2006 - 2007 Polaris Outlaw 500 Service Manual

Fix it like a Pro
GENERAL INFORMATION 1
MAINTENANCE 2
ENGINE 3
FUEL SYSTEM 4
BODY / STEERING / SUSPENSION 5
BRAKES 6
ELECTRICAL 7
WIRE DIAGRAMS 8
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2006-2007 OUTLAW 500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
‘WHERE USED’ TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
SPECIAL TOOL LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
MISC. NUMBERS / CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
COVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
1.1
GENERAL INFORMATION
VEHICLE IDENTIFICATION Engine Serial Number Location
This information can be found on the clutch housing on the right
Model Identification
side of engine. (2)
The machine model number must be used with any
correspondence regarding warranty or service.
Machine Model Number Identification

A 07 GP 50 AA
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Year Designation Emissions & Model Option
Basic Chassis Designation Engine Designation
Engine Designation Number

ES50PLE - Single, Water Cooled, Electric Start, 5-Speed
Manual, DOHC 4 Stroke.
VEHICLE INFORMATION
VIN Identification
Paint Codes
World
Mfg. ID Vehicle Descriptor Vehicle Identifier
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 PAINTED PART COLOR POLARIS

4 X A G P 5 0 A * 7 P 0 0 0 0 0 0 Frame Cloud Silver P-385
}
}
Emissions
Model
Frame Matte Black P-458
Body Engine Individual Serial Number
Year
Style Check Digit*
Plant No*
Replacement Keys
Powertrain
Replacement keys can be made from the original key. To
* -This could be either a number or a letter 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
Unit Serial Number (VIN) Location number. Should both keys become lost, replacement of the
ignition switch assembly is necessary.
Whenever corresponding with Polaris about a particular issue,
the machine model number and serial number are important for
vehicle identification. The machine serial number is stamped on
the left side of the frame tube. (1)
SERIES # PART NUMBER

20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
1.2 RepairPro Service Manual

GENERAL INFORMATION
1
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.
1.3
GENERAL INFORMATION
SPECIFICATIONS
MODEL: 2006- 2007 OUTLAW 500
MODEL NUMBER: A06(07)GP50AA,AB
ENGINE MODEL: ES500PLE041
Category Dimension
Length 71.5 in. / 182 cm
Width 47.5 in. / 121 cm
Height 45 in. / 114 cm
Minimum Turing Radius 67 in. / 170 cm
Wheel Base 51 in. / 130 cm
Ground Clearance 11.5 in. / 29 cm
Dry Weight 439 lbs. / 199 kg
Gross Vehicle Weight 645 lbs. / 292 kg
Oil Capacity 2 qts. / 1.9 ltr
Coolant Capacity 2.25 qts. / 2.1 ltr
Fuel Capacity 3.25 gal. / 12.3 ltr

GENERAL INFORMATION
2006 - 2007 OUTLAW 500 Drivetrain
MODEL NUMBER: A06(07)GP50AA,AB Transmission Type Manual 5 speed 1
ENGINE MODEL: ES500PLE041 Main Sprocket - # Tooth 14
Rear Sprocket - # Tooth 38
Engine Gear Ratio : 1st 2.43
2nd 1.61
Platform Fuji DOHC 4 stroke
3rd 1.29
Engine Model Number ES500PLE041 4th 1.09
Engine Displacement 499cc 5th 0.92
Rev 2.07
Number of Cylinders 1
Chain Size / Deflection 520 O-ring / 1/4-3/8” (6-8mm)
Bore & Stroke (mm) 99.2 x 64.6 mm
Clutch Type Wet Multi Plate
Compression Ratio 10.8:1
Clutch Lever Freeplay 1/8” – 3/16” / 3.1 – 4.7 mm
Compression Pressure 130 psi
Engine Idle Speed 1600 Rpm Steering / Suspension
Cooling System Liquid Front Suspension Dual A-arm / RydeFX™ Shock
Style / Shock
Thermostat Opening Temperature 160°F (71°C)
Front Travel 10 in. / 25.4 cm
Overheat Warning High Temp Light
Rear Suspension Independent A-Arm / RydeFX™
Lubrication Pressurized Dry Sump Style / Shock Compression Adjustable Shock
Oil Requirements PS-4 Synthetic Rear Travel 11 in. / 27.94 cm
Exhaust System 2 to 1 canister style Ground Clearance 11.5 in. / 29 cm
Carburetion Shock Preload Adjustment Threaded shock adjustment
Carburetor model Mikuni BSR 42mm Front and Rear with Spanner Wrench
Main Jet 145 Turning Radius 67 in. / 170 cm

