque of all fasteners in
accordance with the maintenance schedule. Check
TIRE PRESSURE that all cotter pins are in place. Refer to specific
fastener torques listed in each chapter.
CAUTION:
Maintain proper tire pressure. Refer to the warning CV SHAFT BOOT

tire pressure decal applied to the vehicle. INSPECTION
Tire Pressure Inspection (PSI - Cold) Inspect the cv shaft boots in the front of the ATV for
Front Rear damage, tears, wear, or leaking grease. If the rubber
boot exhibits any of these symptoms, replace the
5 5 boot. Refer to Chapter 7 for CV boot replacement, or
have you Polaris dealer replace the boot.
TIRE INSPECTION
G Improper tire inflation may affect ATV
maneuverability.
G When replacing a tire always use
original equipment size and type.
G The use of non-standard size or type
tires may affect ATP handling.
Tire Tread Depth

Always replace tires when tread depth is worn to Inspect Boots
1/8″ (3 mm) or less.
2.39
MAINTENANCE
CLEANING & STORAGE OF Fill the fuel tank. Add Polaris Carbon Clean Fuel
Treatment or Polaris Fuel Stabilizer. Follow the
YOUR ATV instructions on the container for the recommended
amount. (Carbon clean will also reduce the possibility of
Cleaning the ATV bacterial growth in the fuel system.) Allow 15-20
Keeping your ATV clean will not only improve its minutes of operation for the stabilizer to disperse
appearance but it can also extend the life of various through the fuel in the tank and carburetor. Turn the fuel
components. With a few precautions, your ATV can valve off and drain the carburetor bowl.
be cleaned much like an automobile.
Oil and Filter
Washing the ATV Warm the engine and change the oil and filter. Follow
The best and safest way to clean your ATV is with a the procedure in this chapter for proper oil change.
garden hose and a pail of mild soap and water. Use
a professional type washing mitten, cleaning the Air Filter / Air Box
upper body first and the lower parts last. Rinse with Inspect and clean or replace the pre-cleaner and air
water frequently and dry with a chamois to prevent filter. Clean the air box and drain the sediment tube.
water spots. NOTE: If warning and safety labels are
damaged, contact your a Polaris dealer for free Breather Filter
replacement. Inspect and clean or replace the breather filter.
Polaris does not recommend the use of a high Fluid Levels
pressure type car wash system for washing the ATV. Inspect the following fluid levels and change if
If a high pressure system is used, exercise extreme necessary: front gearcase; transmission; brake fluid
care to avoid water damage to the wheel bearings, (change every two years or as required if fluid looks
transmission seals, body panels, brakes and warning dark or contaminated).
labels. NOTE: Grease all zerk fittings immediately
after washing, and allow the vehicle to run for a while Drain the Recoil Housing
to evaporate any water that may have entered the Remove the recoil housing drain plug and drain any
engine or exhaust system. moisture.
Waxing the ATV Storage Tips
Your ATV can be waxed with any non-abrasive Polaris offers storage kits for you ATV, see Page 2.7
automotive paste wax. Avoid the use of harsh for the part numbers of Polaris products.
cleaners since they can scratch the body finish.
Polaris offers a detailing kit for your ATV, see Page Fog the Engine
2.7. Remove the spark plug and add 2-3 tablespoons of
CAUTION: Certain products, including insect Premium 4 Synthetic 0W--40 engine oil. To access the
repellants and chemicals, will damage plastic plug hole, use a section of clear 1/4” hose and a small
surfaces. Use caution when using these plastic squeeze bottle filled with the pre-measured
products near plastic surfaces. amount of oil. Note: Do this carefully! If you miss the
plug hole, oil will drain from the spark plug cavity into the
Storage Tips hole at the front of the cylinder head, and appear to be
See Page 2.7 for the part numbers of Polaris an oil leak. Install the spark plug and pull the engine over
products. slowly with the recoil starter. Oil will be forced in and
around the piston rings and ring lands, coating the
CAUTION: Starting the engine during the storage cylinder with a protective film of fresh oil.
period will disturb the protective film created by
fogging and damage could occur. Never start the If you choose not to use Polaris Fogging Oil, perform
engine during the storage period. the following procedure.
1. Support the front end of the machine so the
Clean the Exterior
engine is level or tilted slightly rearward.
Make necessary repairs and then clean the ATV
thoroughly with mild soap and warm water to remove 2. Remove the spark plug(s). Rotate the piston to
all dirt and grime. Don’t use harsh detergents or high BDC and pour approximately two ounces of
pressure washers. Some detergents deteriorate Polaris oil into the cylinder.
rubber parts. Use dish soap type cleaners only. High 3. Apply dielectric grease to the inside of the spark
pressure washers may force water past seals. plug cap and install the cap onto the plug.
Stabilize the Fuel
2.40
MAINTENANCE
4. Turn the engine over several times to ensure

coverage of piston rings, cylinder walls and
crankshaft bearings.
5. Treat the fuel system with Polaris Carbon Clean.
6. If Polaris fuel system additive is not used, fuel
tank, fuel lines, and carburetor should be
completely drained of gasoline. To eliminate any
fuel remaining in the carburetor, run the engine
until it stops.
Lubricate
Inspect all cables and lubricate with Polaris Cable
Lubricant. Follow lubrication guidelines in the
maintenance section of the service or owner’s manual
to completely grease and lubricate the entire vehicle
with Polaris Premium All Season Grease.
Storage Tips
Battery Storage
Remove the battery from the vehicle and ensure that
it’s fully charged before placing it in storage. See page
2.20 for instructions. Magnum 330
Engine Anti-Freeze
Test engine coolant strength and change if necessary.
Coolant should be replaced every two years. See
Page 2.21 for the proper test procedure.
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 ATP 330/500
Polaris ATV cover. NOTE: Do not use plastic or coated
materials. They do not allow enough ventilation to
prevent condensation, and may promote corrosion and
oxidation.
Transporting the ATV
Follow these procedures when transporting the
vehicle.
1. Turn off the engine and remove the key to prevent
loss during transporting.
2. Always place the transmission in park and lock
the parking brake.
3. Turn the fuel valve off.
4. Be sure the fuel cap, oil cap and seat are installed
correctly.
5. Always tie the frame of the ATV to the transporting
unit securely using suitable straps or rope.
2.41
MAINTENANCE
NOTES
2.42
330 ENGINE
ATP 330 Engine Information . . . . . . . . . . . . . . . . . . 3.2-3.42

ATP 500 Engine Information . . . . . . . . . . . . . . . . . . 3.43-3.96
3.1
330 ENGINE
ES320PFE
ENGINE SECTION
Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . 3.10
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Lubrication/Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11-3.12
Engine Exploded View . . . . . . . . . . . . . . . . . . . . . . . 3.13
Engine Top End Disassembly . . . . . . . . . . . . . . . . . 3.14-3.18
Cylinder Head / Valve Service . . . . . . . . . . . . . . . . . 3.18-3.22
Engine Bottom End Disassembly . . . . . . . . . . . . . . 3.23-3.30
Crankcase & Bearing Assembly . . . . . . . . . . . . . . . 3.31-3.32
Crankshaft End Play Inspection . . . . . . . . . . . . . . . 3.32-3.33
Engine Assembly/Inspection . . . . . . . . . . . . . . . . . . 3.34-3.44
330 Engine
3.2
330 ENGINE
ES320PFE ENGINE SERVICE DATA

Cylinder Head / Valve ES320PFE
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
g In Std 1.3001--1.3041″ (33.023-33.123 mm)
Limit 1.2883″ (32.723 mm)
Ex Std 1.3007-1.3047″ (33.039-33.139 mm)
Limit 1.2889″ (32.739 mm)
Camshaft journal
j OD Mag 1.4935-1.4941″ (37.935-37.950 mm)
PTO 1.4935-1.4941″ (37.935-37.950 mm)
Camshaft journal
j 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 .0022-.0035″ (.055-.090 mm)
Limit .0039″ (.10 mm)
Cylinder
y Head Surface warpage limit .0020″ (.05 mm)
Standard height 2.908″ (73.8 mm)
Valve Seat Contacting
g width In Std .039″ (1.0 mm)
Limit .055″ (1.4 mm)
Ex Std .059″ (1.5 mm)
Limit .071″ (1.8 mm)
Valve Guide Inner diameter .2362-.2367″ (6.000-6.012 mm)
Protrusion above head .681-.689″ (17.3-17.5 mm)
Valve Margin
g thickness In Std .039″ (1.0 mm)
Limit .032″ (0.8 mm)
Ex Std .047″ (1.2 mm)
Limit .032″ (0.8 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 0.0014-0.0024″ (0.035-0.062mm)
Ex 0.0016-0.0026″ (0.040-0.067mm)
Limit .0059″ (0.15 mm)
Overall length
g In 3.979″ (101.0 mm)
Ex 3.987″ (101.2 mm)
Valve Spring
p g Free length
g Std 1.673″ (42.5 mm)
Limit ------
Squareness 0.075″ (1.9 mm)
3.3
330 ENGINE
ES320PFE ENGINE SERVICE DATA

Cylinder / Piston / Connecting Rod ES320PFE
Cylinder Surface warpage limit (mating with cylinder .0020″ (0.050 mm)
head)
Cylinder bore Std 3.0906-3.0913″ (78.50-78.520 mm)
Taper limit .0020″ (0.050 mm)
Out of round limit .0020″ (0.050 mm)
Piston clearance Std .0015-.0032″ (0.038-0.082 mm)
Limit .004″ (0.11 mm)
Boring limit .0020″ (0.5 mm)
Piston Outer diameter Std 3.0881-3.0891″ (78.438-78.462 mm)
.0098″ (.25 mm) 3.0980-3.0989″ (78.688-78.712 mm)
OS
.0197″ (.50 mm) 3.1078-3.1087″ (78.938-78.962 mm)
OS
Standard inner diameter of piston pin bore .7095-.7097″ (18.007-18.013 mm)
Piston Pin Outer diameter .7092--.7095″ (18.001-18.007 mm)
Standard clearance-piston pin to pin bore 0.0-.0005″ (0.0-0.012 mm)
Degree of fit Piston pin must be a push (by hand) fit at 68°
F (20° C)
Piston Ring
g Piston ring
g installed gap
g p Top
p ring
g Std .0079-.0118″ (0.20-0.30 mm)
Limit .039″ (1.0 mm)
Second Std .0138-.0197″ (0.35-0.50 mm)
ring
i Limit .039″ (1.0 mm)
Oil ring
g Std .0079-.0236″ (0.20-0.60 mm)
Limit .059″ (1.5 mm)
Piston Ring
g Standard clearance - Top
p ring
g Std .0014-.0030″ (0.035-0.075 mm)
piston
i ring
i to ring
i groove Limit .0059″ (0.15 mm)
Second Std .0010-.0026″ (0.025-0.065 mm)
ring
i Limit .0059″ (0.15 mm)
Connecting
g Rod Connecting rod small end ID .7095-.7101″ (18.007-18.023 mm)
Connectingg rod small end radial Std 0.0-.0009″ (0.0-0.022 mm)
clearance
l Limit .0012″ (0.03 mm)
Connecting
g rod big
g end side clear- Std .0028-.0118″ (0.07-0.30 mm)
ance Limit .0138″ (0.35 mm)
Connectingg rod big
g end bearing
g Std 0.0007-0.0021″ (0.019-0.053 mm)
clearance
l Limit 0.0026″ (0.065 mm)
Crankshaft Crankshaft runout limit (PTO end) 0.0024″ (0.060 mm)
Crankshaft end play 0.002-0.008″ (0.05-0.20 mm)
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter;
OD: Outer Diameter; Mag: Magneto Side; PTO: Power
Take Off Side
3.4
330 ENGINE
ES320PFE SPECIAL TOOLS Oil Filter Pipe

Fitting (Con-
20mm 36-43 (49-59 Nm)
PART NUMBER TOOL nector)

DESCRIPTION Oil Line Fitting 20 (27 Nm)
2200634 Valve Seat Oil Pump 6mm 4-5 (5-7 Nm)
Reconditioning Kit
Cover
2870390 Piston Support
Block Oil Relief Valve 14mm 14.5-16.5 (20-23 Nm)
Plug
2870159 Flywheel Puller
Recoil Housing 6mm 5-6.5 (7-9 Nm)
2871293 Slotted Nut Socket
PV--43527 Oil Filter Wrench Rocker Cover 6mm 7-8 (9-11 Nm)
Rocker Cover 28mm 39-44 (53-59)
ES320PFE TORQUE Block Plug
Rocker Adjus- 6mm 6-7 (8-10 Nm)
SPECIFICATIONS ter Screw Lock
Nut
ENGINE TORQUE SPECIFICATIONS Stator Plate 6mm 5-6.5 (7-9 Nm)
Fastener Size 330 Starter Motor 6mm 5-6.5 (7-9 Nm)
ES32PFE10
Ft. Lbs. (Nm) Spark Plug 14mm 9-11 (12-15 Nm)
Camshaft 6mm 5-6.5 (7-9 Nm) Oil Cooler 3--3.6 (4--5 Nm)
Chain Tension- Thermistor
er Lever
Camshaft 6mm 5-6.5 (7-9 Nm) ES320PFE ENGINE
Chain Tension-
er FASTENER TORQUE
Camshaft
Chain Tension-
11mm 14-19 (20-25 Nm)
PATTERNS
er Cap
Camshaft 10mm 25-29 (34-40 Nm) Tighten cylinder head, cylinder base, and crankcase
Sprocket fasteners in 3 steps following the sequence outlined
below.
Carburetor 8mm 12-14 (16-20 Nm)
Adaptor
Connecting 8.5mm 29-33 (39-45 Nm) 3 2
5
Rod 6mm
Crankcase 8mm 14-15 (19-21 Nm) 6
Crankshaft 28mm 35-51 (47-69 Nm)
1 4
Slotted Nut
(Drive Sprock-
Cylinder Head
et) Cylinder Base
Cylinder Base 6mm 5-7 (7-9 Nm)
Bolts
Cylinder Head 10mm Refer to Engine
Bolts Assembly for torque pro- 7 5 9
cedure 11
Drive Clutch 7/16 - 20 40 (55 Nm)
3 1
Bolt
Flywheel 16mm 58-72 (78-98 Nm) 10
Oil Hose Fit- 1/2 & 9/16 20 (27 Nm)
tings 2
4 8
Oil Delivery Pi- 12mm 11-15 (15-21 Nm)
pe
Oil Drain Bolt 14mm 14-17 (19-23 Nm) 6
(Crankcase)
Crankcase
3.5
330 ENGINE
PISTON IDENTIFICATION The following components require engine

removal for service:
The piston may have an identification mark or the G Camshaft
piston may not have an identification mark for
piston placement. If the piston has an identification G Connecting Rod
mark, follow the directions for piston placement
G Crankshaft
below. If the piston does not have an identification
mark, the direction for placement of the piston does G Crankshaft Main Bearings
not matter.
G Crankcase
Note the directional and identification marks when
viewing the pistons from the top. The letter “F”, “ ! ENGINE REMOVAL
”, “ "” or : must always be toward the flywheel side
of the engine. The other numbers are used for 1. Clean work area.
identification as to diameter, length and design. Four 2. Thoroughly clean the ATV engine and chassis.
stroke engine rings are rectangular profile. The
3. Disconnect battery negative (-) cable.
numbers or letters on all rings (except oil control rings)
must be positioned upward. See text for oil control 4. Remove the following parts as required.
ring upper rail installation. Use the information below G Seat
to identify pistons and rings. G Left and Right Side Covers (Refer to
Chapter 5)
Engine Oversize Standard G Fuel Tank Cover / Front Cab (Refer to
Model No. Available* Piston
Chapter 5)
(mm) Identification
G Fuel Tank (Refer to Chapter 4)
ES320PFE101 .25 None
5. Disconnect spark plug high tension lead.
.50
6. Disconnect all electrical wires from the engine.
7. Remove springs from exhaust pipe and remove
*Pistons and rings marked 25 are .25mm (.010I) pipe.
oversized. Pistons and rings marked 50 are .50mm
(.020I) oversized 8. Drain engine oil and disconnect oil lines..
9. Remove airbox.
10. Remove carburetor. Insert a shop towel into the
ACCESSIBLE COMPONENTS carburetor flange to prevent dirt from entering the
intake port.
The following components can be serviced or
11. Loosen auxiliary brake master cylinder mount if
removed with the engine installed in the frame:
necessary for clearance.
G Flywheel 12. Refer to PVT System Chapter 6 to remove outer
clutch cover, drive belt, drive clutch, driven clutch,
G Alternator/Stator and inner cover.
G Starter Motor/Starter Drive 13. Starter motor. Note ground cable location. Mark
positive (+) cable mounting angle and remove
G Cylinder Head cable.
G Cylinder 14. Remove transmission linkage rod(s) from gear
selector and secure out of the way.
G Piston/RIngs
15. Remove engine to chassis ground cable.
G Oil pump 16. Remove all engine mount nuts and / or engine
mount plates.
G Rocker Arms
17. Remove engine through right side of frame.
G Cam Chain and Sprockets
3.6
330 ENGINE
ES320PFE ENGINE ES320PFE ENGINE

INSTALLATION NOTES LUBRICATION -
After the engine is installed in the frame, review this Oil Type . . . . . Polaris Premium 0--40W Synthetic
checklist and perform all steps that apply. (PN 2871281)
General Items Oil Pressure

G Install previously removed Specification
components using new gaskets, (ES320PFE) 71-99 PSI @ 3000 RPM,
seals, and fasteners where Polaris 0--40W Synthetic
applicable. (Oil temp at 122_F -50_C)
G Perform regular checks on fluid Capacity . . . . . Approximately 2 U.S. Quarts (1.9 l)
levels, controls, and all important
areas on the vehicle as outlined in Filter . . . . . . . . . . . . . . . PN 3084963
the daily pre-ride inspection checklist
(refer to Chapter 2). OIl Filter Wrench . . . PV--43527
PVT System
Drain Plug/
G Adjust center distance of drive and Screen Fitting . . . . . . 14 ft. lbs. (19 Nm)
driven clutch. (Chapter 6)
G Adjust clutch offset, alignment, and
belt deflection. (Chapter 6)
OIL PRESSURE TEST
G Clean clutch sheaves thoroughly and ES320PFE
inspect inlet and outlet ducts for
proper routing and sealing. (Chapter WARNING: Oil temperature and pressure can cause
6) serious injury and damage. Wear the proper safety
gear when performing these procedures.
Transmission
1. Remove lower blind plug behind oil filter on
G Inspect transmission operation and
crankcase.
adjust linkage if necessary. Refer to
Chapter 2 and Chapter 8. 2. Insert a 1/8” NPT oil pressure gauge adaptor into
the crankcase and attach gauge.
Exhaust
3. Start engine and allow it to reach operating
G Replace exhaust gaskets. Seal temperature while monitoring gauge indicator.
connections with high temp silicone
sealant. ES320PFE
Oil Pressure at 3000 RPM (Engine Hot):
G Check to be sure all springs are in
Standard: 71-99 PSI
good condition. Minimum: 20 PSI at idle
Engine Break In Period
4 Cycle Engine Break-In Period is defined as the first

NOTE: Use Polaris Premium 0--40W Synthetic
10 hours of engine operation or 2 full tanks of fuel.
Engine Lubricant (PN 2871281).
G Use only Polaris Premium 4 All
Season Synthetic Oil, or API certified
“SH” oil.
G Use fuel with a minimum octane of 87 Blind Plug
(R+M)/2 method.
G Change break-in oil and filter at 20
hours or 500 miles, whichever
comes first.
3.7
330 ENGINE
OIL FLOW -- ES320PFE

Oil Cooler Mounted Thermal Valve
This engine is equipped with a thermostatically
controlled valve that directs oil returning to the engine
through a cooler when the oil is hot. Valve operation
is described below. The chart on Page 3.9 describes
the flow of oil through the engine and oil cooler.
Beginning at the engine sump, the oil flows through a
screen in the bottom of the crankcase into the feed
side of the oil pump. Oil then passes through the
crankcase oil passage to the inlet hose, and on to the
oil cooler thermal valve. The thermal valve directs oil
back to the crankcase if oil temperature is low. If oil
temperature is hot, the thermal valve directs oil
through the oil cooler first, and then back to the
crankcase. After passing through the crankcase
passage, oil is pumped through to the oil filter. If the
oil filter is obstructed, a bypass valve contained in the
filter allows oil to bypass the filter element.
At this point, the oil is diverted in two directions. Oil

is supplied to the camshaft through the right front
cylinder head bolt passage and into the camshaft
through the camshaft journal. The camshaft journals,
cam lobes, and rocker arms are lubricated through
holes in the camshaft. Splashed oil lubricates the cam
chain, sprocket, and valve springs, and drains to the
sump.
The other oil path from the filter leads to the crankcase
main oil passage, which leads to the crankshaft. An
oil seal on the stator plate prevents oil from entering
the stator/flywheel area. Oil travels through the
crankshaft to the crank pin, lubricating the connecting
rod large end bearing directly. Oil also passes through
an oil jet (drilled orifice) in the end of the crank pin to
the PTO end main bearings.
Residual oil from the lubrication of the crankshaft and

connecting rod indirectly lubricates the cylinder wall,
piston, rings, connecting rod small end bearing, piston
pin, cam chain drive sprocket, and Magneto end
crankshaft main bearing.
NOTE: The oil lines are designed for high pressure.
DO NOT SUBSTITUTE. Use only genuine Polaris oil
lines.
3.8
330 ENGINE
ES320PFE OIL COOLER ASSEMBLY

330 Engine
Top Bracket
Screws
U--Clips
Shroud
Lower Bracket Oil Cooler Thermistor
36--44 in.lbs.
(4--5 Nm)
Rubber
Mounts
Fan Motor
Threaded Cooler Hose Oil Flow To and From Cooler
OIL FLOW DIAGRAM - ES320PFE
Small End Piston Chain Room

Bearing
Rocker Arm /
Oil Jet Rocker Shaft /
Cylinder Sleeve (Fixed) Sprocket /
Chain
Connecting Rod Indirect
Cam Shaft
Main Bearing Lubrication
Journal
Large End Cam Lobe Cam Shaft Through Front Right

Bearing Journal Cylinder Head Bolt
Passage
Oil Passage In
Cylinder
Crank Pin
Crankcase
Oil Passage
Oil Hoses
Crankshaft Crankcase
In
Oil Passage
Bypass Out
Oil Filter
Pressure Relief
Engine Sump
Crankcase
Oil Pickup Oil Passage
Crankcase
Screen Oil Pump Oil Passage Oil Cooler
3.9
330 ENGINE
ES320PFE ENGINE EXPLODED VIEW

Crankcase Cylinder/
Cylinder Head
ES32PF
Crankshaft Valve Train

and Piston
3.10
330 ENGINE
ENGINE REMOVAL 5. Remove cam chain tensioner plug, sealing

washer, spring and pin. CAUTION: The plug is
REFER TO PAGE 3.6 FOR ENGINE under spring tension. Maintain inward pressure
while removing.
REMOVAL / INSTALLATION NOTES. 6. Remove the two 6x25 mm cam chain tensioner
flange bolts.
CAM CHAIN TENSIONER 7. Tap lightly on tensioner body with a soft face
hammer and remove tensioner.
REMOVAL
1. Remove ignition timing inspection plug from recoil
housing.
To position crankshaft at Top Dead Center (TDC)
on compression stroke:
2. Rotate engine slowly in the direction of rotation
watching intake valves open and start to close.
3. Continue to rotate engine slowly, watching
camshaft sprocket marks and the mark in the
timing inspection hole.
Single TDC Mark Aligned

TDC Mark
CAM CHAIN TENSIONER

Rotation
INSPECTION
1. Pull cam chain tensioner plunger outward to the
end of its travel. Inspect teeth on ratchet pawl (A)
Do Not Use and plunger teeth (B)for wear or damage.
Advance Marks
4. Align single (TDC) mark on flywheel with

projection in inspection hole, and the cam
sprocket pin (facing upward) aligned with the
camshaft to crankshaft center line. NOTE: The B
sprocket marks align with gasket surface and the
cam lobes should be pointing down and valves
should have clearance at this point.
2. Push ratchet pawl and hold it. The plunger should

move smoothly in and out of the tensioner body.
3. Release ratchet pawl and push inward on plunger.
It should remain locked in position and not move
Sprocket marks inward.
align with gasket
surface
3.11
330 ENGINE
4. Measure free length of tensioner spring. Replace 4. Remove cylinder block plug using a 14 mm hex
spring if excessively worn. head wrench.
Cylinder block
plug
Tensioner Spring Free Length: 5. Measure O.D. of rocker shaft. Inspect it for wear
or damage. Compare to specifications.
2.02″ (5.13 cm) Std.
1.92″ (4.88 cm) Limit
5. Replace entire tensioner assembly if any part is

worn or damaged.
ROCKER ARM/SHAFT
INSPECTION
1. Remove rocker cover.
2. Mark or tag rocker arms to keep them in order for
assembly.
Wave
washer
Rocker Shaft O.D.:
.8656-.8661I (21.987-22.0 mm)
Inspect surface
of followers
PTO
3. Inspect each rocker arm cam follower surface. If

there is any damage or uneven wear, replace the
rocker arm. NOTE: Always inspect camshaft
lobe if rocker arms are worn or damaged.
3.12
330 ENGINE
6. Measure I.D. of each rocker arm and compare to CAMSHAFT REMOVAL

specifications.
1. Remove cam shaft end plug (A).
2. Remove camshaft sprocket flange bolt and

Rocker Arm & Support I.D.: washer.
.8669-.8678I (22.020-22.041 mm)
7. Measure I.D. of both rocker arm shaft support

areas and visually inspect surface. Compare to
specifications.
3. Place a clean shop towel in the area below cam

chain sprocket.
Rocker Shaft Oil Clearance:

Std: .0008-.0021I (.020-.054 mm)
Limit: .0039I (.10 mm)
8. Inspect rocker adjuster screws for wear, pitting, or

damage to threads of the adjuster or locknut.
Replace all worn or damaged parts. NOTE: The
end of the adjuster screw is hardened and cannot
be ground or re-faced.
4. Remove sprocket from camshaft and chain.
5. Secure cam chain with a wire to prevent it from
falling into the crankcase.
3.13
330 ENGINE
CAMSHAFT REMOVAL CONT’D

6. Inspect cam sprocket teeth for wear or damage.
Replace if necessary.
Lobe
Inspect for Areas of

Tooth Wear or Damage
2. Remove release lever shaft and return spring

(spacer).
3. Inspect shaft for wear or galling.
7. Remove camshaft. 4. Inspect lobe on end of release lever shaft for wear
and replace if necessary.
AUTOMATIC COMPRESSION
Return spring (spacer)
RELEASE INSTALLATION
1. Slide spring onto shaft.
2. Apply engine oil to release lever shaft.
CAMSHAFT INSPECTION
1. Visually inspect each cam lobe for wear, chafing
or damage.
Dowel pin
Release lever
RELEASE REMOVAL/
Lubrication holes
INSPECTION
Lobe height
NOTE: The automatic compression release
mechanism can be inspected and serviced without
removing the camshaft from the cylinder head. Cam Lobe Height
1. Check release lever shaft for smooth operation Intake
throughout the entire range of rotation. Std: 1.3001-1.3041I (33.023-33.123 mm)
Limit: 1.2883I (32.723 mm)
Exhaust
Std: 1.3007-1.3047I (33.039-33.139 mm)
Limit: 1.2889I (32.739 mm)
3.14
330 ENGINE
2. Thoroughly clean the cam shaft, making sure the CYLINDER HEAD REMOVAL
oil feed holes are not obstructed.
3. Measure height of each cam lobe using a 1. Loosen each of the four cylinder head bolts
micrometer. Compare to specifications. evenly 1/8 turn each time in a cross pattern until
4. Measure camshaft journal outside diameter loose.
(O.D.)
Journal O.D.
A
Journal
2. Remove bolts (A) and tap cylinder head lightly

with a plastic hammer until loose. CAUTION:
Camshaft Journal O.D.: Tap only in reinforced areas or on thick parts of
Mag & PTO End: 1.4935-1.4941I cylinder head casting to avoid damaging casting.
(37.935-37.950 mm) 3. Remove cylinder head and head gasket.
5. Measure ID of camshaft journal bore.
Camshaft Journal I.D.:

Mag & PTO End: 1.4963-1.4970I
(38.005-38.025 mm)
6. Calculate oil clearance by subtracting journal OD

from journal bore ID. Compare to specifications.
Camshaft Oil Clearance:

Std: .0022-.0035I (.055-.090 mm)
Limit: .0039I (.10 mm)
CYLINDER HEAD
Replace camshaft if damaged or if any part is worn
past the service limit.
INSPECTION
1. Thoroughly clean cylinder head surface to
Replace cylinder head if camshaft journal bore is
remove all traces of gasket material and carbon.
damaged or worn excessively.
CAUTION: Use care not to damage sealing
surface.
3.15
330 ENGINE
CYLINDER HEAD WARPAGE 2. Remove spring retainer and spring.
1. Lay a straight edge across the surface of the

cylinder. head at several different points and A
measure warpage by inserting a feeler gauge
between the straight edge and the cylinder head
surface. If warpage exceeds the service limit,
replace the cylinder head.
NOTE: The valve springs should be positioned with

the tightly wound coils against the cylinder head on
progressively wound springs (A).
3. Push valve out, keeping it in order for reassembly
in the same guide.
4. Measure free length of spring with a Vernier
caliper, Ill.1. Check spring for squareness as
Cylinder Head Warpage Limit: shown in Ill.2. Compare to specifications.
Replace spring if either measurement is out of
specification.
.002” (.05mm)
CYLINDER HEAD
DISASSEMBLY Valve Spring
Free Length
WARNING: Wear eye protection or a face shield
during cylinder head disassembly and reassembly.
NOTE: Keep all parts in order with respect to their Ill.1
location in the cylinder head.
1. Using a valve spring compressor, compress the
valve spring and remove the split keeper. NOTE: Coil Fatigue/
To prevent loss of tension, do not compress the Squareness
valve spring more than necessary.
Ill.2
Valve Spring Length:

Std: 1.673I (42.5 mm)
Squareness:
.075I (1.9 mm)
3.16
330 ENGINE
5. Remove valve seals. CAUTION: Replace seals

whenever the cylinder head is disassembled.
Hardened, cracked or worn valve seals will cause
excessive oil consumption and carbon buildup.
4. Inspect split keeper groove for wear or flaring of

the keeper seat area (B). NOTE: The valves
cannot be re-faced or end ground. They must be
replaced if worn, bent, or damaged.
5. Measure diameter of valve stem with a
VALVE INSPECTION micrometer in three places and in two different
directions (six measurements total). Compare to
1. Remove all carbon from valve with a soft wire specifications.
wheel.
2. Check valve face for runout, pitting, and burnt
spots. To check for bent valve stems, mount
valve in a drill or use “V” blocks and a dial
indicator.
Measure valve stem in
several places.
Valve Stem Diameter:

3. Check end of valve stem for flaring, pitting, wear Intake: .2343-.2348I (5.950-5.965 mm)
or damage (A). Exhaust: .2341-.2346I (5.945-5.960 mm)
3.17
330 ENGINE
VALVE INSPECTION CONT’D. NOTE: Valve seat width and point of contact on the
6. Measure valve guide inside diameter at the top valve face is very important for proper sealing. The
middle and end of the guide using a small hole valve must contact the valve seat over the entire
gauge and a micrometer. Measure in two circumference of the seat, and the seat must be the
directions, front to back and side to side. proper width all the way around. If the seat is uneven,
compression leakage will result. If the seat is too
wide, seat pressure is reduced, causing carbon
accumulation and possible compression loss. If the
seat is too narrow, heat transfer from valve to seat is
reduced and the valve may overheat and warp,
resulting in burnt valves.
9. Once thoroughly heated, place cylinder head on
blocks of wood which will allow the old guides to
be removed.
10. Using valve guide driver, drive guides out of the
cylinder head from the combustion chamber side.
Be careful not to damage guide bore or valve seat
when removing guides.
11. Place cylinder head on cylinder head table.
7. Subtract valve stem measurement to obtain stem NOTE: Be sure cylinder head is still at 212° F
to guide clearance. NOTE: Be sure to measure (100° C) before installing new guides.
each guide and valve combination individually. 12. Place a new guide in the valve guide installation
8. Replace valve and/or guide if clearance is tool and press guide in to proper depth. Check
excessive. Compare to specifications. height of each guide above the cylinder head (A).
Refer to specifications.
NOTE: The guide can also be driven in to the
Valve Guide I.D.: proper depth. Inspect the guide closely for cracks
.2362-.2367I (6.0-6.012 mm) or damage if a driver is used.
NOTE: If valve guides are replaced, valve seats must

be reconditioned. Refer to Valve Seat Reconditioning
for procedure.
A
COMBUSTION CHAMBER
Clean all accumulated carbon deposits from
combustion chamber and valve seat area with a soft
wire brush.
Valve Guide Installed Height
Valve Guide Height:

.681-.689I (17.3-17.5 mm)
3.18
330 ENGINE
13. Clean cylinder head, valves, and camshaft oil CYLINDER HEAD ASSEMBLY CONT’D
supply passage (A) thoroughly. 5. Dip valve spring and retainer in clean engine oil
and install spring with closely spaced coils toward
the cylinder head.
Closely spaced
coils toward
cylinder head
14. Spray electrical contact cleaner into oil passage 6. Place retainer on spring and install valve spring
and dry using compressed air. compressor. Compress spring only enough to
allow split keeper installation to prevent loss of
spring tension. Install split keepers with the gap
CYLINDER HEAD ASSEMBLY even on both sides.
CAUTION: Wear eye protection during assembly.
NOTE: Assemble the valves one at a time to maintain

proper order.
1. Install new valve seals on valve guides.
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.
2. Apply engine oil to valve guides and seats.

VALVE SEALING TEST
3. Coat valve stem with molybdenum disulfide 1. Clean and dry the combustion chamber area.
grease. 2. Pour a small amount of clean solvent into the
4. Install valve carefully with a rotating motion to intake port and check for leakage around each
avoid damaging valve seal. intake valve. The valve seats should hold fluid
with no seepage.
3. Repeat for exhaust valves by pouring fluid into
exhaust port.
3.19
330 ENGINE
ENGINE BOTTOM END PISTON REMOVAL

DISASSEMBLY 1. Remove circlip. Note that opening for circlip
access is on the intake side.
Cylinder Removal
Follow engine disassembly procedures to remove
valve cover, camshaft and rocker arms, and cylinder
head.
1. Remove cam chain guide at front of cylinder.
2. Remove the two 6 mm cylinder base bolts.
2. Remove piston circlip and push piston pin out of

piston. If necessary, heat the crown of the piston
slightly with a propane torch. CAUTION: Do not
apply heat to the piston rings. The ring may lose
radial tension.
3. Remove top compression ring.
3. Tap cylinder lightly with a plastic hammer in the
reinforced areas only until loose.
*Using a piston ring pliers: Carefully expand ring

4. Rock cylinder forward and backward and lift it and lift it off the piston. CAUTION: Do not expand the
from the crankcase, supporting piston and ring more than the amount necessary to remove it
connecting rod. Support piston with Piston from the piston, or the ring may break.
Support Block (PN 2870390). *By hand: Placing both thumbs as shown, spread the
5. Remove dowel pins from crankcase. ring open and push up on the opposite side. Do not
scratch the ring lands.
4. Repeat procedure for second ring.
The oil control ring is a three piece design consisting
of a top and bottom steel rail and a center expander
section.
3.20
330 ENGINE
5. Remove the top rail first followed by the bottom CYLINDER INSPECTION CONT’D
rail. 5. Record measurements. If cylinder is tapered or
6. Remove the expander. out of round beyond .002, the cylinder must be
re-bored oversize, or replaced.
CYLINDER INSPECTION
Cylinder Taper
1. Remove all gasket material from the cylinder Limit: .002 Max.
sealing surfaces. Cylinder Out of Round
2. Inspect the top of the cylinder for warpage using a Limit: .002 Max.
straight edge and feeler gauge.
Cylinder Standard Bore Size:
3.0906-3.0913I (78.50-78.520 mm)
PISTON INSPECTION
1. Measure piston outside diameter at a point 5 mm
up from the bottom of the piston at a right angle to
the direction of the piston pin.
Cylinder Warpage:
5 mm
002″ (.05 mm) MAX
3. Inspect cylinder for wear, scratches, or damage.

4. Inspect cylinder for taper and out of round with a Piston
telescoping gauge or a dial bore gauge. Measure
in two different directions, front to back and side to Piston Pin
side, on three different levels (1/2″ down from top,
in the middle, and 1/2″ up from bottom).
2. Subtract this measurement from the maximum

1/2″ Down From Top of Cylinder cylinder measurement obtained in Step 5.
X Y
Piston to Cylinder Clearance
Std: .0015-.0032I (.038-.082 mm)

Limit: .004I (.11 mm)
Y
Piston O.D.:
X
Std: 3.0881-3.0891I (78.438-77.462 mm)
Y
X
1/2″ Up From Bottom
3.21
330 ENGINE
3. Measure piston pin bore. 5. Measure connecting rod small end ID.
Piston Pin Bore:

Connecting Rod Small End I.D.
.7095-.7097I (18.007-18.013 mm)
.7095-.7101I (18.007-18.023 mm)
6. Measure piston ring to groove clearance by

4. Measure piston pin O.D. Replace piston and/or placing the ring in the ring land and measuring
piston pin if out of tolerance. with a thickness gauge. Replace piston and rings
if ring-to-groove clearance exceeds service
limits.
Ring to groove clearance

Piston
Ring
Piston Pin Measurement Locations Feeler Gauge
Piston Pin O.D.
.7092-.7095I (18.001-18.007 mm) Piston Ring-to-Groove Clearance
Top Ring Std: .0014-.0030I (.035-.075 mm)

Limit: .0059I (.15 mm)
Second Ring Std: .0010-.0026I (.025-.065
mm)
Limit: .0059I (.15 mm)
3.22
330 ENGINE
PISTON RING INSTALLED STARTER DRIVE

GAP REMOVAL/INSPECTION
1. Place each piston ring inside cylinder using piston 1. Remove recoil housing bolts and remove
to push ring squarely into place as shown. housing.
Piston ring end gap installed
Feeler Gauge
Cylinder
25-50mm
Piston Ring
2. Measure installed gap with a feeler gauge at both 2. Remove starter drive assembly. Note the thrust
the top and bottom of the cylinder. washer located at the rear of the drive
NOTE: A difference in end gap indicates cylinder mechanism.
taper. The cylinder should be measured for 3. Inspect the thrust washer for wear or damage and
excessive taper and out of round. replace if necessary.
3. If the bottom installed gap measurement exceeds 4. Measure the OD of the starter drive shaft on both
the service limit, replace the rings. ends and record.
NOTE: Always check piston ring installed gap after
re-boring a cylinder or when installing new rings. A Std. Bushing ID:
re-bored cylinder should always be scrubbed .4735″-.4740″ (11.11-12.04 mm)
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with an oil rag Std. Shaft OD:
immediately to remove residue and prevent rust. .470″-.472″ (11.93-11.99 mm)
Piston Ring Installed Gap 5. Measure the ID of the bushing in the recoil
housing (A) and in the crankcase and record.
Top Ring Measure in two directions 90° apart to determine
Std: .0079-.0118I (.20-.36 mm) if bushing is out of round. Calculate bushing
Limit: .039I (1.0 mm) clearance. Replace bushing if clearance exceeds
Second Ring the service limit.
Std: .0138-.0197I (.35-.50 mm)
Limit: .039I (1.0 mm)
Oil Ring
Std: .0079-.0236I (.20-.70 mm) A
Limit: .059I (1.5 mm)
CRANKCASE DISASSEMBLY
NOTE: The recoil starter, starter motor, starter drive,
flywheel, stator, cam chain and sprockets can be
serviced with the engine in the frame.
3.23
330 ENGINE
5. Replace crankshaft seal.

Starter Drive Bushing Clearance:
6. Remove large sealing O-Ring from outer edge of
Std: .0015″-.004″ (.038-.102 mm)
stator plate.
Service Limit:
008″ (.203 mm) CAM CHAIN/TENSIONER
BLADE
6. Inspect gear teeth on starter drive. Replace
1. Remove bolt securing tensioner blade to
starter drive if gear teeth are cracked, worn, or
crankcase (A).
broken.
FLYWHEEL/STATOR
REMOVAL/INSPECTION A
1. Remove flywheel nut and washer.
2. Remove blade and inspect for cracks, wear, or

damage.
3. Remove cam chain. 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 section of chain.
2. Install Flywheel Puller (PN 2871043) and remove Replace if worn past service limit.
flywheel. CAUTION: Do not thread the puller
bolts into the flywheel more than 1/4″ or stator
coils may be damaged.
3. Mark or note position of stator plate on crankcase. Measure 20
Pitch Length
Chain Service Limit:

5.407″ (13.7 cm)
4. Remove bolts and carefully remove stator

assembly, being careful not to damage crankshaft
bushing on stator plate.
3.24
330 ENGINE
DRIVE SPROCKET REMOVAL PRESSURE RELIEF VALVE

/ INSPECTION The pressure relief valve opens to relieve any excess
1. Using the Slotted Nut Socket (PN 2871293), pressure from the oil pump if oil pressure reaches
remove the crankshaft slotted nut (A). NOTE: approximately 71 psi. It must be clean and have
The slotted nut is a left hand thread. adequate spring pressure in order to seal properly.
1. Remove cap bolt, sealing washer, spring, and
relief valve from MAG side crankcase.
B
Remove
2. Remove cam chain drive sprocket (B) and

Woodruff key from crankshaft.
3. Inspect sprocket teeth for wear or damage. 2. Inspect free length of spring and check coils for
distortion.
Relief Valve Spring Free Length:
Std: 2.175″ (5.52 cm)
3. Inspect valve for wear.

4. Check seat area for nicks or foreign material that
Inspect for Areas of may prevent proper sealing of valve.
Tooth Wear or Damage
OIL PUMP
REMOVAL/INSPECTION
4. Inspect Woodruff key for wear. 1. Remove the five screws on the oil pump cover
5. Replace any worn or damaged parts. with an impact driver.
2. Inspect rotors and mating surface of oil pump
cover. Check for nicks, burrs, or surface
irregularities.
Slotted Nut Socket
3. Measure pump end clearance using a feeler
(PN 2871293) gauge and straight edge.
3.25
330 ENGINE
5. Measure rotor tip clearance with a feeler gauge.
Outer Feed Rotor to Crankcase Clearance:
Std: .001-.003 (.0254-.0762 mm) Rotor Tip Clearance:
Wear Limit: .004 (.1016 mm) Std: .005 (.127 mm)
4. Measure clearance between outer feed rotor and Wear Limit: .008 (.2032 mm)
crankcase pocket with a feeler gauge.
OIL PUMP ASSEMBLY

1. Clean and dry all parts thoroughly. Apply clean
engine oil to all parts. Do not use gasket sealer on
the pump cover mating surfaces or clearances
will be incorrect, and oil passages may become
plugged.
2. Install outer feed rotor and inner feed rotor drive
pin.
3. Install inner feed rotor and feed chamber cover
with screw.
4. Tighten screw securely.
5. Install oil pump on crankcase and torque bolts to 6
ft. lbs. (8 Nm).
Pump End Clearance:
Oil Pump Attaching Bolt Torque:
Std: .001-.003 (.0254-.0762 mm) 6 ft. lbs. (8 Nm)
Wear Limit: .004 (.1016 mm)
CRANKCASE SEPARATION
1. Remove flange bolts (11) from magneto side
crankcase evenly in a criss-cross pattern.
3.26
330 ENGINE
2. Use a feeler gauge to measure the connecting rod

big end side clearance.
2. Separate crankcase by tapping with a soft faced

hammer in reinforced areas.
3. Watch the gap along the crankcase mating Connecting Rod Big End Side Clearance:
surface and separate the crankcase evenly.
4. Remove the Mag (RH) crankcase from the PTO Std: .0028-.0118 (0.07-0.30 mm)
case.
Limit: .0138 (.35 mm)
CRANKSHAFT
3. If the clearance exceeds the service limit, either
REMOVAL/INSPECTION the crankshaft, connecting rod or both need to be
replaced. Refer to Steps 1 & 2 under crankshaft
1. Support the MAG side crankcase and crankshaft;
inspection to determine which part(s) are outside
press the crankshaft out. Be careful not to
of specifications.
damage the crankcase mating surface or
connecting rod. NOTE: Markings on connecting rod and cap that
must be aligned for assembly. If marks are not clearly
visible, mark the rod and cap with a permanent
marker.
4. Remove the connecting rod nuts and connecting
rod bearing cap.
NOTE: It may be necessary to lightly tap on the side
of the cap with a plastic mallet to loosen it.
CRANKSHAFT INSPECTION
1. Measure the width of the rod bearing journal.
3.27
330 ENGINE
2. Measure the width of the connecting rod at the big CRANKSHAFT

end.
MAIN BEARING INSPECTION
Connecting Rod Width: 1. Inspect the crankshaft main bearings.
Std: .8233-.8252I (20.88-20.93 mm) NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. Look for signs of discoloration,
3. Visually inspect bearing journal for scoring, scoring or galling. Turn the outer race of each bearing.
damage or excessive wear. Replace crankshaft if The bearings should turn smoothly and quietly. The
it fails visual inspection. inner race of each bearing should fit tightly in the
crankshaft. The outer race should be firm with
4. Measure the O.D. of the crankshaft rod journal in
minimal side to side movement and no detectable up
four places and in two directions away from the oil
and down movement.
hole. Replace the crankshaft if it measures below
the service limit, or if the journal is out of round. 2. Replace bearings if they fail visual inspection.
CONNECTING ROD BEARING

INSPECTION
1. Inspect bearing inserts for unusual wear, peeling,
scoring, damage etc. Replace as necessary.
NOTE: If one insert requires replacement, replace
both connecting rod bearing inserts as a set.
CONNECTING ROD BEARING

CLEARANCE INSPECTION
1. Clean all oil from bearing inserts and crank pin.
2. Place a strip of Plastigauge® across the complete
width of the crank pin.
Rod Bearing Journal O.D.: 3. Install the connecting rod and bearing cap in the
correct orientation.
Std: 1.6531-1.6535I (41.989-42.000 mm)
4. Torque the rod nuts to specification.
Rod Nut Torque:

5. Check oil passage to make sure it is clear.
29-33 ft. lbs. (39-45 Nm)
Oil passage 5. Remove the bearing cap being careful not to

disturb the Plastigauge®.
6. Use the measuring scale on the Plastigauge®
wrapper to measure the thickness of the
Plastigauge®. The rod must not turn during
this procedure.
3.28
330 ENGINE
CRANKCASE INSPECTION
1. Remove all traces of gasket sealer from the
crankcase mating surfaces. Inspect the surfaces
closely for nicks, burrs or damage.
BEARING INSTALLATION
NOTE: To ease crankshaft bearing installation, warm
the crankcase until hot to the touch. Place the bearing
in a freezer.
1. Install the crankshaft bearing so the numbers are
visible.
2. Drive or press the new bearing into the
crankcase, using the proper driver. CAUTION:
NOTE: Use the widest part of the Plastigauge® to Press only on outer race of bearing to prevent
determine the oil clearance. bearing damage.
G Use a 70mm (2.755″) driver- For
Connecting Rod To Crankshaft Clearance: crankshaft main bearings.
Std: .0007-.0021 (.019-.053 mm) END PLAY

Limit: .0026 (.065 mm) INSPECTION/ADJUSTMENT
7. If oil clearance is not within specification, install Before reassembling the crankcase,the following
new rod bearings and recheck the oil clearance. steps should be performed to determine the amount
of crankshaft end play. Excessive end play may
8. If service limit is still exceeded, determine if the cause engine noise at idle and slow speeds. Too little
crankshaft or connecting rod needs to be play will side load the bearings which may lead to
replaced per Crankshaft Inspection and premature bearing failure.
Connecting Rod Inspection.
9. At completion of measurement procedure; Crankshaft End Play Adjustment
remove all traces of Plastigauge® from bearing 1. Make sure crankshaft bearing is firmly seated in
and crankshaft. the MAG side crankcase.
CRANKCASE BEARING
INSPECTION
1. Inspect the crankshaft main bearing in the MAG
side crankcase.
NOTE: Due to extremely close tolerances and
minimal side wear, the bearing must be inspected
visually and by feel. Look for signs of discoloration,
scoring or galling. Turn the inner race of bearing. The
bearing should turn smoothly and quietly. The outer
race should fit tightly in the crankcase. The inner race
should be firm with minimal side to side movement
and no detectable up and down movement.
2. To remove crankshaft bearing, use a blind hole
bearing puller.
NOTE: Bearings are stressed during the removal
procedure and should not be re-used
3.29
330 ENGINE
2. Measure the distance from the MAG side 4. Measure the width of the crankshaft at the
crankcase mating surface to the main bearing bearing seats or, if PTO bearings are installed, the
using a dial caliper and a straight edge. width from MAG side bearing seat to the outside
race of the PTO bearings with a micrometer or dial
caliper and record.
NOTE: If PTO bearings are not installed,

3. Subtract the thickness of the straightedge from measure the width of the bearings and add to
the measurement obtained in Step 2 and record. crankshaft width.
Repeat Step 2 and 3 for the PTO case. If PTO
bearings are not installed in the crankcase,
measure to the bearing seat in the case. Crankshaft Width
5. Subtract the Crankshaft Width measured in Step

4 from the Total Case Width recorded in Step 3,
and record below.
Total End Play

6. Subtract the thickness of the existing shim from
the result of Step 5 to determine if a different shim
is required. The result must be within the
specified range listed below. Increase or
decrease shim thickness as required to bring end
play within range.
MAG Case Depth
+ PTO Case Depth____________________
= Total Case Width____________________
Crankshaft End Play:
008″-.016″ (.02-.04 cm)
3.30
330 ENGINE
ENGINE ASSEMBLY/ CRANKSHAFT

CONNECTING ROD INSTALLATION
INSTALLATION Lubricate all bearings with clean engine oil before
1. Clean all oil off connecting rod, connecting rod assembly.
cap and bearing inserts. 1. Install the crankshaft into the PTO side
2. Install bearing inserts onto connecting rod and crankcase.
cap. 2. Install the proper shim on the magneto end of the
NOTE: First, install bearing tab into groove, then crankshaft.
press the rest of the bearing into place.
3. Apply assembly lube onto the connecting rod CRANKCASE OIL STRAINER
bearings and crank pin. INSPECTION
4. Install rod and cap onto the crankshaft. Ensure
that I.D. marks are aligned. 1. Remove bolt securing oil strainer to the MAG side
crankcase.
2. Remove oil strainer and visually inspect for any
rips, tears or obstructions in screen.
3. Replace oil strainer if it fails visual inspection.
CRANKCASE REASSEMBLY
1. Apply Crankcase Sealant (PN 2871557) to the
crankcase mating surfaces. Be sure the
alignment pins are in place.
Marks 2. Set the crankcase in position carefully. Mate the
crankcase halves by tapping lightly with a soft
faced hammer. Continually check alignment of
the cases during installation, closing the gap
equally until the surfaces are tightly sealed.
NOTE: Procedure during disassembly called for 3. Install the crankcase flange bolts and tighten to
marking of connecting rod and cap. Ensure that each specified torque in 3 steps according to the torque
part is installed in its original location by noting the pattern. See Page 3.2.
marks placed on the parts during disassembly.
5. Tighten rod cap nuts to 1/2 torque specification,
Crankcase Bolt Torque:
then full torque.
14-15 ft. lbs. (19-21 Nm)
Rod Nut Torque:
29-33 ft. lbs. (39-45 Nm)

Crankcase Sealant (3 Bond):
(PN 2871557)
6. Verify that the connecting rod is free to rotate on
the crankshaft journal.
OIL PUMP INSTALLATION
1. Inspect the oil pump sealing surface on the
crankcase. Apply a light film of engine oil to the
surfaces. Install outer and inner rotors over
crankshaft .
3.31
330 ENGINE
2. Install oil pump cover. Torque screws to specified TENSIONER BLADE

torque.
INSTALLATION
Oil Pump Cover Screw Torque: 1. Install the tensioner blade and tighten the
mounting bolt to specified torque.
4-5 ft. lbs. (5-7 Nm)
NOTE: Do not use gasket sealer on the pump mating Tensioner Blade Mounting Bolt Torque:
surfaces.
5-6.5 ft. lbs. (7-9 Nm)
OIL RELIEF VALVE

INSTALLATION OIL FILTER INSTALLATION
Install the oil relief valve, spring, and plug using a new 1. Apply clean engine oil to oil filter gasket. Install
sealing washer. filter until gasket lightly touches seat and then
tighten an additional 3/4 of a turn.
Oil Filter Connector Torque:
36-43 ft. lbs. (49-59 Nm)
PISTON RING INSTALLATION

NOTE: Apply clean engine oil to all ring surfaces and
ring lands. Always check piston ring installed gap
Oil Relief Valve Plug Torque: before rings are installed on piston. See Page 3.36.
If the piston has been in service clean any
14-17 ft. lbs. (19-23 Nm) accumulated carbon from the ring grooves and oil
control ring holes.
1. Place the oil control ring expander in oil ring
CAM CHAIN DRIVE groove with the end gap facing forward. The
expander has no up or down marking and can be
SPROCKET INSTALLATION installed either way. The ends should butt
1. Install the Woodruff key, drive sprocket, and squarely together and must not overlap.
slotted nut. Using the Slotted Nut Socket (PN 2. Install the oil ring top rail with the end gap at least
2871293), tighten the nut to the specified torque. 30° from the end of the expander.
3. Install the bottom rail with the gap at least 30°
from the end of the expander on the side opposite
B the top rail gap.
Tighten
Slotted Nut Torque:
35-51 ft. lbs. (47-69 Nm)
3.32
330 ENGINE
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) and
Ring Profile crankshaft main bearing area.
5. Install the piston on the connecting rod with
the pin casting notch facing the rear of engine
(starter side). The piston pin should be a
push fit in the piston.
Top
“R1” Mark up
Second
“R” Mark up
6. Install the other circlip with the gap facing up or
down. (See Caution with Step 3 above). Push the
4. Install the second ring with the “R” mark facing up. piston pin in both directions to make sure the clips
Position the end gap toward the rear (intake) side are properly seated in the groove.
of the piston.
7. Place the dowel pins in the crankcase and install a
5. Install the top ring (chrome faced) with the “R1” new cylinder base gasket.
mark facing up and the end gap facing forward
8. Lubricate the piston and rings with assembly lube
(toward the exhaust).
and install a sleeve--type ring compressor on the
6. Check to make sure the rings rotate freely in the piston assembly. Verify that the ring gaps are 120
groove when compressed. degrees apart from each other before installation.
PISTON INSTALLATION CYLINDER INSTALLATION

1. Clean the gasket surfaces on the cylinder and 1. Position the Piston Support Block (PN 2870390)
crankcase. Remove all traces of old gasket (A) beneath the piston skirt to support the piston
material. during cylinder installation.
2. Make sure the cylinder mounting bolt holes are
clean and free of debris.
3. Install a new circlip on one side of the piston with
the end gap facing up or down. A
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.
3.33
330 ENGINE
2. Apply clean engine oil liberally to the cylinder bore

and tapered area of the sleeve. Install the
Torque in cross
cylinder with a slight rocking motion until the rings pattern per procedure
are captive in the sleeve.
3. Remove the ring compressor and support block.

4. Push the cylinder downward until fully seated on
Torque
the base gasket.
5-6.5 ft. lbs.
NOTE: If cam chain is installed, hold it up while (7--9 Nm)
rotating the engine to avoid damage to the chain, drive
sprocket teeth, or tensioner blade. Torque all bolts evenly in a cross
5. Install the two 6 mm bolts, but do not tighten. pattern. Apply oil to bolt threads
*Torque bolts to 18 ft. lbs. (24.5 Nm)

CYLINDER HEAD
INSTALLATION *Loosen bolts evenly 180° (1/2 turn)
Clean the gasket surfaces on the cylinder head and *Torque bolts to 11 ft. lbs. (14.7 Nm)
cylinder. Remove all traces of old gasket material.
*From this point, tighten bolts evenly
1. Install the cam chain tensioner guide. Be sure 90° (1/4 turn)
bottom end of guide is located properly in
crankcase. *Finally, tighten another 60° (1/6 turn)
2. Install the two dowel pins and a new cylinder head
gasket. Torque 6mm case bolts to 5--6.5 ft. lbs.
3. Place the cylinder head on the cylinder. Apply a ( 7--9 Nm )
film of engine oil to the cylinder head bolt threads
and washers, and hand tighten the bolts.
4. The following procedure must be used to torque CAM CHAIN/CAMSHAFT
the cylinder head properly:
INSTALLATION
CAUTION: Serious engine damage may result if
the camshaft is not properly timed to the
crankshaft.
3.34
330 ENGINE
Install the cam chain over the crankshaft. 3. Apply Polaris Low Temp Grease (PN 2870577),
or engine assembly lubricant to the camshaft
main journals and cam lobes. Lubricate
automatic compression release mechanism with
clean engine oil. (To install the compression
Plated release mechanism, refer to Page 3.17).
Link
Plate link
aligned w/dot
Sprocket
Mark
Crankcase
Projection
IMPORTANT CAMSHAFT TIMING NOTE: In order

to time the camshaft to the crankshaft, the piston must
be precisely located at Top Dead Center (TDC). This
can be accomplished using one of two methods:
Method 1 -- When the stator assembly is removed. 4. Install the camshaft with the lobes facing
This method uses the cam chain plate links to time the downward and the sprocket alignment pin facing
camshaft and the dot on the cam chain drive sprocket toward intake.
to establish TDC (see Method 1, Page 3.37). It is 5. Disconnect the wire from the cam chain and
important to note that this method can only be used install the cam sprocket with the dot facing
when the stator is removed and the cam chain drive outward.
sprocket is in view. The plate links are not used to time
the camshaft when the flywheel is installed. 6. Loop the cam chain over the cam sprocket,
aligning the plated link on the chain with the dot on
Method 2 -- When the stator assembly is installed. the sprocket.
This method establishes accurate Top Dead Center 7. Install the sprocket on the camshaft. Apply
(TDC) by aligning the single mark on the flywheel with Loctitet 242 (PN 2871949) to the cam sprocket
the notch in the timing inspection hole (see Method 2, bolt and torque to specifications.
Page 3.38). The camshaft sprocket alignment marks
are parallel to the gasket surface, the alignment pin
faces to the intake side, and camshaft lobes are Cam Sprocket Bolt Torque:
pointing down.
25-29 ft. lbs. (34-40 Nm)
Camshaft Installation - Timing Method 1
Refer to Illustration Page 3.37
8. Check all cam timing marks to verify proper cam
If the stator assembly is removed: NOTE: Use this
timing, and install the cam chain tensioner. See
method only when the stator is removed and cam
Cam Chain Tensioner Installation Page 3.36.
chain drive sprocket is in view.
NOTE: The plate links will not align after engine is
1. Rotate the crankshaft until the mark on the cam rotated.
chain drive sprocket is aligned with the crankcase
projection (mark facing downward).
2. Align the single plated link on the cam chain with
the marked tooth of the cam chain drive sprocket.
Use a wire to pull the chain up through the cylinder
and cylinder head, and secure it to hold the chain
in place.
3.35
330 ENGINE
Camshaft Installation - Timing Method 2

Refer to Page 3.38.
1. Apply Polaris Low Temp Grease (PN 2870577),
or molybdenum disulfide grease to the camshaft
main journals and cam lobes. Lubricate
automatic compression release mechanism with
clean engine oil. (To install the compression
release mechanism, refer to Page 3.18).
2. Install the camshaft with the lobes facing
downward and the sprocket alignment pin facing
toward intake. B
3. Disconnect the wire from the cam chain and A
rotate the engine to align the single (TDC ) timing
mark (Top Dead Center) on the flywheel with the
notch in the timing inspection window. Be sure to
use the single TDC mark when installing the cam. 2. Install the tensioner body with a new gasket and
Do not use the advance marks. tighten the bolts to specification.
4. Loop the cam chain onto the cam sprocket with
the dot on the sprocket facing outward and the
alignment marks parallel with gasket surface. Tensioner Bolt Torque:
5. Before positioning the sprocket on the camshaft,
check the position of the cam sprocket alignment 5-6.5 ft. lbs. (7-9 Nm)
pin. When the cam is positioned properly, the
cam sprocket alignment pin is facing to the intake
side. 3. Install the spring, pin, new sealing washer, and
tensioner plug. Torque plug to specification.
6. Install the sprocket on the camshaft. Apply
Loctitet 242 to the cam sprocket bolt and torque
to specifications.
Cam Sprocket Bolt Torque:
25-29 ft. lbs. (34-40 Nm)

timing, and install the cam chain tensioner body
with a new gasket.
8. After tensioner installation, rotate engine at least
two revolutions and re-check marks/timing.
CAM CHAIN TENSIONER

INSTALLATION Tensioner Plug Torque:
1. Release the ratchet pawl (A) and push the 14-19 ft. lbs. (20-25 Nm)
tensioner plunger (B) all the way into the
tensioner body.
4. Slowly rotate engine two to three revolutions and
re-check cam timing once chain is tight.
3.36
330 ENGINE
CAMSHAFT TIMING - METHOD 1
Method 1 - Camshaft Timing with Stator Removed

Crankshaft to Camshaft Centerline
Single Plated Sprocket marks aligned with
Link and Dot on gasket surface at TDC on
Cam Sprocket compression stroke (cam
lobes facing downward)
Single Plated
Link and
Rectangular
Mark Crankcase Projection
on Cam
Chain Drive
Sprocket NOTE: Plated links will not align after engine is rotated.
3.37
330 ENGINE
CAMSHAFT TIMING - METHOD 2
Method 2 - Camshaft Timing Using Flywheel TDC Mark

Do not use dot on sprocket
for cam timing
Decompressor arm stop pin UP

(Cam lobes DOWN)
Sprocket marks aligned with

gasket surface at TDC on
compression stroke (cam
lobes facing downward, de-
compressor arm stop pin UP)
Single TDC Mark Aligned Do Not Use

TDC Mark Advance Marks
For Cam Timing
Rotation
Do Not Use
Advance Marks
Cam Timing
(View through timing inspection hole)
Position crankshaft at TDC
3.38
330 ENGINE
STATOR INSTALLATION STARTER DRIVE ASSEMBLY

NOTE: The stator, flywheel, starter drive, and recoil 1. Be sure the washer is positioned on the back of
can be assembled with the engine in the frame. the drive gear.
Stator
1. Apply a light film of grease to the crankshaft seal.
Apply molybdenum disulfide grease or assembly
lubricant to the crankshaft bushing.
Timing Marks
Starter Drive Grease:
(PN 2871460)
2. Apply Starter Drive Grease (PN 2871460) to the

drive bushing in the crankcase and all moving
2. Apply Crankcase Sealant (PN 2871557) to the surfaces of the starter drive mechanism. Install
stator plate outer surface and install a new the starter drive.
O-Ring.
3. Install the stator plate being careful not to damage
the seal. Align timing reference marks on the
plate and crankcase. Be sure the plate is fully
seated.
NOTE: This is a static timing mark. Strobe timing
should be performed after start up.
4. Torque bolts evenly to specification.
Stator Plate Bolt Torque:
5-6.5 ft. lbs. (7-9 Nm)
5. Seal stator wire grommet with Crankcase Sealant

(PN 2871557).
3. Install recoil housing gasket and recoil housing.
FLYWHEEL INSTALLATION
1. Install flywheel, washer, and nut. Torque flywheel
to specification.
Flywheel Nut Torque:
58-72 ft. lbs. (78-98 Nm)
3.39
330 ENGINE
ROCKER SHAFT/ARM INTAKE VALVE CLEARANCE

INSTALLATION ADJUSTMENT
1. Assemble rocker arms, rocker shaft and wave 1. Insert a .006″ (.15mm) feeler gauge between end
washer into rocker cover. of intake valve stem and clearance adjuster
2. Install and tighten rocker shaft block plug. screw.
3. Apply engine assembly lube to the cam lobes and 2. Using Valve/Clutch Adjuster Tool (PN
cam follower surfaces. PA--44689), loosen adjuster lock nut and turn
adjusting knob until there is a slight drag on the
4. Rotate the engine until the cam lobes are pointing
feeler gauge.
downward.
5. Apply clean engine oil liberally to the valve
springs, cam chain, rocker arms, and camshaft. 330 Engine
6. Apply Crankcase Sealant (PN 2871557) to the
rocker cover mating surfaces. Be sure the
7. Install the rocker cover assembly.
8. Install rocker cover bolts and torque to
specifications.
Rocker Cover Bolt Torque:
7-8 ft. lbs. (9-11 Nm)

Valve Adjuster Tool: PA--44689
9. Adjust valves according to the “INTAKE VALVE
CLEARANCE ADJUSTMENT” procedure. 3. Hold adjuster screw and tighten adjuster lock nut
securely.
10. Install rocker cover block plug.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until
Rocker Cover Block Plug Torque: clearance is correct with locknut secured.
39-44 ft. lbs. (53-59 Nm)

EXHAUST VALVE
11. Install valve adjustment caps with new o-rings. CLEARANCE ADJUSTMENT
Tighten securely.
12. Apply downward pressure on the reel and rotate 1. Insert .006″ feeler gauge(s) between end of
counterclockwise approximately 6-7 turns to exhaust valve stem and adjuster screw(s).
pre-wind the spring. Continue rotating 2. Loosen locknut(s) and turn adjuster screw(s) until
counterclockwise until rope on outer edge aligns there is a slight drag on feeler gauge(s).
with rope guide bushing.
NOTE: The ATP 330 exhaust valve is adjusted the
13. Release rope from notch and allow reel to rewind same as the intake valve. The Valve/Clutch Adjuster
completely. If more pre-wind is required, place rope Tool (PN PA--44689) can be used to adjust the 330
in notch and add additional turns of pre-wind. engines valves.
14. Install ratchet pawl and return spring, with long leg
of spring engaged in reel.
and tighten locknut securely
15. Reinstall friction plate.
NOTE: The friction plate must be positioned with
both end tabs of the friction spring opposite the 5. Repeat adjustment procedure if necessary until
ratchet pawl. clearance is correct with locknut secured.
16. Torque friction plate retaining bolt to 5-6 ft. lbs.
(7-9 Nm).
17. Reinstall recoil housing using a new gasket. Seal
stator wire harness grommet with RTV silicone.
3.40
330 ENGINE

330 Engines
.006″ (.15 mm)
6. 330: Inspect o-rings on the plastic valve plugs,

replace if damaged. Securely fasten valve plugs.
7. Scrape gasket surfaces to remove all traces of
the old gasket.
8. Remove the shop towel from the spark plug
cavity.
9. Install the spark plug. Torque to 14 ft. lbs. (19
Nm).
10. Install the spark plug high tension lead.
11. Install parts removed for access.
330 Engine
Spark Plug Torque: 14 ft. lbs. (19 Nm)
3.41
330 ENGINE
NOTES
3.42
500 ENGINE
EH500PLE
ENGINE SECTION
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3.46--3.48

Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
Engine Fastener Torque Pattern . . . . . . . . . . . . . . 3.49
Engine Removal/Installation Notes . . . . . . . . . . . . 3.49-3.50
EH500PLE Engine Lubrication . . . . . . . . . . . . . . . . 3.50--3.51
EH500PLE Oil Pump Priming Procedure . . . . . . . 3.51
Cooling System Pressure Test . . . . . . . . . . . . . . . . 3.51
Cooling System Specifications . . . . . . . . . . . . . . . . 3.51--3.52
EH500PLE Lubrication/Oil Flow . . . . . . . . . . . . . . . 3.54-3.55
EH500PLE Engine Exploded Views . . . . . . . . . . . . 3.56
EH500PLE Engine Top End Disassembly . . . . . . 3.57-3.66
EH500PLE Cylinder Head Assembly . . . . . . . . . . . 3.66-3.68
EH500PLE Cylinder / Piston Inspection . . . . . . . . 3.69-3.71
EH500PLE Engine Bottom End Disassembly . . . 3.71-3.76
EH500PLE Crankcase & Bearing Inspection . . . . 3.76
EH500PLE Crankshaft End Play Inspection . . . . . 3.77-3.78
EH500PLE Counter Balancer End Play Inspection.3.79
EH500PLE Oil Pump Shaft End Play Inspection . 3.79-3.80
Water Pump Seal Removal / Installation . . . . . . . . 3.81-3.82
EH500PLE Engine Assembly/Inspection . . . . . . . 3.82-3.97
500 Engine
3.43
500 ENGINE
EH500PLE ENGINE SERVICE DATA

Cylinder Head / Valve EH500PLE
Rocker Rocker arm ID .8669-.8678″ (22.020-22.041 mm)
A
Arm Rocker shaft OD .8656-.8661″ (21.987-22.0 mm)
Rocker shaft Oil Std .0008-.0021″ (.020-.054 mm)
Cl
Clearance Limit .0039″ (.10 mm)
Camshaft Cam lobe height
g 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
j OD Mag 1.4935-1.4941″ (37.935-37.950 mm)
PTO 1.4935-1.4941″ (37.935-37.950 mm)
Camshaft journal
j 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 .0022-.0035″ (.055-.090 mm)
Limit .0039″ (.10 mm)
Cylinder
y Surface warpage limit .0020″ (.05 mm)
H d
Head Standard height 3.870″ (98.3 mm)
Valve Seat Contacting
g width In Std .028″ (.7 mm)
Limit .055″ (1.4 mm)
Ex Std .039″ (1.0 mm)
Limit .071″ (1.8 mm)
Valve Inner diameter .2362-.2367″ (6.0-6.012 mm)
G id
Guide Protrusion above head .689-.709″ (17.5-18.0 mm)
Valve Margin
g 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
g In 3.976″ (101.0 mm)
Ex 3.984″ (101.2 mm)
Valve Overall length
g Std 1.654″ (42.0 mm)
S i
Spring Limit 1.575″ (40.0 mm)
Squareness .075″ (1.9 mm)
3.44
500 ENGINE
EH500PLE ENGINE SERVICE DATA

Cylinder / Piston / Connecting Rod EH500PLE
Cylinder Surface warpage limit .0020″ (.05 mm)
(mating with cylinder head)
Cylinder bore Std 3.6221-3.6228″ (92.00-92.02 mm)
Taper limit .0020″ (.050 mm)
Out of round limit .0020″ (.050 mm)
Piston clearance Std .0006-.0018″ (.015-.045 mm)
Limit .0024″ (.060 mm)
Boring limit .020″ (.5 mm)
Piston Outer diameter Std 3.6204-3.6215″ (91.970-91.985 mm)
.0098″ (.25 mm) 3.6304-3.6310″ (92.21-92.23 mm)
OS
.0197″ (.50 mm) 3.6403-3.6407″ (92.46-92.47 mm)
OS
Standard inner diameter of piston pin .9055-.9057″ (23.0-23.006 mm)
bore
Piston Pin Outer diameter .9053-.9055″ (22.994-23.0 mm)
Standard clearance-piston pin to pin .0002-.0003″ (.004-.008 mm)
bore
Degree of fit Piston pin must be a push (by hand) fit at 68° F (20° C)
Piston Piston ringg installed Top p ring
g Std .0079-.0138″ (.20-.36 mm)
Ri
Ring gap Limit .039″ (1.0 mm)
Second Std .0079-.0138″ (.20-.36 mm)
ring
i Limit .039″ (1.0 mm)
Oil ring
g Std .0079-.0276″ (.20-.70 mm)
Limit .059″ (1.5 mm)
Piston Standard clearance Top p ring
g Std .0016-.0031″ (.040-.080 mm)
Ri
Ring piston
i ring--to--ring
i i Limit .0059″ (.15 mm)
groove
Second Std .0012-.0028″ (.030-.070 mm)
ring
i Limit .0059″ (.15 mm)
Connectingg Connecting rod small end ID .9058-.9063″ (23.007-23.020 mm)
R d
Rod Connecting g rod small end Std .0003-.0010″ (.007-.026 mm)
radial
di l clearance
l Limit .0020″ (.05 mm)
Connecting g rod bigg end side Std .0039-.0256″ (.1-.65 mm)
clearance
l Limit .0315″ (.80 mm)
Connecting g rod bigg end Std .0004-.0015″ (.011-.038 mm)
radial
di l clearance
l 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 Side
3.45
500 ENGINE
TORQUE SPECIFICATIONS Water Pump 6mm 5-6.5 (7-9 Nm)

Housing Cover
TORQUE SPECIFICATIONS Stator Plate 6mm 5-6.5 (7-9 Nm)
Fastener Size EH42PLE/ Starter Motor 6mm 5-6.5 (7-9 Nm)
EH50PLE Spark Plug 14mm 9-11 (12-15 Nm)
Ft. Lbs. (Nm)
Thermistor ---- 26 ± 2.1 (35 ± 3
Blind Plug (Oil 1/8 PT 6.5-11 (9-15 Nm) Nm)
Pressure) (28tpi)
Camshaft Sprocket 6mm 5-6.5 (7-9 Nm)
Camshaft Chain 6mm 5-6.5 (7-9 Nm) SPECIAL TOOLS
Tensioner Lever
Camshaft Chain 6mm 5-6.5 (7-9 Nm) PART NUMBER TOOL
Tensioner DESCRIPTION
2200634 Valve Seat
Camshaft Chain 11mm 14-19 (20-25 Nm) Reconditioning Kit
Tensioner Cap 2870390 Piston Support
Carburetor Adaptor 8mm 12-14 (16-20 Nm) Block
Crankcase 8mm 14-15 (19-21 Nm) 2871043 Flywheel Puller
2871283 Crankshaft/Water
Crankshaft Slotted 28mm 35-51 (47-69 Nm) Pump Seal Install
Nut (Cam Chain Kit
Drive Sprocket)
5131135 Water Pump
Cylinder Base 10mm 45-49 (61-67 Nm) Install Kit
Bolts 6mm 6-8 (9-11 Nm) 2870569 Crankshaft Truing
Stand
Cylinder Head 11mm Refer to Engine
Bolts 6mm Assembly for 2870975 Mity Vact
Pressure Test Tool
torque procedure
PV--43527 OIl Filter Wrench
Drive Clutch Bolt 7/16 - 40 (55 Nm)
20
Flywheel 16mm 58-72 (78-98 Nm)
Oil Delivery Pipe 12mm 11-15 (15-21 Nm)
Oil Drain Bolt 14mm 14-17 (19-23 Nm)
(Crankcase)
Oil Filter Pipe Fit- 20mm 36-43 (49-59 Nm)
ting
Oil Hose Fitting 1/8 Pipe 6.5-11 (9-15 Nm)
Thread
Hard Metal Oil Line N/A 11--16 ft.lbs.
Banjo Fitting (15--21 Nm)
Oil Pump 6mm 5-6.5 (7-9 Nm)
Oil Pump Case 5mm 1.5-2 (2-3 Nm)
Screw
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)
Rocker Support 8mm 8-10 (11-13 Nm)
Rocker Adjuster 6mm 6-7 (8-10 Nm)
Screw
Water Pump Impel- 6mm 5-6.5 (7-9 Nm)
ler Nut
3.46
500 ENGINE
PISTON IDENTIFICATION G Crankshaft
The piston may have an identification mark or the

piston may not have an identification mark for ENGINE FASTENER TORQUE
piston placement. If the piston has an identification PATTERNS
mark, follow the directions for piston placement
below. If the piston does not have an identification Tighten cylinder head, cylinder base, and crankcase
mark, the direction for placement of the piston does fasteners in 3 steps following the sequence outlined
not matter. below.
Note the directional and identification marks when
viewing the pistons from the top. The letter “F”, “ !
”, “ "” or : must always be toward the flywheel side 6mm
of the engine. The other numbers are used for
identification as to diameter, length and design. Four 3 2
stroke engine rings are rectangular profile. See text
5
for oil control ring upper rail installation. Use the
information below to identify pistons and rings. 6
1 4
Engine Oversize Piston Standard Cylinder Head

Model Available* Length Piston Iden- Cylinder Base
No. tification Pattern
(mm)
EH50PLE .25 72 mm C
.50 7 5 9 10
*Pistons and rings marked 25 equal .25mm (.010I)
oversized 3 1
Pistons and rings marked 50 equal .50mm (.020I) 8
oversized
2
4 6
ACCESSIBLE COMPONENTS
The following components can be serviced or
removed with the engine installed in the frame:
Crankcase
Pattern
G Flywheel
G Alternator/Stator G Crankshaft Main Bearings
G Starter Motor/Starter Drive G Crankcase
G Cylinder Head *It may be necessary to loosen engine mounts and
G Cylinder move engine slightly to access water pump. Use the
G Piston/Rings Water Pump Mechanical Seal Puller (PN 2872105) to
G Camshaft replace mechanical seal with engine in frame.
G Rocker Arms
G Cam Chain and Sprockets ENGINE REMOVAL (TYPICAL)
G Water Pump / Water Pump
Mechanical Seal* 1. Clean work area.
The following components require engine removal for 2. Thoroughly clean the ATV engine and chassis.
service: 3. Disconnect battery negative (-) cable.
G Oil pump / Oil Pump Drive Gear 4. Remove the following parts as required.
G Counterbalance Shaft or Bearing(s) G Seat
G Connecting Rod G Left and Right Side Covers (Refer to
Chapter 5)
3.47
500 ENGINE
G Fuel Tank Cover / Front Cab (Refer to 3. Clean clutch sheaves thoroughly and inspect inlet
Chapter 5) and outlet ducts for proper routing and sealing.
G Fuel Tank (Refer to Chapter 4) (Chapter 6)
5. Disconnect spark plug high tension lead. Transmission
6. Remove springs from exhaust pipe and remove 1. Inspect transmission operation and adjust linkage
pipe. if necessary. Refer to Chapter 2 and Chapter 8.
7. Drain coolant and engine oil. Exhaust
8. Remove air pre-cleaner and duct. 1. Replace exhaust gaskets. Seal connections with
9. Remove airbox. high temp silicone sealant.
10. Remove carburetor. Insert a shop towel into the 2. Check to be sure all springs are in good condition.
carburetor flange to prevent dirt from entering the Bleed Cooling System
intake port.
1. Remove radiator cap and slowly add coolant to
11. Remove center chain guard on chain drive AWD
top of filler neck.
models.
2. Fill coolant reservoir tank to full mark.
12. Remove center drive and driven sprocket bolts
and remove chain and sprockets as an assembly. 3. Install radiator cap and squeeze coolant lines to
force air out of system.
13. Refer to PVT System to remove outer clutch
cover, drive belt, drive clutch, driven clutch, and 4. Again remove radiator cap and slowly add coolant
inner cover. to top of fill neck.
14. Starter motor. Note ground cable location. Mark 5. Start engine and observe coolant level in the
positive (+) cable mounting angle and remove radiator. Allow air to purge and top off as
cable. necessary. Reinstall radiator cap and bring
engine to operating temp. Check level in
15. Remove transmission linkage rod(s) from gear
reservoir tank after engine is cool and add coolant
selector and secure out of the way.
if necessary.
16. Disconnect coolant temperature sensor wire.
Engine Break In Period
17. Remove engine to chassis ground cable.
4 Cycle Engine Break-In Period is defined as the first
18. Remove all engine mount nuts and / or engine
10 hours of engine operation, or 2 full tanks of fuel.
mount plates.
19. Remove engine through right side of frame. 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
ENGINE INSTALLATION result.
2. Use fuel with a minimum octane of 87 (R+M)/2
NOTES method.
After the engine is installed in the frame, review this 3. Change break-in oil and filter at 20 hours or 500
checklist and perform all steps that apply. miles, whichever comes first.
General Items
1. Install previously removed components using
ENGINE LUBRICATION -
new gaskets, seals, and fasteners where EH500PLE
applicable.
2. Perform regular checks on fluid levels, controls, Oil Type . . . . . . . . . . . . . Polaris Premium 4 Synthetic
and all important areas on the vehicle as outlined (PN 2871281)
in the daily pre-ride inspection checklist (refer to Capacity . . . . . . . . . . . . Approximately 2 U.S.
Chapter 2 or the Owner’s Safety and Quarts (1.9 l)
Maintenance Manual).
Filter . . . . . . . . . . . . . . . . PN 3084963
PVT System
Filter Wrench . . . . . . . . (PV--43527)
1. Adjust center distance of drive and driven clutch.
(Chapter 6) *Drain Plug / Screen Fitting . . 14 ft. lbs. (19 Nm) (If
2. Adjust clutch offset, alignment, and belt fitting is removed, follow oil pump priming procedure).
deflection. (Chapter 6)
3.48
500 ENGINE
*Oil Pressure Specification . . . 20 PSI @ 5500

RPM, Polaris 0W--40 Synthetic (Engine Hot)
(A) Vent Hose to Air Box

OIL PRESSURE TEST - Oil Lines
EH500PLE To Engine
1. Remove blind plug on front left cylinder head.

2. Insert a 1/8 NPT oil pressure gauge adaptor into
the cylinder head and attach the gauge.
3. Start engine and allow it to reach operating
temperature, monitoring gauge indicator.
NOTE: Use Polaris Premium 4 Synthetic Engine

Lubricant (PN 2871281).
1. Clamp or pinch off vent line approximately 2I
Oil Pressure at 5500 RPM (Engine Hot): from oil tank to avoid the end of oil tank vent fitting,
Standard: 20 PSI and the vent line’s pressure relief slit
Minimum: 12 PSI 2. Run engine for 10--20 seconds.
3. Remove the vent line clamp. Note: If the line is
bled properly you should hear air release, if you
OIL PUMP PRIMING do not hear air the line has not bled. The oil pump
PROCEDURE will now be properly primed and ready for field
operation.
NOTE: This priming procedure must be
performed whenever the oil hose connection
between the oil tank and pump inlet has been COOLING SYSTEM
disconnected.
WARNING: Never remove radiator cap when engine
is warm or hot. The cooling system is under pressure
To Air Box and serious burns may result. Allow the engine and
Approx.
cooling system to cool before servicing.
2I
System Pressure Test
1. Remove front cover.
2. Remove recovery bottle hose from coolant filler.
3. Connect a Mity Vact (PN 2870975) to radiator
Oil Tank Slit and pressurize system to 10 PSI. The system
must retain 10 lbs of pressure for five minutes or
Pinch Off longer. If pressure loss is evident within five
Vent Hose minutes, check radiator, all cooling system hoses
and clamps, or water pump seal.
Radiator Cap Pressure Test
1. Remove radiator cap and test using a cap tester
(commercially available).
3.49
500 ENGINE
2. The radiator cap relief pressure is 13 lbs. COOLING SYSTEM

SPECIFICATIONS
FLOW
Radiator
Thermistor
26 ± 2.1 ft.lbs.
(35 ± 3 Nm)
Thermostat Water
Pump
Cylinder Cylinder
Head
COOLING SYSTEM THERMISTOR READING DURING OPERATION

SPECIFICATIONS Condition Approx. Reading Temperature
(Min--Max)
Fan Switch (Off) 149° F (65° C) ± 8° Hot Light 178Ω -- 190Ω 215° F
Fan Switch (On) 180° F (82° C) ± 3° On (102° C)
Hot Light On 221° F (105° C) Fan Off 296Ω -- 316Ω 180° F (82° C)
System Capacity 2.25 Quarts Fan On 236Ω -- 251Ω 195° F (91° C)
Radiator Cap Relief 13 PSI System 2.25 Quarts
Pressure Capacity (2.13L)
Thermostat Starts opening 176° F Radiator
(80° C) Cap Relief 13 PSI
Open 8mm @ 205° F Pressure
(96° C)
RECOMMENDED COOLANT
Use only high quality antifreeze/coolant mixed with
distilled water in a 50/50 or 60/40 ratio, depending on
3.50
500 ENGINE
freeze protection required in your area. CAUTION:

Using tap water in the cooling system will lead to a
buildup of deposits which may restrict coolant flow
and reduce heat dissipation, resulting in possible
engine damage. Polaris Premium 60/40
Antifreeze/Coolant is recommended for use in all
cooling systems, and comes pre-mixed and ready to
use.
COOLING SYSTEM
Pressure test
here with cap
in place
Radiator
Front
View
Vent hole inside cap

liner must be clear.
3.51
500 ENGINE
COOLING SYSTEM -- 4--STROKE BLEEDING PROCEDURE
Use this procedure when a unit overheats and no appar-

ent leaks in the cooling system are found.
Pump hose by
Note: If the coolant level is LOW in the radiator, or if there hand to help
are leaks in the system, the coolant system will not draw purge system
coolant from the reservoir tank.
1. Park Machine on a flat surface. Remove radiator cap and
top off coolant. Leave the cap off of the radiator. Start and idle
machine for 5-10 minutes until steam is visible in the radiator Squeeze Hose
cap area. Here to Help
2. Stop the engine and let cool for a few minutes or until a Purge Air From
System
“glug” is seen at the filler neck or there is a dropping of the
coolant level, indicating that coolant has been pulled into the
system.
Important Tips: Slowly squeezing the hose after the bend
below the filler neck will aid in purging the system of air.
Pump the hose using your hand several times as shown in
the diagram. Elevating the rear of the ATV with a floor jack
(rear tires 4-6, off the ground) also aids the purging of air from
the system. Temperature Sensor
3. Always add coolant to the radiator first, filling to the top of Remote Filler Cooling System
the neck to replace air that has been purged from the system.
Fill the reservoir only after you have completely filled the cool-
Polaris Premium Antifreeze
2871534 Quart
ing system at the radiator filler neck.
2871323 Gallon
4. Repeat Steps 1 and 2 four or five times or until no more
coolant is pulled into the system.
5. In some instances, Steps 1 and 2 may have to be per-
formed with the radiator cap on to prevent coolant loss.
6. To test, install the radiator cap and idle machine until fan
comes on. Make sure the fan comes on before the hot light.
3.52
500 ENGINE
OIL FLOW -- EH500PLE

The chart on Page 3.54 describes the flow of oil
through the EH500PLE engine. Beginning at the oil
tank, the oil flows through a screen fitting in the bottom
of the tank and into the oil supply hose. The feed side
of the oil pump draws oil through the hose and into the
crankcase oil gallery, and then pumps the oil through
another passage to the one way valve. (When the
engine is off, the one way valve closes to prevent oil
in the tank from draining into the crankcase.) The oil
is pumped through a delivery pipe to the oil filter. If the
oil filter is obstructed, a bypass valve contained in the
filter allows oil to bypass the filter element.
At this point, the oil is diverted in two directions. Oil
is supplied to the camshaft through the left front
cylinder stud, and an oil passage in the head. Oil
enters the camshaft through the PTO (L) journal. The
camshaft journals, cam lobes, and rocker arms are
lubricated through holes in the camshaft. The oil
lubricates the cam chain and sprocket and drains to
the sump.
The other oil path from the filter leads through a
delivery pipe to the crankcase main oil 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
stator plate prevents oil from entering the
stator/flywheel area. Oil travels through the
crankshaft to the crank pin, lubricating the connecting
rod large end bearing directly. Oil also passes through
an oil jet (drilled orifice) in the end of the crank pin to
the PTO end main bearings and counterbalancer
gears.
Residual oil from the lubrication of the crankshaft and
connecting rod indirectly lubricates the cylinder wall,
piston, rings, connecting rod small end bearing, piston
pin, oil/water pump drive gears, cam chain and drive
sprocket, and Magneto end crankshaft main bearing.
The one-way valve is located on the front left (PTO)
side of the crankcase. The valve prevents oil in the
tank from draining into the engine sump when the
engine is off. The valve mechanism consists of a
plunger, return spring, guide plug, and sealing
washer. When the engine is running, oil pressure lifts
the plunger off the seat, allowing oil flow. When the
engine is off, spring pressure forces the plunger
against the oil passage seat, preventing oil flow from
the tank to the sump. The one-way valve requires
very little maintenance. If engine oil drains into the
sump when the engine is off, inspect the valve sealing
surface for debris or damage. Inspect the return
spring for distortion or damage.
3.53
500 ENGINE
EH500PLE OIL FLOW DIAGRAM
Internal passage to
camshaft (front left
head bolt)
Oil filter
Oil feed to
filter
From filter
to crankshaft
One way valve
Top fitting is oil

Bottom fitting is oil feed or intake
Oil Tank exhaust or return from bottom of
to tank tank
EH500PLE Oil Flow Chart

Top of Oil Tank Union Fitting (Lower)
Oil Tank
Oil Hose Crankcase Oil Pump Oil Strainer
Oil Gallery (Scavenging)
Union Fitting Screen Fitting
(Upper) (Bottom of Tank)
Oil Hose Crankcase
Small End
Chain Room Sprocket
Crankcase Bearing
Chain
Oil Gallery
Cylinder Sleeve
Oil Pump Cam Shaft Rocker Arm

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

Journal Oil Jet
Crank Pin
Bypass Oil Filter Through Cylinder
Stud Front Left
Delivery Pipe Crankshaft
Crankcase
Delivery Pipe Oil Gallery
3.54
500 ENGINE
EH500PLE ENGINE EXPLODED VIEW
Crankcase Cylinder/
Cylinder
Head
Crankshaft Valve Train

and Piston
3.55
500 ENGINE
ENGINE REMOVAL cam lobe should be pointing down and valves

should have clearance at this point.
REFER TO PAGE 3.47 FOR ENGINE
REMOVAL / INSTALLATION NOTES.
ENGINE TOP END

DISASSEMBLY -- CAM CHAIN
TENSIONER/ROCKER
ARM/CAMSHAFT REMOVAL
1. Remove ignition timing inspection plug from recoil
housing.
TDC “T” Mark 5. Remove cam chain tensioner plug, sealing

washer, and spring. CAUTION: The plug is
under spring tension. Maintain inward pressure
while removing.
6. Remove the two 6x25 mm cam chain tensioner
Rotation flange bolts.
7. Tap lightly on tensioner body with a soft face
hammer and remove tensioner.
Advance Marks
CAM CHAIN TENSIONER
To position crankshaft at Top Dead Center (TDC)
on compression stroke: INSPECTION
2. Rotate engine slowly in the direction of rotation
watching intake valves open and start to close.
3. Continue to rotate engine slowly, watching
camshaft sprocket marks and the mark in the
timing inspection hole.
B
A
1. Pull cam chain tensioner plunger outward to the

end of its travel. Inspect teeth on ratchet pawl (A)
and plunger teeth (B) for wear or damage.
2. Push ratchet pawl and hold it. The plunger should
move smoothly in and out of the tensioner body.
4. Align single (TDC) mark on flywheel with
projection in inspection hole, and the cam
sprocket pin (facing upward) aligned with the
camshaft to crankshaft center line. NOTE: The
3.56
500 ENGINE
3. Release ratchet pawl and push inward on plunger. 3. Measure O.D. of rocker shaft. Inspect it for wear
It should remain locked in position and not move or damage. Compare to specifications.
inward.
Rocker Shaft O.D.:

Tensioner Spring Free Length:
.8656-.8661I (21.987-22.0 mm)
2.02I (5.13 cm)
4. Measure free length of tensioner spring. Replace

spring if excessively worn. Compare to 4. Measure I.D. of each rocker arm and compare to
specifications. specifications.
5. Replace entire tensioner assembly if any part is
worn or damaged.
ROCKER ARM/SHAFT
INSPECTION
Rocker Arm & Support I.D.:

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

assembly.
2. Inspect each rocker arm cam follower surface. If
there is any damage or uneven wear, replace the
rocker arm. NOTE: Always inspect camshaft
lobe if rocker arms are worn or damaged.
3.57
500 ENGINE
5. Measure I.D. of both rocker arm shaft supports 3. Loosen three camshaft sprocket bolts.
and visually inspect surface. Compare to
specifications.
4. Remove camshaft end cap and O-Ring.
Rocker Shaft Oil Clearance:

Std: .0008-.0021I (.020-.054 mm)
Limit: .0039I (.10 mm)
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.
CAMSHAFT REMOVAL Replace if worn or damaged.
6. Place a clean shop towel in the area below cam
chain sprocket and remove sprocket retaining
bolts.
1. Remove thermostat housing.

2. Remove camshaft sprocket inspection cover.
3.58
500 ENGINE
7. Slide camshaft inward to allow removal of cam

sprocket and remove sprocket from camshaft and
chain.
8. Secure cam chain with a wire to prevent it from
falling into the crankcase. C
Sprocket Teeth
1. Check release lever shaft (A) for smooth

operation throughout the entire range of rotation.
Inspect for Areas of Tooth The spring (B) should hold the shaft weight
Wear or Damage against the stop pin. In this position, the actuator
ball (C) will be held outward in the compression
release mode.
9. Inspect cam sprocket teeth for wear or damage.
Replace if necessary. 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
Decompressor Shaft actuator ball for wear and replace if necessary.
RELEASE INSTALLATION
1. Slide spring onto shaft.
Decompressor Ball 2. Apply engine oil to release lever shaft.
The actuator ball must be held outward to allow
installation of the release lever shaft.
Retainer Sleeve
Stop pin
10. Slide camshaft out the PTO side of the cylinder

head.
Spring in relaxed position

RELEASE
REMOVAL/INSPECTION
NOTE: The automatic compression release
mechanism can be inspected and serviced without
removing the camshaft from the cylinder head. The
actuator ball in the camshaft is not replaceable.
Replace the camshaft as an assembly if the actuator
ball is worn or damaged.
3.59
500 ENGINE
If Camshaft Is Removed From Engine: 3. Measure height of each cam lobe using a
micrometer. Compare to specifications.
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: Journal O.D.
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 Journal
compression release will not disengage when the
engine starts. Check operation of mechanism as
outlined in Step 1 of Removal (above). Camshaft Journal O.D.:
NOTE: When shaft is properly installed, actuator
ball will be held in the “out” position. It is important Mag & PTO End: 1.4935-1.4941I
to note that spring pressure is very light. (37.935-37.950 mm)
4. Measure camshaft journal outside diameter

CAMSHAFT INSPECTION (O.D.)
1. Visually inspect each cam lobe for wear, chafing 5. Measure ID of camshaft journal bore.
or damage.
2. Thoroughly clean the cam shaft, making sure the Camshaft Journal I.D.:
oil feed holes are not obstructed.
Mag & PTO End: 1.4963-1.4970I
(38.005-38.025 mm)
Calculate oil clearance by subtracting journal OD

from journal bore ID. Compare to specifications.
Lubrication holes
Camshaft Oil Clearance:
Std: .0022-.0035I (.055-.090 mm)
Lobe height Limit: .0039I (.10 mm)
NOTE: Replace camshaft if damaged or if any part

Cam Lobe Height (Intake & Exhaust): is worn past the service limit.
Std: 1.2884-1.2924I (32.726-32.826 mm) NOTE: Replace cylinder head if camshaft journal
Limit: 1.2766I (32.426 mm) bore is damaged or worn excessively.
3.60
500 ENGINE
CYLINDER HEAD REMOVAL

EH500PLE
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
evenly 1/8 turn each time in a criss-cross pattern
until loose.
3. Remove bolts (B) and tap cylinder head lightly

with a plastic hammer until loose. CAUTION:
Tap only in reinforced areas or on thick parts of
cylinder head casting to avoid damaging the
thread.
4. Remove cylinder head and head gasket.
3.61
500 ENGINE
CYLINDER HEAD EXPLODED VIEW, EH500PLE
EH500PLE
3.62
500 ENGINE
CYLINDER HEAD CYLINDER HEAD

INSPECTION 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)
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 WARPAGE

1. Using a valve spring compressor (A), compress
the valve spring and remove the split keeper.
NOTE: To prevent loss of tension, do not
compress the valve spring more than necessary.
Cylinder Head Warpage Limit:
.002″ (.05 mm)
2. Remove spring retainer and spring.

1. Lay a straight edge across the surface of the NOTE: The valve springs should be positioned with
cylinder head at several different points and the tightly wound coils against the cylinder head on
measure warpage by inserting a feeler gauge progressively wound springs (A).
between the straight edge and the cylinder head
3. Push valve out, keeping it in order for reassembly
surface. If warpage exceeds the service limit,
in the same guide.
replace the cylinder head.
4. Measure free length of spring with a Vernier
caliper. Check spring for squareness. Compare
3.63
500 ENGINE
to specifications. Replace spring if either indicator.

measurement is out of specification
A
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 seat area (B). NOTE: The valves
cannot be re-faced or end ground. They must be
5. Remove valve seals. CAUTION: Replace seals replaced if worn, bent, or damaged.
whenever the cylinder head is disassembled.
Hardened, cracked or worn valve seals will cause
excessive oil consumption and carbon buildup.
Measure valve stem in
several places.
VALVE INSPECTION
1. Remove all carbon from valve with a soft wire
wheel.
Valve Stem Diameter:

Intake: .2343-.2348I (5.950-5.965 mm)
Exhaust: .2341-.2346I (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.
2. Check valve face for runout, pitting, and burnt

spots. To check for bent valve stems, mount
valve in a drill or use “V” blocks and a dial
3.64
500 ENGINE
9. Clean cylinder head, valves, and camshaft oil

supply passage (A) thoroughly.
10. If oil passage blind plug was removed, apply
Crankcase Sealant (PN 2871557) or equivalent
sealer to the threads and install, torquing to 8 ft.
lbs. (11 Nm). CAUTION: Do not allow sealant to
enter oil passage.
11. Spray electrical contact cleaner into oil passage
and dry using compressed air.
CYLINDER HEAD ASSEMBLY

CAUTION: Wear eye protection during assembly.
NOTE: Assemble the valves one at a time to maintain
proper order.
Valve Guide I.D.:
.2362-.2367I (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.
7. Subtract valve stem measurement to obtain stem
to guide clearance. NOTE: Be sure to measure
each guide and valve combination individually.
8. Replace valve and/or guide if clearance is
excessive. Compare to specifications.
NOTE: If valve guides are replaced, valve seats must
be reconditioned. Refer to Valve Seat Reconditioning 1. Install new valve seals on valve guides.
for procedure.
2. Apply engine oil to valve guides and seats.
3. Coat valve stem with molybdenum disulfide
COMBUSTION CHAMBER grease.
4. Install valve carefully with a rotating motion to
avoid damaging valve seal.
5. Dip valve spring and retainer in clean engine oil
and install spring with closely spaced coils toward
the cylinder head.
Clean all accumulated carbon deposits from

combustion chamber and valve seat area with a soft
wire brush.
3.65
500 ENGINE
6. Place retainer on spring and install valve spring 1. Remove cam chain guide at front of cylinder.
compressor. Compress spring only enough to
allow split keeper installation to prevent loss of
spring tension. Install split keepers with the gap
even on both sides.
7. Repeat procedure for remaining valve.
8. When all valves are installed, tap lightly with soft
faced hammer on the end of the valves to seat the
split keepers.
VALVE SEALING TEST

1. Clean and dry the combustion chamber area.
2. Pour a small amount of clean, high flash point
solvent into the intake port and check for leakage
around each intake valve. The valve seats should
hold fluid with no seepage. 2. Loosen all four oil pipe banjo bolts and then
3. Repeat for exhaust valves by pouring fluid into remove the bolts and eight sealing washers.
exhaust port. Remove the pipes.
and tighten locknut securely
6. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.
CYLINDER/PISTON REMOVAL
AND INSPECTION
NOTE: Follow engine disassembly procedures to
remove valve cover, camshaft and rocker arms, and
cylinder head.
3. Loosen hose clamps and remove coolant inlet

hose.
4. Remove the two 6 mm cylinder base bolts.
3.66
500 ENGINE
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.
NOTE: The bolts are inside the water jacket.
3. Remove top compression ring.

*Using a piston ring pliers: Carefully expand ring
and lift it off the piston. CAUTION: Do not expand the
ring more than the amount necessary to remove it
6. Tap cylinder lightly with a plastic hammer in the from the piston, or the ring may break.
reinforced areas only until loose. *By hand: Placing both thumbs as shown, spread the
7. Rock cylinder forward and backward and lift it ring open and push up on the opposite side. Do not
from the crankcase, supporting piston and scratch the ring lands.
connecting rod. Support piston with Piston
Support Block (PN 2870390).
8. Remove dowel pins from crankcase.
PISTON REMOVAL A
4. Repeat procedure for second ring.

The oil control ring is a three piece design consisting
of a top and bottom steel rail and a center expander
section. The top rail has a locating tab on the end
which fits into a notch (A) in the upper oil ring land of
the piston.
1. Remove circlip. Note piston directional arrow 5. Remove the top rail first followed by the bottom
pointing toward the right (Mag) side of engine. rail.
2. Remove piston circlip and push piston pin out of 6. Remove the expander.
piston. If necessary, heat the crown of the piston
slightly with a propane torch. CAUTION: Do not
apply heat to the piston rings. The ring may lose
radial tension.
3.67
500 ENGINE
CYLINDER INSPECTION 4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure
1. Remove all gasket material from the cylinder in two different directions, front to back and side to
sealing surfaces. side, on three different levels (1/2″ down from top,
in the middle, and 1/2″ up from bottom).
5. Record measurements. If cylinder is tapered or
out of round beyond .002, the cylinder must be
re-bored oversize, or replaced.
Cylinder Taper
Limit: .002 Max.
Cylinder Out of Round
Limit: .002 Max.
Standard Bore Size:
3.6221-3.6228I (92.00-92.012mm)
PISTON-TO-CYLINDER
2. Inspect the top of the cylinder for warpage using a
straight edge and feeler gauge. CLEARANCE
Cylinder Warpage: Piston
.002″ (.05 mm)
3. Inspect cylinder for wear, scratches, or damage.

40 mm
1/2″ Down From Top of Cylinder

Piston Pin
Y 1. Measure piston outside diameter at a point 40 mm

X
down from the top of the piston at a right angle to
the direction of the piston pin.
2. Subtract this measurement from the maximum
cylinder measurement obtained in Step 5 above.
Y
X
Piston to Cylinder Clearance
Std: .0006-.0018I (.015-.045 mm)

Y Piston O.D.:
X Std: 3.6204-3.6215I (91.970-91.985 mm)
1/2″ Up From Bottom
3.68
500 ENGINE
PISTON/ROD INSPECTION 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 Pin Bore
Piston Pin Bore:

Feeler Gauge
.9055-.9057I (23.0-23.006 mm)
1. Measure piston pin bore.

Piston Ring-to-Groove Clearance
Top Ring Std: .0016-.0031I (.040-.080 mm)

Limit: .0059I (15 mm)
Second Ring Std: .0012-.0028I (.030-.070 mm)
Limit: .0059I (15 mm)
4. Measure piston ring to groove clearance by

placing the ring in the ring land and measuring
with a thickness gauge. Replace piston and rings
if ring-to-groove clearance exceeds service
Piston Pin Measurement Locations limits.
PISTON RING INSTALLED

Piston Pin O.D.
GAP
.9053-.9055I (22.994-23.0 mm)
1. Place each piston ring inside cylinder using piston
to push ring squarely into place as shown at right.
Feeler Gauge
Cylinder
25-50mm
Piston Ring
3.69
500 ENGINE
2. Remove starter drive assembly. Note the thrust

washer located at the rear of the drive
Piston Ring Installed Gap mechanism.
Top Ring 3. Inspect the thrust washer for wear or damage and
Std: .0079-.0138I (.20-.36 mm) replace if necessary.
Limit: .039I (1.0 mm)
Second Ring
Std: .0079-.0138I (.20-.36 mm) A
Limit: .039I (1.0 mm)
Oil Ring
Std: .0079-.0276I (.20-.70 mm)
Limit: .059I (1.5 mm)
2. Measure installed gap with a feeler gauge at both

the top and bottom of the cylinder. NOTE: A
difference in end gap indicates cylinder taper.
The cylinder should be measured for excessive
taper and out of round.
3. If the bottom installed gap measurement exceeds
the service limit, replace the rings. If ring gap is Std. Bushing ID:
below specified limit, file ring ends until gap is .4735″-.4740″ (11.11-12.04 mm)
within specified range.
NOTE: Always check piston ring installed gap after Std. Shaft OD:
re-boring a cylinder or when installing new rings. A .470″-.472″ (11.93-11.99 mm)
re-bored cylinder should always be scrubbed
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with an oil rag Starter Drive Bushing Clearance:
immediately to remove residue and prevent rust. Std: .0015″-.004″ (.038-.102 mm)
ENGINE BOTTOM END Service Limit:
DISASSEMBLY .008″ (.203 mm)
NOTE: The recoil starter, starter motor, starter drive, 4. Measure the OD of the starter drive shaft on both
flywheel, stator, cam chain and sprockets can be ends and record.
serviced with the engine in the frame.
5. Measure the ID of the bushing in the recoil
housing (A) and in the crankcase and record.
STARTER DRIVE Measure in two directions 90° apart to determine
if bushing is out of round. Calculate bushing
REMOVAL/INSPECTION clearance. Replace bushing if clearance exceeds
the service limit.
1. Remove recoil housing bolts and remove 6. Inspect gear teeth on starter drive. Replace
housing. starter drive if gear teeth are cracked, worn, or
broken.
FLYWHEEL/STATOR
REMOVAL/INSPECTION
1. Remove flywheel nut and washer.
2. Install Flywheel Puller (PN 2871043) and remove
flywheel. CAUTION: Do not thread the puller
bolts into the flywheel more than 1/4″ or stator
coils may be damaged.
3. Mark or note position of stator plate on crankcase.
3.70
500 ENGINE
4. Remove bolts and carefully remove stator CAM CHAIN/TENSIONER

assembly, being careful not to damage crankshaft
bushing on stator plate. BLADE
1. Remove bolt securing tensioner blade to

crankcase (A).
5. Replace crankshaft seal (A). 2. Remove blade and inspect for cracks, wear, or
damage.
B B
6. Remove oil passage O-Ring (B).

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 section of chain.
Replace if worn past service limit.
Chain Service Limit:

5.407″ (13.7 cm)
4. Using the special socket, remove the crankshaft

slotted nut (A). NOTE: The slotted nut is a left
hand thread.
5. Remove cam chain drive sprocket (B) and
Woodruff key from crankshaft.
7. Remove large sealing O-Ring from outer edge of 6. Inspect sprocket teeth for wear or damage.
stator plate. 7. Inspect Woodruff key for wear.
8. Replace any worn or damaged parts.
3.71
500 ENGINE
ONE WAY VALVE 2. Separate crankcase by tapping with a soft faced

hammer in reinforced areas.
The one way valve prevents oil from draining out of the 3. Tap lightly on balancer gear with a brass drift
oil tank and into the crankcase when the engine is off. through the hole in the crankcase if necessary, to
It must be clean and have adequate spring pressure ensure the balancer shaft stays in the PTO side
in order to seal properly. 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
B A angle or the shaft may bend, causing irreparable
D C damage. Tap only lightly on the pump shaft if
necessary.
4. Remove the Mag (RH) crankcase from the PTO
case.
OIL PUMP
REMOVAL/INSPECTION
1. Remove cap bolt (A), sealing washer (B), spring

(C), and one way valve (D) from PTO side
crankcase.
2. Inspect free length of spring and check coils for
distortion.
One Way Valve Spring Free Length:
Std: 1.450″ (3.68 cm)
C A
3. Inspect valve for wear. B
4. Check seat area for nicks or foreign material that
1. Remove pump shaft bearing (A) and thrust
may prevent proper sealing of valve.
washer (B) from pump shaft.
2. Remove (2) bolts holding pump drive gear (C).
CRANKCASE SEPARATION 3. Inspect drive gear teeth for cracks, damage or
excessive wear.
1. Remove flange bolts (10) from magneto side

crankcase evenly in a criss-cross pattern.
3.72
500 ENGINE
4. Remove three oil pump retaining bolts and pump. 9. Measure pump end clearance using a feeler
gauge and straight edge.
Pump End Clearance:
Std: .001-.003 (.0254-.0762 mm)
10. Measure clearance between outer feed rotor and

pump body with a feeler gauge.
5. Inspect mating surface of crankcase and oil

pump. Check for nicks, burrs, or surface
irregularities.
6. Remove the three screws and strainer screen
from pump.
7. Clean screen thoroughly.
Rotor Tip Clearance:
Std: .005 (.127 mm)
11. Measure rotor tip clearance with a feeler gauge.