Pilot Jet 37.5 Toe Out 0 - 1/16 in / .0 - .159 mm
Jet Needle 6GL68-40-2 Wheels / Brakes
Needle Jet O-0 Front
10x5 / 28.3mm - 4/156
Pilot Screw 2.5 Turns Out (Reference Only) Wheel Size / Offset / Bolt Pattern
Float Height 13 mm (0.51") Rear

9x8 / 58.8mm - 4/110
Wheel Size / Offset / Bolt Pattern
Fuel Delivery Fuel Pump
Front Tire
Fuel Requirement 87 Octane (minimum) Dunlop / Radial / 21x7-10
Make / Model / Size
Electrical Rear Tire
Dunlop / Radial / 20x10-9
Alternator Output 200 w @ 3000 RPM Make / Model / Size
Voltage Regulator 3-Phase Recommended Air Pressure 5 psi Front
F/R 5 psi Rear
Lights : Main Headlights Dual Beam 35 watts / 35 watts
Brake - Front Hydraulic Disc
Tail LED
Brake - Rear Hydraulic Disc
Brake 26.9 watts
Neutral / Hot / Reverse 1 watt (ea.)
JETTING CHART
Ignition System DC/CDI Ignition
AMBIENT TEMPERATURE
RPM Limit 9100 ± 100 / Reverse 5000 ± 100
Altitude Below 40o F +40o F + Above
Ignition Timing 30o + 3o BTDC @ 3500 RPM Below 5o C +5o C + Above
Spark plug / Gap NGK DCPR8E/ .035 in./ 0.9 mm 0-1800
150 145
Battery / Model / Amp Hr Maintenance-Free 9 Amp Hr Meters (0-6000)
Circuit Breakers (Amps) Main-15 / Fan-10 / Ignition-5 (Feet) above 1800
142.5 137.5
Starting Electric - Standard (above 6000)
Instrument Cluster N/A
1.5
GENERAL INFORMATION
SPECIAL TOOLS
‘Where Used’ Table
PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN

8712100 or 8712500 Tachometer 2,7
2200634 Valve Seat Reconditioning Kit 3
PU-45257 Valve Spring Compressor 3
PA-46075 Flywheel Puller 3
PA-46087 Crankcase Separator 3
2870390 Piston Support Block 3
2872105 Water Pump Mechanical Seal Puller 3
PA-45958 Cam Chain Tensioner Assembly Tool 3
PA-46076 MAG End Crankshaft Nut Remover/Installer 3
PA-46077 MAG End Crankshaft Installer 3
2871283 Crankshaft/Water Pump Seal Install Kit 3
5131135 Water Pump Install Kit 3
PA-46502 Valve Spring Compressor 3
2870975 Mity Vac™ Pressure Test Tool 3,4
2872314 Carburetor Float Adjustment Tool 4
PS-45259 Gas Fill Tool 5
PS-45261 IFP Positioning / Extraction Tool 5
PA-48282 Rear Hub Tool 5
PV-43568 Fluke™ 77 Digital Multimeter 7
2870630 Timing Light 7
*Special Tools can be ordered through a Polaris Dealer or SPX Corporation (1-800-328-6657).

GENERAL INFORMATION
Special Tool Listing Standard Tools and Engine Tools
Special Tools may be required while servicing your machine. 1
Some of the tools listed are mandatory and other tools may be
substituted with a similar tool, if available. Tools shown may not
apply to a particular vehicle. Polaris recommends 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
PA-46076 Mag End Crank Nut Remover/Install
PA-46502 - Valve Spring Compressor PA-46077 - Mag End Crankshaft Installer
PV-43527 Oil Filter Wrench

PA-46087 - Crankcase Separator
5131135 - Water Pump Install Tool

PA-46075 - Flywheel Puller
2870390 - Piston Support Block
PA-45958 - Cam Chain Tensioner Tool
1.7
GENERAL INFORMATION
Standard Tools and Engine Tools
2871283 - Crank/Water Pump Seal Install Kit

2870303 - Hone Kit
Suspension Tools
2870305 - Stone Replacement Kit
PS-45261 - Shock IFP Positioning / Extraction Tool

2870588 - Hone Oil (12 OZ.)
PS-45259 - Gas Fill Tool

2200634 - Valve Seat Reconditioning Kit
Final Drive
2870459 - Dial Indicator
PV-35667-A - Cylinder Leak down Tester

PA-48282 Rear Hub Tool
2872105 - Water Pump Seal Puller

GENERAL INFORMATION
Fuel & Brake Systems Electrical Tools
1
2870630 - Timing Light

2870975 - Mity Vac™
Electrical Tools
2871745 - Static Timing Light Harness
PV-43568 - Fluke™ 77 Multimeter
2460761 - Hall Sensor Probe Harness
PV-39617 - Current Clamp
PV-39991 - Peak Reading Adapter
2870836 - Battery Hydrometer
PV-37453 - Christie™ Se-Sulfating

8712500 - PV-39951-A - Multi-Battery Charger
Tachometer Tachometer
PV-63070 - Christie™ Multi-Battery Charger
1.9
GENERAL INFORMATION
MISC. NUMBERS / CHARTS Decimal Equivalents
1/64 ................. .0156
SAE Tap / Drill Sizes 1/32 . . . . . . . . . . . . . .0312. . . 1 mm= .0394"
3/64 ................. .0469
Thread Size/ Drill Size Thread Size / Drill Size 1/16 . . . . . . . . . . . . . .0625
#0-80 3/64 1/2-13 27/64 5/64 ................. .0781. . . 2 mm = .0787"
#1-64 53 1/2-20 29/64 3/32 . . . . . . . . . . . . . .0938
7/64 ................. .1094. . . 3 mm =.1181"
#1-72 53 9/16-12 31/64 1/8 . . . . . . . .1250
#2-56 51 9/16-18 33/64 9/64 ................. .1406
#2-64 50 5/8-11 17/32 5/32 . . . . . . . . . . . . . .1563. . . 4 mm = .1575"
#3-48 5/64 5/8-18 37/64
11/64 ................. .1719
3/16 . . . . . . . . . . . . . .1875. . . 5mm= .1969"
#3-56 45 3/4-10 21/32 13/64 ................. .2031
#4-40 43 3/4-16 11/16 7/32 . . . . . . . . . . . . . .2188
#4-48 42 7/8-9 49/64 15/64 ................. .2344. . . 6 mm = .2362"
1/4 . . . . . . . .25
#5-40 38 7/8-14 13/16 17/64 ................. .2656. . . 7 mm = .2756"
#5-44 37 1-8 7/8 9/32 . . . . . . . . . . . . . .2813
#6-32 36 1-12 59/64 19/64 ................. .2969
#6-40 33 1 1/8-7 63/64 5/16 . . . . . . . . . . . . . .3125. . . 8mm= .3150"
21/64 ................. .3281
#8-32 29 1 1/8-12 1 3/64 11/32 . . . . . . . . . . . . .3438. . . 9 mm = .3543"
#8-36 29 1 1/4-7 1 7/64 23/64 ................. .3594
#10-24 24 1 1/4-12 1 11/64 3/8 . . . . . . . .375
#10-32 21 1 1/2-6 1 11/32 25/64 ................. .3906. . . 10 mm = .3937"
13/32 ................. .4063
#12-24 17 1 1/2-12 1 27/64 27/64 ................. .4219. . . 11 mm =.4331"
#12-28 4.6mm 1 3/4-5 1 9/16 7/16 . . . . . . . . . . . . . .4375
1/4-20 7 1 3/4-12 1 43/64 29/64 ................. .4531
1/4-28 3 2-4 1/2 1 25/32 15/32 . . . . . . . . . . . . .4688. . . 12 mm = .4724"
31/64 ................. .4844
5/16-18 F 2-12 1 59/64 1/2 . . . . . . . .5 ..... . . . . . . . 13mm = .5118"
5/16-24 I 2 1/4-4 1/2 2 1/32 33/64 ................. .5156
3/8-16 O 2 1/2-4 2 1/4 17/32 . . . . . . . . . . . . .5313
3/8-24 Q 2 3/4-4 2 1/2
35/64 ................. .5469. . . 14 mm = .5512"
9/16 . . . . . . . . . . . . . .5625
7/16-14 U 3-4 2 3/4 37/64 ................. .5781. . . 15 mm = .5906"
7/16-20 25/64 19/32 . . . . . . . . . . . . .5938
39/64 ................. .6094
Metric Tap / Drill Sizes 5/8 . . . . . . . .625 ... . . . . . . . 16mm=. 6299"
41/64 ................. .6406
21/32 . . . . . . . . . . . . .6563. . . 17 mm =.6693"
Tap Size Drill Size Decimal Nearest 43/64 ................. .6719
Equivalent Fraction 11/16 . . . . . . . . . . . . .6875
3x.50 #39 0.0995 3/32 45/64 ................. .7031. . . 18 mm = .7087"
3x.60 3/32 0.0937 3/32 23/32 . . . . . . . . . . . . .7188
47/64 ................. .7344. . . 19 mm = .7480"
4x.70 #30 0.1285 1/8 3/4 . . . . . . . .75
4x.75 1/8 0.125 1/8 49/64 ................. .7656
5x.80 #19 0.166 11/64 25/32 . . . . . . . . . . . . .7813. . . 20 mm = .7874"
51/64 ................. .7969
5x.90 #20 0.161 5/32 13/16 . . . . . . . . . . . . .8125. . . 21 mm =.8268"
6x1.00 #9 0.196 13/64 53/64 ................. .8281
27/32 . . . . . . . . . . . . .8438
7x1.00 16/64 0.234 15/64 55/64 ................. .8594. . . 22 mm = .8661"
8x1.00 J 0.277 9/32 7/8 . . . . . . . .875
8x1.25 17/64 0.265 17/64 57/64 ................. .8906. . . 23 mm = .9055"
29/32 . . . . . . . . . . . . .9063
9x1.00 5/16 0.3125 5/16 59/64 ................. .9219
9x1.25 5/16 0.3125 5/16 15/16 . . . . . . . . . . . . .9375. . . 24 mm = .9449"
10x1.25 11/32 0.3437 11/32 61/64 ................. .9531
31/32 . . . . . . . . . . . . .9688. . . 25 mm = .9843"
10x1.50 R 0.339 11/32 63/64 ................. .9844
11 x 1.50 3/8 0.375 3/8 1 . . . . . . . . . . 1.0
12x1.50 13/32 0.406 13/32
12x1.75 13/32 0.406 13/32