12. Remove inner and outer feed rotor and pump
chamber body.
8. Remove pump body screw and feed chamber 13. Repeat measurements for scavenge rotor.
cover. 14. Remove inner and outer scavenge rotor and
inspect pump shaft for wear.
OIL PUMP ASSEMBLY

1. Clean and dry all parts thoroughly. Apply clean
engine oil to all parts. Do not use gasket sealer on
the pump body mating surfaces or oil passages
will become plugged.
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.
3.73
500 ENGINE
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)
COUNTER BALANCER SHAFT

REMOVAL/INSPECTION
3. Turn the shaft until balancer counter weights clear
the crankshaft and remove the balancer shaft
from the crankcase.
4. Inspect the balancer drive gear and pump shaft
drive gear.
A 5. Replace the shaft if gear teeth are abnormally
worn or damaged.
6. Inspect the balancer shaft bearings.
minimal wear, the balancer shaft ball bearings must
be inspected visually and by feel. Look for signs of
discoloration, scoring or galling. Turn the inner race
of each bearing. The bearings should turn smoothly
and quietly. The outer race of each bearing should fit
tightly in the crankcase. The inner race should be firm
1. Remove the shim washer (A) from the counter with minimal side to side movement and no detectable
balancer shaft. up and down movement.
CRANKSHAFT
REMOVAL/INSPECTION
A
2. Note the alignment dots on the balancer and

crankshaft gears, the marks must be aligned
during reassembly.
1. Remove the shim washer (A) from the crankshaft.
3.74
500 ENGINE
2. Support the PTO side crankcase and crankshaft; CRANKCASE BEARING

press the crankshaft out. Be careful not to
damage the crankcase mating surface or INSPECTION
connecting rod.
1. Remove the seal from the PTO side crankcase.

3. Use a feeler gauge to measure the connecting rod 2. Inspect the crankshaft main bearings, balancer
big end side clearance. shaft bearings, and pump shaft bearing.
Connecting Rod Big End Side Clearance: minimal wear, the bearings must be inspected
visually, and by feel. Look for signs of discoloration,
Std: .0039-.0256I (.1-.65 mm) scoring or galling. Turn the inner race of each bearing.
Limit: .0315I (.80 mm) 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
4. Place the crankshaft in a truing stand or V-blocks
minimal side to side movement and no detectable up
and measure the runout on both ends with a dial
and down movement.
indicator.
3. Support the crankcase and drive or press the
main bearings out of each crankcase.
Max Runout: .0024″ (.06 mm) 4. To remove balancer shaft bearings and pump
shaft bearing use a blind hole bearing puller.
NOTE: Bearings are stressed during the removal
5. Measure the connecting rod big end radial
process and should not be re-used!
clearance.
Big End Radial Clearance: PUMP SHAFT OIL SEAL/

Std: .0004-.0015I (.011-.038 mm) WATER PUMP MECHANICAL
Limit: .0020I (.05 mm)
SEAL REMOVAL (ENGINE
DISASSEMBLED)
6. Inspect the crankshaft main bearing journals for
scoring and abnormal wear. NOTE: The water pump mechanical seal can be
removed without removing the engine. Refer to Water
Pump Mechanical Seal Installation.
3.75
500 ENGINE
Replace the pump shaft seal and water pump G 28 mm (1.100″) For pump shaft
mechanical seal whenever the crankcase is bearing.
disassembled.
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
1. Remove the pump shaft bearing from the
Magneto (right hand) side crankcase.
2. Pry out the oil seal, noting the direction of
installation with the spring side facing IN (toward
inside of case).
3. Drive the water pump mechanical seal out of the
crankcase from inside to outside. Note: The new
mechanical seal must be installed after the
crankcases are assembled, using a special tool.
See Mechanical Seal Installation.
CRANKCASE INSPECTION
1. Remove all traces of gasket sealer from the
crankcase mating surfaces. Inspect the surfaces 1. Make sure all bearings are firmly seated in the
closely for nicks, burrs or damage. both Mag and PTO crankcase.
2. Check the oil pump and oil passage mating
surfaces to be sure they are clean and not
damaged.
NOTE: To ease bearing installation, warm the
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 to prevent bearing damage.
G 70 mm (2.755″) driver- For
crankshaft main bearings.
2. Measure the distance from the PTO crankcase
G 46 mm (1.810″) For counter balancer
bearings. mating surface to the main bearing using a dial
caliper and a straight edge.
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500 ENGINE
5. Subtract the thickness of the straightedge from

the measurement obtained in Step 4 and record.
Mag Case Depth
6. Add the readings recorded in Step 3 and Step 5

and record below.
Total Case Width
3. Subtract the thickness of the straightedge from

the measurement obtained in Step 2 and record.
PTO Case Depth
7. Measure the width of the crankshaft at the

bearing seats with a micrometer or dial caliper
and record.
Crankshaft Width
8. Subtract the Crankshaft Width measured in Step
7 from the Total Case Width recorded in Step 6,
and record below.
4. Measure the distance from the Magneto
crankcase mating surface to the main bearing
using the same method and record. Total End Play
is required. The result must be within the
specified range listed at right.
Crankshaft End Play:

.008″-.016″ (.02-.04 cm)
3.77
500 ENGINE
COUNTER BALANCER
SHAFT END PLAY ADJUST. Counter Balancer Shaft End Play:
Step 2 .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.
1. Make sure all bearings are firmly seated in the

crankcase.
2. Measure the width of the counter balancer shaft
at the bearing seats with a dial caliper or
micrometer, and record reading.
Step 3 / 4
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. Measure the distance from the Mag crankcase

mating surface to the balance shaft bearing using
a dial caliper and a straight edge. Subtract the
thickness of the straightedge and record.
4. Measure the distance from the PTO crankcase
mating surface to the bearing using the same
method outlined in Step 1, 2, and-3.
5. Add the readings obtained in Step 3 and Step 4.
3. Install the gear on the oil pump and measure the
6. Subtract the counter balancer shaft width
measured in Step 2 from the figure obtained in Step width of the pump and gear. Subtract this
5. measurement from the measurement recorded in
Step 2.
the result of Step 6 to determine if a different shim 4. Subtract the thickness of the existing shim from
is needed. The result must be within the specified
is needed. See Shaft End Play Spec. next page.
range listed at below.
3.78
500 ENGINE
difficult, install two nuts on the end of the threaded

rod and tighten against each other.
Pump Shaft End Play:
3. Install the proper shim on the magneto end of the
.008″-.016″ (.02-.04 cm) crankshaft.
4. Place the balancer shaft in the PTO crankcase
aligning the timing marks on the crankshaft and
balancer gears. Install the proper shim washer on
PUMP SHAFT OIL SEAL the shaft.
5. Inspect the oil pump sealing surface on the
INSTALLATION crankcase. Apply a light film of engine oil to the
surface and install the oil pump.
NOTE: Do not use gasket sealer on the pump mating
surfaces.
NOTE: After engine is assembled and machine is
readied for field operation, oil pump MUST be primed.
Follow oil pump priming procedure on Page 3.47.
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.
1. Install the seal from the outside of the crankcase
7. Install the proper shim washer on the pump shaft.
(water pump side) with the spring facing inward,
toward the pump shaft bearing.
2. Drive or press the seal into place using a 25 mm CRANKCASE ASSEMBLY
(.985″) seal driver, until flush with the outer edge
of the seal bore. 1. Apply Crankcase Sealant (PN 2871557) to the
3. Lubricate the seal lip with grease. crankcase mating surfaces. Be sure the
2. Set the crankcase in position carefully to avoid
CRANKSHAFT/COUNTER damaging the pump shaft seal, and install the
magneto end crankshaft installation tool (follow
BALANCE/OIL PUMP instructions provided with the Crankshaft/Water
INSTALLATION Pump Installation Kit (PN 2871283). Draw the
crankcase halves together by tightening the nut
Lubricate all bearings with clean engine oil before on the tool and tapping lightly in the pump shaft
assembly. area with a soft faced hammer to maintain
alignment. Continually check alignment of the
Use the Crankshaft/Water Pump Installation Kit (PN cases during installation, closing the gap equally
2871283) to prevent damage to the crankshaft and until the surfaces are tightly seated.
main bearings during installation.
3. Remove the tool.
1. Install the crankshaft into the PTO side 4. Install the crankcase flange bolts and tighten in 3
crankcase. Screw the threaded rod into the steps following the pattern on Page 3.3 to
crankshaft until the threads are engaged a specified torque.
minimum of one inch (25.4mm).
2. Install the collar, washer, and nut onto the
threaded rod. Hold the crankshaft and tighten the Crankcase Bolt Torque:
nut to draw the crankshaft into the main bearings
until fully seated. Loosen the nut and remove the 14 ft. lbs. (19 Nm)
threaded rod from the crankshaft. If removal is
3.79
500 ENGINE
Crankcase Sealant: Sealing Washer

Sealing Washer
(Copper or Aluminum)
(PN 2871557)
Coolant Drain
Bolt
WATER PUMP MECHANICAL Oil
Seal
SEAL INSTALLATION
Impeller
1. Clean the seal cavity to remove all traces of old
sealer. Ill. 1 Mechanical Seal
2. Place a new mechanical seal in the seal drive
collar, and install on the pump shaft. 1. After the coolant has been drained, remove the
3. Screw the guide onto the end of the pump shaft. water pump cover, impeller and the sealing
4. Install the washer and nut and tighten to draw seal washer. (Ill. 1)
into place until fully seated.
5. Remove the guide adaptor using the additional
nut as a jam nut if necessary.
WATER PUMP MECHANICAL

SEAL REMOVAL - ENGINE
T-Handle
INSTALLED
Water Pump Mechanical Seal
Puller: (PN 2872105) Main Puller Body
Ill. 2
Replacement T--Handle:
(PN 2872106) 2. Slide the main puller body over the outer portion
of the mechanical seal as shown in Ill. 2 and turn
This tool allows a technician to replace the T-Handle clockwise until it contacts water pump
mechanical water pump seal on EH50PL engines shaft. Continue rotating until outer portion of
without removing the engine and splitting the cases. mechanical seal is separated from the metal seal
body.
3. Insert the puller legs between the water pump

CAUTION: drive shaft and the remaining portion of the
Improper or careless use of this tool or procedure can mechanical seal. Attach the puller legs to the
result in a bent water pump shaft. Pump shaft main puller body. Ill. 3
replacement requires engine removal and crankcase
separation. Use caution while performing this
procedure. Make sure that the puller is parallel to the
shaft at all times. Do not place side loads on the water Main puller
body
pump shaft or strike the puller or shaft in any way.
Position the split

90° to opening
on main puller
Ill. 4 body
3.80
500 ENGINE
4. Ensure that the split between the puller legs is

fully supported by the main body of the tool (Ill 4).
One Way Valve Plug Torque:
Hex Socket Screws
16 ft. lbs. (22 Nm)
Puller Legs
CAM CHAIN DRIVE
SPROCKET INSTALLATION
Lip must grasp inside
of mechanical seal.
B
Ill. 5
A
5. Tighten the hex socket screws on the puller legs
sufficiently so the lip of the puller legs will grasp
the mechanical seal. Ill. 5
Tighten
1. Install the Woodruff key, drive sprocket, and

slotted nut. Tighten the nut to the specified
torque.
Slotted Nut Torque:

Ill. 6
35-51 ft. lbs. (47-69 Nm)
6. Turn the puller T-Handle clockwise until it
contacts the water pump shaft. Continue rotating
until the remaining portion of mechanical seal has
been removed from the cases. Ill. 6 Pump shaft
oil seal can also be replaced at this time if TENSIONER BLADE
necessary.
INSTALLATION
7. The Water Pump Install Kit (PN 5131135) is
required to install the new mechanical seal. This 1. Install the tensioner blade and tighten the
tool is available separately and it is also included mounting bolt to specified torque.
in the Crankshaft/Water Pump Seal Installation
Kit (PN 2871283).
Tensioner Blade Mounting Bolt Torque:
ENGINE ASSEMBLY
6 ft. lbs. (8 Nm)
ONE WAY VALVE

INSTALLATION
Install the one way valve plunger, spring, and plug
using a new sealing washer.
3.81
500 ENGINE
PISTON RING INSTALLATION 6. Check to make sure the rings rotate freely in the
groove when compressed.
NOTE: Apply clean engine oil to all ring surfaces and
Ring Profile
ring lands. Always check piston ring installed gap
before rings are installed on piston. See Page 3.69.
If the piston has been in service clean any
accumulated carbon from the ring grooves and oil
control ring holes.
1. Place the oil control ring expander in oil ring
groove with the end gap facing forward. The Top
expander has no up or down marking and can be Mark up
installed either way. The ends should butt
squarely together and must not overlap.
2. Install the oil ring top rail.
NOTE: The top rail has a locating tab to prevent
rotation. The tab must be positioned in the notch on
the side of the piston as shown (A).
Second
Mark up
ILL. 1
PISTON INSTALLATION
1. Clean the gasket surfaces on the cylinder and
A crankcase. Remove all traces of old gasket
material.
2. Make sure the cylinder mounting bolt holes are
clean and free of debris.
3. Install the bottom rail with the gap at least 30° Tang Outward
from the end of the expander on the side opposite
the top rail gap.(See ILL. 1).
4. Install the second ring with the “R” mark facing up.
Position the end gap toward the rear (intake) side
of the piston.
5. Install the top ring (chrome faced) with the “R”
mark facing up and the end gap facing forward
(toward the exhaust). (See ILL. 1).
3. Install a new circlip on one side of the piston with
the end gap facing up or down, and tang outward.
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.
3.82
500 ENGINE
4. Apply clean engine oil to the piston rings, ring instructions. CAUTION: Make sure the oil
lands, piston pin bore, piston pin, and piston skirt. control ring upper rail tab is positioned properly in
Lubricate the connecting rod (both ends), the notch of the piston. Verify all ring end gaps are
balancer drive gear, and crankshaft main bearing correctly located.
area.
Mag
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
4. Apply clean engine oil liberally to the cylinder bore
in the piston.
and tapered area of the sleeve. Install the
6. Install the other circlip with the gap facing up or cylinder with a slight rocking motion until the rings
down and tang outward. (See Caution with Step 3 are captive in the sleeve.
above). Push the piston pin in both directions to
make sure the clips are properly seated in the
groove.
CYLINDER INSTALLATION
1. Place the dowel pins in the crankcase and install a
new cylinder base gasket.
5. Remove the ring compressor and support block.

6. Push the cylinder downward until fully seated on
the base gasket.
7. Apply a light film of oil to the threads and flange
surface of the cylinder mounting bolts.
8. Install all four bolts finger tight. Rotate the engine
2. Position the Piston Support Block (PN 2870390) and position the piston at BDC.
(A) beneath the piston skirt to support the piston NOTE: If cam chain is installed, hold it up while
during cylinder installation. rotating the engine to avoid damage to the chain, drive
3. Apply clean engine oil to the ring compressor sprocket teeth, or tensioner blade.
(Snap Ont PN RCL30) and install the 9. Tighten the cylinder bolts in three steps in a criss
compressor following manufacturers cross pattern and torque to specifications.
3.83
500 ENGINE
10. Install the two 6 mm bolts. CAM CHAIN/CAMSHAFT

INSTALLATION
Cylinder Bolt Torque:
Install the cam chain over the crankshaft.
10mm - 46 ft. lbs. (62 Nm)
6mm - 6 ft. lbs. (8 Nm)
CYLINDER HEAD
INSTALLATION
Clean the gasket surfaces on the cylinder head and Guide in
cylinder. Remove all traces of old gasket material. recess
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 hand tighten the bolts.
The following procedure must be used to torque the
cylinder head properly:
Torque all bolts evenly in a criss cross

pattern
*Torque bolts to 22 ft. lbs. (30 Nm)
*Torque bolts to 51 ft. lbs. (70 Nm) CAMSHAFT TIMING

*Loosen bolts evenly 180° (1/2 turn) CAUTION: Serious engine damage may result if the
camshaft is not properly timed to the crankshaft.
*Loosen bolts again another 180° (1/2
turn) IMPORTANT CAMSHAFT TIMING NOTE: In order
to time the camshaft to the crankshaft, the piston must
*Torque bolts to 11 ft. lbs. (15 Nm) be precisely located at Top Dead Center (TDC).
*From this point, tighten bolts evenly

90° (1/4 turn)
*Finally, tighten another 90° (1/4 turn)
*Install two 6mm bolts and torque to 6

ft. lbs. (8 Nm)
3.84
500 ENGINE
1. Apply Polaris Premium Starter Drive Grease (PN

2871460) to the camshaft main journals and cam B
lobes. Lubricate automatic compression release A
mechanism with clean engine oil. (To install the
compression release mechanism, refer to Page
3.59).
2. Install the camshaft with the lobes facing
downward and the sprocket alignment pin facing
upward.
Single (TDC)
Mark Aligned
5. Before positioning the sprocket on the camshaft,

check the position of the cam sprocket alignment
pin. When the cam is positioned properly, the
cam sprocket alignment pin (A) is directly in line
with the crankshaft/camshaft centerline (B).
6. Install the sprocket on the camshaft. Apply
Loctitet 242 (PN 2871949) to the cam sprocket
3. Disconnect the wire holding the cam chain and
bolts and torque to specifications.
rotate the engine to align the single (TDC ) timing
mark (Top Dead Center) on the flywheel with the
notch in the timing inspection window. Be sure to
use the single TDC mark when installing the cam. Cam Sprocket Bolt Torque:
Do not use the advance marks. See illustrations.
6 ft. lbs. (8 Nm)
A
Single (TDC)
Mark Aligned
7. Verify TDC mark in timing inspection hole and

alignment pin is directly in line with crankshaft to
4. Loop the cam chain on the cam sprocket with the camshaft centerline. Refer to Ill. on following
dots on the sprocket facing outward and the page.
alignment pin notch facing directly upward. 8. Apply Crankcase Sealant (PN 2871557) to the
camshaft end cap and install using a new O-Ring.

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.
3.85
500 ENGINE
CAMSHAFT TIMING

Dots
Sprocket Alignment Pin
Single TDC Mark Aligned

TDC Mark
Rotation
Do Not Use
Advance Marks
3.86
500 ENGINE
CAM CHAIN TENSIONER 1. Apply a light film of grease to the crankshaft seal.
Apply molybdenum disulfide grease or assembly
INSTALLATION lubricant to the crankshaft bushing.
2. Install a new O-Ring in the oil passage recess in
the crankcase.
3. Apply Crankcase Sealant (PN 2871557) or an
equivalent sealer to the stator plate outer surface
and install a new O-Ring.
B
A
1. Release the ratchet pawl (A) and push the

tensioner plunger (B) all the way into the
tensioner body.
2. Install the tensioner body with a new gasket and
tighten the bolts.
Tensioner Bolt Torque: 4. Install the stator plate being careful not to damage
the seal. Align timing reference marks on the
6 ft. lbs. (8 Nm) plate and crankcase. Be sure the plate is fully
seated.
NOTE: This is a static timing mark. Strobe timing
3. Install the spring, new sealing washer, and should be performed after start up.
tensioner plug. 5. Torque bolts evenly to specification.
Tensioner Plug Torque: Stator Plate Bolt Torque:

17 ft. lbs. (23 Nm) 5-6.5 ft. lbs. (7-9 Nm)
4. Slowly rotate engine two to three revolutions and 6. Seal stator wire grommet with Crankcase Sealant
re-check cam timing. (PN 2871557) or equivalent sealer.
Flywheel
STATOR, FLYWHEEL AND 1. Install flywheel, washer, and nut. Torque flywheel
to specification.
STARTER DRIVE
INSTALLATION Flywheel Nut Torque:
NOTE: The stator, flywheel, starter drive, and recoil 58-72 ft. lbs. (78-98 Nm)
can be assembled with the engine in the frame.
Stator
3.87
500 ENGINE
Starter Drive 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
1. Be sure the washer is positioned on the back of springs, cam chain, rocker arms, and camshaft.
the drive gear. 9. Place a new rocker cover gasket on the cylinder
head and 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:
(PN 2871460)
ROCKER SHAFT/ROCKER Install the thermostat with one of the air bleed holes
positioned next to the upper thermostat cover bolt
ARM ASSEMBLY hole as shown.
INSTALLATION
1. Assemble rocker arms, rocker shaft, and shaft OIL PIPES
supports.
Install the oil pipes with new sealing washers. Tighten
2. Install and tighten rocker arm shaft locating bolt. all bolts evenly to specified torque.
3. Apply starter drive grease to the cam lobes and
cam follower surfaces.
Oil Pipe Bolt Torque:
4. Rotate the engine until the cam lobes are pointing
downward. 20 ft. lbs. (27 Nm)
5. Be sure the dowel pins are in place and install the
rocker shaft assembly.
3.88
500 ENGINE
CYLINDER HONE If cylinder wear or damage is excessive, it will be

necessary to replace the cylinder. Hone only enough
SELECTION/HONING to deglaze the outer layer of the cylinder bore.
PROCEDURE
CAUTION:
A hone which will straighten as well as remove

material from the cylinder is very important. Using a
common spring loaded glaze breaker for honing is not
advised for nicasil cylinders. Polaris recommends
using a rigid hone or arbor honing machine. EXAMPLE OF CROSS HATCH PATTERN
Cylinders may be wet or dry honed depending upon
the hone manufacturer’s recommendations. Wet
honing removes more material faster and leaves a HONING TO OVERSIZE
more distinct pattern in the bore.
If cylinder wear or damage is excessive, it will be
necessary to oversize the cylinder using a new
HONING TO DEGLAZE oversize piston and rings. This may be accomplished
by either boring the cylinder and then finish honing to
A finished cylinder should have a cross-hatch pattern the final bore size, or by rough honing followed by
to ensure piston ring seating and to aid in the retention finish honing.
of the fuel/oil mixture during initial break in. Hone
cylinder according to hone manufacturer’s For oversize honing always wet hone using honing oil
instructions, or these guidelines: and a coarse roughing stone. Measure the piston (see
piston measurement) and rough hone to the size of the
G Use a motor speed of approximately piston. Always leave .002 - .003″ (.05 - .07 mm) for
300-500 RPM, run the hone in and finish honing. Refer to piston-to-cylinder clearance
out of the cylinder rapidly until cutting specifications at the beginning of the chapter before
tension decreases. Remember to honing. Complete the sizing with fine grit stones to
keep the hone drive shaft centered provide the proper cross-hatch finish and required
(or cylinder centered on arbor) and to piston clearance.
bring the stones approximately 1/2″
(1.3 cm) above and below the bore at A finished cylinder should have a cross-hatch pattern
the end of each stroke. to ensure piston ring seating and to aid in the retention
of the fuel/oil mixture during initial break in. Hone
G Release the hone at regular intervals cylinder according to hone manufacturer’s
and inspect the bore to determine if instructions, or these guidelines:
it has been sufficiently deglazed, and
to check for correct cross--hatch.
NOTE: Do not allow cylinder to G Use a motor speed of approximately
heat up during honing. 300-500 RPM, run the hone in and
G After honing has been completed, out of the cylinder rapidly until cutting
inspect cylinder for thinning or tension decreases. Remember to
peeling. keep the hone drive shaft centered
(or cylinder centered on arbor) and to
IMPORTANT: Clean the Cylinder After Honing bring the stone approximately 1/2″
It is very important that the cylinder be thoroughly (1.3 cm) beyond the bore at the end
cleaned after honing to remove all grit material. Wash of each stroke.
the cylinder in a solvent, then in hot, soapy water. Use G Release the hone at regular intervals
electrical contact cleaner if necessary to clean these and inspect the bore to determine if
areas. Rinse thoroughly, dry with compressed air, it has been cleared, and to check
and oil the bore immediately with Polaris 4 Cycle piston fit. NOTE: Do not allow
Lubricant to prevent the formation of surface rust. cylinder to heat up during honing.
The thinner areas of the liner around
the ports will expand causing an
uneven bore.
3.89
500 ENGINE
G After honing has been completed

inspect all port opening areas for
rough or sharp edges. Apply a slight
chamfer to all ports to remove sharp
edges or burrs, paying particular
attention to the corners of the intake
and exhaust ports.
IMPORTANT: Clean the Cylinder After Honing
It is very important that the cylinder be thoroughly

cleaned after honing to remove all grit material. Wash
the cylinder in a solvent, then in hot, soapy water. Use
electrical contact cleaner if necessary to clean these
areas. Rinse thoroughly, dry with compressed air,
and oil the bore immediately with Polaris 4 Cycle
Lubricant to prevent the formation of surface rust.
5. Remove ratchet pawl with spring and inspect.
Replace spring or ratchet pawl if worn, broken, or
RECOIL damaged.
DISASSEMBLY/INSPECTION
CAUTION: Recoil is under spring tension. A face
shield or eye protection is required during this
procedure.
Replace any parts found to be worn or damaged.

1. Remove bolts and recoil housing from engine.
2. Pull recoil rope so it is extended approximately
12-18″.Check handle c-ring for proper tension
and the handle for cracks or damage which may
allow water or dirt to enter the recoil housing.
NOTE: The handle must seal tightly on the recoil
housing to prevent water and dirt from entering.
3. Remove center bolt from recoil friction plate (A).
NOTE: Long arm of spring engages reel. Short end
rests against pawl.
6. Hold reel firmly in housing. Pull rope handle until
A 12-18″ of rope is exposed, and hold reel in place.
4. Inspect plate for wear or damage. Inspect plate

friction spring for wear, damage, and proper
tension. The spring should fit tightly on friction
plate.
3.90
500 ENGINE
7. Place rope in notch on outer edge of reel. To reinstall an old spring:

Release tension on hub and allow reel to unwind
1. Hook outer tab in place in recoil housing and wind
approximately 6-7 turns until spring tension is
spring in a counterclockwise direction one coil at a
released.
time while holding the installed coils in place.
8. Slowly and carefully remove reel from recoil
2. Lubricate the spring with light lubricant such as
housing making sure the spring remains in the
Premium All Season Grease.
housing. Inspect the reel hub and bushing (A) for
wear.
To complete recoil assembly:
A 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 post of the housing and the bushing.
5. Install reel into housing making sure the spring
drive tab on the reel engages the spring and the
reel is fully seated in the housing.
Open end here

9. Unwind rope and inspect for cuts or abrasions.
10. 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.
11. Pull knot out of of recoil reel. Untie knot. Remove
rope from reel.
RECOIL ASSEMBLY
CAUTION: Recoil is under spring tension. A face
shield or eye protection is required during this
procedure.
To install a new spring:
1. Place spring in housing with the end positioned so
the spring spirals inward in a counterclockwise
direction. See photo.
2. Hold spring in place and cut retaining wire.
3.91
500 ENGINE
VALVE SEAT NOTE: Valve seat width and point of contact on the
valve face is very important for proper sealing. The
RECONDITIONING valve must contact the valve seat over the entire
circumference of the seat, and the seat must be the
Valve Seat Inspection proper width all the way around. If the seat is uneven,
compression leakage will result. If the seat is too
Inspect valve seat in cylinder head for pitting, burnt
wide, seat pressure is reduced, causing carbon
spots, roughness, and uneven surface. If any of the
accumulation and possible compression loss. If the
above conditions exist, the valve seat must be
seat is too narrow, heat transfer from valve to seat is
reconditioned. If the valve seat is cracked the cylinder
reduced and the valve may overheat and warp,
head must be replaced.
resulting in burnt valves.
Cylinder Head Reconditioning
1. When thoroughly heated, place cylinder head on
NOTE: Servicing the valve guides and valve seats blocks of wood which will allow the old guides to
requires special tools and a thorough knowledge of be removed.
reconditioning techniques. Follow the instructions 2. Using valve guide driver, drive guides out of the
provided in the cylinder head service tool kit. cylinder head from the combustion chamber side.
CAUTION: Wear eye protection when performing Be careful not to damage guide bore or valve seat
cylinder head service. Valve guide replacement will when removing guides.
require heating of the cylinder head. Wear gloves to 3. Place cylinder head on cylinder head table.
prevent burns. NOTE: Be sure cylinder head is still at 212° F
(100° C) before installing new 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:
A
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. Valve Guide Installed Height
3. Heat cylinder head in an oven or use a hot plate to
bring cylinder head temperature to 212° F (100°
C). CAUTION: Do not use a torch to heat Valve Guide Height:
cylinder head or warpage may result from uneven .689-.709I (17.5-18.0 mm)
heating. Head temperature can be checked with
a pyrometer or a welding temperature stick.
4. Place a new guide in the valve guide installation
Follow the manufacturers instructions provided with
tool and press guide in to proper depth. Check
the valve seat cutters in the Valve Seat
height of each guide above the cylinder head (A).
Reconditioning Kit (PN 2200634). Abrasive stone
NOTE: The guide can also be driven in to the
seat reconditioning equipment can also be used.
proper depth. Inspect the guide closely for cracks
Keep all valves in order with their respective seat.
or damage if a driver is used.
Too Uneven Good Too

Wide Narrow
3.92
500 ENGINE
Reaming The Valve Guide for burrs, nicks, or runout. If the pilot is
bent it must be replaced.
G If the contact area of the cutter is in the
same place, the valve guide is distorted
from improper installation and must be
replaced. Be sure the cylinder head is at
the proper temperature and replace the
guide.
G If the contact area of the initial cut is
greater than 75%, continue to cut the
seat until all pits are removed and a new
seat surface is evident. NOTE: Remove
only the amount of material
necessary to repair the seat surface.
5. 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 (A)
reamer clockwise continually. Continue to rotate
reamer clockwise during removal of the tool.
6. Clean guides thoroughly with hot soapy water and
a nylon brush. Rinse and dry with compressed
air. Apply clean engine oil to guides. 11. To check the contact area of the seat on the valve
7. Install pilot into valve guide. face, apply a thin coating of Prussian Bluet paste
to the valve seat. If using an interference angle
8. Apply cutting oil to valve seat and cutter. (46°) apply black permanent marker to the entire
valve face (A).
12. Insert valve into guide and tap valve lightly into
place a few times.
13. Remove valve and check where the Prussian
Bluet indicates seat contact on the valve face.
The valve seat should contact the middle of the
valve face or slightly above, and must be the
proper width.
G If the indicated seat contact is at the
top edge of the valve face and
contacts the margin area(B) it is too
high on the valve face. Use the 30°
cutter to lower the valve seat.
G If too low use the 60° or 75° cutter to
raise the seat. When contact area is
centered on the valve face, measure
seat width.
9. Place 46° cutter on the pilot and make a light cut.
G If the seat is too wide or uneven, use
10. Inspect the cut area of the seat. both top and bottom cutters to
G If the contact area is less than 75% of the narrow the seat.
circumference of the seat, rotate the pilot G If the seat is too narrow, widen using
180° and make another light cut. the 45° cutter and re-check contact
G If the cutter now contacts the uncut point on the valve face and seat width
portion of the seat, check the pilot. Look after each cut.
3.93
500 ENGINE
A
Valve Seat Width:
Intake Std: .028I (.7 mm)

Limit: .055I (1.4 mm)
Exhaust Std: .039I (1.0 mm)
Limit: .071I (1.8 mm)
Seat
Width
VALVE CLEARANCE
ADJUSTMENT
Bottom - 60° or 75° Seat - 45° or 46°
500 Engine
Top - 30°
NOTE: When using an interference angle, the seat

contact point on the valve will be very narrow, and is
a normal condition. Look for an even and continuous Feeler Gauge for Both Valves
contact point on the black marker, all the way around
the valve face.
14. Clean all filings from the area with hot soapy NOTE:The exhaust valves share a common rocker
water, rinse, and dry with compressed air. arm, and must be adjusted using two feeler gauges.
15. Lubricate the valve guides with clean engine oil, 1. Insert .006 feeler gauge(s) between end of
and apply oil or water based lapping compound to exhaust valve stem and adjuster screw(s).
the face of the valve. Lapping is not required with 2. Loosen locknut(s) and turn adjuster screw(s) until
an interference angle. there is a slight drag on feeler gauge(s). The
16. Insert the valve into its respective guide and lap Valve/Clutch Adjuster Tool (PA--44689) can be
using a lapping tool or a section of fuel line used to adjust the 500 engines valves. NOTE:
connected to the valve stem. Both feeler gauges should remain inserted during
17. Rotate the valve rapidly back and forth until the adjustment of each valve.
cut sounds smooth. Lift the valve slightly off of the
seat, rotate 1/4 turn, and repeat the lapping VALVE CLEARANCE
process. Do this four to five times until the valve is
fully seated, and repeat process for the other .006″ (.15 mm)
valve(s).
3.94
500 ENGINE
SPARK PLUG FOULING Engine Does Not Turn Over

G Dead battery
G Spark plug cap loose or faulty
G Starter motor does not turn
G Choke cable adjustment or
G Engine seized, rusted, or
plunger/cable sticking
mechanical failure
G Foreign material on choke plunger
Engine Runs But Will Not Idle
seat or plunger
G Incorrect spark plug heat range or G Restricted carburetor pilot system
gap G Carburetor misadjusted
G Carburetor inlet needle and seat G Choke not adjusted properly
worn G Low compression
G Jet needle and/or needle jet worn or G Crankcase breather restricted
improperly adjusted
Engine Idles But Will Not Rev Up
G Excessive carburetor vibration
(loose or missing needle jet locating G Spark plug fouled/weak spark
pins) G Broken throttle cable
G Loose jets in carburetor or calibration G Obstruction in air intake
incorrect for altitude/temperature G Air box removed (reinstall all intake
G Incorrect float level setting components)
G PVT system calibrated incorrectly or G Incorrect or restricted carburetor jetting
components worn or mis-adjusted G ETC switch limiting speed
G Fuel quality poor (old) or octane too G Reverse speed limiter limiting speed
high
G Carburetor vacuum slide
G Low compression sticking/diaphragm damaged
G Restricted exhaust G Incorrect ignition timing
G Weak ignition (loose coil ground, G Restricted exhaust system
faulty coil, stator, or ETC switch)
G Cam worn excessively
G ETC switch mis-adjusted
Engine Has Low Power
G Restricted air filter (main or
pre-cleaner) or breather system G Spark plug fouled
G Improperly assembled air intake G Cylinder, piston, ring, or valve wear or
system damage (check compression)
G Restricted engine breather system G PVT not operating properly
G Oil contaminated with fuel G Restricted exhaust muffler
G Restricted oil tank vent G Carburetor vacuum slide
sticking/diaphragm damaged
G Dirty carburetor
TROUBLESHOOTING Piston Failure - Scoring
Engine Turns Over But Fails to Start G Lack of lubrication
G No fuel G Dirt entering engine through cracks in air
G Dirt in fuel line or filter filter or ducts
G Fuel will not pass through fuel valve G Engine oil dirty or contaminated
G Fuel pump inoperative/restricted Excessive Smoke and Carbon Buildup
G Tank vent plugged
G Excessive piston-to-cylinder clearance
G Carb starter circuit
G Wet sumping
G Engine flooded
G Worn rings, piston, or cylinder
G Low compression (high cylinder
leakage) G Worn valve guides or seals
G No spark (Spark plug fouled) G Restricted breather
G Air filter dirty or contaminated
3.95
500 ENGINE
Low Compression G Water pump failure

G Decompressor stuck G Cooling system restriction
G Cylinder head gasket leak G Cooling fan inoperative or turning too
slowly (perform current draw test)
G No valve clearance or incorrectly
adjusted G Ignition timing misadjusted
G Cylinder or piston worn G Low oil level
G Piston rings worn, leaking, broken, or G Spark plug incorrect heat range
sticking G Faulty hot light circuit
G Bent valve or stuck valve G Thermostat stuck closed or not opening
G Valve spring broken or weak completely
G Valve not seating properly (bent or Temperature Too Low
carbon accumulated on sealing surface) G Thermostat stuck open
G Rocker arm sticking Leak at Water Pump Weep Hole
G Cam worn excessively
G Faulty water pump mechanical seal
Backfiring (coolant leak)
G ETC or speed limiter system malfunction G Faulty pump shaft oil seal (oil leak)
G Fouled spark plug or incorrect plug or
plug gap
G Carburetion faulty - lean condition
G Exhaust system air leaks
G Ignition system faulty:
Spark plug cap cracked/broken
Ignition coil faulty
Ignition or kill switch circuit faulty
Ignition timing incorrect
Sheared flywheel key
G Poor connections in ignition system
G System wiring wet
G Valve sticking
G Air leaks in intake
G Lean condition
COOLING SYSTEM
TROUBLESHOOTING
Overheating
G Low coolant level
G Air in cooling system
G Wrong type of coolant
G Faulty pressure cap or system leaks
G Restricted system (mud or debris in
radiator fins or restriction to air flow,
passages blocked in radiator, lines,
pump, or water jacket)
G Lean mixture (restricted jets, vents, fuel
pump or fuel valve)
G Fuel pump output weak
G Restricted radiator (internally or cooling
fins)
3.96
500 ENGINE
NOTES
3.97
FUEL SYSTEM/CARBURETION
Exploded View, Mikuni BST 34 Carburetor . . . 4.2

Exploded View, Mikuni BST 40 Carburetor . . . 4.3
Fuel Tank Asm. Exploded View . . . . . . . . . . . . 4.4--4.5
Fuel Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . 4.4--4.5
Special Tool & Jetting Guidelines . . . . . . . . . . 4.6
Carburetor Jetting . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Main Jet / Pilot Jet Part Numbers . . . . . . . . . . . 4.6
CV Carburetor System Function (4 Cycle) . . . 4.7
CV Carburetor Vent System (4 Cycle) . . . . . . . 4.7
CV Carburetor Operation . . . . . . . . . . . . . . . . . . 4.7-4.9
Disassembly, CV Carburetor . . . . . . . . . . . . . . . 4.10-4.11
Cleaning, CV Carburetor . . . . . . . . . . . . . . . . . . 4.11
Inspection, CV Carburetor . . . . . . . . . . . . . . . . . 4.11--4.12
Assembly, CV Carburetor . . . . . . . . . . . . . . . . . 4.12-4.13
Float Adjustment, CV Carburetor . . . . . . . . . . . 4.13
Needle & Seat Leakage Test . . . . . . . . . . . . . . . 4.14
Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Fuel Pump Service . . . . . . . . . . . . . . . . . . . . . . . 4.14--4.15
Fuel Pump Exploded View . . . . . . . . . . . . . . . . . 4.15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
4.1
1. Ring
BST 34 CARBURETOR EXPLODED VIEW 2. E--Ring
Torque 3. Jet Needle
Specifications 4. Ring
11. 16 in.lbs. 5. Diaphragm
1 (1.8 Nm) 6. Needle Jet
2 20. 18 in.lbs.
51* 7. Screw
3 (2 Nm)
8. Spring Washer
22. 18 in.lbs.
4 (2 Nm) 9. Jet Block
50 24. 9 in.lbs. 10. Washer
(1 Nm) 11. Main Jet
27. 7 in.lbs. 12. Cap
(0.8 Nm)
5 41. 18 ± 4.4 in.lbs.
13. Seal
49 (2 ± 0.5 Nm) 14. Packing
44. 31 in.lbs. 15. E--ring
7 (3.5 Nm)
6 16. Cap
8 47. 10.5 in.lbs.
44* (1.2 Nm)
17. Float Pin
18. Plate
45 51. 18 in.lbs.
19. O--ring
46 (2 Nm)
47* 20. Screw
9 42 21. Float Body Assy.
48 43
41* 22. Screw.
23. Float Assy.
10 40
24. Screw
11*
39 25. Needle Valve
12 26. O--ring
27. Pilot Jet
37
36 38 28. O--ring
13
15 14 13 29. Washer
16 30. Spring
35
31. Adjuster
27*
34 32. Adjuster Screw
26 28
17 29 33. Ring.
33
30 34. Spring
25 32 35. Throttle Valve
31
36. Spring
37. Ring
38. Screw
18 39. Throttle Shaft
24*
23 1 40. Cable Guide
2
3 41. Screw
4 42. Cover
5 43. O--ring
19 44. Guide Holder
45. Spring
22*
Jet Needle 46. Plunger Assy.
“E” Clip Position 47. Air Jet
48. Carburetor Assy.
21 49. Spring
20* Refer to Page 4.4 for Jet Part Numbers
50. Cover Assy.
51. Screw
4.2
1. Cable Guide
BST 40 CARBURETOR EXPLODED VIEW 2. Throttle Shaft Assy.
3. Ring
500 Engine Carburetor 4. Spring
37* 12* 5. Screw

6. Washer
7. Case
11 8. Air Jet
9 10 9. Carburetor
13 10. Plunger Assy.
15 14
11. Spring
8* 12. Plunger Cap
17 13. Cap
16 14. E--Ring
7
15. Packing
6 16. Seal
5 19* 17. Screw
18
21 20 18. Throttle Valve
4
16 19. Pilot Jet
3
20. Needle Valve
36
2 21. O--Ring
22. O--Ring
23. Cover
22 24. Screw
35
24 25. Throttle Adjuster Spring
23
34 26. Washer
28
1 33* 27. Cable Adjuster
28. Clip
25 *5
29. Guide Screw
31*
32 30. O--Ring
26
30 31. Main Jet
27 32. Ring
29 33. Screw
34. Float Body Assy.
Torque 35. Seal
Specifications 36. Float Assy.
31. 16 in.lbs.
37. Screw
(1.8 Nm)
5. 18 in.lbs.
(2 Nm)
33. 18 in.lbs.
(2 Nm) 1
19. 7 in.lbs. 2
(0.8 Nm) 3
24. 18 ± 4.4 in.lbs. 4
(2 ± 0.5 Nm) 5
12. 31 in.lbs.
(3.5 Nm)
8. 10.5 in.lbs.
(1.2 Nm) Jet Needle
37. 18 in.lbs. “E” Clip Position
(2 Nm)
Refer to Page 4.5 for Jet Part Numbers
4.3
2004 FUEL TANK ASSEMBLY
1. Carburetor Mount ATP 330/500

Hardware
2. Carburetor
3. Seal Foam 1
4. Fuel Cover Brackets
5
5. Fuel Valve Knob
6. Vent Line 2
7. Fuel Tank
3
8. Fuel Valve Assy.
9. Main Fuel Outlet 4
10. Reserve Fuel Outlet
6
10 9
FUEL FLOW
Fuel Tank Vent Fuel Tank
Fitting Screens
L Fuel Pump Filter Fuel Valve
Carburetor Vent
Carburetor Engine
L Located Under Left Front Fender
4.4
2005 FUEL TANK ASSEMBLY
1. Carburetor Mount ATP 330/500

Hardware 1
2. Carburetor
3. Seal Foam
4. Fuel Cover Brackets
9
5. Fuel Valve Knob 2
6. Vent Line
3
7. Fuel Tank
8. Fuel Valve Assy.
9. Gas Cap/Gauge 4
10. Dual Fuel Outlet
10
5
FUEL FLOW
Fuel Tank Vent Fuel Tank
Fitting Screens
L Fuel Pump Filter Fuel Valve
Carburetor Vent
Carburetor Engine
L Located Above Oil Tank
4.5
SPECIAL TOOLS outside this temperature and/or altitude range. The

jetting installed in production is not intended for all
PART NUMBER TOOL altitudes and/or temperatures. In addition, air screw
DESCRIPTION / pilot screw adjustments and PVT adjustments may
2870975 Mity Vact be required to suit operating conditions.
Pressure Test Tool
2872314 Carburetor Float
Adjustment Tool CARBURETOR JETTING
WARNING
CAUTION:
Gasoline is extremely flammable and explosive under
certain conditions. A main jet that is too small will cause a lean
operating condition resulting in serious engine
damage. Select the correct main jet carefully for
Always stop the engine and refuel elevation and temperature according to the
outdoors or in a well ventilated area. jetting charts in the Owner’s Safety and
Maintenance Manual for each particular model.
Do not overfill the tank. The tank is at
IMPORTANT: The following guidelines must be
full capacity when the fuel reaches the
bottom of the filler neck. Leave room followed when establishing a main jet setting:
for expansion of fuel. 1. Select the lowest anticipated temperature at
which the machine will be operated.
Never start the engine or let it run in an 2. Determine the lowest approximate altitude at
enclosed area. Gasoline powered engine which the machine will be operated.
exhaust fumes are poisonous and can
cause loss of consciousness and death in 3. Select the correct main jet from the chart below.
a short time. 4. Clutching changes may also be required for
changes in elevation. Refer to clutching chart in
Chapter 1 for recommendations.
Never drain the float bowl when the engine
is hot. Severe burns may result.
MIKUNI JET PART NUMBERS
Do not smoke or allow open flames or
sparks in or near the area where refueling Main Jets Pilot Jets
is performed or where gasoline is stored. Jet Number Part Number Jet Number Part Number
112.5 3130554 40.0 3130624
115 3130555 42.5 3130526
If you get gasoline in your eyes or if you 117.5 3130556
should swallow gasoline, seek medical 120 3130557
attention immediately. 122.5 3130558
125 3130559
If you spill gasoline on your skin or clothing, 127.5 3130560
immediately wash with soap and water and 130 3130561
change clothing. 132.5 3130562
135 3130563
137.5 3130564
140 3130527
JETTING GUIDELINES 142.5 3130566
145 3130567
Changes in altitude and temperature affect air density, 147.5 3130568
which is essentially the amount of oxygen available for 150 3130569
combustion. In low elevations and cold temperatures, 152.5 3130570
the air is more dense and has more oxygen. In higher 155 3130571
elevations and higher temperatures, the air is less 157.5 3130572
dense with reduced oxygen. 160 3131141
162.5 3131142
Polaris ATP Carburetors are calibrated for an altitude 165 3131143
of 0-6000 ft. (0-1800 meters) and ambient 167.5 3131144
temperatures between +40 and +80° F (+5° to +26° 170 3131145
C). Carburetors must be re-calibrated if operated
4.6
CV CARBURETOR SYSTEM VENT SYSTEMS - CV

FUNCTION CARBURETOR
The carburetor float bowl vent lines supply
Carburetor Component Function
atmospheric pressure to the float bowl. The lines
must be free of kinks, restrictions and be properly
System Main Main Main routed. This allows fuel to flow in the proper amount
Components Function Affect and prevents contaminants from entering the
Float Inlet Pipe, Maintains All systems carburetor.
System Needle and specified All throttle
(Level Control) Seat, Float, fuel level in ranges MIKUNI CV CARB
Float Pin float cham-
ber (carbu- OPERATION
retor float
bowl)
The constant velocity carburetor incorporates a
Venting Passages in Supplies All systems mechanically operated throttle plate and a vacuum
Carburetor, atmospheric All throttle
Vent lines pressure to ranges
controlled slide valve (vacuum slide). The venturi
to frame float cham- cross-sectional area in the carburetor bore is
ber increased or decreased automatically by the vacuum
slide, which moves according to the amount of
Starter Choke Lever, Supplies All throttle
(Choke/En- Cable, Plung- additional ranges
negative pressure (less than atmospheric) present in
richment) er, Return fuel air mix- Greatest ef- the venturi.
Spring, Carb ture neces- fect at low
Passages sary for cold throttle set-
A diaphragm attached to the top of the vacuum slide
(Starter Jet, starting tings and is sealed to the slide and to the carburetor body
Starter Bleed idle forming two chambers. The chamber above the
Pipe) diaphragm is connected to the venturi area by a drilled
Pilot (Idle Pilot Jet/ Primarily Mainly idle orifice in the center of the vacuum slide. The chamber
System) Passage- supplies fuel to 1/4 below the diaphragm is vented to atmospheric
ways, Pilot- at idle and throttle pressure by a passage on the air box side of the
Mixture low throttle Minimal ef- carburetor. A spring, installed in the center of the
Screw with positions fect after 1/2 vacuum slide, dampens the slide movement and
Spring throttle assists the return of the slide.
Washer and
Sealing O-
Ring, By- Low Pressure
Diaphragm From Venturi
pass Ports Air Box
(Behind Pressure
Throttle
Plate), Pilot
Air Jet, Pilot
Outlet,
Throttle
Plate From
Air Box
Main Sys- Main Jet, Supplies 1/4 to full
tem Main Air Jet, fuel at mid- throttle
Main Air range and
Passage, high throttle Vacuum
Throttle Slide
Needle Jet, settings.
Plate
Jet Needle,
Vacuum
Slide,
Throttle
Plate
Venturi
= Air Flow = Low Pressure
4.7
CARBURETOR OPERATION CONT’D
When the throttle plate is opened and engine speed

begins to increase, the pressure in the venturi (and
therefore in the chamber above the diaphragm) 4
becomes significantly lower than atmospheric.
Atmospheric pressure in the chamber below the
diaphragm forces the diaphragm upward, raising the
slide against spring pressure. When the pressure 1
above and below the diaphragm are nearly equal, the
slide moves downward under spring pressure. 6
Raising or lowering the slide increases or decreases
the cross sectional area in the venturi, and therefore
the air velocity in the venturi is kept relatively constant.
7
This provides improved fuel atomization and optimum
fuel/air ratio.
5
2
Low Pressure
Diaphragm From Venturi 3
Vacuum
Slide
STARTER SYSTEM (CHOKE

From
Air Box
OR ENRICHMENT)
When the choke cable (1) is activated, the starter
plunger (5) is lifted off the seat.
8
5
Throttle 1
Plate
Venturi
6
7
= Low Pressure
4
= Air Flow
Note: Diagrams are for explanation of theory only, and are not true 2
representations of Mikuni BST carburetor.
PILOT (IDLE AND SLOW) Fuel is drawn into the starter circuit from the float
chamber (2) through the starter jet (3). Starter jet
SYSTEM meters this fuel, which then flows into starter pipe (4)
and mixes with the air (7) coming from the float
This system supplies fuel during engine operation
chamber. The mixture, rich in fuel content, reaches
with throttle valve closed (1) or slightly opened. The
starter plunger and mixes again with the air coming
fuel from float chamber (2) is metered by pilot jet (3)
through a passage (8) extending from underneath the
where it mixes with air coming in through pilot air jet
diaphragm. The rich fuel/air mixture for starting is
(4). The mixture then goes up through pilot passage
discharged through starter outlet (6) in the the main
to pilot screw (5). A part of the mixture is discharged
bore.
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).
4.8
FLOAT SYSTEM
Fuel enters the float chamber (3) by means of the inlet
pipe and passage, through a screen on the back of the
inlet needle seat (4), and around the inlet needle (2).
As the fuel fills the float chamber, the float (1) rises and 1
forces the inlet needle against the seat, shutting off 2
the orifice in the seat. When fuel level is up in float
chamber, floats are up and needle valve remains
pushed up against valve seat. Under this condition,
no fuel enters the float chamber. As the fuel level falls, 7
floats go down and needle valve unseats itself to
admit fuel into the chamber. In this manner, the
needle valve admits and shuts off fuel alternately to A
6
maintain a practically constant fuel level inside the
float chamber.
3
5
Inlet
Pipe
1 3
4
2
MAIN SYSTEM
As throttle valve (1) is opened, engine speed rises,
and this increases negative pressure in the venturi.
Consequently the vacuum slide (2) moves upward.
The fuel in float chamber (3) is metered by main jet (4),
and the metered fuel enters needle jet (5), in which it
mixes with the air admitted through main air jet (6) to
form an emulsion. The emulsified fuel then passes
through the clearance between needle jet (5) and jet
needle (7), and is discharged into the venturi (A).
Mixture proportioning is accomplished in needle jet
(5); the clearance through which the emulsified fuel
must flow is determined ultimately by throttle position
and vacuum slide height.
4.9
PILOT SCREW may be permanently damaged.
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 tampering. Removal of the tamper proof plug
is not permitted. For service purposes, cleaning of the pilot
circuit can be done only by a certified repair shop to ensure air
quality standards are not exceeded.
2. Remove float bowl and carefully remove the

pressed float pin.
Support Here
Pilot Screw location
Brass Plug Installed

NOTE: Be careful not to damage the float pin tower
during the float pin removal. Support the float pin
tower while removing the float pin. This helps to
prevent the float pin towers from breaking off.
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.
Brass Plug Removed
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 4. Remove the pilot mixture screw, spring, flat
impact driver to remove the screws or carburetor washer, and O-Ring. If an anti-tamper plug is
4.10
installed over the pilot screw cavity, it must be 1. Thoroughly clean the carburetor body, jets, and
removed for access. all passages with carburetor cleaner or electrical
contact cleaner.
2. If the carburetor is extremely dirty or
contaminated with fuel residue and varnish, soak
for short periods only in carburetor cleaner, and
O-Ring rinse in hot water.
Washer 3. Replace the jets if they have a buildup of fuel
Spring residue or bacterial growth that cannot be
removed. Even a small amount of residue will
reduce the flow characteristics of the jet.
Pilot Screw 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.
NOTE: The starter jet is not removeable. Upon 5. Use low pressure air to dry carburetor body and
disassembly, place the parts in a container for safe all components.
keeping.
CARBURETOR INSPECTION
Pilot Screw
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
Starter Jet 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.
CARBURETOR CLEANING
WARNING
Jet Needle Needle Jet
Protect eyes from contact with cleaner. Take
appropriate safety measures during these
procedures. Safety glasses and chemical resistant Inspect this
gloves are required. Should you get cleaner in your area
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 not soak
rubber or plastic components (such as the vacuum
slide diaphragm, needle seat screen, or O-Rings in
caustic cleaning solutions. Irreparable damage may
occur. Do not use agitator--type carburetor cleaning 2. Inspect the inlet needle tapered surface for any
equipment. Rubber parts must be cleaned with mild sign of wear or damage. Be sure the spring
detergent and hot water only. loaded pin is free moving and returns freely when
pushed. The inlet needle and seat should be
4.11
pressure tested after assembly. CARBURETOR ASSEMBLY

Inspect the diaphragm (A) for holes, deterioration, or
damage. Make sure the diaphragm is pliable but not
Good Condition Worn, Deposits swollen. The diaphragm should fit properly in the
carburetor body. Replace diaphragm assembly if
diaphragm is damaged.
Seat
Wear areas
Needle
B C
D
A
E
3. Replace parts in proper order. The spring seat

washer (B) is stepped and must be placed on
TOP of “E” Clip (C). Spacer washer (D) must be
installed below the E-Clip. Refer to parts manual
for more information.
4. Be sure the tab (E) on outer edge of diaphragm is
positioned properly in the carburetor body.
Pilot Screw
4.12
CARBURETOR ASSEMBLY CONT’D BST 40

5. 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 2.13.
Pilot Mixture Screw Base Setting

(Set at Factory)
Refer to Specifications Page 1.4 BST 34
FLOAT HEIGHT
ADJUSTMENT
1. Place the carburetor on a level surface as shown
at right to remove weight from float arm. In this
position, the float tongue will rest lightly on the
inlet needle valve pin without compressing the
spring.
2. Measure the height from the float bowl mating

surface to the top of step in float as shown. Both
sides of float should be parallel to each other. The
measurement should be made at the mid-point on
the 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.
3. If adjustment is necessary, bend the tongue
slightly. Be sure float measurement is even on left
and right side.
Float arms even

Float Height:
Std: BST 34 13.0mm (.51″) ± 1 mm

BST 40 14.7mm (.58″) ± 1 mm
NOTE: On BST 40 carburetors, it is important to

press in on the float assembly as shown, to fully seat
the float assembly.
Bend to adjust
float
4.13
NEEDLE AND SEAT

LEAKAGE TEST
1. Install the float bowl. Invert the carburetor and
install a Mity-Vact (PN 2870975) to the fuel inlet
fitting. Apply 5 PSI pressure to inlet fitting. The
needle and seat should hold pressure indefinitely.
1.5 mm
If not, inspect needle and seat and seat O-ring.
.060″
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.
FUEL PUMP
This Polaris ATP is equipped with a pressure
regulated fuel pump (1-3 PSI). The pump is located
Mity Vact (PN 2870975) under the left front fender of the machine.
To test the fuel pump:
1. Turn fuel off.
2. Disconnect impulse line from pump.
FUEL LEVEL 3. Connect Mity-Vact (PN 2870975) to the impulse
line fitting on the pump.
A fuel level test can be performed on some models if 4. Apply 5 inches (Hg) vacuum to the pump fitting.
the drain hose fitting is accessible. Be sure to The diaphragm should hold vacuum indefinitely.
re-attach the bowl drain hose after performing the
test. A fuel level test allows you to observe the height If fuel is present in the impulse line or vacuum
of the fuel in the float bowl without removing the chamber of the pump, the diaphragm is ruptured. The
carburetor. The fuel level can be observed with the pump diaphragms must be replaced.
engine either running or shut off, however, engine
must run briefly to allow fuel level to stabilize..
Fuel Pump
1. Attach a clear line to drain fitting. Be sure line fits
tightly on fitting. Position hose along side of
carburetor as shown.
Fuel Filter
Impulse line
4.14
FUEL PUMP DISASSEMBLY FUEL PUMP EXPLODED

1. Remove the screws from the pump diaphragm VIEW
cover. Note the location of the two longer screws.
1. Fuel Pump Assembly
2. Remove the diaphragm cover gasket,
2. Diaphragm, Gasket Set
diaphragm, and valve body gasket. 3. Screw and Washer Assembly
3. Remove the outlet check valve cover, diaphragm, 4. Screw and Washer Assembly
and gasket. 5. Screw and Washer Assembly
6. Pressure Regulator
7. Fuel Inlet
FUEL PUMP 8. Fuel Outlet
INSPECTION/ASSEMBLY
1. Inspect inlet and outlet check valves for cracks, 4 5
warpage or damage. Inspect the diaphragms for
cracks, holes or swelling.
2. To clean the valves or pump body, remove the set 5
screw and washer. Remove the valve and wash
with soap and water. Carburetor cleaner may be
used to clean the pump body when the check
valves are removed. CAUTION: Some
carburetor cleaners are very caustic and should
not be used to clean the non-metal parts of the
fuel pump.
3. Check the sealing surfaces of the pump body and
covers. Carefully remove all traces of old gasket
and check the surfaces for damage. Replace
diaphragms and gaskets as a set.
4. Reassemble the pump in the reverse order of
disassembly. Tighten all screws evenly.
3
2
8 1
4.15
TROUBLESHOOTING G Loose jets

G Worn jet needle/needle jet or other
FUEL STARVATION/LEAN MIXTURE carburetor parts
G Dirty carburetor (air bleed
Symptoms: Hard start or no start, bog, backfire, passages or jets)
popping through intake / exhaust, hesitation,
detonation, low power, spark plug erosion, engine G Weak or damaged vacuum piston
runs hot, surging, high idle, idle speed erratic. return spring
G No fuel in tank G Fouled spark plug
G Restricted tank vent, or routed
improperly POOR IDLE
G Fuel lines or fuel valve restricted Idle Too High
G Fuel filter plugged G Idle adjusted improperly/idle
G Carburetor vent line(s) restricted mixture screw damaged
G Plugged or restricted inlet needle G Sticky vacuum slide
and seat screen or inlet passage G Throttle cable sticking, improperly
G Clogged jets or passages adjusted, routed incorrectly
G Float stuck, holding inlet needle G Choke cable sticking, improperly
closed or inlet needle stuck adjusted, routed incorrectly
G Float level too low G Plugged or restricted idle jet
G Fuel pump inoperative
G Air leak at impulse line Idle Too Low
G Restricted impulse line (kinked, G Choke cable bending or incorrectly
pinched) adjusted
G Intake air leak (throttle shaft, intake G Idle speed set incorrectly
ducts, airbox or air cleaner cover) G Idle mixture screw misadjusted or
G Ruptured vacuum slide diaphragm, damaged
Vacuum slide stuck closed or sticky G Belt dragging
G Improper spring G Ignition timing incorrect
G Jet needle position incorrect G Worn jet needle/needle jet
G Incorrect pilot screw adjustment G Plugged or restricted idle jet
RICH MIXTURE Erratic Idle

Symptoms: Fouls spark plugs, black, sooty exhaust G Choke cable bending or incorrectly
smoke, rough idle, poor fuel economy, engine runs adjusted
rough/ misses, poor performance, bog, engine loads G Throttle cable incorrectly adjusted
up, backfire. G Air leaks, dirty carburetor passages
G Air intake restricted (inspect intake (pilot circuit)
duct) G Pilot mixture screw damaged or
G Air filter dirty/plugged adjusted incorrectly
G Choke plunger sticking, incorrectly G Tight valves
adjusted choke G Ignition timing incorrect
G Choke cable binding or improperly G Belt dragging
routed
G Dirty air cleaner
G Incorrect pilot air/fuel screw
adjustment G Engine worn
G Faulty inlet needle and seat G Spark plug fouled
G Faulty inlet needle seat O-Ring G Idle speed set incorrectly (speed
limiter)
G Float level too high
G Worn jet needle/needle jet
G Poor fuel quality (old fuel)
G Plugged or restricted idle jet
4.16
BODY/STEERING/SUSPENSION
Torque Specifications and Special Tools . . . . . . . . 5.2

Body Assembly, Exploded View . . . . . . . . . . . . . . . 5.3
Rear Box Assembly, Exploded View . . . . . . . . . . . 5.4
Front Box Assembly, Exploded View . . . . . . . . . . . 5.5
Front Cab & Cover / Side Panel Removal . . . . . . 5.6
Front / Rear Cargo Box Removal & Installation . . 5.7--5.8
ATP 330 Instrument Pod Exploded View . . . . . . . 5.9
ATP 500 Headlight Pod Exploded View . . . . . . . . 5.10
Steering Assembly, Exploded View ATPs . . . . . . . 5.11
A-Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Shaft Ride Assembly Exploded View . . . . . . . . . . 5.13
Shaft Ride Swingarm Removal/Installation . . . . . . 5.13--5.15
Strut Assembly Exploded View 4x4 . . . . . . . . . . . . 5.16
Front Strut Cartridge Replacement . . . . . . . . . . . . 5.17
Front Strut Ball Joint Replacement . . . . . . . . . . . . 5.17--5.18
Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
Steering Post Assembly . . . . . . . . . . . . . . . . . . . . . . 5.18
5.1
SPECIAL TOOLS TORQUE SPECIFICATIONS

PART NUMBER TOOL NOTE: Refer to exploded views throughout this
DESCRIPTION chapter for identification and location of components.
2870871 Ball Joint ITEM TORQUE
Replacement Tool Front A-Arm Attaching Bolt 30 ft. lbs.
2870872 Shock Spanner (41 Nm)
Wrench
Front A-Arm Ball Joint Stud 10-12 ft. lbs.
2870623 Shock Absorber Nut (14-17 Nm)
Spring
Compression Tool Rear Shock Bolt (upper & 25 ft. lbs.
2871572 Strut Rod Wrench
lower) (35 Nm)
2871573 LH Strut Spring Strut Rod Retaining Nut (Top) 15 ft. lbs.
Compressor (21 Nm)
2871574 RH Strut Spring Strut Casting Pinch Bolt 15 ft. lbs.
Compressor (21 Nm)
7052069 Charging Needle Tie Rod End Jam Nut 12-14 ft. lbs.
2200421 Gas Shock (17-19 Nm)
Recharging Kit Tie Rod End Castle Nut 23-24 ft. lbs.
2871352 Shock Rod (32-33 Nm)
Holding Tool Tie Rod End Attaching Bolt 25-30 ft. lbs.
2871199 Seal Sleeve (35-41 Nm)
Installation Tool Kit
2871017 Foxt Body
Holding Tool
2871351 Foxt Shock IFP
Depth Tool
WHEEL, HUB, AND SPINDLE
TORQUE TABLE
ATP 330 4x4 Nuts (37 Nm)
Rear Wheel 27 Ft. Lbs.
ATP 500 4x4
Nuts (37 Nm)
Retaining Nut (95 Nm)
Retaining Nut (108 Nm)
5.2
BODY ASSEMBLY EXPLODED VIEW
O N
L
I
M
K
J
P
G
L
H
A. Front Cab
B. Splash Guards
C. Mud Guard
D. Side Shield F
E. Frame
F. Skid Plate
G. Footwell
H. Frame Extension
I. Seat Assy.
D
J. Seat Latch
K. Compartment Cover C
L. Rear Compartment
M. Mud Guard
N. Rear Compartment Support
O. Seat Latch
A
P. Rear Cab
5.3
BOX ASSEMBLY EXPLODED VIEW

A. Dump Box Shock
B. Box Latch
C. Box Frame
L
D. Side Bumpers M
E. Box Base
F. Taillight Assy.
G. Tailgate Support I
H. Tiedown
I. Tailgate Pivot
K
J. Tailgate Latch
K. Tailgate Rod Latch Assy.
L. Tailgate H
M. Tailgate Cable
D
If Not Equipped: Tailgate Bumper
Available to Help Minimize Noise J
(PN 5412520)
G
F
C
A D
5.4
FRONT BOX ASSEMBLY EXPLODED VIEW
H J
K
A. Radiator Brush Guard

B. Radiator Side Shield
C. Extensions
D. Rack Mount
E. Bumper
F. Front Rack Support L
G. Storage Box Assy. B A
H. Box Seal
I. Box Latch
J. Lid Channel
K. Box Latch
L. Headlight
5.5
COVER/PANEL REMOVAL G 3 screws from bottom right mudflap

G 1 inner screw from front cab to foot
To remove, perform these steps: rest on each side
Seat: G 2 screws under front panel
G Pull release lever at the rear of the seat
G Lift and pull seat rearward, disengaging SIDE PANEL REMOVAL
seat from tabs at the rear of the fuel tank
Side Panels 1. Remove seat. Grasp rear of panel near rear cab.
With a quick and firm motion, pull panel forward
G Remove: Seat and outward to disengage the two rear tabs.
G Disengage tabs at front and rear
Headlight Pod (See Page 5.5--5.6) Step 1.
Front Cover
G Remove: Seat
G Disengage tabs at front and rear
G Lift panel out
Rear Rack
Pull forward and out to disengage
G Remove: Seat
two rear tabs.
G 2 bolts at rear of rack
G 2 bolts at front of rack
2. Place hand on top of side panel behind the fuel
Rear Cab Assembly tank. With a quick and firm motion, push down on
G Remove: Seat the side panel to disengage the top rear tabs.
G Rear rack Then pull up on side panel to disengage front
tabs.
G 1 screw, nut and washer at rear of inner
left footrest
G 4 screws at bottom of left rear mudflap Step 2.
G 1 screw, nut and washer at rear of inner
right footrest
G 4 screws at bottom of right rear mudflap
G 4 bolts and flat washers from top of cab
assembly, under seat
G 2 screws at rear bottom of cab assembly Push down to disengage top rear
near tail light two tabs.
G Disconnect taillight harness 3. To reinstall side panel, align panel tabs with slots
on front cab. Push panel upward and forward until
Front Rack
tabs lock. Bend rear of side panel and insert the
G Remove: 4 screws, lock washers, and two tabs into the rear cab.
flat washers
Front Cab Assembly
G Remove: Seat
G Side panels
G 2 screws at rear of cab at fuel tank
mount bracket
G Front rack
G Front bumper
G Front cover panel
G 3 screws from bottom left mudflap
5.6
Step 3.
A
B
D 11 ft.lbs. (15Nm)
To reinstall, align panel tabs with slots.
Push upward and forward until tabs lock.
27 in.lbs. (3 Nm)
FRONT STORAGE BOX
REMOVAL/INSTALLATION Storage Box Latch Replacement
5. Remove the bolt on the inside of the latch.
1. Open the lid of the front storage box.
Remove the tightening nut, then pull the latch
assembly out.
A
B Remove Tightening Nut
Remove Bolt
2. Remove the 4 bolts that mount the box to the

frame. Remove the two bolts and nuts that
secure the box to the fenders.
REAR BOX
REMOVAL/INSTALLATION
A 1. Lift the box into the dump position.
B
D 4 Bolts
2 Bolts & Nuts
3. Carefully lift the storage box off of the front of the

ATP.
4. Reverse the steps Steps 1--3 for storage box
installation. Torque the 4 storage box bolts to 11
ft.lbs.(15 Nm) and the two bolts to 27 in.lbs. (3 Nm).
5.7
2. Remove the hitch pin for the dump box shock. 3. Remove the three bolts on each side of the
Remove the two hinges that secure the dump box tailgate with a T25 Torx.
to the frame.
Remove Box Hinges A

A B
B
D
D
4. Remove the eight bolts that secure the two

tailgate halves. Carefully pull the tailgate halves
TAILGATE apart.
REMOVAL/DISASSEMBLY
1. Remove the tailgate cables from the tailgate by A
removing the attaching screw. B
C
A
B D
5. Make any repairs as needed to the tail gate or

latch assembly.
2. After both tailgate cables are removed, lift the A

tailgate part way up and pull outward lightly. The B
tailgate will part away from the frame. Note the
notch in the tailgate pivot tube for reassembly.
C
Notch In Pivot Tube D

A
B
5.8
POD EXPLODED VIEW -- ATP 330

Instrument Cluster (speedometer)
Plug Hole
Pod
Pod Screws Choke
Key
Handlebar clamp torque:

11--13 ft. lbs. (15-18 Nm)
Clean knurling when
repositioning handlebars Torque bolts evenly so gap
is equal at rear of handlebar block
Note: For Speedometer (VDO) re-
moval refer Chapter 10 Electrical
Section also.
Disassembly
Assembly
G Remove two top Phillips screws.
G Install key switch and choke cable.
G Lift top half of pod.
G Connect speedometer (VDO) cable to
G Disconnect speedometer (VDO) cable speedometer.
G Disconnect light wire cable. G Install pod onto mounting bracket.
G Remove ignition switch and choke cable. G Install mounting screws
5.9
HEADLIGHT POD EXPLODED VIEW -- ATP 500

Torque bolts evenly so gap
is equal at rear of handlebar block
11-13 ft. lbs.

(15-18 Nm)
A
B
Clean knurling when

repositioning handlebars
E
Note: For Speedometer (VDO) re- Adjuster
moval refer Chapter 10 Electrical D
Section also.
Disassembly
G Remove two side Phillips screws (A).
G Remove one rear Phillips screw (B). C
G Lift top half of pod.
G Disconnect speedometer wire connectors.
G Disconnect oil indicator light wires and gear
position indicator connector.
G Disconnect 12V power plug (where applicable).
G Disconnect headlight harness.
G Remove ignition switch (C) and choke cable (D).
G Remove headlight with adjuster.
G Remove two screws securing bottom
half of pod (E).
Assembly
G Install bottom of pod onto handlebar and secure to brackets.
G Install key switch, choke cable, and headlight.
G Connect 12V power outlet (where applicable)
G Connect headlight.
G Connect speedometer connectors to speedometer.
G Install top of pod onto bottom half, making sure interlocking tabs mate properly.
G Install two side Phillips screws.
G Install one rear Phillips screw.
G To adjust headlight, refer to procedure outlined in Maintenance chapter.
5.10
STEERING ASSEMBLY, EXPLODED VIEW ALL ATP’S

NOTE:
Apply Loctitet 242 to To avoid damage to tie rods and other steering
242
the bolt threads. 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. Be sure inner rod ends
25-30 ft. lbs. are placed between the steering post arms.
(35-41 Nm)
Steering Post
Steering Post
Arm (Frog)
12-14 ft. lbs.

(17-19 Nm)
1 40-45 ft. lbs.

(54-61 Nm)
30 ft. lbs.
(41 Nm)
1
30 ft. lbs.
(41 Nm)
2
25 ft. lbs.
(35 Nm) 8 ft. lbs.
242
(11 Nm)
Always use new bolts Always use new cotter pins upon
1 upon reassembly 2 reassembly. Install w/ open end to-
ward rear of machine.
5.11
A-ARM REPLACEMENT
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. NOTE: On AWD models, install CV joint shields. See Ill.
7. Install new A-arm assembly onto vehicle frame. Torque new bolts to 30 ft. lbs. (41.4 Nm).
Vehicle Frame Bolt 30 ft. lbs. Apply Loctitet 242 to
242
(41 Nm) the bolt threads.
Bolt 30 ft. lbs.

(41 Nm) Ball Joint
Stud
Washer A-Arm Tube
8 ft. lbs.
242
A-Arm Shaft (11 Nm)
25 ft. lbs Nut
(35 Nm).
CV Joint Shield Cotter Pin
(AWD Models)
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.
8. Attach A-arm to hub strut assembly. Tighten ball joint A-arm Attaching Bolt Torque:
nut to 25 ft. lbs. (35 Nm). If cotter pin holes are not
aligned, tighten nut slightly to align. Install a new cotter 30 ft. lbs. (41 Nm)
pin with open ends toward rear of machine. Bend both
ends in opposite directions around nut. Ball Joint Stud Nut Torque:
25 ft. lbs. (35 Nm)

WARNING
Upon A-arm installation completion, test vehicle at low speeds before putting into regular service.
5.12
SWINGARM REMOVAL / 6. Remove the lower shock bolts (D).
REAR DRIVE SHAFT

REMOVAL
1. Safely jack up the ATV and place jackstands
under the ATV frame and rear swingarm.
2. Remove the two rear tires.
3. Remove the brake caliper (A). Do not let the
caliper hang by the brake line.
4. Remove the brake line clamps (B) on axle and
swingarm.
D
A
7. Remove the jam nut from the left side of the
swingarm pivot (F) using a 1 3/4” socket.
B
5. Remove the roll pin (C) from the drive shaft.
8. Remove the swingarm pivot bolts (G) from both

sides of the swingarm. Support the front of the
swingarm during removal.
C G
9. The swingarm is now apart from the frame.

Remove the drive shaft (H) from the transmission.
5.13
Loctitet 242
10. Remove the roller cone bearing (6), roller cup

bearing (8), and foam inserts (7), if needed. Refer Loctitet 242
to the swingarm illustration on the next page.
C
SWINGARM INSTALL / REAR 14 ft.lbs.
(19 Nm)
DRIVE SHAFT INSTALL
1. Reinstall the drive shaft if previously removed.
Install a new roll pin (A) into the driveshaft.
5. Tighten pivot bolts until engaged inside the

swingarm bearings.
6. Torque right side pivot bolt (B) to 120 ft.lbs. (165
Nm). Torque left side pivot bolt (C) to 14 ft.lbs. (19
Nm).
A
120 ft.lbs.
B (165 Nm)
2. Reinstall the roller cone bearing (10), roller cup

bearing (11), and foam inserts (12), if removed.
Refer to the swingarm illustration on the next
page.
3. Align the swingarm pivot holes to the frame.
4. Apply Loctitet 242 (PN 2871950) to right side
pivot bolt (B) and to the left side pivot bolt (C).
Install both into the frame and swingarm.
5.14
7. Apply Loctitet 242 (PN 2871950) to the exposed 11. Route brake lines and secure with the brake line
threads of the left side pivot bolt and lock nut. clamps (D).
8. Install and torque lock nut to 120 ft.lbs. (165 Nm).
Use a 1.75” socket to tighten the lock nut. C
14 ft.lbs. D
(19 Nm)
9. Reinstall the rear shock bolt and torque to 25 12. Install rear wheels and torque wheel nuts to 27
ft.lbs. (35 Nm). Install rear gearcase vent tube. ft.lbs. (37 Nm).
10. Install the brake caliper (C) and torque the brake
caliper bolts to 28 ft.lbs. (38 Nm).
Swingarm Exploded View
1 Apply Loctitet 242 to

242
the bolt threads.

14 ft.lbs.
(19 Nm)
4
5
6
2
1. Rear Axle Assy. 7
2. Swing Arm
3. Skid Plate
242
4. Swing Arm Pivot

120 ft.lbs.
5. Pivot Jam Nut 9 8 (165 Nm)
6. Roller Cone Bearing
7. Pivot Foam
8. Tapered Bearing 3
9. Pivot Plug
120 ft.lbs. 7
10. Driveshaft
242
(165 Nm) 6 8 9
11. Axle to Swingarm Bolts 4 10
5.15
STRUT ASSEMBLY EXPLODED VIEW - 4X4 MODELS
1
21
2
20
19 18
5
6 10 15
16
7
17
9
14
11
12
13
1. Nylok Nut
2. Washer 12. Bearing
3. Spacer Rubber 13. Retaining Ring
4. Upper Pivot Ball 14. Grease Fitting
5. Spacer 15. Washer
6. Lower Pivot Ball 16. Screw
7. Spring Retainer 17. Nylok Nut
8. Spring 18 Rubber Clamp
9. Bolt 19. Washer
10. Flat Washer 20. Front Strut Cartridge
11. Hubstrut 21. Bumper
5.16
FRONT STRUT CARTRIDGE

REPLACEMENT
Refer to Illustrations on Page 5.16.
1. Hold strut rod with holder wrench and remove top
nut. C F
2. Compress spring using strut spring compressor
tools. E
D
B
Strut Rod Holder Wrench (PN 2871572) A
Strut Spring Compressor Tools
(PN 2871573) and (PN 2871574) 7. Using Ball Joint Replacement Tool (PN 2870871),
remove ball joint (F) from strut housing. Refer to
3. Remove upper strut pivot assembly. photos at right.
4. Remove coil spring and collapse strut cartridge. G Install puller guide (A) with extension
5. Remove two pinch bolts from strut casting. cap (B).
6. Remove strut cartridge. G Apply grease to extension cap and
7. Install cartridge until bottomed in strut casting. threads of puller bolt to ease
8. Install pinch bolts with wire clamp(s). Torque removal.
pinch bolts to 15 ft. lbs. (21 Nm). G Thread bolt (D) with nut (C) onto ball
9. Reassemble spring and top pivot assembly. Be joint stud as shown.
sure all parts are installed properly and seated G Hold bolt (D) and turn nut (C)
fully. clockwise until ball joint is removed
10. Torque strut rod nut to specification. Do not over from strut housing.
torque nut.
Strut Rod Nut Torque A

B
15 ft. lbs. (21 Nm)
C
D
FRONT STRUT BALL JOINT
REPLACEMENT
1. Loosen front wheel nuts slightly.
2. Elevate and safely support machine under
footrest/frame area.
CAUTION: Serious injury may result if machine tips 8. To install new ball joint:
or falls. Be sure machine is secure before beginning G Remove extension cap and attach
this service procedure. puller guide using short bolts
3. Remove wheel nuts and wheels. provided in the kit.
4. Remove cotter pin (A) from ball joint castlenut. G Insert new ball joint (E) into driver (F).
5. Remove castle nut (B) and separate A-arm (C) G Slide ball joint/driver assembly into
from ball joint stud. guide.
6. Remove screws (D) and ball joint retaining plate G Drive new joint into strut housing until
plate (E). fully seated.
5.17
DECAL REPLACEMENT
Plastic polyethylene material must be “flame treated”
A prior to installing a decal to ensure good adhesion.
B The flame treating procedure can often be used to
E reduce or eliminate the whitish stress marks that are
sometimes left after a fender or cab is bent, flexed, or
C damaged.
E
D
WARNING
The following procedure involves the use of an
open flame. Perform this procedure in a well ventilated
area, away from gasoline or other flammable materials.
F Be sure the area to be flame treated is clean and free
of gasoline or flammable residue.
9. Apply Loctitet 242 (PN 2871950) to threads of To flame treat the decal area:
retaining plate screws or install new screws with
1. Pass the flame of a propane torch back and forth
pre-applied locking agent. Torque screws to 8 ft.
quickly over the area where the decal is to be
lbs. (11 Nm).
applied until the surface appears slightly glossy.
10. Install A-arm on ball joint and torque castle nut to This should occur after just a few seconds of
25 ft. lbs. (35 Nm). flame treating. Do not hold the torch too close to
11. Reinstall cotter pin with open ends toward rear of the surface. Keep the torch moving to prevent
machine. damage.
2. Apply the decal.
STEERING POST ASSEMBLY
12 ft. lbs. (16 Nm)
1. Tighten to spec.
2. Align cotter pin hole.
3. Install cotter pin.
Bend both ends of cotter
pin around nut in oppo-
site directions.
4. Check steering, must
move freely and easily
from full left to full right
without binding.
12 ft. lbs.
(16 Nm)
75 ft. lbs.
(101 Nm)
5.18
CLUTCH
Service Tools, Supplies & Torques . . . . . . . . . . 6.2

PVT System Operation . . . . . . . . . . . . . . . . . . . 6.2--6.3
PVT Maintenance/Inspection . . . . . . . . . . . . . . 6.3-6.4
PVT Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
PVT Sealing and Ducting Components . . . . . . 6.7
Drive Clutch Exploded View . . . . . . . . . . . . . . . 6.8
Drive Clutch Spring Specifications . . . . . . . . . . 6.8
Shift Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Drive Clutch Inspection . . . . . . . . . . . . . . . . . . . 6.10
Drive Clutch Disassembly . . . . . . . . . . . . . . . . . 6.10-6.12
Drive Clutch Assembly . . . . . . . . . . . . . . . . . . . . 6.12-6.13
Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . 6.13
Drive Belt Removal/Inspection . . . . . . . . . . . . . 6.14-6.15
Drive Belt Installation . . . . . . . . . . . . . . . . . . . . . 6.15
Clutch Alignment /Offset . . . . . . . . . . . . . . . . . . 6.16
Drive Clutch Bushing Service . . . . . . . . . . . . . . 6.17-6.19
Driven Clutch Disassembly/Inspection . . . . . . 6.19-6.20
Driven Clutch Assembly . . . . . . . . . . . . . . . . . . . 6.21
Driven Clutch Bushing Service . . . . . . . . . . . . . 6.21-6.23
EBS Exploded View . . . . . . . . . . . . . . . . . . . . . . 6.24
EBS Drive Clutch Disassembly/Inspection . . . 6.25-6.26
Early 04 EBS Driven Clutch Disass./Insp. . . . 6.26-6.29
All EBS Drive Clutch Bushing Service . . . . . . . 6.29-6.30
Early 04 EBS Driven Clutch Bushing Serv. . . . 6.30-6.32
Late 04--05 EBS Driven Clutch Disass./Insp. 6.32--6.36
Late Late 04--05 EBS Driven Clutch Bushing 6.37--6.38
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39--6.40
6.1
CLUTCH
SPECIAL SERVICE TOOLS PVT OPERATION OVERVIEW

AND SUPPLIES WARNING
TOOL PART NUMBER
DESCRIPTION
All PVT maintenance or repairs should be
Clutch Puller 2870506
performed only by a certified Polaris Master Service
Clutch Holding 9314177 Dealer (MSD) technician who has received the proper
Wrench
training and understands the procedures outlined in
Clutch Holding 2871358 this manual. Because of the critical nature and
Fixture precision balance incorporated into the PVT
Spider Nut Socket 2870338 components, it is absolutely essential that no
Drive Clutch 2870341 disassembly or repair be made without factory
Spider Removal authorized special tools and service procedures.
and Install Tool
Driven Clutch 2870913 The Polaris Variable Transmission (PVT) consists of
Puller three major assemblies: 1) The Drive Clutch; 2) The
Roller Pin Tool 2870910 Driven Clutch; and 3) The Drive Belt. The internal
Clutch Bushing 2871226 components of the drive clutch and driven clutch
Replacement Tool control engagement (initial vehicle movement), clutch
Kit upshift and backshift. During the development of a
Piston Pin Puller 2870386 Polaris ATV, the PVT system is matched first to the
engine power curve; then to average riding conditions
EBS Clutch 2872292
Alignment Tool
and the vehicle’s intended usage. Therefore,
modifications or variations of components at random
EBS Bushing 2201379
Replacement Kit are never recommended. Proper clutch setup and
careful inspection of existing components must be the
Clutch 8700220
Compression Tool primary objective when troubleshooting and tuning.
Clutch Bushing 2871025
Replacement Tool
Kit
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
SPECIAL SUPPLIES PART NUMBER
engine RPM is increased, centrifugal force is created,
Loctitet 680 . . . . . . . . . . . . . . . . . . . . 2870584 causing the shift weights to push against rollers on the
moveable sheave, which is held open by coil spring
RTV Silicone Sealer . . . . . . . . . . . . . 2870661
preload. When this force becomes higher than the
Loctite Gasket Remover . . . . . . . . . . 2870601 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
PVT SYSTEM FASTENER it to rotate, which in turn rotates the driven clutch.
TORQUES At lower RPM, the drive belt rotates low in the drive
clutch sheaves. As engine RPM increases,
Drive Clutch Retaining Bolt . . . 40 ft. lbs. (54 Nm) centrifugal force causes the drive belt to be forced
upward on drive clutch sheaves.
Driven Clutch Retaining Bolt . . 17 ft. lbs. (23 Nm)
PVT Inner Cover Bolts . . . . . . . 12 ft. lbs. (16 Nm) DRIVEN CLUTCH OPERATION
Drive Clutch Spider EBS Clutch) . . . . . 200 ft. lbs.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (271 Nm) Driven clutches primarily sense torque, opening and
closing according to the forces applied to it from the
Drive Clutch Spider Lock Nut (Plastic) . 15 ft. lbs. . drive belt and the transmission input shaft. If the
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (20.3 Nm) torque resistance at the transmission input shaft is
Drive Clutch Cover Plate . . . . . 90 in. lbs. (10 Nm) greater than the load from the drive belt, the drive belt
is kept at the outer diameter of the driven clutch
sheaves.
6.2
CLUTCH
DRIVEN CLUTCH OPERATION CONT’D air ducts, as well as the inner and outer covers,
must be properly sealed to ensure clean air is
As engine RPM and horsepower increase, the load being used for cooling the PVT system. This also
from the drive belt increases, resulting in the belt will prevent water and other contaminants from
rotating up toward the outer diameter of the drive entering the PVT area. A sealed PVT is
clutch sheaves and downward into the sheaves of the especially critical on units subjected to frequent
driven clutch. This action, which increases the driven water forging.
clutch speed, is called upshifting.
Should the throttle setting remain the same and the PVT DRYING
vehicle is subjected to a heavier load, the drive belt
rotates back up toward the outer diameter of the NOTE: If operating the ATV through water, be sure
driven clutch and downward into the sheaves of the to check the PVT cover and other ATV components
drive clutch. This action, which decreases the driven for water ingestion. The ATV should be checked
clutch speed, is called backshifting. immediately. Refer to Owner’s Manual for Safe
In situations where loads vary (such as uphill and Riding Tips.
downhill) and throttle settings are constant, the drive
and driven clutches are continually shifting to maintain
optimum engine RPM. At full throttle a perfectly PVT Drain Plug
matched PVT system should hold engine RPM at the
peak of the power curve. This RPM should be
maintained during clutch upshift and backshift. In this
respect, the PVT system is similar to a power
governor. Rather than vary throttle position, as a
conventional governor does, the PVT system
changes engine load requirements by either
upshifting or backshifting.
PVT
MAINTENANCE/INSPECTION
To drain any water that may be trapped inside the PVT
Under normal operation the PVT system will provide cover, simply remove the PVT drain plug and O--ring
years of trouble free operation. Periodic inspection located on the bottom of the PVT cover and let the
and maintenance is required to keep the system water drain out. The PVT drain plug is shown below.
operating at peak performance. The following list of
items should be inspected and maintained to ensure To further expel water in the PVT cover and to dry out
maximum performance and service life of PVT the PVT system, shift the transmission to neutral and
components. Refer to the troubleshooting checklist at rev engine slightly to expel the moisture. This will also
the end of this chapter for more information. air-dry the belt and clutches. Allow engine RPM to
settle to idle speed, shift transmission to lowest
1. Drive to Driven Clutch Offset, Belt Width. See available range and test for belt slippage. Repeat as
Page-6.16--6.18 needed. Operate ATV in lowest available range for a
2. Drive and Driven Clutch Buttons and short period of time until PVT system is dry.
Bushings, Drive Clutch Shift Weights and
Pins, Drive Clutch Spider Rollers and Roller
Pins, Drive and Driven Clutch Springs. See
Pages 6.11-6.12
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 PVT Drain Plug & O--ring
fresh air through a vented cover. All connecting
6.3
CLUTCH
PVT OVERHEATING/DIAGNOSIS
During routine maintenance or whenever PVT system overheating is evident, it’s 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 if extended low speed operation is anticipated.
GENERAL RANGE OPERATION Low Range: Heavy pulling, basic operational speeds less
GUIDELINES: than 7 MPH, riding through rough terrain (swamps, mountains,
etc.), low ground speeds.
High Range: High ground speeds, speeds above 7 MPH.
Diagnosis of Clutch Drive Belt & Cover Related Issues:

Possible Causes Solutions/What to do
Loading the ATV into a pickup or tall trailer Shift transmission to low range during loading of the ATV to
when in high range. prevent belt burning.
Starting out going up a steep incline. When starting out on an incline, use low range, or dismount the
ATV after first applying the park brake and perform the “K”
turn.
Driving at low RPM or low ground speed Drive at higher speed or use Low Range. The use of Low
(at approximately 3--7 MPH). Range is highly recommended for cooler PVT operating tem-
peratures and longer component life.
Insufficient warm--up of ATVs exposed to Warm engine at least 5 min., then with transmission in neutral,
low ambient temperatures. advance throttle to approx. 1/8 throttle in short bursts, 5 to 7
times. The belt will become more flexible and prevent belt
burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement.
Continuous operation at the point of engagement (initial vehicle
movement) increases PVT temperatures and component wear.
Towing/Pushing at low RPM/low ground Use Low Range only.
speed.
Plowing snow, dirt, etc./utility use. Use Low Range only.
Stuck in mud or snow. Shift the transmission to Low Range, carefully use fast,
aggressive throttle application to engage clutch. Warning:
Excessive throttle may cause loss of control and vehicle
overturn.
Climbing over large objects from a Shift the transmission to Low Range, carefully use fast,
stopped position. aggressive, throttle application to engage clutch. Warning:
Excessive throttle may cause loss of control and vehicle
overturn.
Belt slippage from water or snow ingestion Shift the transmission to neutral. Using the throttle, vary the
into the PVT system. engine rpm from idle to 3/4 throttle. Engage transmission in
the lowest possible range and test for belt slippage Repeat
several times as required. During this procedure, the
throttle should not be held at the full position for more
than 10 seconds. PVT seals should be inspected for damage
if repeated leaking occurs.
Clutch malfunction. Inspection/repair of clutch components should be performed by
a certified Polaris MSD techinician.
6.4
CLUTCH
PVT DISASSEMBLY
NOTE: Some fasteners and procedures will vary.
Driven Clutch Puller (PN 2870913)
Refer to the appropriate parts manual for proper
fasteners and fastener placement. (See Page 6.8).
1. Remove seat.
2. Remove or loosen rear cab fasteners as 8. Remove driven clutch offset spacers from the
necessary to gain access to PVT outer cover. transmission input shaft. NOTE: Remember to
3. Remove PVT air outlet duct hose. keep spacers in order for proper clutch offset on
4. Remove outer cover screws. Refer to Page 6.7. reassembly.
5. Mark the drive belt direction of rotation and
remove drive belt. See Page 6.14 for drive belt Keep Spacers In Order
removal.
6. Remove drive clutch retaining bolt and remove
drive clutch using puller.
9. Remove cover screws and retainer plate.
Inner cover
Retainer Seal
Drive Clutch Puller (PN 2870506)
Clutch Holding Wrench (PN 9314177)
7. Remove driven clutch retaining bolt and driven

clutch. Use puller if necessary.
Foam Seal
10. Remove inner cover retaining bolts at rear of

cover.
11. Remove cover along with foam seal on back of
cover or shaft.
6.5
CLUTCH
PVT ASSEMBLY/INSPECTION 7. Install clutch offset spacer(s) on transmission

input shaft.
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.
Seal this edge to cover on engine side
Offset
Spacer
8. Clean splines inside driven clutch and on the

transmission input shaft.
2. Place a new seal on transmission input shaft. 9. Apply a light film of grease to the splines on the
3. Apply RTV silicone sealant to outside edge of shaft.
inner cover-to-engine seal, to ensure a water tight 10. Install the driven clutch, washer, lock washer, and
fit between the seal and the cover on engine side. retaining bolt. Torque to specification.
Surfaces must be clean to ensure adhesion of
11. Clean end of taper on crankshaft and the taper
silicone sealant.
bore inside drive clutch.
4. Reinstall cover and tighten rear cover bolts just
12. Install drive clutch and torque retaining bolt to
enough to hold it in place.
specification.
5. Fit lip of inner cover seal (A) to engine. Install seal
13. Reinstall drive belt noting direction of rotation. If a
retainer plate and tighten screws securely.
new belt is installed, install so numbers can be
6. Torque rear inner cover bolts (B) to specification. easily read.
14. Only replace PVT outer cover rubber gasket if it is
damaged. Place the gasket with the narrow side
out (C).
B
C
Toward outer cover
PVT Cover Gasket

A
Seal outer edge to cover
with RTV silicone sealant 15. Reinstall PVT outer cover and secure with
screws.
16. Reinstall rear cab assembly, panel and seat.
Inner Cover Bolt Torque (Rear):

12 ft. lbs. (16.6 Nm)
Driven Clutch Retaining Bolt Torque:

17 ft. lbs. (23.5 Nm)
Drive Clutch Retaining Bolt Torque:

40 ft. lbs. (55 Nm)
6.6
CLUTCH
PVT SEALING AND DUCTING COMPONENTS
Drain Plug 2005 CLUTCH COVER

Outer Cover
Inlet Duct
Exhaust Duct
Cover Bolts
Outer Cover Seal
Clutch Seal
Bracket
Inner Cover Inner Cover Seal
DRIVE CLUTCH EXPLODED VIEW

Drive Clutch
Teflont coated
brass bushing
Teflont coated
brass bushing
Mark with permanent

marker before disassembly
6.7
CLUTCH
DRIVE CLUTCH SPRING SPECIFICATIONS

The drive clutch spring has two NEUTRAL FULL UPSHIFT
300
primary functions: ATV TRAVEL
FORCE (POUNDS)
1. Controls clutch engagement 280
RPM. The springs which have a
260
higher rate when the clutch is in
neutral will increase clutch 240
engagement RPM.
220
2. Controls the rate at which the
drive belt moves upward in the 200
drive clutch sheaves. This is
referred to as drive clutch upshift. 180
The drive clutch spring is one of the Green
7041168
160
most critical components of the PVT Purple
7041063
system. It is also one of the easiest to 140 White
7041132
service. Due to the severe relaxation Plain
of the coil spring is subject to during 120 7041021
Blue/Green
operation, it should always be 7041157
inspected for tolerance limits during 100 Black

7041022
any clutch diagnosis or repair.
80
There are other components which
control upshift, but the spring is one of 60
the primary components in insuring
40
optimum performance. It is very
important that the spring is of correct 20
design and is in good condition.
0
CAUTION: Never shim a drive clutch 2.5 2.25 2.00 1.75 1.50 1.25 1.19
spring to increase its compression
rate. This may result in complete COMPRESSED SPRING LENGTH (INCHES)
stacking of the coils and subsequent
clutch component failure.
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.
Primary Clutch Springs Secondary Clutch Springs

PART COLOR WIRE FREE LENGTH PART DESCRIPTION
NUMBER CODE DIAMETER ¦.125I NUMBER
7041021 Plain .157I 4.38I 7041198 Red
7041022 Black .140I 4.25I 7041782 Black 5--coil
7041063 Purple .168I 4.37I 7041501 Gold 6--coil
7041132 White .177I 2.92I 7041499 Silver
7041168 Green .177I 3.05I 7041296 Blue
7041157 Blue/Green .177I 2.53I 7041646 Silver/Blue
6.8
CLUTCH
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.
16
55
53
PN 5630418 PN 5630279 PN 5630095 PN 5630509

50 gr 43 gr 53 gr 55 gr
10 10
10
RH WH
BH
PN 5630709 PN 5630513 PN 5630710 PN 5630711

44 gr 50.5 gr 46 gr 47gr
6.9
CLUTCH
SHIFT WEIGHT INSPECTION BUTTON TO TOWER

1. Inspect as shown, using a clutch holding tool to CLEARANCE INSPECTION
compress the moveable sheave. The contact
surface of the weight should be smooth and free 1. Inspect for any clearance between spider button
of dents or gall marks. Remove shift weight bolts to tower. If clearance exists, replace all buttons
and weights. and inspect surface of towers. See Spider
Removal next page.
Button to Tower Clearance:

.000 - .001I
2. Inspect sheave surfaces. Replace the entire

clutch as an assembly if worn, damaged or
cracked.
Broken Worn Good
NON--EBS -- DRIVE CLUTCH
Inspect the weight pivot bore and pivot bolts for
wear or galling. If weights or bolts are worn or DISASSEMBLY
broken, replace in sets of three with new bolts.
NOTE: A damaged shift weight is usually caused 1. Using a permanent marker, mark the cover,
by a damaged or stuck roller in the spider spider, and moveable and stationary sheaves for
assembly. See roller inspection, Page 6.12. reference, as the previous X’s may not have been
in alignment before disassembly.
WARNING
Mark
The clutch assembly is a precisely balanced unit.
Never replace parts with used parts from another
clutch assembly!
All PVT maintenance or repairs should be performed
only by a certified Polaris Master Service Dealer
(MSD) technician who has received the proper
training and understands the procedures outlined in
this manual. Because of the critical nature and
precision balance incorporated into the PVT “X”
system, it is absolutely essential that no attempt Mark
at disassembly or repair be made without factory
authorized special tools and service procedures.
6.10
CLUTCH
DRIVE CLUTCH DISASSEMBLY CONT’D NON--EBS--SPIDER REMOVAL

2. Remove cover bolts evenly in a cross pattern and
remove cover plate. 1. Remove the limiter nut using the Clutch Spider
Nut Socket (PN 2870338). Install clutch in
3. Inspect cover bushing (A). The outer cover holding fixture and loosen the spider
bushing is manufactured with a Teflont coating. (counterclockwise) using Clutch Spider Install
Wear is determined by the amount of Teflon™ Tool (PN 2870341).
remaining on the bushing.
Cover Bushing inspection
Cover Bushing Inspection:
Replace the cover bushing if more

brass than Teflont is visible on the Clutch Holding Fixture:
bushing. Refer to bushing replace- (PN 2871358)
ment in this chapter.
Spider Removal Tool:
(PN 2870341)
4. Inspect area on shaft where bushing rides for
wear, galling, nicks, or scratches. Replace clutch
assembly if worn or damaged. NOTE: It is important that the same number and
5. Remove and inspect spring. (See Page 6.8) thickness of washers are reinstalled beneath the
spider during assembly. Be sure to note the number
and thickness of these washers.
Inspect shaft
To maintain proper clutch balance

and belt-to-sheave clearance, be
sure to reinstall original quantity
and thickness washers
6.11
CLUTCH
Moveable Sheave Bushing Inspection button is positioned toward the solid roller pin. It is
recommended to switch all buttons to the rubber
2. Inspect the Teflont coating on the moveable version during service (if needed).
sheave bushing.
Moveable Sheave Bushing Inspection:

Replace the cover bushing if more brass REASSEMBLY
than Teflont is visible on the bushing.
Refer to bushing replacement in this
chapter. NOTE: It is important that the same number and
thickness of washers are reinstalled beneath the
spider during assembly. The Teflon bushings are
Roller, Pin and Thrust Washer Inspection self-lubricating. Do not apply oil or grease to the
bushings.
3. Inspect all rollers, bushings and roller pins by
pulling a flat metal rod across the roller. Turn roller 1. Reassemble drive clutch in the following
with your finger. If you notice resistance, galling, sequence. Be sure the “X”, or the marks that were
or flat spots, replace rollers, pins and thrust made earlier, are aligned during each phase of
washers in sets of three. Also inspect to see if assembly.
roller and bushing are separating. Bushing must a) “X”, or the marks that were made earlier on
fit tightly in roller. Use the Roller Pin Tool (PN cover
2870910) to replace rollers and pins. Take care b) X on spider, making sure spacer washers
not to damage roller bushing or bearing surface of
are installed underneath spider and
the new pin during installation. positioned properly in recess.
c) “X”, or the marks that were made earlier
under weight
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: The rubber side of the
6.12
CLUTCH
7. Reinstall clutch spring.
Engine
Rotation
Nut on trailing side

2. Install moveable sheave onto fixed sheave.
3. Install spider spacers. Use same quantity and 8. Reinstall cover, aligning bosses on the tower and
thickness as were removed. cover. Torque cover bolts evenly to specification
4. Compress spider buttons for each tower and
install spider, making sure that “X”, or the marks
that were made earlier, on spider aligns with “X”,
or the marks that were made earlier on the
moveable sheave.
5. Torque spider to specification using the holding
fixture and spider tool. Torque with smooth
motion to avoid damage to the stationary sheave.
Refer to Page 6.3 for torque specification.
CAUTION:
Be sure the 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.
Spacer washers Spider Torque:

200 ft. lbs. (271 Nm)
6. Install limiter nut on top of spider using the Clutch
Cover Screw Torque:
Spider Nut Socket (PN 2870338). Torque to 15 ft.
90 in. lbs. (10.4 Nm)
lbs. Reinstall shift weights using new lock nuts on
the bolts.
6.13
CLUTCH
NON--EBS -- DRIVE BELT ALL MODELS -- DRIVE BELT

TENSION REMOVAL/INSPECTION
NOTE:Belt tension is not adjustable on EBS 1. Remove outer PVT cover as described in PVT
models. Disassembly.
2. Mark drive belt direction of rotation so that it can
NOTE:Pinch the sheaves lightly together with clamp be installed in the same direction. NOTE:
to prevent the belt from being pushed into the driven Normally positioned so part numbers are easily
sheave. read.
1. Place a straight edge on top of the belt between 3. To remove drive belt, apply brake, pull upward
drive and driven clutch. and rearward on belt to open driven clutch
sheaves, pull out and down on belt to slip over the
2. Push down on drive belt until it is lightly tensioned.
driven clutch outer sheave.
3. Measure belt deflection as shown in illustration.
Straight Edge
1 1/8″ (28.5 mm)
Belt Deflection (Tension):
1 1/8″ (2.9 cm) - 1 1/4″ (3.2 cm)
If belt deflection is out of specification, adjust by

removing or adding shims between the driven clutch
sheaves.
G Remove shims to decrease belt
deflection
G Add shims to increase belt deflection
See Driven Clutch Disassembly/Inspection, Pages
6.19 - 6.20.
NOTE:When reinstalling the belt with the drive clutch
NOTE: At least one shim must remain between the and driven clutch already removed follow these steps:
inner and outer sheave of the driven clutch. If proper
belt deflection cannot be obtained, measure drive belt G Install the driven clutch.
width, length, and center distance of drive and driven G Install the belt onto the driven clutch.
clutch, outlined in this section; all have an effect on G Loop the drive clutch through the
belt deflection. belt.
G Install the drive clutch onto the
crankshaft.
6.14
CLUTCH
4. Measure belt width and replace if worn. deflection is the desired goal -- not a specific
Generally, belts should be replaced if clutches center distance.
can no longer be adjusted to provide proper belt 8. Replace belt if worn past the service limit. Belts
deflection. with thin spots, burn marks, etc., should be
G The top edges have been trimmed on replaced to eliminate noise, vibration, or erratic
some drive belts. It will be necessary PVT operation. See Troubleshooting Chart at the
to project the side profiles and end of this chapter for possible causes.
measure from corner to corner.
G Place a straight edge on each side of
the drive belt.
G Place another straight edge on top of
belt.
G Measure the distance where the side
straight edges intersect the top, as
shown in the illustration.
Center
Distance
Projected Belt Clutch Center Distance -

Width 10″ +.1 / -.05 (254 +2.5 / -1.3mm)
Belt Nominal Length - 40.875″± 3/16
(103.8 cm ± .48 cm)
ALL MODELS -- DRIVE BELT

INSTALLATION
1. Loop belt over drive and over top of driven
sheave.
Belt Width:
2. While pushing down on top of belt, turn the back
New 1.174 - 1.188″ (2.98-3.02 cm) or moveable driven sheave clockwise.
Wear Limit 1.125″ (2.86 cm)
5. Inspect belt for loose cords, missing cogs, cracks,

abrasions, thin spots, or excessive wear.
Replace if necessary.
6. 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.
7. Measure belt length with a tape measure around
the outer circumference of the belt. Belts which
measure longer than nominal length may require
driven shimming or engine adjustment for a
longer center distance to obtain proper belt 3. The belt then should be able to be pushed down
deflection. Belts which measure shorter than into and between the sheaves.
nominal length may require driven shimming or a NOTE: Be sure to position belt so part number is
shorter center distance. Remember, proper belt easily read.
6.15
CLUTCH
ALL MODELS -- CLUTCH NOTE: On some models, minor adjustments can be

made by adding shims between the frame and front
ALIGNMENT lower left engine mount to increase the distance at
point “A”. If a shim is present, it can be removed to
1. Remove belt and install the Clutch Offset decrease the distance at point “A”.
Alignment Tool) as shown.
Offset Alignment Tool Shim Kit (PN 2200126)

(PN 2872292) - EBS
(PN 2870654) STD
B
ALL MODELS -- CLUTCH
OFFSET
Important: Inspect clutch alignment and center
A distance before adjusting offset.
Offset is correct when rear of tool contacts rear of
1/8I +0 / -- 1/16 inner sheave with driven clutch pushed completely
3.2mm +0 / -- 1.6 mm) inward on shaft and bolt torqued. Adjust offset by
adding or removing spacer washers between back of
driven clutch and spacer.
Spacer Washer (PN 7556401)
1. Install offset alignment tool as shown. Remember

to measure above and below the shaft
2. With tool touching rear of driven clutch inner centerlines.
sheave, the distance at point “A” should be 1/8″.
NOTE:If the distance is greater than 1/8″ or less than
1/16″, clutch alignment must be adjusted as follows: Offset Alignment Tool
should contact rear edge
3. Remove drive and driven clutch. See PVT of driven clutch sheave
Disassembly, Page 6.5.
4. Remove PVT inner cover.
5. Loosen all engine mounts. Move front of engine
to the right or left slightly until alignment is correct. Driven Clutch Offset
6. Tighten engine mounts and verify alignment is To adjust, add or remove
correct. washers from behind the
driven clutch
7. Measure belt deflection and measure offset both
above and below shaft centerlines. Adjust if
necessary.
Center line
Measure offset above and below

centerline
6.16
CLUTCH
NON--EBS -- DRIVE CLUTCH 2. Remove nut from puller rod and set aside.
BUSHING SERVICE
Piston Pin Puller
*Clutch Bushing Replacement Tool Kit (PN
(PN 2870386)
2871226)
Stamp Qty. Part Description Part #

#2 1 P--90 Drive/Driven 5020628
Clutch Bushing
Install Tool
Main Puller Adaptor (#8)
#3 1 Drive Clutch Cover 5020629
Bushing Removal/
Installation Tool (all
clutches) 3. Install the Main Puller Adapter (#8) (PN 5020632)
onto the Piston Pin Puller (PN 2870386).
#5 1 P--90 Driven Clutch 5020631
Cover Bushing Re-
moval Tool
#8 1 Main Puller Adapter 5020632
#9 1 Adapter Reducer 5010279
#10 1 Number Two Puller 5020633
Adapter

MOVEABLE SHEAVE -
BUSHING REMOVAL
4. Insert the Number Two Adapter (#10) (PN
5020633) into the bushing from belt side as
#3 #5
#2 shown. With towers pointing toward vise, slide
sheave and bushing onto puller rod.
5. Install the nut removed in Step 2 onto end of puller
rod and hand tighten. Turn puller barrel to
increase tension on sheave if needed. Nut is left
hand thread
#10 #9
#8
1. Install handle end of the Piston Pin Puller (PN

2870386) securely into bench vise and lightly
grease puller threads.
Piston Pin Puller (PN 2870386)

6. Turn sheave and puller barrel together
counterclockwise on puller rod until bushing is
removed.
7. Remove nut from puller rod and set aside.
6.17
CLUTCH
8. Pull bushing removal tool and adapter from puller NON-- EBS --DRIVE CLUTCH
rod. Remove bushing from tool and discard.
COVER - BUSHING REMOVAL
MOVEABLE SHEAVE -
Piston Pin Puller
BUSHING INSTALLATION (PN 2870386)
1. Place the Main Puller Adapter (#8) (PN 5020632)
onto the puller.
2. Apply Loctitet 680 (PN 2870584) to the back
side of new bushing. Push bushing into center of
sheave on tower side by hand.
Main Puller
Adaptor (#8)
Bushing (PN 3576504)
Loctitet 680 (PN 2870584)
1. Install the Main Puller Adapter (#8) (PN 5020632)
onto the Piston Pin Puller (PN 2870386).
3. Insert the Clutch Bushing Installation Tool (#2) (PN
5020628) into center of sheave and with towers 2. From outside of clutch cover, insert the Drive
pointing away from vise, slide sheave onto puller Cover Bushing Remover (#3) (PN 5020629) into
rod. cover bushing.
4. Install nut on puller rod and hand tighten. Turn
barrel to apply additional tension if needed.
5. Turn sheave and barrel together
counterclockwise until bushing is seated.
3. With inside of cover toward vise, slide cover onto

puller.
4. Install nut onto puller rod and hand tighten. Turn
puller barrel to increase tension as needed.
7. Remove sheave from puller.
8. Remove installation tool.
6.18
CLUTCH
Bushing (PN 3576510)

5. Turn clutch cover counterclockwise on puller rod Loctitet 680 (PN 2870584)
until bushing is removed.
6. Remove nut from puller rod and set aside. 2. With the Main Puller Adapter (#8) (PN 5020632)
on the puller, insert cover onto puller rod, placing
7. Remove bushing and bushing removal tool from outside of cover toward vise.
puller. Discard bushing.
3. Install nut on rod and hand tighten. Turn puller
barrel to apply more tension if needed.
NON--EBS -- DRIVE CLUTCH 4. Turn clutch cover and barrel together
COVER - BUSHING counterclockwise on puller rod until bushing is
seated.
INSTALLATION 5. Remove nut from puller rod and take installation
tool and clutch cover off rod.
NON--EBS -- DRIVEN CLUTCH

1. Apply Loctitet 680 (PN 2870584) to the back

side of new bushing. Working from inside of
cover, insert bushing and bushing installation tool
into center of clutch cover.
Used to adjust
belt tension. One must
always be installed.
CAUTION:
Wear eye protection when removing snap ring to

prevent serious personal injury.
6.19
CLUTCH
6. Inspect ramp buttons in the moveable sheave and

replace if worn. NOTE: The ramp buttons are
secured by Torxt screws (T20).
Belt deflection adjustment

washers
1. Apply and hold downward pressure on the helix,

or place driven clutch in the Clutch Compression
7. Remove moveable sheave and note the number
Tool (PN 8700220).
of spacer washers. One spacer must remain
2. Remove snap ring retainer. between the sheaves when adjusting belt
deflection.
Note hole location of spring
in helix and sheave
Inspect bushings for wear
3. Note the location of the spring and remove helix. Moveable Sheave Bushing Inspection:
4. Note the location of the spring in the moveable Replace the bushing if more brass than
sheave, and remove the spring. Teflont is visible on the bushing. Re-
5. Check alignment of tabs on spring. Replace the fer to bushing replacement in this
spring if tabs are misaligned or the spring coils are chapter.
distorted.
8. Inspect the Teflont coating on the moveable
sheave bushing.
9. Inspect driven clutch faces for wear or damage.
10. Clean and inspect splines on helix and
transmission input shaft.
11. Lube splines with a light film of grease. Do not
lubricate the bushings!
6.20
CLUTCH

ASSEMBLY
Align boss spline
to install helix
Moveable Spring 4. Line up boss spline and push helix down until it
Example: Helix Sheave Tension
2 -- 1 Heavy engages the splines 1/2″ to 3/4″.
Spring/ 2 -- 2
Position 1 -- 1
2 -- 3
1 -- 2 1/3
1 -- 3 Soft turn
Refer to General Information Chapter 1 for driv-
en clutch spring color and production setting.
1. Install moveable sheave with spacer washers.