GENERAL INFORMATION
Coversion Table
Unit of Measure Multiplied by Converts to

1
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 = Kilo pascals (kPa)
Kilo pascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilo pascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilo pascals (kPa)
ð(3.14)xR2xH (height) = Cylinder Volume
°C to °F: 9 (°C + 40)+ 5 - 40 = °F
°F to °C: 5 (°F + 40) + 9 - 40 = °C
1.11
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.
kg/cm2: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in2: 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. 1 mm = 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.

MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2
RECOMMENDED PRE-RIDE FLUID LEVEL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
0 - 50 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
50 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
LUBRICANTS AND SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
CARBURETOR PILOT SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
THROTTLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL (ETC) ADJUSTMENT . . 2.13
CHOKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
AIR FILTER AND PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
AIR BOX DRAIN TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
CRANKCASE BREATHER FILTER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE OIL AND FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
EXHAUST PIPE / SPARK ARRESTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE MOUNT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
LIQUID COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
RECOVERY BOTTLE COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 2.18
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
RADIATOR SCREEN REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
FINAL DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
REVERSE LOCK-OUT LEVER INSPECTION AND CABLE ADJUSTMENT. . . . . . . . . 2.19
SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
DRIVE CHAIN INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
DRIVE CHAIN TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
DRIVE CHAIN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
REAR DRIVESHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
REAR DRIVESHAFT BOOT “PRESSURE EQUALIZING” . . . . . . . . . . . . . . . . . . . . . . . 2.22
2.1
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
BATTERY INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
BATTERY TERMINALS / BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
ENGINE- TO- FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
STEERING INSPECTION / TIE ROD ENDS AND HUBS . . . . . . . . . . . . . . . . . . . . . . . 2.26
TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
SUSPENSION SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
REAR SHOCK COMPRESSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
BRAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
HOSE / FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BRAKE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
WHEEL REMOVAL: FRONT OR REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and
lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use
genuine Polaris parts available from your Polaris dealer.
2
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately
10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition

• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use
and determine the cause or see your dealer.
Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:
= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
= SEVERE USE ITEM --If vehicle is subjected to severe use, decrease interval by 50%
(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm
use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required
under these conditions. Fluid changes, cable, 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 imme-
diately and monitor level. If oil level begins to rise, discontinue use and determine cause.)
E= Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING
Improperly performing the procedures marked could result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
2.3
MAINTENANCE
Pre-Ride Maintenance Interval
Periodic Maintenance Chart
Maintenance Interval
(whichever comes first)
Item Remarks
Miles
Hours Calendar
(KM)
Steering - Pre-Ride -
Front / Rear Suspension - Pre-Ride -
Tires - Pre-Ride -
Brake Fluid Level - Pre-Ride -
Brake Lever Travel - Pre-Ride -
Brake Systems - Pre-Ride - Make adjustments as needed.
Wheels / Fasteners - Pre-Ride -
Frame Fasteners - Pre-Ride -
Engine / Trans Oil Level - Pre-Ride -
E
Drive Chain - Pre-Ride -
Throttle - Pre-Ride - Check operation
Clutch - Pre-Ride - Check operation and adjustment
Engine Stop Switch - Pre-Ride - Check operation
Air Filter / Pre-Filter - Pre-Ride - Inspect; clean often
E
Air Box Sediment Tube - Pre-Ride - Drain deposits when visible
E
Check level daily,
Coolant - Pre-Ride -
change coolant every 2 years
Check operation;
Head Lamp / Tail Lamp - Pre-Ride -
apply dielectric grease if replacing
Check freeplay daily; have dealer replace if
A-arm Ball Joint - Pre-Ride
wheel moves excessively
Check pre-ride for tears, punctures, leaking.
Pre-Ride
Rear Shaft Assembly - - Check post-ride for bulging / ballooning.
Post-Ride
Replace if damaged. Burp if bulging.
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service ( California)
Recommended Pre-Ride Fluid Level Checks

ITEM TYPE NOTES SEE PAGES
Engine / Trans Oil Polaris PS-4 Synthetic Engine Oil Add to proper level on dipstick 2.14
Polaris Premium 60/40 Pre–mixed Allow engine and cooling system to cool completely
Antifreeze/Coolant or a 50/50 and check level in radiator. Fill to top of filler neck. If
Coolant / Level 2.18
mixture high quality antifreeze/ reservoir was empty or extremely low, fill radiator
coolant and distilled water before filling reservoir tank to full line
Fill to indicated level inside reservoir.
Brake Fluid Polaris DOT 3 or DOT 4 Brake Fluid 2.29
Use the sight glass to ensure the proper fluid level.
NOTE: Quick Reference Lubricants and maintenance product part numbers are listed on page 2.9
MAINTENANCE
0 - 50 Hour Maintenance Interval
Item Remarks
Hours Calendar
Miles
(KM) 2
Air Filter,
- Weekly - Inspect; replace as needed
E Main Element
Engine / Trans Oil
1H - -
Perform a break-in oil change at 1 hour or 1
E Change (Break-In) tank of gas
Engine / Trans
E Oil Change
10 H - 100 (160) Check pre-ride level
Oil Filter Change 10 H - 100 (160) Replace with oil change

E
Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test
Engine Breather
E Filter (in air box)
20 H Monthly 200 (320) Inspect; replace if necessary
Check clearance. Re-shim only if out of
Valve Lash 50 H - -
specification.
General Lubricate all grease fittings, pivots, cables,
Lubrication
50 H 3M 500 (800)
etc.
Inspect daily;
Drive Chain 50 H 6M 500 (800)
adjust and lubricate as needed
Inspect; tighten fasteners; grease
Front / Rear Suspension 50 H 6M 500 (800) (especially after washing or driving in high

water levels) See page 2.6
Carburetor Float Bowl 50 H 6M 500 (800) Drain bowl periodically and prior to storage
Throttle Cable / ETC Inspect; adjust; lubricate;
E 50 H 6M 500 (800)
Switch replace if necessary
Inspect; adjust; lubricate;
E Choke Cable 50 H 6M 500 (800)
replace if necessary
Clutch cable 50 H 6M 500 (800) Inspect, lubricate, adjust
Carburetor Air Intake /
E 50 H 6M 500 (800) Inspect ducts for proper sealing / air leaks
Flange
Inspect coolant strength seasonally;
Cooling System 50 H 6M 500 (800)
pressure test system yearly
Steering 50 H 6M 500 (800) Lubricate
E Emission Control System Service (California)
2.5
MAINTENANCE
Item Maintenance Interval Remarks