Important: At least one spacer washer must be
installed. Teflont 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 5. While holding downward pressure on helix, wind
specifications at the beginning of this section. moveable sheave counterclockwise
approximately 1/3 turn (120°).
The driven clutch, helix/moveable assembly has
several different spring locations which affect clutch 6. Push helix into place and install snap ring.
shifting and RPMs. The greatest amount of spring
tension will raise engine RPMs during clutch upshift
and allow quicker backshift or downshift when pulling NON--EBS -- DRIVEN CLUTCH
or negotiating a hill, for example. The least amount of
tension will create a slower downshift and a harder
BUSHING SERVICE
upshift.
NOTE:Bushings are installed at the factory using
Loctitet. 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.
6.21
CLUTCH
Main Puller Adapter (#8)
Clutch Bushing
Adapter Removal Tool (#5)
Reducer (#9)
Piston Pin Puller
(PN 2870386) 5. Working from the top, install Driven Clutch
Bushing Removal Tool (#5) (PN 5020631) into the
1. Install Main Puller Adapter (#8) (PN 5020632) center of clutch sheave with smaller diameter
onto the Piston Pin Puller (PN 2870386). toward bushing to be removed. See illustration.
2. Insert Adapter Reducer (#9) (PN 5010279) onto
the puller, sliding it inside the main adapter.
3. Remove ramp buttons from moveable sheave.
4. Using a hand held propane torch, apply heat

directly on bushing until tiny smoke tailings
appear.
CAUTION:
Clutch components will be hot! In order to avoid

serious burns, wear heat resistant insulated gloves for
the rest of the removal process.
6.22
CLUTCH
6. Install sheave onto puller. 2. Start new bushing evenly in moveable sheave.
7. Install nut onto puller rod and tighten by hand. Apply Loctitet 680 (PN 2870584) to the back
Turn puller barrel for further tension if needed. side of new bushing.
8. Turn clutch sheave counterclockwise until

bushing is removed. Repeat Steps 5 - 8 for other
bushing.
10. Remove adapters from puller. 3. Install sheave onto puller with new bushing
upward as shown. Install the Number Two Puller
11. Remove bushing and removal tool from adapters.
Adapter (#10) (PN 5020633).
Discard bushing.

MOVEABLE SHEAVE -
BUSHING INSTALLATION
Number Two Puller

Adapter (#10) 4. Install nut onto puller rod and hand tighten against
Piston Pin Puller installation tool.
(PN 2870386) 5. Turn clutch sheave counterclockwise until
bushing is seated.
1. Working from the top, insert Number Two Puller 6. Remove nut from puller rod and set aside.
Adapter (#10) (PN 5020633) onto the puller. See
illustration at above.
6.23
CLUTCH
ENGINE BRAKING SYSTEM (EBS) EXPLODED VIEW
Drive Clutch Assembly Flat Spacer

Retaining
Ring
Ramp
2.25″ PTFE
One Way Washer
Clutch Drive Ramp Bushing
Washer
Brass Washer
Shift Weights
Compression
Coil Torque to
Spring
Spring 200 Ft. Lbs.
(271 Nm) Bushing
Spacer Sleeve Screw

Cover
Bushing
Roller
Roller/Bushing
One Way Clutch Bushing
Assembly
(Driven)
Spider Lock Nut

Flat Washer
Drive Belt
Bolts, Lock PTFE Washer
Washers
Retaining
Ring
Early 2004 Driven Clutch Assembly

NOTE: See LATE 2004--2005 Driven Clutch section for
Late 2004--2005 Models
NOTE: Refer to the correct section of Chapter 6 when servicing the driven clutch. Two different
style EBS Driven clutches were used. The Drive clutches did not change. Refer to the “EARLY
2004” or “LATE 2004” DRIVEN CLUTCH section for service.
ATP 500 models built before July 14, 2003 will have the “EARLY 2004” EBS driven clutch and
models built on and after this date will have the “LATE 2004--2005” EBS driven clutch.
6.24
CLUTCH
EBS DRIVE CLUTCH EXPLODED VIEW
Mark with permanent

marker before disassembly
One way clutch
EBS Drive Clutch
EBS -- ONE-WAY CLUTCH EBS -- DRIVE CLUTCH

INSPECTION (DRIVE INSPECTION
CLUTCH)
NOTE: Remove cover, spring, and spider following
1. Rotate one-way clutch clockwise (as viewed from
instructions for drive clutch removal, then proceed as
the cover plate side). The clutch should rotate on
follows:
the shaft with only slight amount of drag. Verify
there is no binding or rough spots. When rotated 1. Remove moveable sheave spacer sleeve and the
counterclockwise, the clutch should lock to the brass washer. Visually inspect the washer for
shaft without slipping. If problems are noted in damage. Measure the thickness and compare to
either direction, continue with disassembly. specification. Replace if worn or damaged.
6.25
CLUTCH
Brass Washer Thickness PTFE Washer Thickness

Standard: .030″ (.76mm) Standard: .030″ (.76mm)
Service Limit: .025″ (.64mm) Service Limit: .025″ (.64mm)
2. Lift one-way clutch off shaft. Replace as an EBS -- MOVEABLE SHEAVE

assembly if worn, damaged, or if problems were
noted. BUSHING INSPECTION
1. Inspect the Teflont coating on the moveable
sheave bushing. Inspect BOTH sheaves for signs
of wear, grooving or cracking. Clean surfaces with
a 3Mt pad if needed
Replace the cover bushing if more

brass than Teflont is visible on the
bushing. Refer to bushing replacement
in this chapter.
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.
Shaft Diameter
Standard: 1.3745″ - 1.375″
Service Limit: 1.3730″
4. Remove 2 1/2″ PTFE washer from shaft. Visually

inspect the washer for damage. Measure the
thickness and compare to specification. Replace
if worn or damaged.
6.26
CLUTCH
EARLY 2004 -- EBS DRIVEN

CLUTCH Lock to Shaft and Outer Sheave
CAUTION: The driven clutch must be
disassembled from the helix end to lessen the
chance of damage to seals in the one-way clutch.
Review all information below before proceeding.
EARLY 2004 -- ONE-WAY

CLUTCH PRELIMINARY
INSPECTION (DRIVEN)
1. With drive belt removed and transmission in gear, 3. Remove driven clutch from the transmission input
hold the inner sheave and rotate the outer sheave shaft. Do not attempt disassembly of the driven
of the driven clutch in a counterclockwise clutch from the outside snap ring. The driven
direction as shown at right. The sheave should clutch must be disassembled from the helix side
rotate with only a slight amount of drag. There or the one-way clutch seals may be damaged.
should not be any binding or rough spots.
Move Freely
Do not disassemble from this side
4. Place the driven assembly into the clutch holder.

Push helix inward. Remove snap ring, washer,
2. When rotated clockwise, the outer sheave should helix, and spring. NOTE: The spring is a
lock to the shaft and inner sheave without compression spring only and has no torsional
slipping. wind.
6.27
CLUTCH
sparingly to the tapered head portion of the roller

retaining screws. Do not allow locking agent to
contact the inside of the rollers. Do not lubricate the
roller or roller pin.
Heat Area
Roller
Lightly Apply Loctitet
680 To Tapered
Portion Of Screw
Dry Locking
Agent Applied
NOTE: Rotating the moveable sheave so that the To New Screws
rollers are not in contact with either helix ramp
surfaces will lessen the effort needed to push the helix
inward.
7. Inspect moveable sheave bushing for wear.
5. Remove spring seat washer and inspect for wear Inspect BOTH sheaves for signs of wear,
or damage. Replace if worn. grooving or cracking. Clean surfaces with a 3Mt
6. Inspect surface of rollers for flat spots and wear. pad if needed
Rollers must rotate freely on pins without
excessive clearance. Check the roller pin and
roller bore for wear and replace if necessary.
Rollers

ROLLER PIN DISASSEMBLY
Replace the bushing if more brass than
New roller retaining bolts have a dry locking agent
Teflont is visible on the surface of the
applied to the threads. Before attempting to remove
bushing.
the roller pins, heat the threaded area lightly with a
propane torch. Wear heat resistant gloves during
this procedure. Use a high quality hexagonal
wrench in good condition to avoid screw damage. A 8. Check for movement of the shaft in the one-way
small amount of valve grinding compound can be clutch. If the shaft can be moved laterally, or if the
applied to the tip of the hex wrench to ensure a tight one-way clutch does not function properly as
fit. Always use new bolts if they are removed for described in Step 1 and 2 on Page 6.18, replace
inspection. Apply Loctitet 680 retaining compound
6.28
CLUTCH
driven clutch assembly. 4. Install puller adapter (Item 10 from kit PN

2871226).
5. Install main adapter (Item D) onto puller.
Puller Tool (A/B)

Side “A” toward
sheave Nut (C)
Main Adapter Puller Adapter (10)

(D)
Piston Pin
Puller
6. With towers pointing toward the vise, slide sheave
ALL 2004 -- EBS DRIVE onto puller rod.
BUSHING SERVICE 7. Install removal tool (Item A/B) into center of
sheave with “A side” toward sheave.
EBS CLUTCH BUSHING REMOVAL AND 8. Install nut (C) onto end of puller rod and hand
INSTALLATION (Use Tool Kit PN 2201379) tighten. Turn puller barrel to increase tension on
sheave if needed. Using a hand held propane
The contents of this kit include:
torch, apply heat around outside of bushing until
Item Qty Part Description Part No tiny smoke tailings appear.
A/B 1 EBS Puller Tool 5132027 9. Turn sheave counterclockwise on puller rod until it
C 1 EBS Puller Nut 5132501 comes free. Lift sheave off puller.
D 1 EBS Main Adapter 5132029
E 1 EBS Bushing 5132028 11. Pull bushing removal tool and adapter from puller
Removal Tool rod. Remove bushing from tool and discard.
1 Instructions 9915111
EBS Drive Moveable Bushing Installation
Also required: Clutch Bushing Replacement
Tool Kit (PN 2871226) (ATV Clutch Kit) or (PN 1. Place main adapter (Item 8) on puller.
2871025) (For all clutches) Piston Pin Puller
(PN 2870386) Puller Tool (A/B)
Nut (C)
Side “A” toward
REMOVAL AND INSTALLATION sheave
INSTRUCTIONS
NOTE: Bushings are installed at the factory using
Loctitet 609. In order to remove bushings it will be
necessary to apply heat evenly to the area around
each bushing. Clean all residual Loctite from bushing
bore prior to installing new bushing. Bushing
EBS Drive Clutch Moveable Sheave
Bushing Removal Main Adapter Piston Pin
(8) Puller
1. Remove clutch as outlined previously in this
chapter.
2. Install handle end of Piston Pin Puller (PN EBS Drive Clutch Moveable Sheave
2870386) securely into bench vise and lightly Bushing Installation
grease puller threads. 2. Apply Loctitet 609 evenly to bushing bore inside
3. Remove nut from puller rod and set aside. moveable sheave.
6.29
CLUTCH
3. Set bushing in place on sheave. 3. With main adapter on puller, insert cover onto
4. Insert installation puller tool (Item A/B) with “A” puller rod, placing outside of cover toward vise.
side down, into center of bushing. 4. Install nut on rod and hand tighten. Turn puller
5. With towers pointing upward, slide sheave, barrel to apply more tension if needed.
bushing and tool onto puller rod. 5. Turn clutch cover counterclockwise on puller rod
6. Install nut on puller rod and hand tighten. Turn until bushing is seated.
barrel to apply additional tension if needed. 6. Remove nut from puller rod. Take installation tool
7. Turn sheave counterclockwise, making sure and clutch cover off rod.
bushing is drawn straight into bore. Continue until
bushing is seated.
EARLY 2004 -- EBS DRIVEN
9. Remove sheave from puller. BUSHING SERVICE
10. Remove installation tool.
EBS Driven - Bushing Removal
EBS Drive Clutch Cover Bushing Removal 1. Install puller adapter (Item 10) onto puller.
1. Install main adapter (Item 8) on puller.
Removal Tool (3) Nut (C)
Adapter
Reducer (9)
Main Adapter
(8) Piston Pin Ill. 1
Puller
2. Insert EBS main adapter (Item D) onto puller. See
EBS Drive Clutch Cover Bushing Removal Ill. 1.
3. Install bushing removal tool (Item E) into center of
2. Install adapter reducer (Item 9). clutch sheave. See Ill. 2.
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.
8. Remove bushing and bushing removal tool from
puller. Discard bushing.
Bushing
EBS Drive Clutch Cover Bushing Installation
Removal Tool (E)
1. Apply Loctitet 609 evenly to bushing bore in Ill. 2
cover.
4. Install sheave onto puller.
2. Working from inside of cover, insert new bushing
and bushing installation tool into center of clutch
cover.
6.30
CLUTCH
5. Install left hand nut onto puller rod and tighten by 3. Using a hand held propane torch, apply heat
hand. Turn puller barrel for further tension if around outside of bushing until tiny smoke tailings
needed. appear.
6. Using a hand held propane torch, apply heat CAUTION: Clutch components will be hot! In
evenly around outside of bushing until tiny smoke order to avoid serious burns, wear insulated
tailings appear. gloves during the removal process.
CAUTION: Clutch components will be hot! In 4. Flip sheave over onto puller.
order to avoid serious burns, wear insulated
5. Install bushing tool (Item 2).
gloves during the removal process.
6. Install left hand nut (C) and spacer onto puller rod
7. Turn clutch sheave counterclockwise until and tighten by hand. Turn puller barrel for further
bushing is removed and sheave comes free. tension if needed.
8. Remove nut (C) (left hand thread) from puller rod 7. Turn clutch sheave counterclockwise until
and set aside. bushing is removed and sheave comes free.
9. Remove adapters from puller. 8. Remove nut (C) (left hand thread) from puller rod
10. Remove bushing and remove tool from adapters. and set aside.
Discard bushing. 9. Remove adapters from puller.
EBS Driven - Bushing Installation
1. Slide adapter (Item 10) onto puller. EBS Driven Clutch Outer Bushing Removal
Bushing
EBS Driven Clutch Bushing Installation Tool (2) Nut (C)
Puller Tool (A/B) Nut (C)

Side “B” toward
sheave
Adapter
Reducer (9)
Main Adapter
(8)
Bushing

Puller Adapter (10) Discard bushing.
2. Apply Loctitet 609 evenly to bushing bore inside EBS Driven - Backside (Outer) Bushing
moveable sheave. Installation
3. Install sheave onto puller (belt surface up). 1. Install puller adapter (Item 10) onto puller.
4. Place new bushing on side B of installation tool 2. Install adapter (Item 9) onto puller.
(Item A/B) and slide both over puller rod.
5. Install nut (C) onto puller rod and hand tighten EBS Driven Clutch OuterBushing Installation
against installation tool.
6. Turn clutch sheave counterclockwise until Nut (C)
bushing is seated. Bushing Bushing
Tool (2)
7. Remove nut (C) (left hand thread) from puller rod
and set aside.
8. Remove installation tool and clutch sheave from
puller.
EBS Driven - Backside (Outer) Bushing Removal

1. Install main puller adapter (Item 8) onto puller. Bushing
Tool (2)
2. Install adapter reducer (Item 9). Puller Adapter Adapter
(10) (9)
6.31
CLUTCH
3. Apply Loctitet 609 evenly to bushing bore inside drive clutch rotational speed, the one--way clutch
moveable sheave. locks to the drive clutch shaft and engine braking
4. Install sheave face down on puller. occurs. Essentially the driven clutch has become the
“driving” clutch. The stop plate (bow plate) that is fixed
5. Install new bushing on installation tool (Item 2)
to the transmission shaft rotates in the pocket of the
and install assembly into sheave.
sheave, allowing the stationary sheave to rotate with
6. Install left hand thread nut (C) onto puller rod and the moveable sheave as the rollers move to the other
hand tighten against installation tool. side of the ramp, providing instant EBS braking.
7. Turn clutch sheave counterclockwise, making Engine braking (EBS) continues until the drive clutch
sure bushing is drawn straight into bore. speed exceeds the one--way clutch speed, or until the
Continue until bushing is seated. throttle is applied and the engine reaches clutch
8. Remove nut (C) (left hand thread) from puller rod engagement speed, lifting the belt off of the one--way
and set aside. clutch.
puller. CAUTION: The driven clutch must be
disassembled from the helix end to reduce spring
pressure. Review all information below before
proceeding.
LATE 2004--2005 -- EBS DRIVEN DISASSEMBLY/ASSEMBLY
DRIVEN CLUTCH 1. Remove driven clutch from the transmission input
DISASSEMBLY/INSPECTION - shaft. Do not attempt disassembly of the driven
Late 2004 EBS Driven Clutch Operation clutch from the outside snap ring. The driven
clutch must be disassembled from the helix side.
The late model EBS driven clutch provides the same
engine braking abilities as the earlier EBS driven
clutch.
One--way Clutch
Drive Clutch
Driven Do not disassemble from this side

Downhill 2. It is important to mark the position of the shaft,
Belt Rotation stop plate, and sheave before disassembly. Mark
the helix and inside sheave also. This will aid in
reassembly.
Stop Plate
Drive
When the ATV is moving downhill the drive train turns

the driven clutch, belt, and one way clutch in the
direction of engine rotation. When the one--way
clutch (see exploded view of drive clutch) exceeds the
6.32
CLUTCH
Mark Components Before Disassembly

B
Mark Components Before Disassembly NOTE: Rotating the moveable sheave so that the
rollers are not in contact with either helix ramp
surfaces will lessen the effort needed to push the helix
inward.
4. Remove helix (C), spring (D), and spring seat
washer (E) and inspect for wear or damage.
Replace if worn.
NOTE: Note the keyed spline on the shaft and
helix for reassembly. The keyed shaft ensure
proper alignment of the helix to the shaft.
C
3. Place the driven assembly into the clutch holder.
Push helix inward. Remove snap ring (A) and D
washer (B). NOTE: The spring is a compression
spring only and has no torsional wind.
6.33
CLUTCH
E
Heat Area
Roller
Lightly Apply Loctitet
680 To Tapered
Portion Of Screw
Dry Locking
Agent Applied
To New Screws
5. Inspect surface of rollers for flat spots and wear. Roller

Retaining Screw
Rollers must rotate freely on pins without
excessive clearance. Check the roller pin and
roller bore for wear and replace if necessary.
Rollers
6. Inspect moveable sheave bushing for wear.

Inspect BOTH sheaves for signs of wear,
grooving or cracking. Clean surfaces with a 3Mt
pad if needed
Inspect Bearings
ROLLER PIN DISASSEMBLY

New roller retaining bolts have a dry locking agent
applied to the threads. Before attempting to remove
the roller pins, heat the threaded area lightly with a
propane torch. Wear heat resistant gloves during
this procedure. Use a high quality hexagonal
wrench in good condition to avoid screw damage. A Inspect Sheave Surface
small amount of valve grinding compound can be
applied to the tip of the hex wrench to ensure a tight
fit. Always use new bolts if they are removed for
inspection. Apply Loctitet 680 retaining compound
sparingly to the tapered head portion of the roller
Replace the bushing if more brass than
retaining screws. Do not allow locking agent to
Teflont is visible on the surface of the
contact the inside of the rollers. Do not lubricate the bushing. See “EBS DRIVEN BUSHING
roller or roller pin. SERVICE” later in this chapter.
6.34
CLUTCH
7. Check for movement of the shaft in the stationary 9. Remove the snap ring (F).
sheave. The shaft should rotate freely until the
stop plate makes contact with the sheave casting.
Some lateral movement is allowable. The
amount of movement shall be limited to prevent
the plate from raising out of the sheave pocket. F
10. Remove the stop plate (G) and spacer washer

(H).
Stop Plate/Shaft Clutch Disassembly

8. It is important to mark the position of the shaft,
stop plate, and sheave before disassembly. This
will aid in reassembly. H
Mark Components Before Disassembly
11. Remove the shaft (I) from the sheave assembly.

Inspect washers and bearing for wear.
Stop Plate
6.35
CLUTCH
LATE 2004--2005 -- DRIVEN DRIVEN BUSHING SERVICE” later in this

chapter for replacement of driven bushings .
CLUTCH REASSEMBLY 2. Be sure to use the alignment marks for
reassembly.
1. Simply reverse the steps of the disassembly
process. Replace any parts needed. See “EBS
LATE 2004--2005 EBS DRIVEN CLUTCH EXPLODED VIEW

2 3
1
4
5 14
6 7
14 15
16
9
10 6
1. Snap Ring
2. Spacer 11
3. Stationary Ramp (Helix)
4. Spring
5. Spacer Washer
6. Moveable Bearing
7 12
7. Sheave 1
13
8. Bearing
9. Screw
10. Taper Roller
11. Shaft
12. Washer
13. Plate
14. Washer
15. Spring Lock Washer
16. Bolt
6.36
CLUTCH
LATE 2004--2005 -- EBS 8. Remove nut (C) (left hand thread) from puller rod
and set aside.
DRIVEN BUSHING SERVICE 9. Remove adapters from puller.
EBS Driven - Bushing Removal
Discard bushing.
1. Install puller adapter (Item 10) onto puller. EBS Driven - Bushing Installation
1. Slide adapter (Item 10) onto puller.
EBS Driven Clutch Bushing Installation
Puller Tool (A/B) Nut (C)

D Side “B” toward
sheave
Bushing
Ill. 1
2. Insert EBS main adapter (Item D) onto puller. See Puller Adapter (10)
Ill. 1.
2. Apply Loctitet 609 evenly to bushing bore inside
3. Install bushing removal tool (Item E) into center of
moveable sheave.
clutch sheave. See Ill. 2.
3. Install sheave onto puller (belt surface up).
4. Place new bushing on side B of installation tool
(Item A/B) and slide both over puller rod.
5. Install nut (C) onto puller rod and hand tighten
against installation tool.
6. Turn clutch sheave counterclockwise until
bushing is seated.
7. Remove nut (C) (left hand thread) from puller rod
and set aside.
puller.
Bushing
EBS Driven - Backside (Outer) Bushing Removal
Removal Tool (E)
Ill. 2 1. Install main puller adapter (Item 8) onto puller.
2. Install adapter reducer (Item 9).
4. Install sheave onto puller.
5. Install left hand nut onto puller rod and tighten by around outside of bushing until tiny smoke tailings
hand. Turn puller barrel for further tension if appear.
needed.
CAUTION: Clutch components will be hot! In
6. Using a hand held propane torch, apply heat order to avoid serious burns, wear insulated
evenly around outside of bushing until tiny smoke gloves during the removal process.
tailings appear.
CAUTION: Clutch components will be hot! In 4. Flip sheave over onto puller.
order to avoid serious burns, wear insulated 5. Install bushing tool (Item 2).
gloves during the removal process. 6. Install left hand nut (C) and spacer onto puller rod
7. Turn clutch sheave counterclockwise until and tighten by hand. Turn puller barrel for further
bushing is removed and sheave comes free. tension if needed.
6.37
CLUTCH
7. Turn clutch sheave counterclockwise until 8. Remove nut (C) (left hand thread) from puller rod
bushing is removed and sheave comes free. and set aside.
8. Remove nut (C) (left hand thread) from puller rod 9. Remove installation tool and clutch sheave from
and set aside. puller.
9. Remove adapters from puller.
EBS Driven - Stationary Sheave (Inner) Bushing
EBS Driven Clutch Outer Bushing Removal
Removal
Bushing
Tool (2) 1. Install puller adapter onto puller.
Nut (C)
2. Install adapter reducer.
Adapter
Reducer (9) C
Main Adapter
(8)

Discard bushing.
EBS Driven - Backside (Outer) Bushing Bushing Tool (2)
Installation
1. Install puller adapter (Item 10) onto puller.
2. Install adapter (Item 9) onto puller. around outside of bushing until tiny smoke tailings
appear.
EBS Driven Clutch OuterBushing Installation
CAUTION: Clutch components will be hot! In
order to avoid serious burns, wear insulated
Nut (C)
gloves during the removal process.
Bushing Bushing
Tool (2)
Bushing
Tool (2)
Puller Adapter Adapter
(10) (9)
3. Apply Loctitet 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 assembly into sheave. 4. Install bushing tool (Item 2)
6. Install left hand thread nut (C) onto puller rod and
5. Install the left hand nut (C) and spacer onto puller
hand tighten against installation tool. rod and tighten by hand. Turn puller barrel for
7. Turn clutch sheave counterclockwise, making further tension if needed.
sure bushing is drawn straight into bore. 6. Turn clutch sheave counterclockwise until both
Continue until bushing is seated. bushings are removed and sheave comes free.
6.38
CLUTCH
TROUBLESHOOTING
Situation Probable Cause Remedy

Engine RPM -Wrong or broken drive clutch spring. -Replace with recommended spring.
below specified
operating range -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application.
although engine
is properly -Driven clutch spring broken or installed -Replace spring; refer to proper installation location.
tuned. wrong .
Erratic engine -Drive clutch binding. a. Disassemble drive clutch; inspect shift weights for wear
operating RPM and free operation.
during accelera- b. Clean and polish stationary shaft hub; reassemble clutch
tion or load vari- without spring to determine problem area.
ations.
-Belt worn unevenly - thin/burnt spots Replace belt
-Driven clutch malfunction. a. Replace ramp buttons.

b. Inspect movable sheave for excessive bushing clearance/
replace.
-Sheave face grooved. -Replace the clutch.

Engine RPM -Incorrect drive clutch spring (too high -Install correct recommended spring.
above specified spring rate).
operating
range. -Drive clutch shift weights incorrect for ap- -Install correct recommended shift weights.
plication (too light).
-Drive clutch binding. -Disassemble and clean clutch, inspecting shift weights and
rollers. Reassemble without the spring and move sheaves
through entire range to further determine probable cause.
-Driven clutch binding. -Disassemble, clean, and inspect driven clutch, noting worn
sheave bushing and ramp buttons and helix spring location.
-Converter sheaves greasy; belt slippage. -Clean sheaves with denatured alcohol or brake cleaner,
install new belt.
Harsh drive -Drive belt worn too narrow. -Replace belt.
clutch engage-
ment. -Excessive belt/sheave clearance with new -Perform belt/sheave clearance adjustment with shim wash-
belt. ers beneath spider.
Drive belt turns -Wrong belt for application. -Replace with correct belt.
over
-Clutch alignment out of spec. -Adjust alignment offset.
-Engine mount broken or loose. -Inspect/adjust or replace.

PVT cover -Plugged air intake or outlet -Clear obstruction.
overheating
(melting) -Belt slippage due to water, oil, grease, -Inspect system. Clean , repair or replace as necessary.
etc., rubbing on cover Seal PVT system ducts.
-Clutches or weight being applied to cover -Remove weight. Inform operator.

while in operation
-Use of High vs. low range -Instruct operator on guidelines for operation in proper driving
range for different terrain as outlined in Owner’s Safety and
Maintenance Manual.
Water ingestion -Cover seals or ducts leaking -Find leak and repair as necessary.
-Operator error -Instruct operator on guidelines for operation in wet terrain as

outlined in Owner’s Safety and Maintenance Manual.
6.39
CLUTCH
TROUBLESHOOTING
Situation Probable Cause Remedy

Belt slippage -Belt worn out -Replace belt.
-Water ingestion -Inspect and seal PVT system.
-Belt contaminated with oil or grease -Inspect and clean.

Belt burnt, thin -Abuse (continued throttle application when -Caution operator to operate machine within guidelines.
spots vehicle is stationary, excess load)
-Dragging brake -Vehicle operated with park brake on. Inspect brake system.
-Slow, easy clutch engagement -Instruct firm, effective use of throttle for efficient engage-
ment.
PVT noise -Belt worn or separated, thin spots, loose -Replace belt.
belt
-Broken or worn clutch components, cover -Inspect and repair as necessary.
hitting clutches
6.40
FINAL DRIVE
Final Drive Torque Specifications . . . . . . . . . . . 7.2

AWD Front Drive Axle Removal . . . . . . . . . . . . 7.2-7.3
AWD Front Drive Axle Installation . . . . . . . . . . 7.3
Front CV Joint Boot Replacement . . . . . . . . . . 7.4-7.7
AWD Front Hub Disass./Ass. . . . . . . . . . . . . . . 7.7
Front Propshaft Removal . . . . . . . . . . . . . . . . . . 7.7
U-Joint Disassembly . . . . . . . . . . . . . . . . . . . . . . 7.8
U-Joint Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7.9
Driveshaft / Propshaft Views . . . . . . . . . . . . . . . 7.10--7.11
Front Gearcase Removal . . . . . . . . . . . . . . . . . . 7.12
Early Front Gearcase Operation . . . . . . . . . . . 7.9
Early Front Gearcase Disass/Ass. . . . . . . . . . 7.13--7.18
Early Front Gearcase Diagnosis . . . . . . . . . . . 7.18-7.19
Early Front Gearcase Exploded View . . . . . . . 7.20
Late Front Gearcase Operation . . . . . . . . . . . . 7.21
Late Front Gearcase Disass/Ass. . . . . . . . . . . 7.21-7.27
Late Front Gearcase Diagnosis . . . . . . . . . . . . 7.28--7.29
Front Gearcase Installation . . . . . . . . . . . . . . . . 7.29
Late Front Gearcase Exploded View . . . . . . . . 7.30
Rear Axle Operation . . . . . . . . . . . . . . . . . . . . . . 7.31-7.32
Rear Axle Hub Removal . . . . . . . . . . . . . . . . . . 7.33
Rear Axle Removal . . . . . . . . . . . . . . . . . . . . . . . 7.34-7.35
Rear Axle Installation . . . . . . . . . . . . . . . . . . . . . 7.35
Rear Axle Tube/Bearing Removal . . . . . . . . . . 7.36-7.37
Rear Axle Tube/Bearing Installation . . . . . . . . 7.37
Rear Axle Tube Assembly . . . . . . . . . . . . . . . . . 7.38--7.39
Rear Carrier Disassembly . . . . . . . . . . . . . . . . . 7.39-7.42
Rear Carrier Assembly . . . . . . . . . . . . . . . . . . . . 7.42-7.43
Rear Carrier Installation . . . . . . . . . . . . . . . . . . . 7.44
Rear Carrier Exploded View . . . . . . . . . . . . . . . 7.45
7.1
FINAL DRIVE
WHEEL, HUB, AND SPINDLE FRONT DRIVE AXLE

TORQUE TABLE REMOVAL
1. Set the ATP in park. Remove hub dust cap.
2. Remove cotter pin.
ATP 330 4x4 Nuts (37 Nm) 3. Loosen the hub retaining nut.
Rear Wheel 27 Ft. Lbs. 4. Loosen - but do not remove - the wheel nuts.
ATP 500 4x4
Nuts (37 Nm) 5. Safely lift and support the front of the ATP.
Retaining Nut (95 Nm) CAUTION:
Retaining Nut (108 Nm) Serious injury could occur if machine tips or falls.
Refer to exploded views and text for torque values of 6. Remove wheel.
other fasteners 7. Remove the two brake caliper attaching bolts.
CAUTION: Locking nuts, and bolts with pre--applied CAUTION: Do not hang the caliper by the brake
locking agent should be replaced if removed. The line. Use wire to hang the caliper to prevent
self-locking properties of the nut or bolt are reduced possible damage to the brake line.
or destroyed during removal.
Special Tools
PART NUMBER TOOL DESCRIPTION
2870872 Shock Spanner Wrench
2870871 Ball Joint Replacement
Tool
2872608 Roller Pin Removal Tool
8700226 CV Boot Clamp Pliers
HEAVY DUTY REAR SPRING
8. Remove hub.
(7042324--385) Heavy Duty Spring
50 lbs. per inch of spring compression
7.2
FINAL DRIVE
9. Remove cotter pin and nut from lower A-arm ball FRONT DRIVE AXLE
joint. Remove lower A-arm from ball joint.
INSTALLATION
1. Install new spring ring on drive shaft. Apply an
anti--seize compound to splines.
2. Install a new circlip onto the drive shaft before
installing into front gearcase. Align splines of
drive shaft with front gearcase and install by
lightly tapping on drive shaft with rubber faced
hammer.
2005 Front Driveshaft
Install new circlip

10. Pull strut assembly out while pivoting front drive
shaft downward until it clears strut assembly.
2004 Front Driveshaft

3. Install drive shaft in strut.
4. Install lower ball joint, torque nut to 25 ft. lbs. (34.5
Nm) and install new cotter pin.
5. Install hub and tighten hub nut to 70 ft. lbs. (95
Nm).
New Cotter Key
11. With short, sharp jerks, remove drive shaft from

front gearcase.
Front Hub Retaining Nut Torque
70 ft. lbs. (95 Nm)
DRIVESHAFT AND CV JOINT

HANDLING TIPS
Care should be exercised during driveshaft removal
or when servicing CV joints. Driveshaft components
are precision parts.
7.3
FINAL DRIVE
Cleanliness and following these instructions is very 2004 ATP -- FRONT DRIVE
important to ensure proper shaft function and a
normal service life. SHAFT CV JOINT BOOT
G The complete driveshaft and joint should REPLACEMENT (4X4)
be handled by getting hold of the
interconnecting shaft to avoid 1. Remove wheel, brake caliper and wheel hub.
disassembly or potential damage to the Refer to Front Drive Axle Removal Page 7.2 for
driveshaft joints. procedure.
G Over-angling of joints beyond their 2. Remove cotter pin and castle nut from A-arm ball
capacity could result in boot or joint joint.
damage.
G Make sure surface-ground areas and
splines of shaft are protected during
handling to avoid damage.
G Do not allow boots to come into contact
with sharp edges or hot engine and
exhaust components.
G The driveshaft is not to be used as a lever
arm to position other suspension
components.
G Never use a hammer or sharp tools to
remove or to install boot clamps.
G Be sure joints are thoroughly clean and
that the proper amount and type of
grease is used to refill when joint boots
are replaced and when joints are
cleaned. Refer to text for grease
capacity of CV joints and CV joint boots. 3. Disconnect A-arm from ball joint using a tie rod
fork.
DRIVE SHAFT (CV) BOOT

INSPECTION
Check the front and rear driveshaft cv boots for any
tears or leaking grease. If the driveshaft boot loses all
of the grease cv joint failure will occur.
4. Slide strut off end of drive shaft and tie it up out of

the way of the shaft.
5. Remove clamps from rubber boot using the
proper boot clamp pliers.
6. Remove the large end of the boot from the CV
joint, slide the boot back and separate the wheel
spindle and CV joint assembly from the axle shaft
by pulling the shaft sharply outward, away from
the CV joint. It may be necessary to tap the CV
joint assembly outward with a soft faced hammer.
7.4
FINAL DRIVE
CV BOOT REPLACEMENT CONT’D

11. Position large end of boot on CV joint, purge
Retaining ring excess air by partially compressing axle into CV
bell, lift one edge of boot to let out excess air
Secure with clamp.
FRONT SHAFT Joint Capacity

30 Grams
Boot Capacity
30 Grams
Pull shaft to remove from

CV joint
7. Remove small clamp and boot from driveshaft. Front outboard joint capacity:
NOTE:If the ATV has been operated with a damaged 30g if boot is replaced only.
boot, the CV joint grease may be contaminated. Another 30g (60g total) if joint is
Inspect the grease carefully for contamination, and cleaned.
clean the joint thoroughly if necessary. Front drive
axle CV boot replacement requires 30g of grease. If
CV joint is cleaned, an additional 30g of grease is
required. Refer to information following. 2005 ATP -- FRONT DRIVE
8. Before installing the new boot, remove all grease SHAFT CV JOINT BOOT
from the boot area and shaft.
NOTE: It is very important to use the correct type and
REPLACEMENT
quantity of grease. Use only the grease contained in 1. Remove wheel, brake caliper and wheel hub.
the boot kit. DO NOT use a substitute grease and DO Refer to Front Drive Axle Removal Page 7.2 for
NOT overfill or underfill the CV joint. procedure.
2. Remove cotter pin and castle nut from A-arm ball
joint.
CV Joint Grease -30g (PN 1350046)
CV Boot Clamp Pliers:

Earless Type (PN 8700226)
Boot Replacement requires 30g
Boot replacement with complete CV

joint cleaning requires an additional
30g. (Total 60g)
9. Slide the new clamp and boot (small end first)

over the splined shaft, then slide (tap) the CV joint
3. Disconnect A-arm from ball joint using a tie rod
into the splines of the axle. Install small boot
fork.
clamp.
10. Add grease through large end of boot.
7.5
FINAL DRIVE
8. Before installing the new boot, remove all grease

from the boot area and shaft.
NOTE: It is very important to use the correct type and
quantity of grease. Use only the grease contained in
the boot kit. DO NOT use a substitute grease and DO
NOT overfill or underfill the CV joint.
CV Joint Grease -3.5 oz. (Refer to

parts manual for boot kit)
CV Boot Clamp Pliers:
Earless Type (PN 8700226)
Boot replacement with complete CV

joint cleaning requires the entire 3.5 oz.
of grease.
4. Slide strut off end of drive shaft and tie it up out of
the way of the shaft.
9. Slide the new clamp and boot (small end first)
5. Remove clamps from rubber boot using the over the splined shaft, then slide (tap) the CV joint
proper boot clamp pliers. into the splines of the axle.
6. Remove the large end of the boot from the CV 10. Add grease through large end of boot.
joint, slide the boot back and separate the wheel
spindle and CV joint assembly from the axle shaft 11. Install a new boot onto the axle shaft and fill the
by pulling the shaft sharply outward, away from CV joint and boot with the correct type and
the CV joint. It may be necessary to tap the CV amount of grease.
joint assembly outward with a soft faced hammer. 12. 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
Retaining ring boot and the shaft. This will allow the air pressure
to equalize in the CV boot in the position that the
joint will spend most of its life. Before you remove
your instrument, be sure the small end of the boot
is in its correct location on the axle. CARE MUST
BE TAKEN TO AVOID DAMAGE TO THE
NEWLY INSTALLED BOOT.
Pull shaft to remove from

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

NOTE: If the ATV has been operated with a damaged
boot, the CV joint grease may be contaminated.
Inspect the grease carefully for contamination, and
clean the joint thoroughly if necessary. Front drive
axle CV boot replacement requires 3.5 oz. of grease.
7.6
FINAL DRIVE
13. Install the small clamp on the boot. 3. Inspect the bearing.
Front Shaft minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by hand,
inspect for rough spots, discoloration, or corrosion.
3.5 oz. The bearings should turn smoothly and quietly, with
no detectable up and down movement and minimal
movement sideways between inner and outer race.
4. Inspect bearing housing for scratches, wear or
damage. Replace housing if damaged.
FRONT HUB ASSEMBLY

3.5 oz.
1. Support bottom of hubstrut housing.
2. Start bearing in housing.
3. Press bearing into place until outer race bottoms
on housing.
FRONT HUB DISASSEMBLY
CAUTION:
1. Remove outer snap ring.
CAUTION: When using an arbor press be sure to
press only on the outer race, as bearing damage may
occur.
4. Install snap ring into groove.
FRONT PROP SHAFT

REMOVAL
1. Using Roll Pin Removal Tool (PN 2872608),
remove the roll pin from prop shaft at rear of
housing. Slide prop shaft back and away from
front housing. Pull sharply forward to remove
from transmission shaft.
2. From the back side, tap on the outer bearing race

with a drift punch in the reliefs as shown.
Roll Pin Remover Tool (PN 2872608)

NOTE: Drive bearing out evenly by tapping on outer
race only. Once bearing is at bottom of casting, NOTE: If removing front housing, use roll pin removal
support casting on outer edges so bearing can be tool to remove the pins from both front drive axles.
removed.
7.7
FINAL DRIVE
U-JOINT DISASSEMBLY 4. Force U-joint cross to one side and lift out of inner
yoke.
CAUTION: Wear eye protection at all times.
1. Remove internal or external snap ring from all
bearing caps.
NOTE: If yoke or bearing is removed, cross bearing

must be replaced. Note orientation of grease fitting
and mark inner and outer yoke for correct
re-positioning during installation.
2. Support inner yoke as shown and drive outer yoke
down (bearing cap out) with a soft face hammer.
3. Support U-joint in vise as shown and drive inner

yoke down to remove remaining bearing caps.
7.8
FINAL DRIVE
U-JOINT REASSEMBLY
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 inward.
5. Repeat Steps 1-3 to install bearing caps on outer

yoke.
6. Seat all bearing caps against snap rings by
supporting cross shaft and tapping on each
corner as shown.
2. Using a suitable arbor or vise, fully seat bearing

cap in one side. Continually check for free
movement of bearing cross as bearing caps are
assembled.
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.
3. Install snap ring to contain bearing cap just

installed. Repeat procedure for other side.
4. Install outer yoke, aligning marks made before
disassembly.
7.9
FINAL DRIVE
FRONT DRIVE AXLE EXPLODED VIEW

NOTE: Refer to your parts manual for the proper replacement parts.
2005 -- Front Drive Axle Components

Inner CV Joint
Circlip Inner Boot Outer Boot Circlip
Circlip
Outer CV Joint
Clamp
2005 -- Front Drive Boot Replacement Kits

Inner Clamp 3.5 oz. Grease
Boot
3.5 oz.
Outer Clamp
2004 -- Front Drive Axle Components
Boot Drive Axle
CV Joint Assy Clamps Circlip Yoke

U--Joint Assy
7.10
FINAL DRIVE
DRIVE SHAFT EXPLODED VIEW

NOTE: Refer to your parts manual for the proper replacement parts.
Front Prop Shaft Components

Yoke, Front Gearcase O-Ring
Prop Shaft
Cross and Bearing Kit Zerk
Spring Pin
Yoke, Propshaft to Transmission
Rear Prop Shaft Components
Spring Pin
Zerk
Yoke, Propshaft to Transmission
7.11
FINAL DRIVE
FRONT GEARCASE 8. Pull the hub and strut assembly out and pull the
drive--shaft out of the hub.
REMOVAL
1. Stop engine, place machine in Park and set
parking brake.
2. Loosen right front wheel nuts slightly.
3. Elevate and support machine under
footrest/frame area.
CAUTION: Serious injury may result if machine tips
or falls. Be sure machine is secure before beginning
this service procedure. Wear eye protection when
removing and installing bearings and seals.
4. Remove right wheel nuts and wheel.
5. Remove the front brake caliper and suspend the
safely suspend the brake caliper from the frame
with a piece of wire.
9. Pull both driveshafts from the front gearcase.

Replace the circlip on the driveshaft end for
reassembly.
10. Remove the roller pin from the front prop shaft.
Use the Roller Pin Removal Tool (PN 2872608).
11. Remove bolts securing bottom of housing to
frame. Bolts are accessible through the skid
plate. Remove vent line. Remove the front
gearcase from right side of frame.
Front Gearcase Removal
CAUTION: Do not hang the caliper by the brake line.

Use wire to hang the caliper to prevent possible
damage to the brake line.
6. Remove the front hub from the drive shaft.
7. Remove cotter pin, lower ball joint nut and A-arm
from ball joint.
Remove 4 Bolts
7.12
FINAL DRIVE
EARLY 2004 -- FRONT Output

GEARCASE OPERATION -- Hub
(CENTRALIZED HILLIARD) Roller Cage

& Bearings
NOTICE: ATP models built before July 14, 2003
will have the EARLY 2004 front gearcase and
ATPs built after this date will have the LATE
2004- 2005 front gearcase. Be sure to follow the
correct procedure when servicing the front
gearcase. There is no difference in theory of Armature
operation, only a difference in parts Plate
configuration. See Chapter 2 when servicing the
fluid in the front gearcase.
Normal Operation: With the AWD switch off the
vehicle drives only the rear wheels (2 wheel drive). Disengagement: As the front and rear wheels gain
When the AWD switch is activated it engages the traction, rotating very close to the same speed, the
Hilliard, locking both front axles into All Wheel Drive. front wheels “overdrive” the output hubs and the
rollers are forced outward, disengaging the AWD.
The vehicle is now back to rear wheel drive until the
Coil next loss of traction.
Cover Roller Cage and Bearing’s Ro-

tate Inward and Grip the Out-
put Hub for AWD Engagement
Output
Hub Roller
Cage
Armature
Plate
4x4 Engagement: When the AWD switch is

activated, a 12 VDC current charges the central coil Roller Cam
Output Hub Rollers
which creates a magnetic field. This magnetic field
attracts an armature plate keyed to a roller cage that
contains 14 rollers and roller cam. The difference in
rpm by input shaft and front axles the forces the rollers
up the external cam. The rollers engage themselves
to the output hubs that link both front axles, resulting
in True All Wheel Drive.
CAUTION: If the rear wheels are spinning, release

the throttle before turning the AWD switch on. If AWD
is engaged while the wheels are spinning, severe
drive shaft and clutch damage could result.
7.13
FINAL DRIVE
EARLY 2004 ATP -- FRONT 3. Remove output shaft assembly.
GEARCASE
1. Drain and properly dispose of used oil. Remove
any metal particles from the drain plug magnet.
2. Remove bolts and output shaft cover.
NOTE: Be careful not to misplace the thrust bearing

located between the two output shafts.
4. Clean all parts and inspect spacers for wear.
Inspect ring gear for chipped, broken, or missing
teeth.
5. Remove the roll cage assembly, rollers, and
H--springs.
Front Gearcase Coil Resistance:

22.8--25.2 Ohms
Gearcase Coil Resistance

NOTE: To test the gearcase coils resistance, use the
coil harness. The gearcase coils should measure
between 22.8 ohms and 25.2 ohms.
6. Thoroughly clean all parts. Inspect the rollers (A)

for nicks and scratches. The rollers must slide up
and down freely within the roller cage surfaces
(B).
7.14
FINAL DRIVE
B C D
Coils
A E
C F
7. Inspect the ring gear (C) for consistent wear 10. Inspect the armature plate (F) for a consistent
patterns. The surfaces should be free of nicks wear pattern. Uneven wear of the armature plate
and scratches. (F) indicates a warped plate, which may cause
8. Inspect roll cage (B) sliding surface. This surface intermittent operation.
must be clean and free of nicks, burrs or 11. Remove the thrust bearing (G) from the output
scratches. Remove and inspect the H--springs. hub (D). Inspect the thrust bearing (G) and the
dowel (H).
B
H D
H--spring
9. Remove the ring gear (C), the output hub (D), the 12. Remove the other output hub from the main
shim (E), and the armature plate (F) from the gearcase.
output cover.
7.15
FINAL DRIVE
EARLY 2004 ATP -- FRONT

GEARCASE
REASSEMBLY/INSPECTION
1. Replace all O--rings, seals, and worn
components.
2. Press the pinion shaft seal into the pinion cover,
until the seal is flush with the sealing surface.
3. Inspect bearings on output and pinion shafts. To
replace, press new bearing on to shaft.
13. Remove the O--ring and seal from the output The bearings should turn smoothly and quietly, with
cover. no detectable up and down movement and minimal
movement side to side.
4. Install pinion shaft, bearing, and input cover with
new o-ring and torque bolts to 14 ft. lbs (19 Nm).
14. Remove the input cover, bearing, and the pinion

gear. Inspect the pinion gear for chipped, broken,
or missing teeth. Inspect the output shaft
bushing. Replace as needed. Clean the inside Cover Bolts Torque
surfaces of both gearcase halves.
14 ft. lbs. (19 Nm)
5. Install the output hub into the gearcase housing.

The output hub should spin freely.
7.16
FINAL DRIVE
8. Install the shim onto the ring gear.
6. Install the ring gear into the gearcase housing.

9. Install the armature plate onto the ring gear.
7. Slide the roll cage into the ring gear. Insert the
rollers as the roll cage is installed.
NOTE: Be sure armature plate tabs are placed into
the slots on roll cage.
10. Apply grease to the thrust bearing. Insert the
thrust bearing onto the output hub. Insert the
output hub, dowel, and thrust bearing into the ring
gear.
7.17
FINAL DRIVE
11. Install output cover with new o-ring and torque

bolts to 14 ft. lbs. (19 Nm).
EARLY 2004 ATP -- 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). The gearcase coils should
measure between 22.8 ohms and 25.2 ohms.
2. Check the minimum battery voltage at the wire
(Grey & Brown/White) that feeds the hub coil wire.
There should be a minimum of 11.80--12.0 Volts
present for proper operation.
Cover Bolts Torque
14 ft. lbs. (19 Nm)
12. Install new seals into the gearcase housing and

gearcase housing cover.
3. Inspect the armature plate for a consistent wear

pattern. There should one or 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. See Illustration
1.
7.18
FINAL DRIVE
Armature Plate
Gearcase Cover
Coil
Check for wear bands

U--shaped insert
ILL. 1 Possible Side Cutaway View of Centralized Hilliard Cover

Wear Ring on
Armature Plate 5. Inspect the rollers in the roll cage for nics and
scratches. The rollers must slide up and down
and in and out freely within the roll cage sliding
surfaces.
OK Condition
Bad Condition
(Wear from Coil
On Armature Plate)
4. Check to make sure the coil is seated in the

U--shaped insert that is pressed into the gearcase
cover. The top of the coil should be seated below
the U--shaped insert. The U--shaped insert
controls the pole gap. If the top of the coil is above
the surface of the U--shaped insert it raises the
armature plate, thereby increasing pole gap. If
the pole gap increases the coil will not be strong
enough to engage the AWD system. If this is the
cause order a new Plate Cover Assembly (PN
3233952).
7.19
FINAL DRIVE
EARLY 2004 ATP -- FRONT GEARCASE EXPLODED VIEW
1
2
3
4 5
6 18
28 7 9 21
8 10
22 11
12 17 20
36
13
14 22
15 19
16 23
13 24
35 25
34 26
6 27
28
29
33
32 30
31
Ref. Qty. Description Ref. Qty. Description

1 Asm., Mid Gearcase 20. 1 O-- Ring
1. 1 Cover, Output 21. 1 Seal
2 1 O-- Ring 22. 11 Kit, Bolt
3. 1 Insert 23. 1 Cover, Input
4. 1 Coil 24. 1 Bearing, Roller Ball
5. 1 Kit, Shim Set (Incl. Shims) 25. 1 Shaft, Pinion, 11T
6. 2 Bearing, Roller Ball 26. 1 Bushing
7. 1 Hub, Race/Output, Male 27. 1 Gearcase, LH
8. 1 Pin, Dowel 28. 2 Seal, Oil
9. 1 Bearing, Roller Ball 29. 1 Plug, Oil Fill
10. 1 Clutch Housing/Ring Gear 30. 4 Washer, Spring Lock
11. 1 Spring 31. 4 Screw
12. 14 Kit, Roll 32. 1 Plug, Oil Drain
13. 2 Ring, Retaining 33. 1 Washer
14. 1 Bushing 34. 1 Bearing, Needle, Roller Thrust
15. 1 Hub, Race/Output, Female 35. 1 Roll Cage, Aluminum
16. 1 Bushing 36. 1 Plate Armature
17. AR Line, Fuel
18. 1 Clip
19. 1 Clamp, Hose
7.20
FINAL DRIVE
LATE 2004--2005 ATP -- drive shaft and clutch damage could result.
FRONT GEARCASE Roller Cage and Roller’s Rotate Inward and

Grip the Output Hub for AWD Engagement
OPERATION -- CENTRALIZED
HILLIARD) Output
Hub
Engaging Front Gearcase: The AWD switch may Rollers
be turned on or off while the vehicle is moving. Initially,
the vehicle’s electronic system will not enable the
AWD until the engine RPM is below 3100. Once
enabled, the AWD remains while the front gearcase
is moving, it will not disengage until the rear wheels
regain traction.
Engage the AWD switch before getting into conditions
where the front wheel drive may be needed. If the rear
wheels are spinning , release the throttle before
Roller Cage
switching to AWD.
& Bearings
CAUTION: Switchting to AWD while the rear wheels
are spinning may cause severe drive shaft and
gearcase damage. Always switch to AWD while the Disengagement: As the front and rear wheels gain
rear wheels have traction or are at rest. traction, rotating very close to the same speed, the
front wheels “overdrive” the output hubs and the
Normal Operation: With the AWD switch off the rollers are forced outward, disengaging the AWD.
vehicle drives only the rear wheels (2 wheel drive). The vehicle is now back to rear wheel drive until the
When the AWD switch is activated it engages the next loss of traction.
Hilliard, locking both front axles into All Wheel Drive.
LATE 2004--2005 ATP-- FRONT

Roller Cage
GEARCASE
1. Drain and properly dispose of used oil. Remove
any metal particles from the drain plug magnet.
Output 2. Remove bolts and output shaft cover.
Hub
Armature
Plate Cover
Coil
4x4 Engagement: When the AWD switch is

activated, a 12 VDC current charges the central coil
which creates a magnetic field. This magnetic field
attracts an armature plate keyed to a roller cage that
contains 14 rollers and roller cam. The difference in
rpm by input shaft and front axles the forces the rollers
up the external cam. The rollers engage themselves
to the output hubs that link both front axles, resulting
in True All Wheel Drive.
CAUTION: If the rear wheels are spinning, release

the throttle before turning the AWD switch on. If AWD
is engaged while the wheels are spinning, severe
7.21
FINAL DRIVE
7. Inspect the ring gear (C) for consistent wear

patterns. The surfaces should be free of nicks
Front Gearcase Coil Resistance: and scratches.
22.8--25.2 Ohms
B
Gearcase Coil Resistance
NOTE: To test the gearcase coils resistance, use the
coil harness. The gearcase coils should measure
between 22.8 ohms and 25.2 ohms.
3. Remove output shaft assembly.
C A
8. Inspect roll cage (B) sliding surface. This surface

must be clean and free of nicks, burrs or
scratches. Remove and inspect the H--springs.
NOTE: Be careful not to misplace the thrust bearing

located between the two output shafts.
4. Clean all parts and inspect spacers for wear.
Inspect ring gear for chipped, broken, or missing
teeth.
H--spring
5. Remove the roll cage assembly, rollers, and
H--springs.
9. Use a flat head screwdriver to remove the
retaining clip from the output cover.
6. Thoroughly clean all parts. Inspect the rollers (A)

for nicks and scratches. The rollers must slide up
and down freely within the roller cage surfaces
(B).
7.22
FINAL DRIVE
10. Remove the spacer washer (D), armature plate

(E), and rubber O--ring from the output cover. H
G
O--ring
F
E
13. Inspect the magnetic coil (I) in the output housing.

11. Inspect the armature plate (E) for a consistent NOTE: See “FRONT GEARCASE DIAGNOSIS”
wear pattern. Uneven wear of the armature plate later in this chapter for more details on the coil.
(E) indicates a warped plate, which may cause
intermittent operation. NOTE: See “FRONT 14. Inspect the back lash pad (J) for excessive wear.
GEARCASE DIAGNOSIS” later in this chapter for NOTE: The backlash for the centralized hilliard is set
more details. at the factory. No readjustment is required.
E J
12. Remove the output hub (G) from the cover.

Remove the thrust bearing (F) from the output 15. Remove the other output hub (K) from the main
hub (G). Inspect the thrust bearing (F) and the gearcase. Inspect the inner bearing (L) for wear.
dowel (H). If there is excessive wear, replace bearing as
needed.
7.23
FINAL DRIVE
18. Remove and replace the O--rings and seals from

the assembly.
K
L
16. Remove the input cover (M), bearing (N), and the
pinion gear (O). Inspect the pinion gear (O) for
chipped, broken, or missing teeth. Replace the
input cover O--ring.
17. Inspect the output shaft bushing. Replace as

needed. Clean the inside surfaces of both
gearcase halves.
7.24
FINAL DRIVE
LATE 2004 --2005 ATP --

FRONT GEARCASE A
REASSEMBLY/INSPECTION
1. Replace all O--rings, seals, and worn
components.
2. Press the pinion shaft seal into the pinion cover,
until the seal is flush with the sealing surface.
3. Inspect bearings on output and pinion shafts. To
replace, press new bearing on to shaft.
The bearings should turn smoothly and quietly, with 6. Install the other output hub (B) and thrust bearing
no detectable up and down movement and minimal (C) into the output cover. Apply a small amount of
movement side to side. grease onto the thrust bearing.
4. Install pinion shaft, bearing, and input cover with
new o-ring and torque bolts to 14 ft. lbs (19 Nm).
B C
Input Cover Bolts Torque:
14 ft. lbs. (19 Nm)
5. Install the output hub (A) into the gearcase

housing. The output hub should spin freely.
7.25
FINAL DRIVE
7. Install the armature plate (D) and spacer washer

(E) into the output cover. NOTE: Be sure
backlash plate is in place.
Backlash Plate 11. Install the output cover assembly onto the main
gearcase.
8. Install the retaining ring (F) into the output cover. NOTE: Be sure armature plate tabs are placed into
Be sure the retaining ring is properly seated into the slots on roll cage. (See Reference Photo)
the cover.
9. Install the ring gear onto the output hub on the Photo for reference only!
output cover.
Armature Plate Tabs Fit Into Rollcage Slots
NOTE: This photo is for reference only, the armature

plate is actually installed in the output cover.
10. Install the rollers and roll cage into the ring gear.
Insert the rollers as the roll cage is installed. 12. Install output cover with new o-ring and torque
bolts to 14 ft. lbs. (19 Nm).
7.26
FINAL DRIVE
NOTE: Be sure the square O--ring is placed flat on the

cover surface, if the O--ring is twisted fluid leakage
may occur.
17. Turn the screw in until it is lightly seated, then turn

the screw out 1/4 turn.
18. Set the gearcase upright. Rotate the pinion shaft
at least 4 times. This ensures the ring gear
completes one full rotation.
Cover Bolts Torque
14 ft. lbs. (19 Nm)
13. Install new seals into the gearcase housing and

gearcase housing cover.
Back Lash Pad (Thrust Pad) Adjustment
14. Lay the gearcase on the side with the output cover
facing up.
15. The backlash screw is loctited into place. Use a
heat gun to lightly heat up the Loctitet on the
screw (1).
19. If a tight spot is felt during rotation, loosen the
backlash screw another 1/8 turn. Perform the
previous step again. Repeat this procedure until
the pinion shaft rotates smoothly 4 times (1
1 revolution of ring gear).
16. Using a hex wrench, turn the back--lash screw out

3--4 turns. Re--apply red Loctitet onto the
bottom screw threads.
7.27
FINAL DRIVE
LATE 2004--2005 ATP-- FRONT

ILL. 1 Possible
GEARCASE DIAGNOSIS Wear Ring on
Armature Plate
Symptom: AWD Will Not Engage.
1. Check the gearcase coil resistance. To test the
gearcase coil resistance, use the coil harness
(Grey & Brown/White). The gearcase coils should
measure between 22.8 ohms and 25.2 ohms. OK Condition
2. Check the minimum battery voltage at the wire
(Grey & Brown/White) that feeds the hub coil wire.
There should be a minimum of 11.80--12.0 Volts
present for proper operation.
Bad Condition
(Wear from Coil
On Armature Plate)
4. Check to make sure the coil is seated in the

U--shaped insert that is pressed into the gearcase
cover. The top of the coil should be seated below
the U--shaped insert. The U--shaped insert
controls the pole gap. If the top of the coil is above
the surface of the U--shaped insert it raises the
3. Inspect the armature plate for a consistent wear armature plate, thereby increasing pole gap. If
pattern. There should one or two distinct wear the pole gap increases the coil will not be strong
bands (one band inside the other). If only one enough to engage the AWD system. If this is the
band of wear is present (or if there is wear cause order a new Plate Cover Assembly (PN
between the two bands, inspect the coil area as 3233952).
indicated in Step 4. A band with an interrupted
wear mark may indicate a warped plate, which
may cause intermittent operation. See Illustration Gearcase Cover
1.
Armature Plate Coil
U--shaped insert
Side Cutaway View of Centralized Hilliard Cover

Check for wear bands
7.28
FINAL DRIVE
5. Inspect the rollers for nics and scratches. The

rollers must slide up and down and in and out
freely within the roll cage sliding surfaces. New Roller 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.
FRONT GEARCASE
INSTALLATION (ALL Premium Front Hub Fluid
(PN 2871654)
MODELS)
1. To install gearcase, reverse removal procedure. Front Housing Capacity
Use new spring pin in front prop shaft. 5.0 fl. oz. (148 ml)
2. Torque mounting bolts to 30 ft.lbs. (41 Nm).

Front Housing Mount Bolt Toque:
30 ft.lbs. (41 Nm)
30 ft.lbs. (41 Nm)
7.29
FINAL DRIVE
LATE 2004--2005 ATP FRONT GEARCASE -- CENTRALIZED

HILLIARD EXPLODED VIEW
31 30 18 21
19 22 20
2 9
37 24
25
22
5 23
28 13 10 26
7
11
1 3
4
36 12
6 34
8 6
17
35
14
28
15
16
27
33 29
32

1 Asm., Mid Gearcase 20. 1 O-- Ring
1. 1 Cover, Output 21. 1 Seal
2. 1 O-- Ring 22. 11 Kit, Bolt
3. 1 Insert 23. 1 Cover, Input
4. 1 Coil 24. 1 Bearing, Roller Ball
5. 1 Kit, Shim Set (Incl. Shims) 25. 1 Shaft, Pinion, 11T
6. 2 Bearing, Roller Ball 26. 1 Bushing
7. 1 Hub, Race/Output, Male 27. 1 Gearcase, LH
8. 1 Pin, Dowel 28. 2 Seal, Oil
9. 1 Dowel 29. 1 Plug, Oil Fill
10. 1 Clutch Housing/Ring Gear 30. 4 N/A
11. 1 Spring 31. 4 N/A
12. 14 Kit, Roll 32. 1 Plug, Oil Drain
13. 2 Retaining Ring 33. 1 Washer
14. 1 Bushing 34. 1 Bearing, Needle, Roller Thrust
15. 1 Hub, Race/Output, Female 35. 1 Roll Cage, Aluminum
16. 1 Bushing 36. 1 Plate Armature
17. 1 Vent 37. 1 Backlash Plate
18. 1 N/A
19. 1 N/A
7.30
FINAL DRIVE
REAR AXLE HOUSING Shift Yoke

Clutch Gear
OPERATION
The ATP has three traction operational modes: AWD,
2x4, and Turf (See Pic 1). Like most Polaris ATVs
AWD and 2x4 operation are standard, but with the
ATP’s Versatrac system the ATP can make much
tighter turns with less soil damage.
When the Turf option is chosen on the selector, the

rear differential becomes unlocked for tighter turns.
An electrical solenoid mounted on the rear axle Shift Yoke Slides Clutch Gear to
housing actuates the shift yoke and slides the clutch Pic 3 Lock & Unlock Rear Differential
gear to lock and unlock the rear axle housing. When
the clutch gear is unlocked the rear axle is in Turf
mode and when it is locked it is in 2x4 mode. See Pic
2, Pic 3, and Pic 4.
Clutch Gear
Pic 1 2X4 Mode
Clutch Gear
Axle
Solenoid Moves Shift Yoke Locked
Turf Mode
Pic 2 Clutch Gear
Axle
Unlocked
Pic 4
7.31
FINAL DRIVE
REAR CARRIER OPERATIONAL MODES

2x4 Mode Turf Mode
Both rear wheels rotate at same speed. Rear wheels can rotate at
different speeds. (Allows
for sharper turning)
AWD Mode
Rear wheels rotate as same speed.

Front wheels rotate as same speed when AWD activated.
7.32
FINAL DRIVE
REAR AXLE/CARRIER ASSEMBLY

35--45 ft.lbs.
A. Rear Carrier Assembly (48--61 Nm)
E 25--35 ft.lbs.
B
B. Rear Axle Tubes
(34--48 Nm)
C. Rear Hubs
D. Rear Actuator Solenoid
E. Rear Hitch
F. Brake Rotors B
G. Fill Plug
C
H. Drain Plug
24--32 ft.lbs.
(33--43 Nm)
D Side View
80 ft.lbs.
(108 Nm) 28--39 ft.lbs. A
(38--53 Nm)
C
G
40--50 ft.lbs 30--45 in. lbs.
(54--68 Nm) H (3--5 Nm)
REAR HUB INSPECTION

1. Support machine securely with rear wheels
elevated.
2. Grasp wheel/hub and check for movement.
3. If movement is detected, inspect hub, hub nut
torque and bearing condition and correct as
necessary.
REAR HUB REMOVAL /

INSTALLATION Remove O--ring
1. Safely support the rear of the ATP.
2. Remove the rear wheel , cotter pin, and spindle
nut.
3. Remove the rear brake caliper and safely
suspend the brake caliper from the chassis. Do
not let the brake caliper hang from the brake line.
4. Remove the axle O--ring from the axle.
5. Pull the rear hub and brake disc from the axle.
Remove Hub
7.33
FINAL DRIVE
6. Reverse the steps for removal for reassembly.

7. Refer to the “REAR AXLE ASSEMBLY --
INSTALLATION” Steps 4--7 for torque
specifications.
REAR AXLE ASSEMBLY --

REMOVAL
1. Jack up the back of the ATP and support the
frame and swing arm with jack stands.
2. Remove the rear wheels.
3. Remove the brake lines from their guides (arrow).
Remove the brake calipers and rest the calipers
on the frame. Do not let the calipers hang from the 5. Remove the hose clamp from the rear carrier
brake lines. breather hose and remove the breather hose.
6. Remove the bottom shock bolts and shocks (both
sides).
Remove Shock Bolt

CAUTION:
7. Remove the four bolts and nuts (each side) that
Use caution with ATP supported on jackstands.
secure the rear axle tube assembly to the swing
Serious injury could occur if machine tips or falls.
arm. Also remove the front bolt of the skid plate
under the axle.
Remove 4 Bolts Each Side
4. Disconnect the harness from the differential lock

solenoid. The harness plug is located under the 8. Slowly slide back the rear axle assembly from the
seat area. swing arm and frame assembly. The input shaft will
also slide out of the transmission propshaft.
7.34
FINAL DRIVE
25 ft.lbs.
Rear Axle Assembly
5. Reinstall the rear brake calipers to each side.

Torque the brake caliper bolts to 18 ft.lbs. (24
REAR AXLE ASSEMBLY -- Nm).
INSTALLATION
Caliper Bolts -- 18 ft.lbs.
1. Mate the rear axle assembly up to the swingarm.
2. Lubricate the input shaft splines. Slide the input
shaft of the rear carrier into the driveshaft yolk
from the transmission.
3. Attach the swingarm to carrier bolts previously
removed to secure the rear axle assembly to the
swingarm. Torque the bolts to 29--31 ft.lbs.
(39--42 Nm).
29--31 ft.lbs.
6. Install hubs and cone washer with domed side
Swingarm facing outward. Install a new cotter pin.
7. Torque spindle nut and wheel nuts. See torque
specs below.
29--31 ft.lbs. 80 ft.lbs.

(108 Nm)
Driveshaft
Axle Tube to Carrier Bolt Torque:

28--39 ft.lbs. (38--53 Nm)
Axle Tube to Swingarm Bolt Torque Hub Cap

29--31 ft. lbs. (39--42 Nm)
20 ft.lbs.
(27 Nm)
4. Install the shock bolts and torque the bolts to 25
ft.lbs. (35 Nm).
7.35
FINAL DRIVE
REAR AXLE TUBE REMOVAL 4. Remove the axle tube to carrier bolts on each side
and carefully pull the axle and axle tubes from the
/ DISASSEMBLY rear carrier.
1. Remove the hub O--rings. Remove the hub from
the axle. Perform on both sides.
Remove Axle & Tube
Remove O--ring
5. The axle and tube may come out as an assembly

or the axle tube may slide off of the axle. Be sure
to remove the bearing spacer inside the tube.
Bearing Spacer
Axle
Remove Hub
2. Remove the rear carrier skid plate.
Axle & Tube
Remove Skid
Plate
3. Remove the rear axle tube to rear carrier bolts

(each side).
7.36
FINAL DRIVE
6. Remove the hitch from the rear carrier if

necessary.
Snap Ring
2. Remove the bearing from the axle tube with a

bearing puller. Inspect the bearing surface for
scoring or nicks. Spin the bearing to check the
ball bearings for smoothness. Replace the
7. Inspect the axle splines for wear or nicks. bearing if needed.
Bearing
Snap Ring
REAR AXLE TUBE BEARING 3. Reinstall the bearing using a press.
NOTE: Be sure to properly lubricate the bearing
REMOVAL / INSTALLATION before installation of the remaining components.
1. With the axle tubes removed, remove the snap
ring from the axle tube. Refer to the “REAR AXLE
ASSEMBLY -- REMOVAL” and “REAR AXLE
TUBE REMOVAL / DISASSEMBLY“ earlier in this
chapter for procedures to remove the rear axle
tubes.
7.37
FINAL DRIVE
REAR AXLE TUBE

Axle
INSPECTION / ASSEMBLY Axle Tube
1. Replace the oil seal on the solenoid side axle
tube.
NOTE: Be sure to insert the bearing spacer inside the
axle tube assembly before installing the new seal. Spacer
3. Install the the other axle into the other axle tube.
Be sure the bearing spacer inside the axle tube is
inserted through the axle while the axle is installed
into the axle tube.
Oil Seal Location
4. Carefully install the axle tube assemblies to the
rear carrier housing. Align the axles splines with
the splines in the rear carrier. Apply 3 Bond
Sealant (PN 2871557) to the mating surfaces of
the axle tube assembly and rear carrier. Use the
alignment dowels to properly fit the axle tube to
the rear carrier.
Apply Sealant
Axle Oil Seal
2. Insert the axle into the axle tube assembly. Be

sure the bearing spacer inside the axle tube is
inserted through the axle while the axle is installed Alignment Dowel
into the axle tube. Use caution as to not damage
the oil seal.
5. Install the axle tube to rear carrier bolts. Torque

the bolts in a criss cross patter to 28--39 ft.lbs.
(38--53 Nm) each side. Install the hitch if
previously removed, torque the hitch bolts to
35--45 ft.lbs. (47--61 Nm).
7.38
FINAL DRIVE
REAR CARRIER
35--45 ft.lbs.
DISASSEMBLY
SERVICE NOTE: The pinion gear assembly is NOT
intended to be disassembled from the case, as it
requires special OEM tooling in order to properly
reassemble. If there is any damage to the pinion gear,
bearings or case, the assembly must be replaced.
Pinion and ring gear shimming information is NOT
provided due to OEM manufacturing requirements.
Sealant
PN (2871557) 1. Drain and properly dispose of used oil.
2. Refer to the “REAR AXLE ASSEMBLY
28--39 ft.lbs. REMOVAL” and “REAR AXLE TUBE REMOVAL
/ DISASSEMBLY“ procedures to access the rear
carrier assembly.
6. Reinstall the hubs to each axle. Install the axle 3. Remove the bolts that secure the carrier cover (A)
O--ring onto the outside of the hub. bolts to the carrier housing (B).
Install Hub & O--ring Remove Cover Bolts
7. Reinstall the skid plate. Torque the bolts to 17 ft. B

lbs. (23 Nm)
17 ft. lbs. (23 Nm)
7.39
FINAL DRIVE
4. Remove the carrier assembly (C) from the 6. Remove the electric actuator (F) from the carrier
housing. Inspect the bevel gear teeth for chipped, housing (D) by turning the solenoid
worn, or broken teeth. counterclockwise.
C F
5. Remove the bearings from each side of the carrier 7. Inspect the tip of the solenoid (F) for wear. If the
assembly (C). Inspect the bearings (D) for tip of the solenoid is flat the solenoid may need to
smoothness and wear. Be sure to keep the shims be replaced.
together for reassembly.
8. Remove the clutch gear (G) from the carrier cover

(B) and shift yoke (H).
C
B
G
D E
J
H
K
7.40
FINAL DRIVE
9. Inspect the shift yoke (H), shift lever (I), and shift 12. Thread the bolt into the shift yoke pivot shaft (L).
lever return spring (J).
I&J
13. Carefully pull the shift yoke pivot shaft (L) out of
the carrier cover.
10. Remove the set screw (K).
14. Remove the shift lever (M) and springs (N) from
the shift yoke (H). Inspect the components for
wear and replace as needed.
11. Remove the shift yoke pivot shaft (L) Use a .25 in.--
20 coarse thread bolt approximately 3 in. long to
thread into the pivot shaft. Thread the bolt in and
pull the shift yoke pivot (L) up and out of the case. N
M
H
7.41
FINAL DRIVE
15. Remove the pinion shaft seal (M) using a seal REAR CARRIER ASSEMBLY
puller.
1. Replace all O-rings, seals, and worn
components. Replace the O--ring and oil seal on
the carrier housing.
NOTE: Grease all seals and O--rings with Polaris All
M Season Grease (PN 2871322) upon assembly.
16. SPECIAL NOTE: The Pinion assembly is NOT

intended to be disassembled, as it requires
special OEM tooling in order to properly assemble
the pinion assembly. If there is any damage to the
pinion gear, bearings or case, the assembly must
be replaced. 2. Install the original shims (A) onto the carrier
assembly (B) on both sides. Install the bearings
(C), replace with new bearings if needed.
C A
7.42
FINAL DRIVE
3. Install the carrier assembly (B) into the carrier 7. Install the electric acuator (J) into the carrier
housing (B). cover.
B J
4. Install the spring lever and shift yoke into the 8. Install the new lightly greased O--ring (K) onto the
carrier cover, if previously removed. carrier cover.
5. Assemble the shift yoke (D), shift lever (G), spring
lever (F), and return spring (E).
6. Use the bolt that was used to remove the shift
yoke shaft (H) to reinsert the shift yoke pivot shaft
(H) into the carrier cover. Place the shift yoke
assembly into the carrier cover and secure with
the shift yoke pivot shaft (H).
Install Shift Yoke Assembly
9. Install the carrier cover bolts. Tighten and torque

the bolts in a criss cross patter to 25--35 ft.lbs.
(34--48 Nm).
Cover Bolts: 25--35 ft.lbs.
H
Carrier Cover
F
G D
E
7.43
FINAL DRIVE
REAR CARRIER
INSTALLATION
1. To install carrier:
G Follow “REAR AXLE TUBE
INSPECTION/ASSEMBLY” procedure
to install the axle and axle tubes.
G Then follow the “REAR AXLE
ASSEMBLY INSTALLATION” to install
the axle/carrier assembly to the chassis.
2. Add Polaris ATV Angle Drive Fluid (PN 2871653)
to rear carrier. Refer to Chapter 2 “REAR
CARRIER LUBRICATION” for more details.
Torque drain plug to 30--45 in.lbs. (3--5 Nm).
Torque fill plug to 40--50 ft.lbs. (54--68 Nm).
NEW PHOto
Fill Plug
40--50 ft.lbs Drain Plug
(54--68 Nm) 30--45 in. lbs.
(3--5 Nm)
Rear Gearcase Capacity:
18 fl. oz. (532 ml)

or
Bottom of Threads of Fill Plug Hole
7.44
FINAL DRIVE
REAR CARRIER EXPLODED VIEW

8 11
9
10 22
23
7 12 24
13 14 15
6 13
4 5 12
16 21
3
17 20
2 18
40 19
25
41
26
39 27
1
38
37 28
3
4
33
36 29
35 32 30
34
31

1. 1 Asm., Rear Differential 22. 3 Nut, Hex, Flanged, Hitch
2. 1 Nut, Pinion 23. 1 Hitch
3. 2 Bearing, Cone, Pinion 24. 3 Bolt, Hex Flanged, Hitch
4. 2 Bearing, Cup, Pinion 25. 1 Vent, Tube
5. AR Spacer, Pinion 26. 1 Cover, Half, Carrier
6. 1 Spacer, Bearing, Pinion 27. 6 Bolt, Hex, Flanged
7. 1 Plug, Drain 28. 1 Gear, Clutch
8. 1 Seal, Oil, Shaft 29. 1 Yoke, Shift
9. 1 O-- ring 30. 1 Spring, Lever, Shift
10. 1 Housing, Half, Carrier 31. 1 Lever, Shift
11. 1 Plug, Fill, Check 32. 2 Spring, Return, Shift
12. 2 Washer, Thrust, Side Gear 33. 8 Bolt, Hex, Ring Gear
13. 2 Gear, Side, Diff 34. 1 Case, Half, Diff.
14. 2 Gearcase, Rear Housing 35. 1 Pin, Cross, Diff.
15. 2 Washer, Thrust, Pinion 36. 1 Pin, Roll, Diff.
16. 1 Cover, Half, Diff. Case 37. Spacer, Pinion
17. AR Spacer, Bearing, Diff. 38. 1 Asm., Hypiod Gear
18. 1 Bearing, Tapered Roller 39. Spacer, Bearing, Diff.
19. 1 O-Ring, Housing Halves 40. 1 Bearing, Diff.
20. 1 Shaft, Pivot, Shift Yoke 41. 1 Bearing, Cone, Diff.
21. 1 Screw, Set
7.45
FINAL DRIVE
NOTES
7.46
TRANSMISSION
Transmission, Specifications/Lubrication . . . . 8.2

Shift Linkage Inspection . . . . . . . . . . . . . . . . . . . 8.2
Gear Shift Selector Removal . . . . . . . . . . . . . . . 8.2
Transmission Removal . . . . . . . . . . . . . . . . . . . . 8.3--8.4
Transmission Installation . . . . . . . . . . . . . . . . . . 8.4
Transmission Disassembly . . . . . . . . . . . . . . . . 8.5-8.10
Transmission Reassembly . . . . . . . . . . . . . . . . . 8.10-8.14
Transmission Troubleshooting . . . . . . . . . . . . . 8.15
Transmission Exploded View . . . . . . . . . . . . . . 8.16--8.17
8.1
TRANSMISSION
TORQUE SPECIFICATIONS Lubricate the tie rod ends with a light aerosol
lubricant or grease.
ITEM TORQUE
Transmission Case Bolts 27--34 ft. lbs. 2. Note orientation of tie rod end studs with the ends
(37--46 Nm)
that are up down (vertical). Remove both rod end
Bell Crank Nut 12--18 ft. lbs. bolts from transmission bell crank and the shifter.
(16--24 Nm) Remove rod assembly and adjust rod ends as
Transmission Drain Plug 14--18 ft. lbs. needed.
(19--24 Nm)
Transmission Mount Bolts 25 ft. lbs.
(35 Nm)
Park Lockout Plunger 14--18 ft. lbs.
(19--24 Nm)
Strut Casting Pinch Bolt 15 ft. lbs.
(21 Nm)
Shift Cover Bolt Torque 6--12 ft. lbs.
(12--16 Nm)
NOTE: Refer to the exploded view of the transmission

at the end of this chapter for more torque and
lubrication information.
Shift LInkage Rod
LUBRICATION
Refer to maintenance section for transmission GEAR SELECTOR REMOVAL
lubricant type and capacity.
1. Disconnect linkage rod from gear selector handle.
2. Remove two bolts attaching gear selector mount
to machine frame.
SHIFT LINKAGE INSPECTION 3. Lift gear selector out of mounting bracket and
away from frame.
NOTE: Shift rod is preset at time of manufacture.
Transmission
Shifter Assy.
Shift LInkage Rod
Linkage Rod
1. Inspect shift linkage tie rod ends, clevis pins, and

pivot bushings and replace if worn or damaged.
8.2
TRANSMISSION
TRANSMISSION REMOVAL 4. Disconnect shift linkage

transmission bellcrank.
rod end from
1. Remove seat, rear rack, rear cab, air box, and

exhaust system, and right footwell (if required for
access). Linkage Rod
Transmission Mounting
Vent Line
Transmission
Switch
Front
5. Disconnect gear position switch harness.
2. Disconnect transmission vent line.

3. Drain transmission lubricant.
6. Remove auxiliary brake mounting bracket from

frame and secure out of way for transmission
removal.
7. Remove PVT outer cover, both drive and driven
clutch, and inner PVT cover (refer to Clutch
Chapter 6).
8. Use the Roll Pin Removal Tool (PN 2872608) to
remove the roll pins from the front prop shaft (4x4
models) and the rear prop shaft. Remove the
front propshaft.
8.3
TRANSMISSION
2. Align rear output shaft to rear propshaft yoke and

roll pin hole.
3. Slide rear output shaft into propshaft yoke.
4. Position transmission in frame.
5. Install front propshaft (4x4 models) and roll pin.
6. Loosely install left side and rear mounting
brackets.
7. Loosely install lower right bracket bolt.
Remove 8. Loosely install front mounting bolts.
Roll Pin 9. Tighten mounting fasteners in order A-F as
shown.
NOTE: Align clutches as outlined in Clutch Chapter 6.
9. Loosen or remove the bolts that secure the rear

gearcase. Move the rear gearcase back just
enough to slide the rear propshaft from the Transmission Mounting
transmission shaft. Bolts Torque
25 ft. lbs. (34.5 Nm)

10. Remove the park lock spring.
Park Lock Spring
11. Remove left side transmission bracket, rear

bracket, and lower right bracket bolt. D
E C
12. Remove front transmission-to-engine mount
bolts. See illustration.
Tighten Bolts In Sequence A through E
13. Remove transmission from right side of frame.
TRANSMISSION INSTALLATION
1. Install transmission from right side of vehicle.
8.4
TRANSMISSION
TRANSMISSION DISASSEMBLY
1. Place the bellcrank in neutral position.
Spring
2. Remove the nut, and washer that secure the bell
crank. Remove the bellcrank.
5. Mark the detent gear with a white pen. Remove

the detent gear from the case.
3. Remove the e--clip and then remove the

transmission switch.
Transmission
Switch
NOTE: It may be helpful to place a mark just above
the keyed spline. Note the raised edge on the detent
gear for reassembly.
4. Remove the five bolts that secure the cover.
Remove the detent spring.
8.5
TRANSMISSION
6. Mark the shift lockout disc, this will indicate which NOTE: It may be helpful to accent the timing marks
side of the disc faces outward during assembly. using a white marking pen.
Remove the shift lockout disc.
9. Remove the bolts on the LH transmission case.
Tap the cover off with a soft face hammer if
necessary. NOTE: Leave mounting bracket
attached to the LH cover.
Bracket
NOTE: It may be helpful to place a mark just above

the keyed spline. Note the raised edge on the detent
gear for reassembly. 10. Lift shift rail 0.5--1” (12.70--25.40 mm). Then
rotate the shift rail/forks and shift drum, so the the
7. Remove the shift shaft and detent lever. forks’ pins disengage for the drum.
11. Remove the shift drum.

8. Note the timing marks on the shift gears. Remove
the shift gears from the case.
8.6
TRANSMISSION
NOTE: You may have to tap the shift drum from the 15. Remove the bearing from the reverse shaft using
backside of the case to aid in removal. a puller.
12. Remove the upper gear cluster and shift forks.
You may need to move the assembly back and
forth to aid in removal.
16. Remove the park lock engagement dog. Remove

the wave spring and reverse engagement dog.
13. Set the upper gear cluster on a flat surface and
inspect the components.
Engagement
Dogs
14. Remove the shift forks from the assembly. Note 17. Remove the bearing from the input shaft with a
the correct position of each fork. puller.
8.7
TRANSMISSION
18. Remove the snap ring and washer from the 22. Use a press to remove the gear from the shaft.
reverse shaft.
23. Make note of the direction of the gear and hub

19. Remove low gear (33T) and the needle bearing. location.
24. Remove the gear, split bearing, and washer from

20. Remove the reverse gear shaft. the reverse shaft.
21. Remove the rest of the bearings from the shafts.
8.8
TRANSMISSION
25. Slide off the shift dogs and wave springs. 28. Remove the pinion shaft retainer plate and the
pinion shaft.
26. Remove the snap ring, washer, gear, and split

bearing. 29. Remove the front housing cover screws.
27. Remove bearing and the helical gear. 30. Remove the front housing cover, shim, thrust
button, and thrust button shim.
8.9
TRANSMISSION
31. Remove the shafts as an assembly. TRANSMISSION REASSEMBLY

1. Reinstall the chain onto the front output shaft and
rear output shaft.
32. Remove the silent chain from the assembly for

shaft inspection.
2. Install front and rear output shafts into the case.
Note Location of Hubs
33. Clean all components in a parts washer and 3. Before installing the cover make sure the sealing
inspect for wear. surfaces are clean and dry, and shafts are fully
34. Inspect engagement dogs of gears and replace if seated in the transmission case. Apply Crankcase
edges are rounded. Sealant (PN 2871557) to the mating surfaces.
35. Inspect gear teeth for wear, cracks, chips or
broken teeth. Note the location of the hubs on the
gear.
36. Remove seals from transmission case.
IMPORTANT: New seals should be installed after the

transmission is completely assembled.
37. Inspect bearings for smooth operation. Check for
excessive play between inner and outer race.
Crankcase Sealant
(PN 2871557)
8.10
TRANSMISSION
4. Reinstall the thrust button shim, thrust button, and

other shims into the cover. Reinstall cover and
torque bolts in a criss-cross pattern in 3 steps to
27--34 ft. lbs. (36.50--46 Nm).
Pinion Retainer Plate

Bolt Torque:
NOTE: Make sure that the case locating pins (knock
6-- 12 ft. lbs. (8-- 16 Nm)
pipes) are in place.
9. Install the a new needle bearing, the 24T reverse
sprocket, washer, and a new snap ring. Install the
Front Cover Bolt Torque: shift dogs and wave spring. Install the washer, a
new needle bearing and the high gear. Install the
27--34 ft. lbs. (36.50--46 Nm) press fit gear and ball bearing.
5. Install new front and rear output shaft seals.

Apply grease to the seal lips. Cover the splines of
the shaft to protect the seal lips during installation.
6. Install pinion shaft with bearing.

7. Install retainer plate with flat side toward bearing.
8. Apply Loctitet 262 (Red) (PN 2871951) to screw
threads and torque screws to 6--12 ft. lbs. (8--16
Nm).
NOTE: Install a new snap ring at this time. When

installing the new snap ring, open the the snap ring
just far enough to go over the shaft, to avoid stressing
the snap ring. If the snap ring is over--stressed, it
could come off the shaft and cause internal damage
to the transmission.
8.11
TRANSMISSION
10. Slide the reverse shaft assembly through the TRANSMISSION REASSEMBLY CONT’D
silent chain.
NOTE: Use caution when installing the fork, the

spring can easily fall out.
11. Install a new needle bearing, the low gear, the NOTE: Installing the shift rail will aid in keeping the
thrust washer and the snap ring. Use of a new shift forks, shift dogs, and the springs in place.
snap ring is recommended.
15. Carefully install the shaft assembly and gear
12. Install the engagement dogs, wave springs, and cluster as a unit into their respective bearing case
bearing. recesses. Tap with a soft face hammer to seat
shaft assemblies.
13. Install the ball bearing onto the end of the input 16. Position the shift forks up and so the the pins point
shaft. toward the 9 o’clock position, before installing the
14. As the engagement dogs are installed onto the shift drum assembly.
shaft, place the wave springs into the spring
groove. Keep the spring in place while the fork is
being installed on the shaft and while placing the
shafts into the case.
8.12
TRANSMISSION
17. Replace and grease the O--rings on the shift drum

before installation.
Front Cover Bolt Torque:

27--34 ft. lbs. (36.50--46 Nm)
18. Install the shift drum into the case.
22. Grease the seal lips of the input shaft seal. Apply
electricians tape or somehow cover the splines of
the shaft to protect the seal lips during installation.
Install new input shaft seal.
23. Install drain plug with a new sealing washer.
Torque drain plug to 14--18 ft. lbs. (19--24 Nm).
Drain Plug Torque:

14-- 18 ft. lbs. (19-- 24 Nm)
24. Place a small amount of grease (PN 2871551)

into the pocket before installing the sector gear.
Install the shift gear (16T) on the shift drum shaft.
Install the sector gear in the bushing pocket on the
NOTE: Make sure shift shaft pins are properly left side. Aligning the timing marks on the gears.
positioned in the slot on selector arms. 25. Install the shift shaft.
19. Lift the shift rail slightly and rotate the rail/fork
assembly so it meshes with the tracks on the
shiftdrum. Be sure the wave springs are properly
in place and that the shift rail is seated into the
pocket on the backside of the case.
20. Install the helical gear and bearing onto the pinion
shaft.
21. Clean the mating surfaces of the case and cover. Sector Gear
Apply Crankcase Sealant (PN 2871557) to the
mating surfaces. Be sure the locating pins (knock
pipes) are in place. Reinstall cover and torque
bolts in a criss-cross pattern in 3 steps to 27--34 ft.
Shift Shaft
lbs. (36.50--46 Nm).
NOTE: Note the location of the skip tooth on the

splines. Apply a light coating of grease on the gear
teeth.
8.13
TRANSMISSION
26. Install the lockout disc with the raised edge facing
outward. Use the white marks that were
previously applied for reference.
Lockout Disc
29. Install the park lockout assembly. Torque park

lockout to 12 -- 14 ft. lbs. (16--19 Nm).
27. Install the detent star with the raised edge facing
outward. Note the keyed spline on the end of the 30. Apply Crankcase Sealant (PN 2871557) onto the
shaft. cover and case mating surfaces. Install the cover
and torque the cover bolts to 6--12 ft. lbs. (12--16
Nm). Torque the bottom left corner bolt first.
Detent Star
6--12 ft.lbs.
Tighten This Bolt First (12--16 Nm)
28. Install the detent pawl spring. Install a new o--ring
onto the shift shaft after the detent pawl is Park Lockout Cover Bolt Torque:
assembled to the shaft. Place a small amount of
grease on the small O--ring on the shift shaft and 6-- 12 ft. lbs. (12-- 16 Nm)
on the detent star. Grease the o--ring on the end
of the shift drum.
31. Install a new bellcrank onto the shift shaft. Note
the keyed spline on the bellcrank and shaft.
Install the washer and nut. Torque the bellcrank
nut to 12--18 ft. lbs. (16--24 Nm).
8.14
TRANSMISSION
G Transmission oil type/quality

G Transmission torque stop
adjustment (where applicable)
G Engine torque stop adjustment
(where applicable)
G Drive belt deflection
G Loose fasteners on rod ends
G Loose fasteners on selector box
G Worn rod ends, clevis pins, or pivot
arm bushings
G Linkage rod adjustment and rod end
positioning
G Shift selector rail travel
Bellcrank Nut Torque: G *Worn, broken or damaged internal
transmission components
12-- 18 ft. lbs. (16-- 24 Nm)
*NOTE: To determine if shifting difficulty or problem
is caused by an internal transmission problem, isolate
the transmission by disconnecting linkage rods from
transmission bellcranks. Manually select each gear
TROUBLESHOOTING range at the transmission bellcrank, and test ride
vehicle. If it functions properly, the problem is outside
CHECKLIST the transmission.
Check the following items when shifting difficulty is If transmission problem remains, disassemble
encountered. transmission and inspect all gear dogs for wear
G Idle speed adjustment (rounding), damage. Inspect all bearings, circlips,
thrust washers and shafts for wear.
8.15
TRANSMISSION
ATP 4X4 TRANSMISSION EXPLODED VIEW
262
262
TORQUE SPECIFICATIONS
Item Torque
1 12-- 18 fl.lbs. (16-- 24 Nm) FOR REASSEMBLY
3 6--12 ft.lbs. (8--16 Nm)
Apply Polaris All
18 14--18 ft.lbs. (19--24 Nm) Purpose Grease.
37 27--34 ft.lbs. (37--46 Nm) Apply Polaris
Crankcase Sealant
39 14--18 ft.lbs. (19--24 Nm)
Apply Loctitet 262 to
45 6--12 ft.lbs. (8--16 Nm)
262
the bolt threads.

68 14--18 ft.lbs. (19--24 Nm)
NOTE: Refer to you parts manual to obtain the correct transmission part numbers
8.16
TRANSMISSION
4X4 TRANSMISSION EXPLODED VIEW, CONT.

ATP 4x4 Transmission 35. 1 Shim (.450 x .265)
1. 1 Nut, Lock (12-- 18 ft.lbs.) 36. 1 Front Output Cover
2. 1 Bellcrank 37. 1 Screw (27-- 34 ft.lbs.)
3. 8 Screw (6-- 12 ft.lbs.) 38. 1 Washer
4. 1 Cover 39. 1 Plug (14-- 18 ft.lbs.)
5. 1 Detent Pawl 40. 1 Spiral Pinion Shaft
6. 1 Compression Spring 41. 1 Ball Bearing
7. 1 O-- ring 42. 1 Spacer
8. 1 Shift Shaft 43. 1 Retaining Ring
9. 1 31T Sector Gear 44. 1 Center Drive Bearing Cover
10. 1 Main Gearcase 45. 4 Hex Screw (6-- 12 ft.lbs.)
11. 1 Retaining Ring 46. 1 Helical Gear
12. 1 6 Pin Rotary Switch 47. 4 Ball Bearing
13. 1 O-- ring 48. 1 Park Plate
14. 1 Detent Star 49. 1 6-- Face, Park Engagement Dog
15. 1 Lockout disc 50. 2 Wave Spring
16. 1 16T Sector Gear 51. 3 6-- Face, Engagement Dog
17. 1 O-- ring 52. 2 Retaining Ring
18. 1 Oil Fill Plug (14-- 18 ft.lbs.) 53. 2 Washer
19. 1 Washer 54. 1 33T Gear
20. 4 Knock Pipe 55. 3 Split Cage Needle Bearing
21. 1 Vent Tube 56. 1 Reverse Shaft
22. 1 Shift Drum 57. 1 6-- Face, Sprocket
23. 2 Triple Lip Seal 58. 1 Washer
24. 4 Ball Bearing 59. 1 6 Face, Gear
25. 1 Thrust Washer 60. 1 40T Helical Gear
26. 1 22/18T Sprocket 61. 2 Shift Fork
27. 1 42 Pitch Silent Chain 62. 2 Dowel Pin
28. 1 31T Spiral Gear 63. 1 Shift Shaft Rail
29. 1 Main Rear Output Shaft 64. 1 Silent Chain
30. 1 Shim (2.0 x 1.5) 65. 1 Input Shaft
31. 1 Bearing 66. 1 LH Cover
32. 1 22/22T Sprocket 67. 1 Dual Lip Seal
33. 1 Main Front Output Shaft 68. 1 Park Lockout Assy. (14-- 18 ft.lbs.)
34. 1 Thrust Button 69. 1 Tie Clamp
8.17
TRANSMISSION
NOTES
8.18
BRAKES
Special Tools/Specifications/Torques . . . . . . . . . . . 9.2

Brake System Service Notes . . . . . . . . . . . . . . . . . 9.3
Brake Noise Troubleshooting . . . . . . . . . . . . . . . . . 9.3
Hydraulic Brake System Overview . . . . . . . . . . . . . 9.4
Hydraulic Caliper Bleeding . . . . . . . . . . . . . . . . . . . 9.5--9.7
Master Cylinder Removal . . . . . . . . . . . . . . . . . . . . 9.7
Master Cylinder Installation . . . . . . . . . . . . . . . . . . . 9.7--9.8
ATP Brake System Overview . . . . . . . . . . . . . . . . . 9.9--9.11
Front Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
Front Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Rear Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14-9.15
Rear Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . 9.15--9.16
Brake Burnishing . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
Brake Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . 9.16
Brake Caliper Removal/Inspection . . . . . . . . . . . . . 9.17-9.19
Brake Caliper Reassembly . . . . . . . . . . . . . . . . . . . 9.19-9.20
Front Caliper Exploded View . . . . . . . . . . . . . . . . . 9.21
Rear Caliper Exploded View . . . . . . . . . . . . . . . . . . 9.22
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.1
BRAKES
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION
2870975 Mity Vact Pressure Test Tool
SPECIFICATIONS
Front Brake Caliper
Item Standard Service Limit

Brake Pad Thickness .298″ / 7.6mm .180″ / 4.6mm
Brake Disc Thickness .150-.164″ / 3.810-4.166mm .140″ / 3.556mm
Brake Disc Thickness Variance Between - .002″ / .051mm
Measurements
Brake Disc Runout - .010″ / .254mm
Rear Axle Brake Caliper
Item Standard Service Limit

Brake Pad Thickness .298″ / 7.6mm .180″ / 4.6mm
Brake Disc Thickness .150-.164″ / 3.810-4.166mm .140″ / 3.556mm
Brake Disc Thickness Variance Between - .002″ / .051mm
Measurements
Brake Disc Runout - .010″ / .254mm
Master Cylinder I.D. - Front .750″

Master Cylinder I.D. - Aux. Rear .750″
TORQUE SPECIFICATIONS
Item Torque Torque
(ft. lbs. except where noted*) (Nm)
Front Caliper Mounting Bolts 18.0 24
Rear Caliper Mounting Bolts 28.0 38
Master Cylinder Handle Bar *25 in. lbs. 3.0
Clamp Bolt
Front Master Cylinder Reservoir Cover *5 in. lbs. 0.56
Bolt
Brake Line Banjo Bolt 15.0 21
Brake Line Flare Fittings 12--15 16--20
Front Brake Disc 18.0 24
Front Wheel Mounting Nuts 27.0 37
Caliper Bleed Screw Torque *35--60 in.lbs. 4--6.8
Rear Master Cyl. Bleed Screw Torque *25--30 in.lbs. 2.8--3.4
NOTICE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures
are used when torquing certain bolts and fasteners.
9.2
BRAKES
2004 -- 2005 BRAKE LINE G Do not over-fill the master cylinder

fluid reservoir.
IDENTIFICATION G Make sure the brake lever and pedal
returns freely and completely.
2004 and 2005 ATP models have two different
styles of brake lines. The two styles of brake lines G Adjust stop pin on front caliper after
are “pipe fit” style and “banjo” style. Be sure to pad service.
use the proper torque specifications when G Check and adjust master cylinder
installing the brake lines back into the brake reservoir fluid level after pad service.
caliper. Refer to the pictures below to identify G Make sure atmospheric vent on
which style of brake line your ATV contains. reservoir is unobstructed.
G Test for brake drag after any brake
PIPE FIT STYLE system service and investigate
cause if brake drag is evident.
G Make sure caliper moves freely on
guide pins (where applicable).
CAUTION:
Use only DOT 3 brake fluid as an
assembly aid for all procedures described in this chapter to
prevent brake system contamination. DO NOT USE
LUBRICANTS OF ANY KIND FOR ASSEMBLY.
BRAKE NOISE
Torque: 12--15 ft.lbs. (16--21 Nm)
TROUBLESHOOTING
BANJO STYLE
Dirt or dust buildup on the brake pads and disc is the
most common cause of brake noise (squeal caused
by vibration). If cleaning does not reduce the
occurrence of brake noise, Permatext Disc Brake
Quiet (PN 2872113) can be applied to the back of the
pads. Follow directions on the package. This will
keep pads in contact with caliper piston(s) to reduce
the chance of squeaks caused by dirt or dust.
NOTICE: Use only Polaris recommended products to
service your ATP brake system. Use Polaris approved
Torque: 15 ft.lbs.(21 Nm) brake cleaner only.
BRAKE SYSTEM SERVICE

NOTES
Polaris disc brake systems are light weight, low
maintenance and perform well in the conditions ATPs
routinely encounter. However, there are a few things
to remember when replacing disc brake pads or
performing brake system service to ensure proper
system function and maximum pad service life.
G Perform a brake burnishing
procedure after installing new pads
to maximize service life.
G Optional pads are available to suit
conditions in your area. Select a pad
to fit riding style and environment.
9.3
BRAKES
Brake Noise Troubleshooting HYDRAULIC BRAKE SYSTEM

Possible Cause Remedy
Dirt, dust, or im- Spray disc and pads
OPERATION OVERVIEW
bedded material with CRC Brake Kleent
on pads or disc or equivalent non-flam- Typical Hydraulic Brake System
Compensating port
mable aerosol brake compensates
Must be clear E
cleaner. Remove pads for temperature
and/or disc hub to clean to allow
proper dia- changes by allow-
imbedded material from phragm move- ing fluid back to
disc or pads. C master cylinder
ment
Pad(s) dragging on F
disc (noise or Adjust pad stop
premature pad wear) (front calipers)
Check position of
Improper adjustment controls & switches.
A B
Insufficient lever or Set to proper level
pedal clearance
Clean compensating port
Master cylinder res- Inspect.
ervoir overfilled Repair as necessary Move-
Clean piston(s) seal able D
Brake
Master cylinder Pad G
compensating port
restricted
Educate operator
Master cylinder pis-
ton not returning com- The Polaris disc brake system consists of the
pletely following components or assemblies: brake lever;
master cylinder; hydraulic hose; brake calipers (slave
Caliper piston(s) not cylinder); brake pads; and brake discs, which are
returning secured to the drive line.
When the hand activated brake lever (A) is applied it
Operator error (riding
contacts piston (B) within the master cylinder. As the
the brake / park brake
master cylinder piston moves inward it closes a small
applied)
opening (compensating port C) within the cylinder and
Loose wheel hub or Check wheel and hub starts to build pressure within the brake system. As
bearings for abnormal the pressure within the system is increased, the piston
movement. (D) located in the brake caliper moves outward and
Brake disc warped or Replace disc applies pressure to the brake pad. This pad contacts
excessively worn the brake disc and moves the caliper in its floating
Brake disc Inspect and repair as bracket, pulling the stationary side pad into the brake
misaligned or loose necessary disc. The resulting friction reduces brake disc and
Noise is from other If noise does not vehicle speed. As the lever pressure is increased, the
source (chain, axle, change when brake is braking affect is also increased.
hub, disc or wheel) applied check other
sources. Inspect and The friction applied to the brake pads will cause the
repair as necessary pads to wear. As these pads wear, the piston within
the caliper moves further outward and becomes self
Wrong pad for Change to a softer or
adjusting. Fluid from the reservoir fills the additional
conditions harder pad
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 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
9.4
BRAKES
when the lever is released and the master cylinder

piston is outward. As the temperature within the
hydraulic system changes, this port compensates for
Bleed Screw
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 have adequate space to
allow for fluid expansion. Never overfill the
reservoir! Fill to 1/4″ - 5/16″ (.64 - .80 cm) from top
of the cylinder.
This system also incorporates a diaphragm (E) as part
of the cover gasket; and a vent port (F) located
between the gasket and the cover. The combination
diaphragm and vent allow for the air above the fluid to
equalize pressure as the fluid expands or contracts.
Make sure the vent is open and allowed to function. BRAKE BLEEDING - FLUID
Do not over tighten the reservoir cap, this could block
the vent. If the reservoir is over filled or the diaphragm CHANGE
vent is plugged the expanding fluid may build
pressure in the brake system leading to brake failure. NOTICE: When bleeding the brakes or replacing the
fluid, always start with the caliper farthest from the
When servicing Polaris ATP brake systems, use only master cylinder.
Polaris DOT 3 Brake Fluid (PN 2870990).
CAUTION:
WARNING: Once a bottle is opened, use what is
necessary and discard the rest in accordance with
Always wear safety glasses during these
local laws. Do not store or use a partial bottle of brake
procedures. Brake fluid will damage finished
fluid. Brake fluid is hygroscopic, meaning it rapidly
surfaces. Do not allow brake fluid to come in
absorbs moisture. This causes the boiling
contact with finished surfaces.
temperature of the brake fluid to drop, which can lead
to brake fade and the possible loss of control. NOTICE: Do not remove brake lever when reservoir
fluid level is low.
HYDRAULIC This procedure should be used to change fluid or
bleed brakes during regular maintenance.
CALIPER BLEEDING
1. Clean reservoir cover thoroughly.
This caliper is a single piston design. See Page 9.9 2. Remove screws, cover and diaphragm (C) from
for basic ATP brake operation. The basic procedure reservoir.
for bleeding the brake system is the same as outlined 3. Inspect vent slots (A) in cover and remove any
on page 9.5 - 9.6, however, each system must be bled debris or blockage.
separately.
Hydraulic Auxiliary Brake inspection and adjustment
C Sight
is outlined in Chapter 2.
Glass
B
A
9.5
BRAKES
4. If changing fluid, remove old fluid from reservoir BRAKE BLEEDING CONT’D
with a Mity Vact pump or similar tool.
NOTICE: 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.
Mity Vact (PN 2870975)
7. Slowly pump brake lever (D) until pressure builds
and holds.
8. While maintaining lever pressure, open bleeder
5. Add brake fluid to the indicated MAX level inside screw. Close bleeder screw and release brake
reservoir. lever. NOTE: Do not release lever before bleeder
screw is tight or air may be drawn into caliper.
Bleeder Screw Torque

MAX
35--60 in.lbs. (4--6.8 Nm)
9. Repeat procedure until clean fluid appears in

bleeder hose and all air has been purged. Add
fluid as necessary to maintain level in reservoir.
CAUTION:
Maintain at least 1/2″ (1.27 cm) of brake fluid in the

reservoir to prevent air from entering the master
cylinder.
Polaris DOT 3 Brake Fluid
10. Tighten bleeder screw securely and remove
(PN 2870990) bleeder hose. Torque the bleeder screw to 25--30
in.lbs. (2.80 --3.40 Nm).
11. Repeat procedure Steps 5-9 for the remaining
6. Begin bleeding procedure with the caliper that is caliper(s).
farthest from the master cylinder. Install a box 12. Add Polaris Dot 3 Brake Fluid (PN 2870990) to
end wrench on caliper bleeder screw. Attach a MAX level inside reservoir.
clean, clear hose to fitting and place the other end
in a clean container. Be sure the hose fits tightly
on fitting.
Bleed Screw
Master Cylinder Fluid Level:
MAX level inside reservoir
Sight glass must look dark, if sight

glass is clear, fluid level is too low
9.6
BRAKES
13. Install diaphragm, cover and screws. Tighten 2. Place a shop towel under brake line connection at
screws to 5 in. lbs. (0.56 Nm). master cylinder. Loosen banjo bolt; remove bolt
and sealing washers.
CAUTION:
Brake fluid will damage finished surfaces. Do not

allow brake fluid to come in contact with finished
surfaces.
3. Remove master cylinder from handlebars.
4. Hold brake upright and continue to remove
master cylinder. Cover brake line to avoid
spillage.
MASTER CYLINDER
INSTALLATION
Notice: When replacing the brake master cylinder
assembly or master cylinder parts, use the correct
Reservoir Cover Torque parts. There are different brake master cylinders for
the different Polaris ATP models. Refer to your parts
5 in. lbs. (0.56 Nm)
manual or guide for the correct parts. This master
cylinder is not serviceable and is replaced as a
unit.
14. Field test machine at low speed before putting
into service. Check for proper braking action and 1. Install master cylinder on handlebars. Torque
lever reserve. With lever firmly applied, lever mounting bolts to 25 in. lbs. (3 Nm). Torque the
reserve should be no less than 1/2″ (1.3 cm) from inside bolt first as indicated in the illustration to the
handlebar. right.
15. Check brake system for fluid leaks and inspect all 5 in.lbs. (0.56 Nm)
hoses and lines for wear or abrasion. Replace
hose if wear or abrasion is found.
MASTER CYLINDER
REMOVAL
1. Clean master cylinder and reservoir assembly.
Make sure you have a clean work area to Torque this bolt first
disassemble brake components.
Torque both bolts to
25 in.lbs. (3 Nm)
NOTICE: To speed up the brake bleeding procedure,

the master cylinder can be purged of air before brake
line is attached. Fill with DOT3 Brake Fluid (PN
2870990) and pump lever slowly two to three times
with finger over the outlet end to purge master cylinder
of air.
9.7
BRAKES
2. Place new sealing washers on each side of banjo

line and torque banjo bolt to specification.
Torque to 15 ft.lbs.
(21 Nm)
Banjo Bolt
Sealing Washers
Brake Line
Handle Bar Master Cylinder Clamp

Bolt Torque : 25 in. lbs. (3 Nm)
Brake Line Banjo Bolt Torque

15 ft. lbs. (21 Nm)
3. Fill reservoir with DOT3 Brake Fluid (PN

2870990).
Polaris DOT 3 Brake Fluid
(PN 2870990)
4. Follow bleeding procedure on Pages 9.5-9.6.