Miles
Hours Calendar
(Km)
Inspect; tighten fasteners; grease after washing
Upper Steering Post (A) 50 H 3M 500 (800)
ATV or driving in water
Inspect; tighten fasteners; grease (also after
Front A-arms (B) 50 H 3M 500 (800)
washing ATV or driving in water)
Rear Control Arm Inspect; tighten fasteners; grease (also after
50 H 3M 500 (800)
Bushings (C) washing ATV or driving in water)
Stabilizer Bar (D) 50 H 6M 500 (800) Grease
E
Rear Control Arm Disassemble, clean, inspect bearings and seals,
100 H 12 M 1000 (1600)
E Needle Bearings (E) grease, reassemble
C E
B D
A E C
E

MAINTENANCE
Item Remarks
Hours Calendar
Miles
(Km) 2
Oil Tank Vent Hose 100 H 12M 1000 (1600) Inspect routing, condition
E
Check for leaks at tank cap, lines, fuel valve,

Fuel System 100 H 12M 1000 (1600) filter, pump, carburetor.
E
Replace lines every two years

Fuel filter 100 H 12 M 1000 (1600) Replace yearly
E
Coolant System
100 H 12 M 1000 (1600) Pressure test system annually
Pressure Test
Inspect; clean external surfaces;
Radiator 100 H 12M 1000 (1600)
change coolant every 2 years
Cooling Hoses 100 H 12M 1000 (1600) Inspect for leaks
Engine Mounts 100 H 12M 1000 (1600) Inspect
Exhaust Pipe 100 H 12M 1000 (1600) Inspect

Spark Plug 100 H 12M 1000 (1600) Inspect; replace as needed
E

Ignition Timing - 12M - Inspect
E
Inspect for wear, routing, security; apply
Wiring 100 H 12M 1000 (1600) dielectric grease to connectors subjected to
water, mud, etc.
Clutch Plates 100 H 12M 1000 (1600) Inspect; replace worn parts
Brake Fluid 200 H 24M 2000 (3200) Change every two years
Front Wheel Bearings 300 H 36M 3000 (4800) Inspect; replace as needed
Spark Arrestor 300 H 36M 3000 (4800) Clean out as required
E Idle Speed - Adjust as needed
Inspect periodically;
Toe Adjustment -
adjust when parts are replaced
Headlight Aim - Adjust as needed
2.7
MAINTENANCE
Maintenance References
2. Brake Fluid
(Right hand and Foot
Brake Master Cylinder)
1. Engine Oil and Filter
3. Rear Drive Chain
Sight
Glass
Fill to Indicated
Level
Oil Filter Location
III. # Item Lube Rec. Method Frequency*

Perform break–in oil / filter
Engine Oil / Check dipstick and add to
1. Polaris PS-4 Synthetic change at one hour; change oil
Transmission proper level.
every 10hrs / 100mi. **
Fill master cylinder reservoirs
Polaris DOT 3 or DOT 4 As required. Change fluid every
2. Brake Fluid to indicated level inside
Brake Fluid 2 years or 200 hours. ***
reservoir.
Apply to chain link plates and
3. Drive Chain Polaris Chain Lube As required *
rollers.
* More often under severe use, such as operation in mud, water, sand or under severe loads.
** Every 10 hours of operation (refer to Maintenance Schedule for additional information). Change more often in extremely dirty
conditions such as continuous operation in water, mud or sand, continuous hot, cold, or short trip cold weather operation.
NOTE: Excessive clutch plate residue will accelerate oil change intervals.
*** Every 24 months or 200 hours of operation (refer to Maintenance Schedule for additional information).
More often under severe conditions such as continuous operation in water, mud or sand.