Check all connections for leaks and repair if
necessary.
9.8
2005 Models 2004 Models
1 All Banjo Style Fittings 2
15 ft.lbs. (21Nm) All Flare or Pipe Fit Style Fit--
9.9
tings:12--15 ft.lbs. (16--21Nm)
BRAKES
3
Caliper Bleed Screws: Rear Master Cylinder Bleed
2 Screws 5 in.lbs. (0.56 Nm) 3 35--60 in.lbs.(4--6.8 Nm) 4 Screws: 25--30 in.lbs.(2.8--3.4 Nm)
1 or or2
15 ft.lbs. 3
(21Nm)
2 2 4
1 or 2
2
Apply Pipe Sealant
to Threads 1
ATP BRAKE SYSTEM / TORQUE’S
Rear Auxiliary Brake

2
2 2 1
3
3 Rear Brake System
1 or 2
1 or 2
2
BRAKES
ATP BRAKE SYSTEM EXPLODED VIEW

REAR BRAKE SYSTEM A
A. Rear Brake Caliper
B. Rear Brake Lines
C. Brake T--Fitting
D. Brake Line from Brake MC B
E. Foot Dual Master Cylinder H
F. Foot MC Brake Mount Assy.
G. Foot Brake Assy.
H. Rear Brake Fluid Reservoir
C
Brake Line
From Front
A
G
F
E
FRONT BRAKE SYSTEM

A. Front Brake Caliper
B. Front Brake Lines E
C. Brake Cross Fitting D
D. Brake Line to Rear MC
E. Brake Handle Assy.
F. Brake Switch
G. Brake Line Protector F
C
B
A
A
G
9.10
BRAKES
ATP BRAKE SYSTEM OPERATION
FRONT HANDLE BRAKE SYSTEM
When the front brake is applied, all

brake calipers are active and under
pressure. This gives the operator 4
wheel disc braking.
The front brake system is integrated

into the rear brake foot pedal. This al-
Front Brake lows 4 wheel disc braking.
From Front
Master Cylinder
Rear Master Cylinder

to Rear Caliper
REAR HANDLE BRAKE SYSTEM
When the rear foot brake is applied, only

the two rear brake calipers are active and
under pressure.
The rear master cylinder will only allow

fluid to flow to the rear brake calipers,
not to the front brake calipers.
9.11
BRAKES
FRONT PAD REMOVAL

1. Elevate and support front of machine.
6. Measure the thickness of the pad material.

Replace pads if worn beyond the service limit.
CAUTION:
Use care when supporting vehicle so that it does

not tip or fall. Severe injury may occur if machine
tips or falls.
2. Remove the front wheel. Loosen pad adjuster Measure
Thickness
screw 2-3 turns.
3. Remove caliper from mounting bracket.
4. Push caliper piston into caliper bore slowly using
a C-clamp or locking pliers with pads installed.
Front Brake Pad Thickness
New .298″ / 7.6 mm
Service Limit .180″ / 4.6 mm
NOTICE: 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.
5. Push mounting bracket inward and slip outer
brake pad past edge. Remove inner pad.
9.12
BRAKES
FRONT BRAKE PAD

INSTALLATION
1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease, and install
rubber dust boots.
18 ft. lbs.
(25 Nm)
Torque Specifications
Front Caliper Mounting Bolt:
18 ft. lbs. (25 Nm)
4. Slowly pump the brake lever until pressure has

been built up. Maintain at least 1/2″ (12.7 mm) of
brake fluid in the reservoir to prevent air from
entering the brake system.
5. Install the adjuster screw and turn clockwise until
Polaris Premium All Season Grease stationary pad contacts disc, then back off 1/2
turn (counterclockwise).
(PN 2871423)
2. Compress mounting bracket and make sure dust

boots are fully seated. Install pads with friction
material facing each other. Be sure pads and disc
are free of dirt or grease.
3. Install caliper on hub strut, and torque mounting
bolts.
6. Verify fluid level in reservoir is up to MAX line

inside reservoir and install reservoir cap.
9.13
BRAKES
Master Cylinder Fluid

Up to MAX line inside reservoir
7. Install wheels and torque wheel nuts.
Front Wheel Nut Torque
27 ft. lbs. (37 Nm)
NOTICE: When removing caliper, be careful not to

damage brake line. Support caliper so as not to kink
REAR BRAKE PAD REMOVAL or bend brake line.
1. Remove the left tire and support the machine. 4. Push caliper pistons into caliper bore slowly with
2. Remove brake line clamps. The clamps must be pads installed.
removed to properly hang the caliper after
removal from the brake disc.
NOTICE: Brake fluid will be forced through

compensating port into master cylinder fluid reservoir
when piston is pushed back into caliper. Remove
3. Remove caliper mounting bolts and lift caliper off excess fluid from reservoir as required.
of disc. 5. Push mounting bracket inward and slip outer
brake pad past edge. Remove inner pad.
9.14
BRAKES
6. Clean the caliper with brake cleaner or alcohol. Polaris Premium All Season Grease
7. Measure the thickness of the pad material.
Replace pads if worn beyond the service limit. (PN 2871423)
2. Compress mounting bracket and make sure dust

boots are fully seated. Install pads with friction
material facing each other. Be sure pads and disc
are free of dirt or grease.
bolts.
Measure
Thickness
Rear Brake Pad Thickness

New .298″ / 7.6 mm
Service Limit .180″ / 4.6 mm
REAR BRAKE PAD Rear Caliper Mounting

Bolts: 28 ft. lbs. (38 Nm)
INSTALLATION
1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease, and install Rear Caliper Mounting Bolts
rubber dust boots.
Torque: 28 ft. lbs. (38 Nm)
4. Slowly pump the brake lever until pressure has

been built up. Maintain at least 1/2″ (12.7 mm) of
brake fluid in the reservoir to prevent air from
entering the brake system.
5. Tighten the adjuster screw and turn clockwise
until stationary pad contacts disc, then back off
1/2 turn (counterclockwise).
9.15
BRAKES
0-1″ micrometer. Replace disc if worn beyond

service limit.
6. Verify fluid level in reservoir is up to MAX line

inside reservoir and install reservoir cap.
Front / Rear Brake Disc Thickness
New .150-.165″ (3.8-4.19 mm)

Master Cylinder Fluid Service Limit .140″ / 3.556 mm
Up to MAX line inside reservoir
Brake Disc Thickness Variance
Service Limit: .002″ (.051 mm)
7. Install wheels and torque wheel nuts. difference between measurements.
3. Mount dial indicator as shown to measure disc

Rear Wheel Nut Torque runout. Slowly rotate the disc and read total
runout on the dial indicator. Replace the disc if
27 ft. lbs. (37 Nm) runout exceeds specifications.
BRAKE BURNISHING
PROCEDURE
It is required that a burnishing procedure be
performed after installation of new brake pads to
extend service life and reduce noise.
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 warpage may
result. Repeat this procedure 10 times.
Brake Disc Runout
BRAKE DISC INSPECTION Service Limit .005″ (.127 mm)
1. Visually inspect the brake disc for nicks,
scratches, or damage.
2. Measure the disc thickness at eight different
points around the pad contact surface using a
9.16
BRAKES
BRAKE DISC REMOVAL / Use care when supporting vehicle so that it does
not tip or fall. Severe injury may occur if machine
REPLACEMENT tips or falls.
1. Remove brake pads. See ”FRONT BRAKE PAD
NOTICE: To reduce the possibility of warpage,
REMOVAL” or “REAR BRAKE PAD REMOVAL”
try removing the brake disc mounting bolts
earlier in this chapter.
before applying heat to the bolts.
2. Using a line wrench or box end wrench to loosen
1. Apply heat to the hub in the area of the brake disc and remove brake line to caliper. Place a
mounting bolts to soften the bolt locking agent. container under caliper to catch fluid draining
from brake line.
18 ft. lbs. (24 Nm)

new bolts have
pre-applied
locking agent.
2. Remove bolts and disc.

3. Clean mating surface of disc and hub. 2005 ATP -- Banjo Style
4. Install disc on hub.
5. Install new bolts and tighten to specified torque.
Front Brake Disc Mounting Bolt Torque
18 ft. lbs. (24 Nm)
CAUTION: Always use new brake disc mounting

bolts. The bolts have a pre-applied locking agent
which is destroyed upon removal.
FRONT/REAR BRAKE
2004 ATP -- Pipe Fitting
CALIPER REMOVAL
3. Remove brake caliper and drain fluid into
NOTICE: The front and rear brake caliper/pad container. Do not reuse brake fluid.
assemblies are very similar. Perform the same
procedures for caliper removal and installation on the
front and rear of the ATP.
FRONT/REAR CALIPER
The mounting bolt torque values do differ, refer to DISASSEMBLY
the torque values in this chapter.
NOTICE: The front and rear brake caliper/pad
assemblies are very similar. Perform the same
CAUTION: procedures for caliper disassembly/assembly.
9.17
BRAKES
1. Remove brake pad adjuster screw.

Remove
Mounting Bracket
4. Remove piston, dust seal and piston seal.

2. Push upper pad retainer pin inward and slip brake
pads past edge.
5. Clean the caliper body, piston, and retaining

bracket with brake cleaner or alcohol.
3. Remove mounting bracket, pin assembly and NOTICE: Be sure to clean seal grooves in caliper
dust boot. body.
Clean Components
9.18
BRAKES
FRONT/REAR BRAKE FRONT/REAR BRAKE

CALIPER INSPECTION CALIPER ASSEMBLY
1. Inspect caliper body for nicks, scratches or wear. NOTICE: The front and rear brake caliper/pad
Measure bore size and compare to specifications. assemblies are very similar. Perform the same
Replace if damage is evident or if worn beyond procedures for caliper disassembly and assembly.
service limit.
1. Install new O-rings (A) in the caliper body (B). Be
sure groove is clean and free of residue or brakes
Front Caliper Piston Bore I.D. may drag upon assembly.
Std. 1.253-1.254″ (31.83-31.85 mm) C

Service Limit 1.255″ (31.88 mm) B
2. Coat piston with clean Polaris DOT 3 Brake Fluid

(C). Install piston (D) with a twisting motion while
pushing inward. Piston should slide in and out of
bore smoothly, with light resistance.
3. Lubricate the mounting bracket pins with Polaris
Premium All Season Grease, and install the
2. Inspect piston for nicks, scratches, wear or
rubber dust seal boots.
damage. Measure diameter and replace if
damaged or worn beyond service limit.
Polaris Premium All Season Grease

3. Inspect the brake disc and pads as outlined for
brake pad replacement this section. See Pages (PN 2871423)
9.12--9.13.
4. Compress the mounting bracket and make sure
the dust seals are fully seated. Install the pads as
9.19
BRAKES
shown on Page 9.10--9.11 Clean the disc and 2005 ATP -- Banjo Fitting
pads with brake parts cleaner or denatured
alcohol to remove any dirt, oil or grease.
Refer below
15 ft.lbs.
(21 Nm)
Torque Specifications
Front Caliper Mounting Bolt:
18 ft. lbs. (25 Nm)
Rear Caliper Mounting Bolt:
28 ft. lbs. (38 Nm)
2004 Pipe Fit Brake Line:

FRONT/REAR BRAKE 12--15 ft. lbs. (16--20 Nm)
CALIPER INSTALLATION 2005 Banjo Brake Line:
15 ft. lbs. (21 Nm)
NOTICE: The front and rear brake caliper/pad
assemblies are very similar. Perform the same 2. Install brake line and tighten securely with a line
procedures for caliper installation and removal on the wrench.
front and rear of the ATP. The mounting bolt torque 3. Install the adjuster screw and turn until stationary
values do differ, refer to the torque values in this pad contacts disc, then back off 1/2 turn.
chapter.
bolts.
2004 ATP -- Pipe Fitting
Refer below
12--15 ft.lbs.
(16--20 Nm)
4. Follow brake bleeding procedure outlined on
Pages 9.5-9.6.
5. Install wheels and torque wheel nuts to
specification.
Front / Rear Wheel Nut Torque

27 ft. lbs. (37 Nm).
9.20
BRAKES
FRONT CALIPER EXPLODED VIEW
APPLY POLARIS DOT 3 BRAKE FLUID

3 (PN 2870990) TO COMPONENT
APPLY POLARIS PREMIUM

ALL SEASON GREASE (PN 8570063)
Bleeder Screw
35--60 IN. LBS. Caliper Assembly
(4--6.8 NM)
Slide Pin Boot
3 Piston
Socket Set
Screw Both Slide Pins
Slide Pin Boot
Brake Pads
Square
3 O--Rings
Front Caliper Mount Bolt

18 FT. LBS.
(25 NM)
Caliper Mount
9.21
BRAKES
REAR CALIPER/REAR BRAKE EXPLODED VIEW

APPLY POLARIS DOT 3 BRAKE FLUID REAR CALIPER APPLY POLARIS PREMIUM
3 (PN 2870990) TO COMPONENT ALL SEASON GREASE (PN 8570063)
Caliper
Bleed Screws
35--60 in.lbs. Slide Pin Boot
(4--6.8 Nm)
Both Slide Pins

3 Piston
Bracket
Slide Pin Boot
Brake Pads
Caliper Mounting Bolts

28 FT. LBS. 3 Square O--rings
(38 NM)
REAR BRAKE Auxiliary

Reservoir
Brake Line Clamp

& Screw
Return
Spring
15 ft. lbs.
(21 Nm)
Auxiliary 12--15 ft. lbs.

Master (16--20 Nm)
Cylinder
Foot Brake Assembly 8 ft. lbs.

(11 Nm)
Cylinder Mount
8 ft. lbs.
(11 Nm)
Use new cotter key during reassembly
9.22
BRAKES
TROUBLESHOOTING
Brakes Squeal
G Dirty/contaminated friction pads
G Improper alignment
G Worn disc
G Worn disc splines
Poor Brake Performance
G Air in system
G Water in system (brake fluid contaminated)
G Caliper/disc misaligned
G Caliper dirty or damaged
G Brake line damaged or lining ruptured
G Worn disc and/or friction pads
G Incorrectly adjusted lever
G Incorrectly adjusted stationary pad
G Worn or damaged master cylinder or components
G Improper clearance between lever and switch
Lever Vibration
G Disc damaged
G Disc worn (runout or thickness variance exceeds
service limit)
Caliper Overheats (Brakes Drag)
G Compensating port plugged
G Pad clearance set incorrectly
G Auxiliary brake pedal incorrectly adjusted
G Brake lever or pedal binding or unable to return
fully
G Parking brake left on
G Residue build up under caliper seals
G Operator riding brakes
Brakes Lock
G Alignment of caliper to disc.
9.23
BRAKES
NOTES
9.24
ELECTRICAL
Special Tools/Service Notes . . . . . . . . . . . . . . . . . . 10.2

Timing Check Procedure . . . . . . . . . . . . . . . . . . . . . 10.2-10.3
Trans. Gear Position Switch Testing . . . . . . . . . . . 10.3
Front Gearcase Engagement Limiter . . . . . . . . . . 10.4
Rear Gearcase Solenoid Operation . . . . . . . . . . . 10.4
Instrument Cluster Overview . . . . . . . . . . . . . . . . . 10.5-10.8
Instrument Cluster Remove/Install . . . . . . . . . . . . . 10.8-10.9
Speedometer Test . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10-10.13
Resistor Module Operation . . . . . . . . . . . . . . . . . . . 10.14
ECM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14--10.15
Coolant Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . 10.16--10.17
Fan Control/Motor Current Draw Tests . . . . . . . . . 10.17-10.18
Electronic Throttle Circuit System Operation . . . . 10.18--10.19
330 Oil Cooler Fan Control Test . . . . . . . . . . . . . . 10.19
330 Fan Motor Current Draw Test . . . . . . . . . . . . 10.20
Ignition System Troubleshooting . . . . . . . . . . . . . . 10.20--10.21
CDI Output Tests/Charging Output Tests . . . . . . . 10.21--10.24
Flywheel Identification / DC/CDI Overview . . . . . . 10.25
ES32PF 210 Watt Alternator, Exploded View . . . 10.26
EH50PL 250 Watt Alternator, Exploded View . . . 10.27--10.28
Ignition System Testing Flowchart . . . . . . . . . . . . . 10.29
Charging System Testing Flowchart . . . . . . . . . . . 10.30
Battery Activation/Service . . . . . . . . . . . . . . . . . . . . 10.31-10.37
Head Light/Brake Light Lamp Service . . . . . . . . . . 10.38-10.40
Starter System Troubleshooting . . . . . . . . . . . . . . . 10.41
Starter Motor Service . . . . . . . . . . . . . . . . . . . . . . . . 10.42-10.44
Starter Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
Starter Assembly Exploded View . . . . . . . . . . . . . . 10.44
Starter System Testing Flow Chart . . . . . . . . . . . . 10.45
10.1
ELECTRICAL
SPECIAL TOOLS TIMING CHECK PROCEDURE

PART NUMBER TOOL 1. The ignition timing check hole is in the starter
DESCRIPTION recoil/magneto housing. Remove the check plug.
PV--43568 Fluket77 Digital
Multimeter NOTE: The ignition timing marks are stamped on the
outside of the flywheel. Ignition timing must be
2870630 Timing Light
inspected with the engine at room temperature (68°F
2870836 Battery / 20° C).
Hydrometer
2460761 Hall Sensor Probe 2. With the transmission in neutral, start the engine
Harness and set engine speed to indicated speed ± 200
2871745 Static Timing Light RPM.
Harness 3. Direct the timing light at the ignition timing check
hole and check the ignition timing. NOTE: Do not
allow the engine to warm up. The timing will retard
approximately 2° when the engine is warm.
ELECTRICAL SERVICE If the ignition timing is not within the specified range,
NOTES adjust the stator plate position as described in the
following text.
Keep the following notes in mind when diagnosing an
electrical problem.
G Refer to wiring diagram for stator and
electrical component resistance Timing
specifications. Inspection
Hole
G When measuring resistance of a
component that has a resistance value
under 10 Ohms, remember to subtract
meter lead resistance from the reading.
Connect the leads together and record
the resistance. The resistance of the
component is equal to tested value minus
the lead resistance.
G Become familiar with the operation of
your meter. Be sure leads are in the
proper jack for the test being performed
(i.e. 10A jack for current readings). Refer
to the Owner’s manual included with your
meter for more information. Flywheel
G Voltage, amperage, and resistance Rotation 32
values included in this manual are
obtained with a Fluket 77 Digital
Multimeter (PV--43568). This meter is
used for when diagnosing electrical Timing
problems. Readings obtained with Pointer
other meters may differ. 30
G Pay attention to the prefix on the
28
multimeter reading (K, M, etc.) and the
position of the decimal point. ATP 330 ATP 500
30_ @ 5000 RPM 30_ @ 3500 RPM
G For resistance readings, isolate the
component to be tested. Disconnect it
from the wiring harness or power supply.
10.2
ELECTRICAL
Stator Adjustment GEAR POSITION INDICATOR

1. Remove the magneto housing. SWITCH TEST
2. Remove the flywheel.
3. Loosen the stator plate screws and adjust the
stator plate position. NOTE: Moving the stator
plate clockwise retards (delays) the ignition Drum Switch Continuity --ATP
timing. Moving the plate counterclockwise
advances it.
A B C D E F
High Range F F
Rotation Low Range F F
Neutral F F
Reverse F F
Retard Advance
Park F F
TYPICAL IGNITION TIMING CURVE * ACTUAL ADVANCE POINT
MAY VARY BY SEVERAL HUNDRED RPM ABOVE OR BELOW 5000 . USE
THE POINT OF MAXIMUM ADVANCE WHEN CHECKING IGNITION TIMING

IGNITION TIMING (DEGREES) B.T.D.C.
MAXIMUM ADVANCE POINT (*)

30
28
26 EH50PL ES32PF
24
22
20
18
16
14
12
10
8
0 1000 2500 3000 3500 4000 4500 5000 5500 6000
EH50PL ES32PF
Drum Switch Wire Identification
10.3
ELECTRICAL
FRONT GEARCASE 2004 ATP Rear Differential Circuit

ENGAGEMENT LIMITER
AWD models are equipped with a front gearcase
engagement limiter system which prevents front gear
case engagement if engine RPM is above 3100. This
is accomplished by electronic module (attached to the
bulkhead under the front cover) or an electronic WHT/GRN
speedometer if equipped, which monitors engine
RPM via the Yellow/Red alternator wire. AWD must
be selected (button pushed) prior to reaching 3100
RPM, or the Speedometer will electronically
disconnect the ground path for the front AWD coil
(Brown/White wire) until RPM falls below 3100. If
AWD is selected (button pushed) below 3100 RPM,
the connection to ground will be maintained by the
See Shematic for More
module at any RPM. The ground path is interrupted
Details on Switch Wiring
only if an attempt is made to engage the front hubs
with engine RPM above 3100. Refer to the diagrams
and test procedures provided. 2005 ATP Rear Differential Circuit
WARNING: The engagement limiter is a safety
(Sure Power Box)

feature designed to protect the front drive
REGULATOR
components and should never be disabled, except for WHT/GRN
testing purposes. Serious injury or death may result if
the limiter system is disabled or left in the testing
mode.
REAR GEARCASE (CARRIER)

SOLENOID
See Shematic for More

Details on Switch Wiring
If the rear carrier fails to switch from operational

modes:
G Check the connector located under
the left rear fender. Look for loose
Solenoid wires or bad connections.
G Check for power from the connector,
to ensure the solenoid has power to
The differential solenoid is located on the rear gear be activated.
case. The solenoid actuates the carrier into 2x4 and G Check the operator’s switch wires for
Turf modes. (Refer to Chapter 7 for more information loose connections.
on rear carrier operation.)
G Remove solenoid from carrier and
The 2004 and 2005 ATP rear differential circuits are ensure the solenoid tip is actuating.
different. The 2004 ATP utilizes a single differential CAUTION: Do not power the solenoid with 12 Volts
switch located under the front cab. The 2005 ATP rear for more than 1 second, or damage may occur to the
differential switch is located within the Control Module solenoid.
(Sure Power Box) that is located under the front cab.
10.4
ELECTRICAL
INSTRUMENT CLUSTER numbers in Mile Per Hour (MPH) and Kilometers Per
Hour (KPH). (C) The Rider Information Center
OVERVIEW-- ATP 330 / 500 performs a number of functions (See Illustration 2):
(A) Speedo Needle (also flashes Refer to Illustration 2:

during warning condition) 1. Odometer/Tachometer/Trip meter/Hour Meter
(B) Speedometer * Odometer records the miles traveled by the ATP.
in MPH/KPH
*Tachometer displays engine RPM. This feature will
also display with the vehicle in motion NOTE: Small
RPM fluctuations from day to day are normal because
of changes in humidity, temperature, and elevation.
*Trip meter records the miles traveled by the ATP on
each trip it it’s reset before each trip. To reset the trip
meter, select the trip meter mode. Press and hold the
mode button (override button) until the total changes
to 0. NOTE: In the Rider Information Center, the trip
meter display contains a decimal point, but the
odometer displays without a decimal point.
*Hour Meter logs the total hours the engine has been
in operation.
(C) Rider Information Center Ill.1 2.Programmable Service Interval/Diagnostic

Mode
*Service Interval -- The purpose of the
programmable service interval is to provide the
5 2 4 1 consumer and their dealer with a convenient way to
schedule routine maintenance. When the ATP leaves
3 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
6 ATP is started as a reminder that ATP maintenance
is due. NOTE: To reset the Service Interval, follow the
directions on the on Page 10.7, “Setting New Service
Interval”.
*Diagnostic Mode is for informational purposes only.
8 Consumers should return the ATP to their Polaris
7 Ill.2 dealer. See “Diagnostic Mode Operation” on the
next page for more information.
Introduction 3. Check Engine Warning Indicator
Refer to Illustration 1: The word HOT will display alpha numerically when the
The Polaris ATP Instrument Cluster is powered by engine is overheating. Do not continue to operate the
battery voltage (12 VDC) and requires inputs from the ATP if this warning appears. Refer to Chapter 3
engine RPM, transmission gear, and wheel speed “Cooling System Troubleshooting” for help with
sensor for proper operation. Two harnesses plug into diagnosis of overheating.
the cluster head; one from the right front wheel 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 right front brake caliper bracket and the needle
also flashes during a warning condition. The
speedometer needle indicates speed in MPH and
KPH. NOTE: The flashing needle could indicate a
hot engine, low battery warning, or the No. 10 Pin
could be grounded. (B) The speedometer features
10.5
ELECTRICAL
4. High/Low Battery Voltage

This warning usually indicates that the ATP is being
operated at an RPM too low to keep the battery
charged. A low battery warning may also occur under
normal operation if the machine is at idle and high
electrical load (lights, cooling fan, accessories) is
applied. Driving at a higher RPM or connecting a
battery charger will usually clear the warning.
5. Engine Hour Display Indicator
Displays number of hours of engine operation. Ill. 2
6. AWD Indicator Screen 2: Tachometer (Ill. 3) indicates engine rpm

Illuminates when the electrical portion of the AWD for setting idle speed.
system is enabled.
7. Gear Indicator
Specifies what position the shift lever and
transmission are in. This area is blank if a fault occurs.
8. Mode Indicator
Indicates which modes are being utilized.
DIAGNOSTIC MODE
NOTE: This gauge features auto shut--off protection Ill.3
if the voltage on the DC bus is excessive. This is
usually the result of an open battery condition, and the Screen 3: AWD diagnostic screen. This screen
gauge is designed to survive such an event. indicates whether or not current is flowing through the
AWD coil on models with switchable AWD.
NOTE: If the gauge will not indicate what gear it is in
and will not allow AWD operation, AWD can still be
enabled by holding in the mode/override button.
To enter the diagnostics mode:
1. Turn the key switch off and wait 10 seconds.
2. Set the park brake and shift the transmission to
neutral.
3. Hold the mode/reverse override button as you
turn the key switch on.
4. Release the switch as soon as the display is AWD Off
activated.
Use the mode/reverse override button to toggle
through the diagnostic screens.
The initial screen display refers to the software
version installed on your ATP. This information is only
displayed briefly.
Screen 1: The first screen indicates battery voltage.
Refer to Ill. 2.
AWD On
10.6
ELECTRICAL
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 readings is within normal
parameters.
628 Ohms in High
Screen 5: Programmable service interval. The

purpose of the programmable service interval is to
provide the consumer and dealer with a convenient
23 Ohms in Park reminder for routine maintenance. When the ATP
leaves the factory, this feature is set at 50 hours.
Once the service interval mode is set with the hours

when service is due, the hours of actual engine
operation are subtracted from the set hours until 0 is
reached. When the counter reaches 0, the wrench
icon will flash quickly for 10 seconds each time the
vehicle is started as a reminder that the periodic
maintenance is due.
158 Ohms in Neutral
Set at 50 hrs. from Factory
75 Ohms in Reverse SETTING A NEW SERVICE INTERVAL:
Setting Service Interval After Countdown (zero):

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
297 Ohms in Low flashing. When the wrench stops blinking, your
service hours are set.
NOTE: If you scroll past the intended number, hold
the button down until the count turns over to 0. You
can then reset the number.
Turn Service Interval OFF:

1. If the service interval is enabled (functioning) on
your ATP and you wish to turn it off, toggle to the
10.7
ELECTRICAL
service interval mode. NOTE: To leave the diagnostic mode, turn the key
2. Press and hold the mode button for approximately switch off and on.
7 seconds until the word OFF appears in the Rider
Information Center. The service interval is now off. NOTE: Any movement of the tires will trigger the
3. To enable (turn on) the service interval mode, speedometer out of the diagnostic mode and into
repeat the steps above in “Setting Service Interval standard display mode.
After Countdown”.
Change Service Interval Time: SPEEDOMETER REMOVAL

If you would like to change the service interval time,
(for example change the interval from 50 hrs. to 55 1. Remove the three screws that secure the
hrs.). Follow the steps below: headlight pod cover and disconnect the wire
1. While in the service interval mode, press and hold connectors from the instrument cluster.
the mode button for approximately 7 seconds until the
word OFF appears in the Rider Information Center.
2. Wait 5 seconds and then press the mode button in
until the wrench icon flashes. Press the mode button
again to set the desired service increment. Release
the button and wait for the wrench icon to stop
flashing. The new service interval is now set.
Screen 6: Miles/Kilometers toggle, The display in

the trip meter and odometer can be changed to
display either kilometers or miles. The current display
mode will be shown as “KM” or “MP”. To 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. 2. Push the instrument cluster out from the backside
of the pod, while securely holding the pod.
MP = Miles
Km = Kilometers
NOTE: As long as you are in the diagnostic mode, the

wrench icon will remain lit.
10.8
ELECTRICAL
Bezel
Instrument Cluster
Rubber Mount Align Index Points
Pod
Push Instrument
Cluster Outward
NOTE: Do not remove the rubber grommet in the pod.

Only remove the rubber grommet if necessary. The 3. Hold the pod assembly securely and insert the
bezel is a snap--on assembly and is a serviceable instrument cluster into the pod assembly. Twist
part. the instrument cluster gently in a clockwise
motion to properly seat the instrument cluster into
the pod assembly. Apply pressure on the bezel
SPEEDOMETER INSTALLATION while pressing down on the instrument cluster.
1. Spray a soap and water mixture onto the outer
surface area of the instrument cluster. This will
help the instrument cluster slide into the pod
assembly more easily.
NOTE: Be sure the key on the instrument cluster

housing is aligned with the keyway in the rubber
grommet, to ensure proper alignment.
NOTE: Do not allow alcohol or petroleum products to

2. Be sure the rubber grommet inside the pod is fully come in contact with the instrument cluster lens.
installed and that the indexing key is in the
headlight pod keyway.
10.9
ELECTRICAL
SPEEDOMETER TROUBLESHOOTING
TEST 1 - NO ALL WHEEL DRIVE
Note: If AWD icon comes on, instru-
START HERE ment cluster is O.K. Proceed to me-
chanical tests (in Service Manual).
Check the AWD icon on instrument clus-
SPEED CHECK ter to verify it’s operation. The AWD
READOUT
N SPEEDOMETER
switch is directly powered by switched
OK?
(PERFORM 12 volts (red/white). The gear switch
TEST 2) only interfaces with the instrument clus-
ter. To enable AWD, the cluster must be
Y displaying low or high gear, or reverse
gear with the override button pushed in.
-- KEY SWITCH ON
-- TRANSMISSION IN NOTE: The 2004 and 2005 ATPs
NEUTRAL have different wire colors. Identify
16 Pin Connector
-- AWD SWITCH ON the correct wire color for each year. 1. 04--Red; 05 Org/Wht-- 12V Constant
2. Red/White-- 12V Switched
Y 3. Grey/Orange-- Mode/Override button
4. Black-- Ignition Kill
5. 04 --N/C; 05-- Grn
6. 04 --N/C; 05-- Blu
7. Yellow/Red-- RPM Input
8. Brown-- Ground
ON HUB COIL
CONNECTOR NOT AN INSTRUMENT 9. Blue White-- Engine Overheat Switch
10. N/C
(LEAVE IT CONNECTED) N CLUSTER PROBLEM; 11. N/C
MEASURE FOR 12V FROM CHECK AWD SWITCH 12. Purple/White-- Fuel Sender (not used)
BROWN/WHITE TO THE 13. Brown/Red-- Neutral
AND WIRING 14. White
COIL BODY 15. N/C
(GROUND) 16. Brown/White-- AWD Coil
Note: Reversing polarity when connecting

the battery or other DC power source
Y backwards will fail the AWD control and
the instrument cluster If the key switch
and the AWD switch are turned on.
LEAVE AWD
SWITCH ON
TURN KEY SWITCH OFF N REPLACE
WIRING INSTRUMENT
DISCONNECT 16 PIN
PROBLEM CLUSTER
CONNECTOR FROM CLUSTER
TURN KEY SWITCH ON Y
CHECK FOR 12V
FROM BRN/WHITE
TO GROUND
LEAVE KEY
SWITCH OFF
REMOVE THROTTLE PROCEED TO
CONTROL COVER MECHANICAL AWD
Y DISCONNECT THROTTLE N COMPONENTS
TURN KEY SWITCH OFF CONTROL HARNESS IF AWD PROBLEM
RECONNECT CLUSTER CHECK FOR CONTINUITY PERSISTS.
LEAVE HEADLIGHT POD ACROSS AWD
DISASSEMBLED INDICATOR BULB
SHIFT TO LOW OR HIGH
LEAVE AWD ON
10.10
ELECTRICAL
TEST 2 -- NO SPEEDOMETER AND/OR ODOMETER DISPLAY
Note: Before starting diagnosis, turn off speedometer and wait 10 seconds, S
then turn on again to see if problem clears Y CHECK FOR
MINIMUM 6VDC N REPLACE
SPEEDO
ON PIN B TO
START HERE 3 Pin Connector PIN C
REPLACE
KEY & STOP SPEEDO
SWITCHES ON A: D.C. Power
B: Signal Y MEASURE
C: Ground S BACK OF
Y SPEEDO
CHECK S
REPLACE N WHEEL
CHECK
SPEEDO SENSOR
SPEED AT BACK OF SPEEDO:
POINTER
SENSOR
POWER Y CHECK FOR 10--12
MOVE? SUPPLY
(SEE VDC ON PIN A TO PIN
PIN A
TEST 6) C ON THE 3 PIN CON-
Y NECTOR?
16PIN MEA-
SURE 12VDC N REPAIR
ON PINS 1 WIRING N
&8 AND 2 & 8 REPLACE
SPEEDO REPLACE
SPEEDO
N N
N
Y
ODOMETER TEST ODOMETER Y Y SPEEDO
DISPLAY DRIVE POINTER
CHANGE? MOVE? OK
VEHICLE
TEST 3 -- NO REVERSE SPEED LIMIT 16 Pin Connector

(VEHICLE EXCEEDS 7--9 MPH IN REVERSE) 1. 04--Red; 05 Org/Wht-- 12V Constant 9. Blue / White-- Engine Overheat Switch
2. Red/White-- 12V Switched 10. N/C
3. Grey/Orange-- Mode/Override button 11. N/C
4. Black-- Ignition Kill 12. Purple / White-- Reverse Gear
START HERE 5. 04 --N/C; 05-- Grn 13. Green/White-- Neutral
6. 04 --N/C; 05-- Blu 14. White
7. Yellow/Red-- RPM Input 15. N/C
N 8. Brown-- Ground 16. Brown/White-- AWD Control
CHECK
IS THE SPEEDO
READ OUT
SPEEDOMETER NOTE: Mode/Override button provides a grounding
(PERFORM TEST 2)
OK? (sinking) input to the instrument cluster.
NOTE: The 2004 and 2005 ATPs
Y INSPECT WIRING
have different wire colors. Identify
AND CDI
the correct wire color for each year.
N
TEST TRANSMISSION
SHIFT INTO REVERSE: N (SHIFT) SWITCH AND
H Measure Harness Side
IS REVERSE INDICA- WIRING
TOR ON? RESTART ATV
H
TURN KEY SWITCH OFF JUMPER TO PIN 4 Y REPLACE
Y REMOVE 16 PIN PLUG
(BLACK) TO PIN 8 SPEEDO
(BROWN). DOES
FROM BACK OF ENGINE STOP?
SPEEDOMETER HEAD
10.11
ELECTRICAL
TEST 4 - NO AWD HUB SAFETY LIMIT NOTE: The 2004 and 2005 ATPs
NOTE: IF THE AWD ICON DOES NOT COME ON OR IF 12
VDC IS NOT REGISTERING AND AWD IS ENGAGING the correct wire color for each year.
ABOVE 3100 RPM,IT MAY BE A MECHANICAL PROBLEM. START HERE
IS
SPEEDO
Y FUNCTIONING N CHECK
ATV IN NEUTRAL SPEEDO
CORRECTLY?
TOGGLE TO TACHOMETER
Y SETTING & REV ENGINE. (TEST NO. 2)
HOLD UNTIL DISPLAY STABILIZES.
DOES IT APPEAR
ACCURATE?
RESTART ATV
N
ENGINE IDLING
MEASURE AC VOLTAGE
Y REPLACE
TURN KEY SWITCH OFF SPEEDOMETER
BETWEEN PIN 7 AND
1. RAISE ATV WHEELS OFF GROUND AND REMOVE 16 PIN PIN 8.
SUPPORT IN A SAFE MANNER. CONNECTOR FROM OVER 3 VAC?
BACK OF
2. MONITOR VOLTAGE AT HUB COIL INSTRUMENT
CONNECTOR, BETWEEN BROWN/WHITE CLUSTER.
AND GROUND
CHECK CHARGING SYSTEM

(STATOR, REGULATOR,
AND WIRING)
TURN
AWD OFF.
START THE ENGINE
REV AND HOLD THE N 16 Pin Connector
RPM’S ABOVE 3100. NO PROBLEM 1. 04--Red; 05 Org/Wht-- 12V Constant 9. Blue White-- Engine Overheat Switch
TURN AWD ON.
2. Red/White-- 12V Switched 10. N/C
DOES FRONT
3. Grey/Orange-- Mode/Override button 11. N/C
DRIVE
ENGAGE? 4. Black-- Ignition Kill 12. Purple /White--Fuel Sender (not used)
5. 04 --N/C; 05-- Grn 13. Brown / Red-- Neutral
6. 04 --N/C; 05-- Blu 14. White
8. Brown-- Ground 16. Brown/White-- AWD Coil
Y
INSPECT
HUB COIL WIRING
Y FOR SHORT CIRCUITS N
IS THE TO GROUND. (DISCONNECT REPLACE
AWD ICON ON? CONNECTOR & MEASURE SPEEDOMETER
BETWEEN HUB COIL
BROWN/WHT
& GROUND.)
N Y
MECHANICAL PROBLEM REPAIR HUB COIL WIRING
10.12
ELECTRICAL
TEST 5 REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR
(Engine loses spark when vehicle speed is above 7-9 mph.)
START HERE
16 Pin Connector
CHECK 1. 04--Red; 05 Org/Wht-- 12V Constant 9. Blue White-- Engine Overheat Switch
INSTRUMENT SPEEDOMETER 2. Red/White-- 12V Switched 10. N/C
CLUSTER FUNC- 3. Grey/Orange-- Mode/Override button 11. N/C
(PERFORM TEST 2)
TION OK? 4. Black-- Ignition Kill 12. Purple / White-- Fuel Sender (not used)
5. 04 --N/C; 05-- Grn 13. Brown / Red-- Neutral
6. 04 --N/C; 05-- Blu 14. White
Y 8. Brown-- Ground 16. Brown/White-- AWD Control
NOTE: The 2004 and 2005 ATPs
CHECK FUEL &
SHIFT TO LOW OR the correct wire color for each year. IGNITION SYSTEMS
HIGH GEARS.
Y Y
DOES GEAR INDICATOR
DISPLAY CORRECTLY?
TURN KEY SWITCH OFF
REMOVE 16 PIN
PLUG FROM BACK OF PROBLEM N REPLACE
INSTRUMENT CLUSTER REMAINS? SPEEDOMETER
RESTART ATV AND
N TEST DRIVE
TEST TRANSMISSION SWITCH

CHECK RELATED WIRING NOTE: OVERRIDE SWITCH PLAYS NO ROLE IN
REVERSE GEAR OUTPUT
TEST 6 WHEEL SPEED SENSOR

Tools Required: To Sensor Red
Brn
G Static Timing Light Harness (PN 2871745)
G Hall Sensor Probe Harness (PN 2460761) or 680Ω
Wht
equivalent jumper wires.
To test wheel speed sensor: -- + To Sensor
LED White
1.Disconnect 3 Pin connector from speedometer. 12V To Sensor
2. Connect wires from test light to sensor 3 Pin Blk Black
connector as shown at right, using the Hall Sensor
Probe Harness (PN 2460761) or jumper leads.
3. Elevate front right side of vehicle until tire is off the
ground.
4. Slowly turn right front wheel while observing the
test light.
Static Timing Light Harness
5. If light flashes, sensor is O.K. Be sure connections
are good and 9 volt battery is in good condition. (PN 2871745)
WHEEL SPEED
SENSOR LOCATION
(RIGHT WHEEL)
10.13
ELECTRICAL
RESISTOR MODULE ECM OPERATION (SURE

OPERATION POWER BOX)
ECM or Sure Power Box
(Located Under Front Cab Area)
Resistor Located Under Front Cab
The resistor module located under the front cab

modifies and helps to transmit the proper signals from
the various sensors located on the ATP to the 53 OR/WHT
instrument cluster for diagnostic purposes. 26 OR/BLK
55 BRN
47 R/WHT
21 RED
20 RED 56 ORANGE
62 ORANGE
04 BLU/WHT
22 BROWN
The ECM (Sure Power box) integrates three

electronic features found on the Polaris ATV. These
features are alternator rectifier/regulator, engine
temperature controller, solid state circuit breaker
outputs, and rear carrier controls.
Regulator:
The regulator takes the output of the 3--phase
alternator and applies it to the battery. SCRs are used
to connect and disconnect the alternator from the
batter to achieve regulation of the battery voltage.
The regulator circuit produces current on the
BATTERY pin (Pins E & F). If a high voltage transient
is detected on the BATTERY pin this causes the
regulator to assume an open battery condition. The
high voltage transient will cause the regulator to turn
off for a short period of time. If there truly is an open
battery then the regulator will remain off as the
minimum battery requirement will not be met. The
regulator will not turn on unless there exists a battery
voltage in excess of the minimum battery voltage
requirement.
10.14
ELECTRICAL
Rev. BAT
Alternator BAT+
Engine Temperature Controller: 3 Phase Protect
Input
The engine temperature controller has several Regulator
Mosfet & BAT_PROT
features. Its primary function is to control the fan Driver
motor. The fan motor is turned on and off at preset Ground
temperatures as determined by the engine IPS ACC_PWR
temperature thermistor. If the engine temperature
continues to rise it will turn on an engine hot indicator. Run
The module also contains provisions for detecting an Hot Lamp
open thermistor. An open thermistor will cause the
Thermistor Controller IPS Fan
engine hot indicator to light and cause the fan motor
to come on. Solenoid
The engine temperature controller is enabled by the Differential
Pos.
RUN signal (Pin G). The controller can only come on Transmission Signal Differential Solenoid
if the RUN signal is active. The engine hot output Solenoid Neg.
provides a grounded output for a lamp. The FAN
output (Pin J) is protected against short circuit and
overload by electronic means internal to the module.
The FAN output has a linear current limit. If the Wire Pin Description
maximum temperature of the switching device is Color
exceeded the fan output will turn off until the device
Orange A BAT_PROT -- Protected battery
has cooled. and output used to power the headlight
B and instrument cluster.
Solid State Circuit Breaker Outputs:
The module provides two solid state circuit breaker Brown C GND -- Battery Negative
outputs. The first output (BAT_PROT) is active at all and
times. This output is routed to the key switch and the H
left hand control assembly (LHCA) to provide power Blue/ D HOT_LAMP -- Engine hot signal.
for lamps, pod, and front hub coils. The second output White Provides a ground path for a lamp.
(ACC_PWR) is enabled by the RUN signal. This
Red E BAT+ -- Positive side of battery.
second output is used for accessories. and Both pins should be used to carry
The BAT_PROT output is protected from overloads F current.
and short circuits. If a overload or short circuit occurs
that output turns off. The output can be reset by Red / G Enables ACC_PWR, FAN, Hot
removing load from it by turning the key switch or White Lamp when on.
LHCA switch off. Orange J Power to the fan.
The ACC_PWR switch has a linear current limit. If the / Black
maximum output current is exceeded the output
Orange K ACC_PWR -- This signal provides
voltage will be reduced. If the maximum temperature /White power to the accessories.
of the solid--state device is exceeded it will shut off.
It will automatically turn back on when it has cooled.
10.15
ELECTRICAL
2004 ATP 500 -- COOLANT the specified temperature, it becomes conductive and
sends power to the fan motor through to the
TEMPERATURE SENSOR Orange/Black wire. The ground path for the fan motor
is through the Brown harness wire.
TEST (HOT INDICATOR)
CAUTION: Keep hands away from fan blades
during this procedure. Serious personal injury
could result.
To Fan To 10 Amp Breaker
TO HARNESS SPLICE 2005 ATP 500 -- COOLANT

TEMPERATURE SENSOR
With the ignition switch (and engine stop switch) “ON”, (THERMISTOR) TEST
power is delivered to the hot light via the Red/White
wire. The Blue/White wire (ground) out of the
instrument cluster is connected to the coolant
temperature sensor on the cylinder head. In normal
operating conditions, the temperature sensor is
non-conductive (open). If engine coolant reaches the
specified temperature, the sensor becomes
conductive completing the ground path for the light.
With engine cold, disconnect lead and measure
resistance of sensor between connector terminal and
ground. There should be no continuity or very high
resistance (megohms).
Hot Indicator On 221° F (105° C)
NOTE: 2004 ATP models use a fan control switch

instead of a thermistor, see “2004 ATP 500 -- FAN
2004 ATP 500 -- FAN CONTROL CIRCUIT OPERATION / TESTING”.
CONTROL CIRCUIT If the thermistor circuit is open the engine Hot light and
fan will both come on. With engine cold, disconnect
OPERATION / TESTING lead and measure resistance of sensor between the
two Yellow/Black connector terminals. There should
The fan switch is located on the radiator. Power is be no continuity or very high resistance (see chart
supplied to the fan switch via the Red/Black wire when below).
the ignition key is ON. When the fan switch reaches
10.16
ELECTRICAL
See “Engine Temperature Controller” on Page 10.5

for information on thermistor operation.
Fan Motor
SITUATION OHMS DIAGNOSIS / Or/Blk
READING ACTION Or/Blk
Hot light ON & Above 50k Open Thermistor /
Fan ON Replace Thermis- Brn
tor Connect ammeter
Hot light ON Below 178 Engine Overheat to R/B and Or/Blk
or Bad Thermistor Red/Blk
THERMISTOR READING DURING OPERATION

Condition Approx. Reading Temperature
(Min--Max) Fan
Switch
Hot Light 1559Ω -- 1655Ω 290° F Harness
On/Off (143° C)
Fan Off 3362Ω -- 3570Ω 240° F
(Temp Falling) (116° C)
1. Disconnect the harness from the fan switch on
Fan On 2444Ω -- 2594Ω 260° F 2004 models.
(Temp Rising) (127° C)
2. Connect a DC ammeter in between the fan switch
harness wires as shown.
2004 ATP 500 -- FAN 3. Verify fan is free to rotate. Turn ignition key and
CONTROL SWITCH BYPASS engine stop switch to “ON” position. Read the
current draw on ammeter with fan running.
TEST 4. If the fan motor draws more than 7.5 Amps,
1. Disconnect harness from fan switch on radiator. replace the motor.
2. Place a jumper wire between the Red/Blk and Fan Motor Current Draw:
Org/Blk wires in the connector.
Less Than 7.5 Amps
3. With the parking brake on, turn the ignition key
(and engine stop switch) “ON”. The fan should
start running.
4. If the fan runs with the jumper wire installed,
check the fan control switch and connector
terminals. If the fan does not run or runs slowly
with the jumper wire installed, check the fan motor
wiring, ground, and motor condition (refer to Fan
Motor Testing this section). Repair or replace as
necessary.
2004 ATP 500 -- FAN MOTOR

CURRENT DRAW
A current draw test will provide a good indication of fan
motor condition. A worn or damaged fan motor will
draw more current, which causes a reduction in blade
speed and reduced cooling.
10.17
ELECTRICAL
2005 ATP 500 -- FAN MOTOR REFER TO PARTS MANUAL FOR FAN
SWITCH APPLICATION
CURRENT DRAW Fan Switch Continuity No Continuity
A current draw test will provide a good indication of fan Part Number (On) (Off)
motor condition. A worn or damaged fan motor will 4010161 180° F (82° C) 149° F (65° C)
draw more current, which causes a reduction in blade ± 3°F ± 8°F
Fan Motor
ELECTRONIC THROTTLE
CONTROL (ETC) SWITCH
Or/Blk Or/Blk
The Electronic Throttle Control (ETC) system is
Brn designed to stop the engine of an ATV in the event of
a mechanical problem with the throttle mechanism.
Connect ammeter The ETC switch is mounted independently of the
to Or/Blk in series 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 CDI
1. Disconnect the harness from the fan motor on black wire to ground, which prevents ignition spark.
2005 models. This is the same as turning the key or engine stop
2. Connect a DC ammeter in between the fan switch switch “OFF”.
harness wires as shown. Test the ETC switch at the harness connector. NOTE:
3. Verify fan is free to rotate. Turn ignition key and Adjust throttle cable freeplay (ETC switch) and make
engine stop switch to “ON” position. Read the sure throttle mechanism is functioning properly before
current draw on ammeter with fan running. testing the switch. Refer to Maintenance Chapter 2
for cable adjustment procedure.
4. If the fan motor draws more than 8.8 Amps,
replace the motor.
Fan Motor Current Draw:
Less Than 8.8 Amps
2004 ATP 500 -- COOLANT