MAINTENANCE
LUBRICANTS AND SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products
PART NO. DESCRIPTION

ENGINE LUBRICANT 2
2874414 Engine Oil (Quart) PS 4 Synthetic (4-Cycle)
2874415 Engine Oil (Gallon) PS 4 Synthetic (4-Cycle)
GREASE / SPECIALIZED LUBRICANTS
2871322 Premium All Season Grease (3 oz. cartridge)
2871423 Premium All Season Grease (14 oz. cartridge)
2876006 Rear Shaft Grease
2871460 Starter Drive Grease
2871312 Grease Gun Kit
2871329 Dielectric Grease
2872073 Chain Lube (Aerosol)
COOLANT
2871323 60/40 Coolant (Gallon)
2871534 60/40 Coolant (Quart)
ADDITIVES / SEALANTS / THREAD LOCKING AGENTS / MISC.
2870791 Fogging Oil (12 oz. Aerosol)
2871326 Premium Carbon Clean (12 oz.)
2870652 Fuel Stabilizer (16 oz.)
2870585 Loctite™ Primer N, Aerosol, 25 g
2870990 DOT 3 Brake Fluid
2872189 DOT 4 Brake Fluid
2871956 Loctite™ Thread Sealant 565 (50 ml.)
2871949 Loctite™ Threadlock 242 (50 ml.)
2870584 Loctite™ RC 680–Retaining Compound (10 ml.)
2870587 Loctite™ 518 Gasket Eliminator / Flange Sealant (50 ml.)
2871957 Black RTV Silicone Sealer (3 oz. tube)
2871958 Black RTV Silicone Sealer (11 oz. cartridge)
8560054 Silicone Sealer (14 oz. cartridge)
2871557 Crankcase Sealant, 3–Bond 1215
2872893 Engine Degreaser
2.9
MAINTENANCE
GENERAL VEHICLE INSPECTION FUEL SYSTEM AND AIR INTAKE

AND MAINTENANCE
Fuel System
Pre-Ride / Daily Inspection
Perform the following pre-ride inspection daily, and when WARNING
servicing the vehicle at each scheduled maintenance.
Gasoline is extremely flammable and
• Tires – check condition and pressures explosive under certain conditions.
• Chain - Check tension, lubricate, adjust as needed • Always stop the engine and refuel outdoors or in a well
ventilated area.
• Fuel and oil tanks – fill both tanks to their proper level;
Do not overfill oil tank • Do not smoke or allow open flames or sparks in or near
the area where refueling is performed or where gasoline
• All brakes – check operation and adjustment (includes is stored.
auxiliary brake
• Do not overfill the tank. Do not fill the tank neck.
• Throttle – check for free operation
• If you get gasoline in your eyes or if you swallow
• Headlight/Taillight/Brakelight – check operation of all gasoline, seek medical attention immediately.
indicator lights and switches
• If you spill gasoline on your skin or clothing,
• Engine stop switch – check for proper function immediately wash it off with soap and water and
change clothing.
• Wheels – check for loose wheel nuts and axle nuts;
check to be sure axle nuts are secured by cotter pins • Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can result in
• Air cleaner element – check for dirt or water; clean or loss of consciousness or death in a short period of time.
replace
• Never drain the float bowl when the engine is hot.
• Steering – check for free operation, noting any unusual Severe burns may result.
looseness in any area
• Loose parts – visually inspect vehicle for any damaged Fuel Lines
or loose nuts, bolts or fasteners
Fuel Pump
• Engine coolant – check for proper level at the recovery
bottle Fuel Inlet
Frame, Nuts, Bolts, and Fasteners

Periodically inspect the torque of all fasteners in accordance
with the maintenance schedule. Check that all cotter pins are in
place. Refer to specific fastener torques listed in each chapter. Fuel Outlet
Pulse Line
1. Check fuel lines for signs of wear, deterioration, damage,

or leakage. Replace if necessary.
2. Be sure fuel lines are routed properly and secured with
cable ties.
CAUTION
Make sure lines are not kinked or pinched.

MAINTENANCE
3. Replace all fuel lines every two years. 6. Turn valve on, start engine and inspect for leaks.
Vent Lines Carburetor Draining