FAN CONTROL SWITCH
OPERATION TEST
NOTE: 2005 ATP models use a thermistor instead of
a fan control switch.
1. Place switch in a liquid bath and submerse it to the
base of the threads. Do not allow threads to
contact container or inaccurate reading will result.
2. Heat the liquid slowly and monitor the
temperature with a thermometer or Fluket meter
pyrometer. The switch should be closed
(conductive) at the “ON” temperature indicated in
the chart, and stay conductive until the “OFF”
temperature is reached.
10.18
ELECTRICAL
ETC OPERATION TEST 2004 ATP 330 -- THERMISTOR

Remove throttle block cover by carefully releasing all JUMPER
tabs around edge of cover.
Place transmission in neutral and apply parking
brake.
Start engine and open throttle lever slightly until
engine RPM is just above idle speed.
Hold throttle cable with fingers at point “A” as shown
below and release throttle lever. If the ETC system is
functioning properly, the engine will lose spark and
stop.
Electronic Throttle Control (ETC) Switch

(Composite Throttle Housing)
ETC switch contacts Thermistor Jumper
are closed in a fault
condition (throttle cable
slack). Switch contacts are open NOTE: A thermistor jumper is installed on 2004 330
during normal operation engines to modify the thermistor resistance fan ’ON’
temperature. When diagnosing fan or overheat
issues check this thermistor jumper if installed before
testing. Follow the steps in the “OIL COOLER FAN
CONTROL TEST” below.
ATP 330 -- OIL COOLER FAN

CONTROL TEST
A Oil Cooler Fan Notes - ATP 330
G Thermistor resistance decreases
with temperature
Blk
G Both fan and hot indicator should be
Brn
on with the thermistor unplugged
G Fan blade should rotate drawing air
in through cooler (blowing on engine)
THERMISTOR RESISTANCE
VS. TEMPERATURE
Oil Resistance Fan Hot Light
Temperature ON/OFF ON/OFF
± 20%
77° F 100KΩ Fan OFF
CDI UNIT
(25° C) OFF
240° F 3.5KΩ Fan OFF
(116° C) OFF
10.19
ELECTRICAL
260° F 2.5KΩ Fan ON OFF FAN MOTOR CURRENT DRAW

(127° C)
290° F 1.6KΩ Fan ON Hot Indi-
ATP 330
(143° C) cator ON
Connect ammeter leads

Oil Cooler Fan Circuit - ATP 330 between exposed
’HOT’ indication and fan ’ON’ with resistor Orange/Black terminals at
leads disconnected from module and key on fan connection.
(2004 Models Only)
YEL/BLK
Battery Voltage Resistor Lead
YEL/BLK
RED/W
YEL/BLK
YEL/BLK
Brn Or R/Wht
THERMISTOR
OR/BLK
BRN Connect only: Red/White (2004 ATP) or Brown
RED/W Vehicle
Control (2005 ATP) terminals at fan connection.
Speedometer Module
BLU/W A current draw test will provide a good indication of fan

R/W motor condition. A worn or damaged fan motor will
draw more current, which causes a reduction in blade
Thermistor / Fan Control Test - ATP 330 1. Turn key to off.
2. Disconnect the thermistor.
G Turn key switch to ON and engine stop
switch to RUN. Do not start engine. 3. Reconnect fan motor connector to place a DC
ammeter in series as shown in the Illustration.
G Test voltage on R/W wire at vehicle 4. Be sure fan blade is free to rotate.
control module. R/W wire should have
5. Turn ignition key and engine stop switch to “ON”
12--14 Volts DC (battery voltage)
position. Read the current draw on ammeter with
G Disconnect thermistor leads and resistor fan running.
jumper from the main harness 6. If the fan motor draws more than 7.5 Amps,
(Black/Yellow wires) - Fan and Hot replace the motor.
indicator ON? (If not, test speedometer,
fan motor and circuit)
IGNITION SYSTEM
G Test the resistance of the thermistor (refer
to temperature/resistance table).
TROUBLESHOOTING
Replace thermistor if out of specified range.
No Spark, Weak or Intermittent Spark
See the wiring diagram or chart for
thermistor resistance values at various oil G No12 volt power or ground to CDI
temperatures. The resistance of the G Spark plug gap incorrect
thermistor is approximately100kΩ at 77°F.
G Fouled spark plug
G Replace vehicle control module and test G Faulty spark plug cap or poor
system if all else appears okay. connection to high tension lead
G Related wiring loose, disconnected,
shorted, or corroded
G Engine Stop switch or ignition
switch faulty
G ETC switch misadjusted or faulty
G Poor ignition coil ground (e.g. coil
mount loose or corroded)
G Faulty stator (measure resistance
of all ignition related windings)
10.20
ELECTRICAL
G Incorrect wiring (inspect color

coding in connectors etc) 2004 ATP 500 Stator Resistances
G Faulty ignition coil winding
(measure resistance of primary and
secondary)
G Worn magneto (RH) end
Crankshaft bearings
G Sheared flywheel key
G Flywheel loose or damaged
G Excessive crankshaft runout on
magneto (RH) end - should not
exceed .005″
G Faulty CDI module
2004 ATP 500 -- CDI 2004--2005 ATP 330 & 2005

CRANKING OUTPUT TEST ATP 500 -- CDI OUTPUT TEST
USING PEAK READING
The following peak voltage tests will measure the
amount of output directly from each component. A ADAPTOR OR A VOLT METER
peak reading voltmeter must be used to perform the
tests. A variety of peak reading adaptors are 330 ATP
commercially available for use with the Fluket 77
Digital Multimeter (PV--43568), which will allow peak
voltage tests to be performed accurately. Follow the
directions provided with the adaptor. All
measurements are indicated in DC Volts. Readings
obtained without a peak reading adaptor will be
significantly different.
Test output from the CDI and pulse (trigger) coil and
compare to the table. The following measurements A
are obtained when cranking the engine with the
electric starter, spark plug installed. The starter
system must be in good condition and the battery fully
charged. Re-connect all CDI wires to stator wires. Disconnect
CDI module wire from ignition coil primary terminal.
Connect one meter lead to engine ground and the
2004 ATP 500 -- 250 Watt 4 Stroke
other to the ignition coil primary wire leading from the
CDI module (A). Crank engine and check output of
Coil Connect Meter Reading CDI wire to coil. Reconnect coil wire to CDI.
Wires To: (Without Peak
Reading Volt me- NOTE: See wiring schematic for static Ohms test
ter) readings.
Exciter 1 Black/Red and 34 DCV Test Connect Meter Reading

Red Wires To:
Pulse White/Red and 3.3 DCV 330 -- CDI White/Blue to 200 DCV ± 20%
(Trigger) White Output Ground
Perform this test using a multimeter and with the ATV 500 -- CDI White/Blue to 500 DCV ± 20%
off. All readings are in ohms. Output Ground
10.21
ELECTRICAL
2005 ATP 330 & 500 -- CDI

Current Draw Inspection
CRANKING OUTPUT TEST
Key Off
The following peak voltage tests will measure the
amount of output directly from each component. A
peak reading voltmeter can be used to perform the
tests. A variety of peak reading adaptors are
commercially available for use with the Fluke t 77 + --
Digital Multimeter (PV--43568) and other digital VOMs
which will allow peak voltage tests to be performed
accurately. Follow the directions provided with the
adaptor. All measurements are indicated in DC Volts.
Readings obtained without a peak reading adaptor will
Ill. 1
be significantly different.
Disconnect the stator connectors from the CDI
module. Test output from the detection and pulse Current Draw - Key Off:
(trigger) coil, and compare to the chart. The following Maximum of .01 DCA (10 mA)
measurements were obtained when cranking the
engine with the electric starter, spark plug installed.
The starter system must be in good condition and the
battery fully charged.
200 & 240 Watt 4 Stroke DC/CDI Ignition
Test Connect Reading Reading

Meter (With (With Peak
Wires To: VOM) Reading
Adapter)
Pulse Coil White/Red 0.15 Volts 4.5 Volts
and White AC DC
CURRENT DRAW - KEY OFF

CAUTION: Do not connect or disconnect the battery
cable or ammeter with the engine running. Damage
will occur to electrical components.
Connect an ammeter in series with the negative
battery cable. Check for current draw with the key off.
If the draw is excessive, loads should be
disconnected from the system one by one until the
draw is eliminated. Check component wiring as well
as the component for partial shorts to ground to
eliminate the draw.
Refer to Illustration 1 on the next page.
10.22
ELECTRICAL
2004 ATP 500 -- CHARGING 2004 ATP 500--ALTERNATOR

SYSTEM “BREAK EVEN” OUTPUT TEST (AC AMP)
TEST This test measures AC amperage from the alternator.
CAUTION: Do not allow the battery cable or CAUTION: This test simulates a “full load” on the
ammeter to become disconnected with the alternator at idle. Do not increase idle RPM or perform
engine running. Follow the steps below as this test longer than required to obtain a reading. The
outlined to reduce the chance of damage to alternator stator windings may overheat. 3--5
electrical components. seconds is acceptable.
WARNING: Never start the engine with the ammeter
connected in series. Damage to the meter or meter To Calculate Available Alternator Output
fuse will result. Do not run test for extended period of
time. Do not run test with high amperage accessories. 200W
P
I = = 16.7 Amps
The “break even” point of the charging system is the E 12V
point at which the alternator overcomes all system
loads (lights, etc.) and begins to charge the battery. 250W
= 20.8 Amps
Depending on battery condition and system load, the 12V
break even point may vary slightly. The battery should
be fully charged before performing this test. I = Current in Amps
P = Power in Watts
1. Connect a tachometer according to manufacturer’s E = Electromotive Force (Volts)
instructions.
2. With the negative cable still connected to the 1. Maximum alternator output will be indicated on the
battery, connect one meter lead (set to DC amps) meter. DO NOT increase engine RPM above idle.
to the battery post and the other to the negative
battery cable 2. Place the red lead on the tester in the 10A jack.
3. With engine off and the key and kill switch in the 3. Turn the selector dial to the AC amps position.
ON position, the ammeter should read negative 4. Connect the meter leads to the wires leading from
amps (battery discharge). Reverse meter leads if the alternator (see schematic for proper wire
a positive reading is indicated. colors).
4. Shift transmission into neutral and start the engine. 5. Start the engine and let it idle. See proper reading
With the engine running at idle, disconnect the below for each model.
negative cable from the battery post without
disturbing the meter leads. Observe meter readings
Alternator Current Output:
5. Increase engine RPM while observing ammeter
and tachometer.
500: Minimum of 7 AC Amps at Idle
6. Note RPM at which the battery starts to charge
(ammeter indication is positive).
7. With lights and other electrical load off, the “break
even” point should occur at approximately 1500
2004--2005 ATP 330 & 2005
RPM or lower. ATP 500 -- CHARGING
8. Turn the lights on and engage parking brake lock
to keep brake light on.
SYSTEM “BREAK EVEN”
9. Repeat test, observing ammeter and tachometer. TEST
With lights on, charging should occur at or below
2000 RPM. CAUTION: Do not allow the battery cables to
become disconnected with the engine running.
Follow the steps below as outlined to reduce the
chance of damage to electrical components.
The “break even” point of the charging system is the
point at which the alternator overcomes all system
loads (lights, etc.) and begins to charge the battery.
Depending on battery condition and system load, the
10.23
ELECTRICAL
break even point may vary slightly. The battery should TEST 1: Resistance Value of Each Stator Leg
be fully charged before performing this test.
1. Measure the resistance value of each of the three
WARNING: Never start the engine with an ammeter stator legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3.
connected in series. Damage to the meter or meter Each should measure: 330 -- 0.50 Ω
fuse will result. Do not run test for extended period of 500 -- 0.43 Ω
time. Do not run test with high amperage accessories.
1. Connect a tachometer to the engine. Test Connect Me- Reading In
ter Wires To: Ohms
2. Using an inductive amperage metering device,
(set to DC amps) connect to the negative battery 330 -- Charge Coil Yel to Yel 0.50 Ω ± 20%
cable 330 -- Charge Coil Yel to Grnd Open
3. With engine off and the key, kill switch, and lights
500 -- Charge Coil Yel to Yel 0.43 Ω ± 20%
in the ON position, the ammeter should read
negative amps (battery discharge). Reverse 500 -- Charge Coil Yel to Grnd Open
meter lead if a positive reading is indicated.
4. Shift transmission into Park and start the engine. 2. When measuring any of the Yellow wires to
With the engine running at idle, observe meter ground, the reading should be infinite (open).
readings. NOTE: If there are any significant variations in ohm’s
5. Increase engine RPM while observing ammeter readings between the three legs; it is an indication that
and tachometer. one of the three stator legs maybe weak or failed.
6. Note RPM at which the battery starts to charge
(ammeter indication is positive). TEST 2: Resistance Value of Stator Leg to Ground
7. With lights and other electrical loads off, the 1. Measure the resistance value of each of the stator
“break even” point should occur at approximately legs to ground: Y1 to Ground, Y2 to Ground, Y3 to
1500 RPM or lower. Ground.
8. With the engine running, turn the lights on and NOTE: Any measurement other than Infiniti (open)
engage parking brake lock to keep brake light on. will indicate a failed or shorted stator leg.
9. Repeat test, observing ammeter and tachometer.
With lights on, charging should occur at or below TEST 3: Measure AC Voltage Ouput of Each
2000 RPM. Stator Leg at Charging RPM
2004--2005 ATP 330 & 2005 1. Set the selector dial to measure AC Voltage.
2. Start the engine and let it idle.
ATP 500 -- ALTERNATOR 3. While holding the ATV at a specified RPM,
OUTPUT TEST (AC AMP) separately measure the voltage across each ’leg’
of the stator by connecting the meter leads to the
Three tests can be performed using a multimeter to wires leading from the alternator (Y1 to Y2, Y1 to
determine the condition of the stator (alternator). Y3, Y2 to Y3).
4. Refer to the table below for approximate Voltage
(3 Stator Wires are Yellow) AC readings according to RPM. Test each leg at
Y1 the specified RPM in the table. Example: The
Y2 alternator current output reading should be
Y3 approximately 17 Vac at 1300 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.
ATV RPM AC Voltage (Vac)

Reading Reading
1300 17 Vac ± 25 %
3000 40 Vac ± 25 %
5000 65 Vac ± 25 %
10.24
ELECTRICAL
FLYWHEEL IDENTIFICATION
Flywheel Identification Stamp Location

The flywheel can be identified by the stamp mark in location A. Refer to “I.D.” location in chart below. Do not
use the cast mark to determine flywheel application.
Engine Application Type Cast Stamp Comment I.D. Stamp

ATP 330 -- ES320PFE N/A N/A N/A 210W N/A
ATP 500 -- EH500PLE N/A N/A N/A 240W N/A
DC / CDI IGNITION
The ATP has incorporated into it’s design a DC/ CDI At the CDI, 12 volt DC current charges an internal
ignition system. capacitor to build up the initial ignition charge. A small
A/C signal from the Trigger (Pulse) coil closes a
Some of the advantages of DC ignition are:
thyristor (located in the CDI) at a point
G Stronger, more consistent spark at pre--determined in the crankshaft rotation by magnets
low rpm for better performance on the flywheel’s outer diameter. This signal releases
G Easier starts the electrical charge which saturates the coil for
G Simpler component design for ease ignition. DC/CDI systems have the ability to ignite
of trouble shooting and maintenance with as little as 6 volts of power.
Operation Overview:
The DC/CDI system relies on battery power for ignition. NOTICE: Do not remove the wiring
Instead of generating DC voltage via magnetic harness from the CDI box while the key
induction, a 12 volt DC current is supplied directly to the switch is on or while the engine is
CDI unit from the battery. running. Damage to the CDI box may
occur!
NOTE: Maximum Timing 500 Maximum Timing 330
DC/CDI systems and compo-

nents are not interchangeable
with any other system.
10.25
ELECTRICAL
COMPONENTS OF ES320PFE 210 WATT ALTERNATOR

DC/CDI IGNITION -- 2004--2005 ATP 330
330 MODELS
Note: DC/CDI components are not compatible with any other type of ignition
Refer To Wiring Diagrams For
Specified Stator Coil Resistance Ω Ignition Coil
Meter
Primary
NOTICE: Do not remove .3 Ω
the wiring harness from Ignition Kill
Coil Lead Winding
the CDI box while the key Wire
switch is on or while the (Black)
engine is running. Dam-
age to the CDI box may Resistor
occur! Cap
12 Volt DC
Supply Wire
(Red) Ω
Meter
10.5KΩ
Secondary Coil
Check coil mount to verify
CDI Box
Pulse Coil (Trigger) ground to engine (0-.2 Ω )
Air Gap: .016-.030″
(.4-.75mm) Ω
Meter
520Ω
2004 ATP --
Magnetic Switch
2005 ATP --
Magnetic Switch
Stator Plate
Battery Charge Coils
Flywheel and
Ring Gear Casting
10.26
ELECTRICAL
COMPONENTS OF EH500PLE / 250 WATT ALTERNATOR -- 2004

ATP 500
NOTE: CDI boxes may look the same but have

different internal circuitry. Be sure to always use
the correct CDI box part number. Ignition Coil
Primary Winding Resistor
Refer To Wiring Diagrams For Cap
Specified Stator Coil Resistance Meter
.3 Ω
Ignition Kill
Wire
(Black)
Coil Lead 250 W

(2 Wires)
Ignition
Coil
Meter
10.5k Ω
Pulse Coil (Trigger)
Air Gap: .016-.030″
(.4 - .75 mm) Check coil mount for good
Stator ground to engine (0-.2Ω )
CDI Box Plate
2004 ATP --
Magnetic
Switch
Ignition Exciter
Coils
Battery Charging
Coils
Flywheel and
Ring Gear Casting
10.27
ELECTRICAL
COMPONENTS OF EH50PLE / 250 WATT ALTERNATOR (DC/CDI

IGNITION) -- 2005 ATP 500
NOTE: CDI boxes may look the same but have

different internal circuitry. Be sure to always use
the correct CDI box part number.
Refer To Wiring Diagrams For

Specified Stator Coil Resistance
Resistor
Cap
Check coil mount for good

ground to engine (0-.2Ω )
Ignition
Coil
Meter
10.5k Ω
Stator
Plate
CDI Box
Pulse Coil (Trigger)

Air Gap: .016-.030″
(.4 - .75 mm)
2005 ATP -- Magnetic Switch
Battery Charging
Coils
Flywheel
10.28
ELECTRICAL
IGNITION SYSTEM TESTING

Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they
are clean and tight. Also be sure that colors match when wires are connected. Use the following pages as a guide
for troubleshooting. The resistance values are also given on the specification pages.
Condition: No Spark or intermittent spark
Verify 12 Volt DC power is present on the white/blue wire to CDI. Replace Spark Plug.
Disconnect the black wire at the CDI module to

isolate the ignition from the kill system. Verify -Test the ignition switch, engine stop
the CDI has a good ground (brown) for opera- switch, and speed limiter circuit for
tion. Yes shorts to ground.
-Check connectors for moisture,
Does it have spark? wire color matching or corrosion.
No
Verify that 12 VDC power is getting to the CDI Inspect connectors, wiring and
module. Refer to the wiring schematic for meter grounds to the component in ques-
connections and specifications. Compare results tion. Replace the component if a
to the specifications on the exploded views. Are No
wiring problem cannot be found.
all within specifications?
Yes
Check coil ground connection between engine and coil Clean coil mounting area.
mount using an ohmmeter. The coil mount should No
Repair ground wire connections.
have good continuity to ground on the engine (0-.2 Ω).
Yes
Disconnect and check the secondary coil. Resis-

tance values should be:
Primary Side - Primary Wire Tab to Ground
(on coil mount or engine): .3 to .5 Ohms
Secondary Side High Tension Wire to engine
ground- Cap installed - 10,500Ω No Replace the ignition coil.
Cap removed - 6300Ω
Are these values within specs?
Yes
If all of the above tests are within specifications, and all grounds, connections, and wire color coding
have been inspected, perform voltage output tests on following page or replace the CDI module.
10.29
ELECTRICAL
CHARGING SYSTEM TESTING FLOW CHART

Whenever charging system problems are suspected, proceed with the following system check.
Using a multitester set on D.C. volts, mea-

sure the battery open circuit voltage (See Remove the battery and properly ser-
Page 10.33). It should be 12.4 volts or vice. Reinstall the fully charged battery
more. Is it? No
or a fully charged shop battery.
Yes
Meter Setting: DC Volts

With the transmission in neutral, start the
engine and increase RPM to between 3000
and 4000. Read battery voltage with the Check Key off Current Draw
multitester. Readings should increase to be- Yes
tween 13.0 and 14.6 V D.C. Are they?
No
Meter Setting: DC Amps Check for owner modification, and

Perform system “Break Even Amperage” discuss operating habits. The battery
test outlined on previous pages. will continually discharge if operated
Yes
below the “Break Even” RPM. Con-
Does charging occur as specified? tinued problems would call for battery
inspection.
No
Ohm stator wire (white) If bad replace, if good,

continue with alternator output test.
Meter Setting: AC Amps
Disconnect the alternator wires leading from Inspect the wiring harness be-
the regulator/rectifier. Using a multitester, per- tween the panel and the stator for
form an Alternator Output (AC amp) test. damage. If no damage is found,
See test procedure on previous pages for pro- No remove the recoil and flywheel.
cedure. Inspect the flywheel magnets, sta-
Is output above ?? Vac for 330 (see chart Pg. tor coils and stator wire harness
10.24 for Vac readings)? for damage. Repair or replace
Is output above ?? Vac for 500? (see chart any damaged components.
Pg. 10.24 for Vac readings)?
Yes
Meter Setting: DC Volts
Reconnect the alternator wires. Note: Red
Check regulator/rectifier connections
wire must be connected to harness. Battery
No and ground, battery connections, cir-
voltage must be present on red wire terminal
cuit breaker and connecting wires.
on harness side of voltage regulator connector.
Repair or replace faulty wiring or
components.
Is it?
Yes
If all of the previous tests indicate a

good condition, but the charging voltage
does not rise above battery voltage at the
connector or wire harness, replace the volt-
age regulator.
10.30
ELECTRICAL
BATTERY IDENTIFICATION SEALED LOW MAINTENANCE

NOTICE: It is important to identify what type of BATTERY
battery you have installed in your ATP. Different types
of batteries require different service procedures. NOTE: All Low Maintenance batteries are fully
Proper servicing and upkeep of your battery is very charged and tested at the factory before
important for maintaining long battery life. installation. Expected shelf life varies on storage
Your ATP may have a Conventional Battery or a conditions. As a general rule before placing the
Sealed Low Maintenance Battery. To identify which battery into service, check the battery condition
type of battery your ATP has, refer to the illustration and charge accordingly.
below and follow the correct service and charging Battery Check:
procedures that follow in the manual.
1. Check the date label on the side of the battery to
CONVENTIONAL BATTERY calculate when to check voltage. The battery
should be checked every 3 months.
2. Check the voltage with a voltmeter or multimeter.
Removable
A fully charged batter should be 12.8 V or
Caps higher.
3. If the voltage is below 12.8 V, the battery will need
to be recharged.
Top View
Electrolyte Level
Indicator
Side View
SEALED LOW
MAINTENANCE BATTERY
No Caps New Batteries: Batteries must be fully charged
(Non--removable before use or battery life can be reduced by
sealed top) 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
Top View battery charger can cause battery damage.
Low Maintenance batteries are permanently
sealed at the time of manufacture. The use of
lead--calcium and AGM technology instead of
lead--antimony allows the battery acid to be fully
Polaris sticker absorbed. For this reason, a Low Maintenance
battery case is dark and the cell caps are not
removable, since there is no need to check
electrolyte level.
NEVER attempt to add electrolyte or water to a Low
Maintenance battery. Doing so will damage the
Side View case and shorten the life of the battery. Refer to the
Battery Activation and Maintenance Video (PN
10.31
ELECTRICAL
9917987) for proper instruction on servicing Low 25--50% 11.5--12.0 V Needs At least 13
Maintenance batteries. Charge hours,
NEVER attempt to add electrolyte or water to a Low verify state
Maintenance battery. Doing so will damage the of charge
case and shorten the life of the battery. Refer to the 0--25% 11.5 V or Needs At least 20
Battery Maintenance Video (PN 9917987) for proper less Charge hours
instruction on servicing Low Maintenance
batteries.
How To service a Low Maintenance battery: SEALED LOW MAINTENANCE
1. Remove battery from the vehicle BATTERY INSPECTION/
2. Test battery with a voltage meter or load tester to
determine battery condition. This will determine REMOVAL
the length of time required to charge the battery to
full capacity. Refer to capacity table. The battery is located under the seat.
3. Charge battery using a variable rate charger.
Battery
Location
SEALED LOW MAINTENANCE
BATTERY CHARGING
If battery voltage is 12.8 V or less, the battery may
need recharging. When using an automatic charger,
refer to the charger manufacturer’s instructions for
recharging. When using a 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 1. Disconnect holder strap and remove cover.
becomes very warm to the touch. Allow it to cool
before resuming charging. 2. Disconnect battery negative (-) (black) cable first,
followed by the positive (+) (red) cable.
Battery Charging Reference Table
CAUTION
State of Voltage Action Charge
Charge Time (*See Whenever removing or reinstalling the battery,
note below) disconnect the negative (black) cable first and
100% 12.8--13 V None, None Re- reinstall the negative cable last!
check volt- quired 3. Remove the battery.
age at 3
mos. after
manufac- SEALED LOW MAINTENANCE
ture date
75--100% 12.5--12.8 V May need 3--6 hours BATTERY INSTALLATION
slight
charge 1. Clean battery cables and terminals with a stiff wire
brush. Corrosion can be removed using a
50--75% 12.0--12.5 V Needs 5--11 hours solution of one cup water and one tablespoon
Charge baking soda. Rinse well with clean water and dry
thoroughly.
2. Route the cables correctly.
10.32
ELECTRICAL
3. Reinstall battery, attaching positive (+) (red) cable SEALED LOW MAINTENANCE
first and then the negative (-) (black) cable. Coat
terminals and bolt threads with Nyogelt Grease BATTERY LOAD TEST
(PN 2871329).
4. Reinstall the holder strap. CAUTION: To prevent shock or component
damage, remove spark plug high tension leads
and connect securely to engine ground before
SEALED LOW MAINTENANCE proceeding.
NOTE: This test can only be performed on machines
BATTERY TESTING with electric starters. This test cannot be performed
with an engine or starting system that is not working
Whenever a service complaint is related to either the properly.
starting or charging systems, the battery should be
A battery may indicate a full charge condition in the OCV
checked first. test and the specific gravity test, but still may not have
Following are three tests which can easily be made on the storage capacity necessary to properly function in
a battery to determine its condition: OCV Test, the electrical system. For this reason, a battery capacity
Specific Gravity Test and Load Test. 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
SEALED LOW MAINTENANCE or greater. Engage the starter and observe the battery
BATTERY -- OCV - OPEN voltage while cranking the engine. Continue the test for
15 seconds. During cranking the observed voltage
CIRCUIT VOLTAGE TEST should not drop below 9.5 volts. If the beginning voltage
is 12.6 volts or higher and the cranking voltage drops
Battery voltage should be checked with a digital below 9.5 volts during the test, replace the battery.
multitester. Readings of 12.8 volts or less require
further battery testing and charging. See charts and
Load Test. SEALED LOW MAINTENANCE
NOTE: Lead-acid batteries should be kept at or near BATTERY OFF--SEASON
a full charge as possible. If the battery is stored or
used in a partially charged condition, or with low
STORAGE
electrolyte levels, hard crystal sulfation will form on To prevent battery damage during extended periods
the plates, reducing the efficiency and service life of of non-use, the following basic battery maintenance
the battery. items must be performed:
NOTE: Use a voltmeter or multimeter to test batter G Remove the battery from the
voltage. machine and wash the case and
battery tray with a mild solution of
OPEN CIRCUIT VOLTAGE baking soda and water. Rinse with
State of Maintenance YuMicront lots of fresh water after cleaning.
charge Free Type G Using a wire brush or knife, remove
100% 13.0V 12.70V any corrosion from the cables and
75% Charged 12.80V 12.50V terminals.
50% Charged 12.50V 12.20V G Charge at a rate no greater than 1/10
25% Charged 12.20V 12.0V of the battery’s amp/hr capacity until
0% Charged less than 12.0V less than 11.9V the voltage reaches 13.0VDC or
* At 80_F greater.
NOTE: Subtract .01 from the specific gravity reading at 40_ F.
G Store the battery either in the
machine with the cables
disconnected, or store in a cool
place.
10.33
ELECTRICAL
NOTE: Stored batteries lose their charge at the rate Conventional Lead--Acid batteries and Sealed Low
of up to 1% per day. Recharge to full capacity every Maintenance batteries. Before service, identify the
30 to 60 days during a non-use period. If the battery battery type in the vehicle. Use the section that
is stored during the winter months, electrolyte will applies to the battery.
freeze at higher temperatures as the battery
discharges. The chart below indicates freezing points
by specific gravity.
Electrolyte Freezing Points

WARNING
Specific Gravity Freezing
of Electrolyte Point Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from con-
1.265 -75° F tact with skin, eyes or clothing. Antidote:
1.225 -35° F
External: Flush with water.
1.200 -17° F
Internal: Drink large quantities of water or milk.
1.150 +5° F
Follow with milk of magnesia, beaten egg, or
1.100 +18° F vegetable oil. Call physician immediately.
1.050 +27° F Eyes: Flush with water for 15 minutes and get
prompt medical attention.
SEALED LOW MAINTENANCE Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc. away. Ventilate
BATTERY CHARGING when charging or using in an enclosed space.
Always shield eyes when working near batter-
PROCEDURE ies. KEEP OUT OF REACH OF CHILDREN.
1. Remove the battery from the ATV to prevent WARNING:The gases given off by a battery are
damage from leaking or spilled acid during explosive. Any spark or open flame near a battery can
charging. cause an explosion which will spray battery acid on
2. Charge the battery with a variable rate charging anyone close to it. Should there be contact with
output. Charge as needed to raise the voltage to battery acid, wash the affected area with large
12.8VDC or greater. quantities of cool water and seek immediate medical
3. Install battery in vehicle with positive terminal attention.
toward the front. Coat threads of battery bolt with NOTE: New Battery: Battery must be fully charged
a corrosion resistant Nyogelt Grease (PN before use or battery life will be significantly reduced
2871329). 10-30% of the battery’s full potential.
4. Route cables so they are tucked away in front and
behind battery. To activate a new battery:
5. Connect battery cables. 1. Remove vent plug from vent fitting. Remove cell
caps.
WARNING
2. Fill battery with electrolyte to upper level marks on
To avoid the possibility of sparks and explosion, case.
connect positive (red) cable first and negative (black) 3. Set battery aside to allow for acid absorption and
cable last. stabilization for 30 minutes.
6. After connecting the battery cables, install the 4. Add electrolyte to bring level back to upper level
cover on the battery and attach the hold down mark on case. NOTE: This is the last time that
strap. 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.
CONVENTIONAL BATTERY Examples: 1/10 of 9 amp battery = .9 amp; 1/10
of 14 amp battery = 1.4 amp; 1/10 of 18 amp
ACTIVATION/ SVC battery = 1.8 amp (recommended charging
To ensure maximum service life and performance rates).
from a battery, perform the following steps.
NOTE: This section contains information for both
10.34
ELECTRICAL
6. Check specific gravity of each cell with a

hydrometer to assure each has a reading of 1.270 CAUTION
or higher. Whenever removing or reinstalling the battery,
disconnect the negative (black) cable first and
reinstall the negative cable last!
BATTERY
3. Remove the battery.
TERMINALS/TERMINAL BOLTS 4. Remove the filler caps and add distilled water
Use Polaris corrosion resistant Nyogelt grease (PN only as needed to bring each cell to the proper
2871329) on battery bolts. See Battery Installation on level. Do not overfill the battery.
Page 10.35.
Refill using only distilled water. Tap water
contains minerals which are harmful to a battery.
CONVENTIONAL BATTERY
Do not allow cleaning solution or tap water inside
INSPECTION/REMOVAL the battery. Battery life may be reduced.
The battery is located under the seat. 5. Reinstall the battery caps.
INSTALLATION
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 Nyogelt Grease
(PN 2871329).
4. Install clear battery vent tube from vehicle to battery
vent. WARNING: Vent tube must be free from
Inspect the battery fluid level. When the battery fluid obstructions and kinks and securely installed. If not,
nears the lower level, remove the battery and fill with battery gases could accumulate and cause an
distilled water only to the upper level line. To remove explosion. The vent tube should be routed away
the battery: from frame and body to prevent contact with
electrolyte. Avoid skin contact with electrolyte, as
severe burns could result. If electrolyte contacts the
vehicle frame, corrosion will occur.
5. Reinstall the holder strap.
Maintain
between upper CONVENTIONAL BATTERY
and lower level
marks TESTING
Whenever a service complaint is related to either the
starting or charging systems, the battery should be
checked first.
Following are three tests which can easily be made on
1. Disconnect holder strap and remove covers. a battery to determine its condition: OCV Test,
2. Disconnect battery negative (-) (black) cable first, Specific Gravity Test and Load Test.
followed by the positive (+) (red) cable.
10.35
ELECTRICAL
CONVENTIONAL BATTERY OPEN CIRCUIT VOLTAGE

OCV - OPEN CIRCUIT State of Conventional YuMicront
charge Lead-acid Type
VOLTAGE TEST 100% 12.60V 12.70V
Charged 12.40V 12.50V
Battery voltage should be checked with a digital 75% Charged 12.10V 12.20V
multitester. Readings of 12.6 volts or less require 50% Charged 11.90V 12.0V
further battery testing and charging. See charts and 25% Charged less than less than 11.9V
Load Test on below. 0% Charged 11.80V
NOTE: Lead-acid batteries should be kept at or near
a full charge as possible. Electrolyte level should be SPECIFIC GRAVITY
kept between the low and full marks. If the battery is State of Conventional YuMicront
stored or used in a partially charged condition, or with charge* lead-acid Type
low electrolyte levels, hard crystal sulfation will form 100% 1.265 1.275
on the plates, reducing the efficiency and service life Charged 1.210 1.225
of the battery. 75% Charged 1.160 1.175
50% Charged 1.120 1.135
25% Charged less than 1.100 less than 1.115
CONVENTIONAL BATTERY 0% Charged
SPECIFIC GRAVITY TEST * At 80_F
NOTE: Subtract .01 from the specific gravity reading at 40_ F.
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 LOAD TEST
charge/discharge cycle, the electrolyte goes from a
heavy (more acidic) state at full charge to a light (more CAUTION: To prevent shock or component
water) state when discharged. The hydrometer can damage, remove spark plug high tension leads
measure state of charge and differences between and connect securely to engine ground before
cells in a multi-cell battery. Readings of 1.270 or proceeding.
greater should be observed in a fully charged battery. NOTE: This test can only be performed on machines
Differences of more than .025 between the lowest and with electric starters. This test cannot be performed
highest cell readings indicate a need to replace the with an engine or starting system that is not working
battery. properly.
A battery may indicate a full charge condition in the OCV
test and the specific gravity test, but still may not have
the storage capacity necessary to properly function in
the electrical system. For this reason, a battery capacity
Battery Hydrometer (PN 2870836) 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
1.10 done in the OCV test. The reading should be 12.6 volts
1.15 or greater. Engage the starter and observe the battery
Detail A voltage while cranking the engine. Continue the test for
1.20
15 seconds. During cranking the observed voltage
1.25 should not drop below 9.5 volts. If the beginning voltage
1.30 is 12.6 volts or higher and the cranking voltage drops
below 9.5 volts during the test, replace the battery.
Continued on next page
10.36
ELECTRICAL
CONVENTIONAL BATTERY CONVENTIONAL BATTERY

OFF SEASON STORAGE CHARGING PROCEDURE
To prevent battery damage during extended periods 1. Remove the battery from the ATV to prevent
of non-use, the following basic battery maintenance damage from leaking or spilled acid during
items must be performed: charging.
G Remove the battery from the 2. Charge the battery with a charging output no
machine and wash the case and larger than 1/10 of the battery’s amp/hr rating.
battery tray with a mild solution of Charge as needed to raise the specific gravity to
baking soda and water. Rinse with 1.270 or greater.
lots of fresh water after cleaning. 3. Install battery in vehicle with positive terminal
NOTE: Do not get any of the baking toward the front. Coat threads of battery bolt with
soda into the battery or the acid will a corrosion resistant dielectric grease.
be neutralized.
G Using a wire brush or knife, remove
any corrosion from the cables and Dielectric Grease
terminals.
(PN 2871329)
G Make sure that the electrolyte is at
the proper level. Add distilled water
if necessary. 4. Connect battery cables.
G Charge at a rate no greater than 1/10
of the battery’s amp/hr capacity until WARNING
the electrolyte’s specific gravity
To avoid the possibility of explosion, connect positive
reaches 1.270 or greater.
(red) cable first and negative (black) cable last.
G Store the battery either in the
machine with the cables 5. After connecting the battery cables, install the
disconnected, or store in a cool cover on the battery and attach the hold down
place. strap.
6. Install clear battery vent tube from vehicle to
NOTE: Stored batteries lose their charge at the rate battery vent. WARNING: Vent tube must be free
of 1% per day. Recharge to full capacity every 30 to from obstructions and kinks and securely
60 days during a non-use period. If the battery is installed. If not, battery gases could accumulate
stored during the winter months, electrolyte will freeze and cause an explosion. Vent should be routed
at higher temperatures as the battery discharges. away from frame and body to prevent contact with
The chart below indicates freezing points by specific electrolyte. Avoid skin contact with electrolyte, as
gravity. severe burns could result. If electrolyte contacts
the vehicle frame, corrosion will occur.
Electrolyte Freezing Points
Specific Gravity Freezing behind battery.
of Electrolyte Point
8. Reinstall battery, attaching positive (+) (red) cable
1.265 -75° F first and then the negative (-) (black) cable. Coat
1.225 -35° F terminals and bolt threads with Dielectric Grease
1.200 -17° F (PN 2871329).
1.150 +5° F 9. (Conventional Lead/Acid Batteries Only) Install
clear battery vent tube from vehicle to battery vent.
1.100 +18° F WARNING: Vent tube must be free from
1.050 +27° F obstructions and kinks and securely installed. If not,
battery gases could accumulate and cause an
explosion. Vent should be routed away from frame
and body to prevent contact with electrolyte. Avoid
skin contact with battery electrolyte, severe burns
could result. If electrolyte contacts the vehicle
frame, corrosion will occur.
behind battery.
10.37
ELECTRICAL
11. Reinstall battery cover and holder strap.
Do not run the engine with the battery

disconnected. Electrical components can become
damaged.
HIGH BEAM HEADLIGHT

BULB REPLACEMENT (ATP
500)
CAUTION: Do not service while headlight is hot.
Serious burns may result. Protect lamp during install. 6. Carefully remove headlamp bulb from housing.
7. Reverse procedure to install new headlamp bulb.
Remove 3 screws
HEADLIGHT HOUSING
REPLACEMENT
1. Remove three Phillips screws on the headlight
pod.
2. Lift pod cover up. Unplug instrument cluster from
harness.
3. Unplug headlamp from wiring harness.
4. Remove O-Ring from headlight pivot pins.
5. Pull the headlight housing up to release from the
locking tabs.
Position Snap pins

knob in into tabs
slot and
secure
1. Remove three Phillips screws on the headlight in lock-
pod. ing tabs
2. Lift pod cover up.
3. Disconnect instrument cluster harness. Route
4. Remove rubber shield from headlamp housing. Adjustment plug over
Knob Stop handlebar
5. Push in and turn plastic retainer counter
clockwise and remove.
6. Lift the adjusting knob up to remove from the

locking tabs.
10.38
ELECTRICAL
7. Carefully pull the assembly up and out of pod.

25’ (7.6 m)
Lamp Center Height
2″ (5.1 cm)
2. Measure the distance from the floor to the center

8. Reverse the steps to install the new housing and of the headlight and make a mark on the wall at
reassemble the pod. the same height.
3. Start the engine and turn the headlight switch to
high beam.
4. Observe headlight aim. The most intense part of
the headlight beam should be aimed 2″ (5.1 cm)
below the mark placed on the wall in Step 2
NOTE: Rider weight must be included on the
seat. On machines with separate low beam
lights, the drop should be 8″ (20.3 cm) in 25’ from
the center of the low beam lamp.
5. Adjust beam to desired position .
5 1/8″
(13 cm)
LOWER HEADLAMP
REMOVAL/INSTALLATION
NOTE: The distance from the headlamp parting line
to the end of the adjustment knob stop is 5 1/8, (13
cm). See illustration. Lower Headlamps
9. Adjust the headlight aim by turning the adjusting

knob. Turn Harness Assembly
HIGH BEAM HEADLIGHT Loosen

Tighten
ADJUSTMENT
The headlight beam can be adjusted to any position
desired by turning the adjusting knob located on the
Headlamp
bottom right side of the headlight pod. Adjustments
1. Place the vehicle on a level surface with the
headlight approximately 25’ (7.6 m) from a wall.
10.39
ELECTRICAL
1. Turn the back of the headlight harness in a BRAKE LIGHT SWITCH

counter--clockwise direction to loosen.
2. Pull the harness assembly out from the headlight 1. Remove the front cover.
assembly.
3. Remove the headlamp and replace with a new Brake Light
headlamp. Switch Location
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. Front of Frame
4. Install the new headlamp and harness assembly

into the headlight assembly. Turn the headlight
harness clockwise to secure the headlamp into
place.
5. Adjust headlight aim by turning adjusting bolts.
TAILLIGHT/BRAKELIGHT
LAMP REPLACEMENT
If the taillight/brakelight does not work the lamp may Brake Lamp Switch
need to be replaced.
2. Disconnect wire harness from switch.
3. Connect an ohmmeter across switch contacts.
Reading should be infinite (∞).
4. Apply brake at handlebar lever and check for
continuity between switch contacts. Replace
switch if there is no continuity or greater than .5
ohms resistance when the brake is applied with
slight pressure.
NOTE: If replacing the brake lamp switch, apply pipe
Screw locations
sealant to the threads.
1. At the inside panel by the tail gate latch, remove

the two screws holding lens assembly in place.
2. Remove lamp and replace with new
recommended lamp. Always apply Nyogelt
Grease (PN 2871329) to the contacts before
assembly.
3. Reinstall the lens assembly removed in step 1.
4. Test the taillight/brakelight to see it is working.
HEADLAMP SWITCH
Probe the headlamp plug wires at back of connector.
Turn headlight on. Test for battery voltage across the
connections.
G 330 -- Brown and Green
G 500 Low Beam -- Brown and Green
G 500 High Beam -- Brown and Yellow
10.40
ELECTRICAL
STARTER SYSTEM
TROUBLESHOOTING
Starter Motor Does Not Turn
G Battery discharged. Low specific
gravity
G Loose or faulty battery cables or
corroded connections (see Voltage
Drop Tests)
G Related wiring loose, disconnected,
or corroded
G Poor ground connections at battery
cable, starter motor or starter
solenoid (see Voltage Drop Tests)
G Faulty key switch
G Faulty kill switch
G Faulty starter solenoid or starter
motor.
G Engine problem - seized or binding
(Can engine be rotated easily with
recoil starter?)
G NOTE: The ATP 330 will not pull
start or key start if the battery is
disconnected or completely dead.
Starter Motor Turns Over Slowly
G Battery discharged - low specific
gravity
G Excessive circuit resistance - poor
connections (see Voltage Drop Test
below)
G Engine problem - seized or binding
(Can engine be rotated easily?)
G Faulty or worn brushes in starter
motor
G Automatic compression release
inoperative
Starter Motor Turns - Engine Does Not Rotate
G Faulty starter drive
G Faulty starter drive gears or starter
motor gear
G Faulty flywheel gear or loose
flywheel
10.41
ELECTRICAL
STARTER VOLTAGE DROP

TEST
The Voltage Drop Test is used to test for bad
connections. When performing the test, you are
testing the amount of voltage drop through the
connection. A poor or corroded connection will
appear as a high voltage reading. Voltage shown on
the meter when testing connections should not
exceed .1 VDC per connection or component.
To perform the test, place the meter on DC volts and
place the meter leads across the connection to be
tested. Refer to the chart on 10.27 to perform voltage
drop tests on the starter system.
3. Remove brush terminal end of housing while

Voltage should not exceed holding other two sections together.
.1 DC volts per connection
STARTER MOTOR
DISASSEMBLY
NOTE: Use only electrical contact cleaner to clean
starter motor parts. Some solvents may leave a
residue or damage internal parts and insulation.
1. Note the alignment marks on both ends of the
starter motor casing. These marks must align
during reassembly.
4. Remove shims from armature shaft. NOTE: All

shims must be replaced during reassembly.
BRUSH
INSPECTION/REPLACEMENT
Brush Set
2. Remove the two bolts, washers, and sealing

O-Rings. Inspect O-Rings and replace if damaged.
1. Using a digital multitester, measure the resistance

between the cable terminal and the insulated brush.
The reading should be .3 ohms or less.
10.42
ELECTRICAL
2. Measure the resistance between the cable 9. Remove the electrical tape and reinstall the two
terminal and brush housing. Make sure the brush small phenolic washers, the large phenolic
is not touching the case. The reading should be washer, flat washer, and nut.
infinite.
3. Remove nut, flat washer, large phenolic washer,
two small phenolic washers, and O-Ring from ARMATURE TESTING
brush terminal. Inspect the O-Ring and replace if
1. Remove armature from starter casing. Note
damaged.
order of shims on drive end for reassembly.
Brush Length 2. Inspect surface of commutator. Replace if
excessively worn or damaged.
5/16″ (.8 cm)
Brush Length Service Limit:

5/16″ (.8 cm)
4. Remove brush plate and brushes. Measure

length of brushes and replace if worn past the
service limit. Replace springs if they are 3. Using a digital multitester, measure the
discolored or have inadequate tension. resistance between each of the commutator
5. Inspect surface of commutator for wear or segments. The reading should be .3 ohms or
discoloration. See Steps 3-6 of armature testing. less.
6. 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.
7. Place a wrap of electrical tape on the threads of
the terminal bolt to prevent O-Ring damage
during reinstallation.
8. Install the O-Ring over the bolt. Make sure the
O-ring is fully seated.
4. Measure the resistance between each

commutator segment and the armature shaft.
The reading should be infinite (no continuity).
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.
10.43
ELECTRICAL
STARTER ASSEMBLY
Starter Motor Exploded View
Rear Brkt Assy
Carbon
Washer Set Brush
Set
Armature
1. Place armature in field magnet casing. Rubber Rings

2. Place shims on drive end of armature shaft with Washer
O-ring
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 Set Bolt Assy
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.
Weight Spring
4. Install O-Ring on other end of field magnet casing.
Make sure it is in good condition and not twisted
on the case. Return Spring
5. Align casing marks and install housing, pushing
back brushes while installing shaft in bushing.
6. Reinstall starter motor housing bolts. G Method 1 : Screw the overrun clutch out to the
Make sure O-Rings are in good condition and engaged position on the pinion shaft assembly.
seated in groove. Use a small piece of wire with the end bent in a
7. Inspect permanent magnets in starter housing. hook and pick the old spring out of its channel.
Make sure they are not cracked or separated from Slide it off the end of the shaft. Slide the new spring
housing. over the overrun clutch and into the spring groove.
Make sure that the spring is positioned between
CAUTION: Use care when handling starter housing. the shoe alignment pins and the back flange of the
Do not drop or strike the housing as magnet damage anti kick-out shoes.
is possible. If magnets are damaged, starter must be G Remove the lock ring, end washer, spring
replaced. retainers and clutch return spring. Screw the
overrun clutch off the end of the pinion shaft.
STARTER DRIVE Remove the old spring and install a new one.
Lightly grease the pinion shaft and reinstall the
Pinion Gear - Anti Kick-out Shoe, Garter clutch, spring, retainers, end washer and lock ring
in the reverse order. Make sure the end washer is
Spring Replacement
positioned properly so that it will hold the lock ring
If the garter spring is damaged, the overrun clutch in its groove.
may fail to return properly. The replacement spring is
(PN 7042039). Use either of the following methods to
remove and install a new garter spring.
10.44
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.
With the tester on the VDC position, place the tes-

ter’s black lead on the battery negative and the red
lead on the battery positive. Remove battery and properly service.
Install fully charged shop battery to continue
No test.
Reading should be 12.4 V D. C. or greater.
Yes
Check voltage on both sides of circuit

Disconnect White/Red engagement coil wire from breaker, ignition switch/engine stop switch
the starter solenoid. Connect tester black wire to and starter button. The voltage on both
battery ground. Connect red tester lead to White/ sides should be the same. NOTE: The igni-
Red harness wire at solenoid. Turn on ignition tion switch and engine stop switch must be
switch and depress the starter button. Tester
No
on and the key switch turned to “Start”. Re-
should read battery voltage. place the defective component.
Test starter solenoid coil by connecting an ohmmeter between the solenoid

red wire and the solenoid mounting plate. Resistance should be 3.4Ω.
Yes Check solenoid ground path by measuring resistance between mounting
Voltage Drop Testing plate and battery negative terminal (-).
See Page 10.42 for instructions.
Reconnect the solenoid. Connect the tester black

lead to the battery positive and the red lead to the Clean the battery-to-solenoid cable ends or
solenoid end of the battery-to-solenoid wire. De- No replace the cable.
press 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 Replace the starter solenoid.
to solenoid end of solenoid-to-starter cable. De-
press 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 Clean the solenoid-to-starter cable ends or
lead to the starter end of the same cable. Depress No replace the cable.
the starter button. The reading should be less than
.1 V D.C.
Yes
If all of these indicate a good condition, yet the starter still fails to turn, the
starter must be removed for static testing and inspection.
10.45
ELECTRICAL
NOTES
10.46
ELECTRICAL
WIRING DIAGRAM -- 2004 ATP 330

ELECTRICAL
NOTES:
ELECTRICAL
See *
for Differences in
ATP 330 Schematics
WIRING DIAGRAM 2004 ATP 330 (BUILT AFTER JULY 14, 2003)
* Black Wire
Added for
Ground
ELECTRICAL
WIRING DIAGRAM 2004 ATP 330 (BUILT AFTER JULY 14, 2003)
NOTES:
ELECTRICAL

ELECTRICAL
NOTES:
ELECTRICAL

ELECTRICAL
NOTES:
ELECTRICAL

ELECTRICAL

2005 Polaris ATP 330&500 SERVICE MANUAL

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GENERAL INFORMATION

2004-2005 330/500 ATP

Machine Model Number Identification

ENGINE DESIGNATION NUMBERS

Body Style Emissions Model * This could be either

ENGINE SERIAL NUMBER LOCATION

UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION

TRANSMISSION I.D. NUMBER-

COLD WEATHER KITS FOR 4 CYCLE ATVS

ACCESSORY ENGINE HEATER

Series # Part Number

MODEL: . . . . . . . . . . 2004 ATP 330 4x4

Category Dimension / Capacity

MODEL: . . . . . . . . . . 2004 ATP 500 4x4

Category Dimension / Capacity

MODEL: . . . . . . . . . . 2004 ATP 330 4x4

Compression Pressure 70--90 psi w/ decompressor High 4.41:1

MODEL: . . . . . . . . . . 2004 ATP 500 4x4

Compression Pressure 50--90 psi w/ decompressor High 5.12:1

Instrument Cluster Analog Speedo w/ LCD

MODEL: . . . . . . . . . . 2005 ATP 330 4x4

Category Dimension / Capacity

MODEL: . . . . . . . . . . 2005 ATP 500 4x4

Category Dimension / Capacity

MODEL: . . . . . . . . . . 2005 ATP 330 4x4

Compression Pressure 70--90 psi w/ decompressor High 4.41:1

MODEL: . . . . . . . . . . 2005 ATP 500 4x4

Compression Pressure 50--90 psi w/ decompressor High 5.12:1

ACCESSORY HEAVY DUTY SPRINGS

ATP 330 & 500

STANDARD TORQUE SPECIFICATIONS

Bolt Size Threads/In Grade 2 Grade 5 Grade 8

Standard Tools and Engine Tools

2870569 -- Crankshaft True Kit

2870386 -- Piston Pin Puller

2871445 -- Piston Pin Puller Adapter

2870968 -- Counter Balance Puller

PV--43527 Oil Filter Wrench

2870967 -- Slotted Nut Socket PA--44689 -- Valve/Clutch Adjuster

2870390 -- Piston Support Block

Standard Tools and Engine Tools

2870303 -- Hone Kit 2871283 -- Crank/Water Pump Seal

2870305 -- Stone Replacement Kit

2870588 -- Hone Oil (12 oz.)

2200634 -- Valve Seat

2872292 -- EBS Clutch Align Tool

PV--35667--A -- Cylinder Leak 9914177--A -- Drive Clutch Holding Tool

8700220 -- Clutch Compression Tool

Clutch (PVT) Tools Suspension Tools

2870871 -- ATV Ball Joint Tool Kit

2871351 -- Shock IFP Depth Tool

2871071 -- Shock Body Holding Tool

2871226 -- Clutch Bushing

2870623 -- Shock Spring Compressor

2201379 -- EBS Bushing

2871573 & 2871574 -- Strut

2871358 -- Clutch Holding Fixture

Suspension & Transmission Tools Electrical Tools

2870872 -- Shock Spanner Wrench

2870630 -- Timing Light