Check engine, fuel tank, oil tank, and carburetor vent lines for The carburetor float bowl should be drained periodically, or
signs of wear, deterioration, damage, or leakage. Replace every before extended periods of storage, to remove moisture or
two years. sediment from the bowl.
2
Be sure vent lines are routed properly and secured with cable NOTE: The bowl drain screw is located on the
ties. bottom left side of the float bowl.
1. Turn fuel valve to the “Off” position.
CAUTION 2. Place a clean container beneath the bowl drain spigot or
bowl drain hose.
3. Turn drain screw out two turns and allow fuel in the float
Make sure lines are not kinked or pinched
bowl and fuel line to drain completely.
4. Inspect the drained fuel for water or sediment.
Fuel Valve 5. Tighten drain screw.
6. Turn fuel valve to “On”.
7. Start machine and check for leaks.
NOTE: All tubes attached to the carburetor must be
checked for pinching or blockage, as this will effect
engine performance.
Fuel Valve
Drain Screw
The fuel system strains the fuel through screens located in the
fuel valve. There is no fuel filter to service. To service the fuel
valve:
1. Shut off fuel supply at fuel valve. Remove line clamps and
fuel lines from the tank.
2. Remove the tank and drain remainder of fuel into a
appropriate container.
3. Remove fuel valve by loosening the screws holding the
valve to the tank.
4. Inspect the valve for damage or debris. Replace the valve
if problems are found.
5. Reverse the procedures to install the fuel valve.
2.11
MAINTENANCE
Carburetor Pilot Screw Adjustment 6. Slowly turn mixture screw counterclockwise until idle
speed increases to maximum RPM. Continue turning
NOTE: The pilot screw is covered by a brass welsh counterclockwise until idle RPM begins to drop.
plug per EPA requirements. Removal will be
7. Center the pilot screw between the points in Step 5 and 6.
required to perform these procedures.
8. Readjust idle speed to specification.
NOTE: Always check throttle cable freeplay after
adjusting idle speed and adjust if necessary.
Idle Speed Adjustment

NOTE: Adjusting the idle speed effects throttle
cable freeplay and electronic throttle control (ETC)
FRONT adjustment. Always check throttle cable freeplay
(Engine Side) after adjusting idle speed and adjust if necessary.
BSR Carburetor
Pilot Screw Location
1. Start the engine and warm it up to operating temperature

(about 10 minutes). Idle Screw
2. With engine off, turn pilot screw in (clockwise) until lightly
seated. Turn screw out the specified number of turns.
Pilot Screw Initial Setting:

Outlaw 500 - 2.5 Turns Out
1. Start engine and warm it up thoroughly.
2. Adjust idle speed by turning the idle adjustment screw in
NOTE: Do not tighten the pilot screw forcefully (clockwise) to increase or out (counterclockwise) to
against the seat or the screw and/or seat will be decrease RPM.
permanently damaged.
Idle Speed
CAUTION 1600 ± 100 RPM
The pilot screw is calibrated at the factory to meet Throttle Inspection

EPA / CARB regulations for air quality standards
and is sealed with a brass plug to prevent Check for smooth throttle opening and closing in all handlebar
tampering. Removal of the tamper proof plug is positions. Throttle lever operation should be smooth and lever
not permitted. For service purposes, cleaning of must return freely without binding.
the pilot circuit can be done only by a certified
repair shop to ensure air quality standards 1. Place the gear selector in neutral.
are not exceeded. 2. Set parking brake.
3. Start the engine and let it idle.
3. Connect an accurate tachometer that will read in increments
4. Turn handlebars from full right to full left. If idle speed
of + or - 50 RPM such as the PET 2100DX (PN
increases at any point in the turning range, inspect throttle
8712100DX) or the PET 2500 (PN 8712500). Start engine.
cable routing and condition. Adjust cable tension as needed
4. Set idle speed to 1600 RPM. until lock-to-lock turning can be accomplished with no rise
5. Slowly turn mixture screw clockwise using the pilot screw in engine rpm.
or an appropriate sized screwdriver until engine begins to 5. Replace the throttle cable if worn, kinked, or damaged.
miss.
6. Inspect ETC cover seal and switch cavity by removing the
cover. Verify that no dirt, water or mud is present.

MAINTENANCE
To remove the ETC cover: 5. Turn adjuster until 1/16” to 1/8” (1-2mm) freeplay is
achieved at thumb lever. After making adjustments,
1. Use a medium flat blade screwdriver and insert blade into quickly actuate the thumb lever several times and reverify
the pocket of the cover starting on the #1 position freeplay.
2. Twist screwdriver slightly while lifting on the cover to
release snap.
3. Repeat procedure at the other five locations as shown.
2
2
3
1
6
Direction of Travel
5 4
Freeplay
1/16”-1/8”
(1-2mm)
6. Tighten lock nut securely and slide boot completely in

place to ensure a water–tight seal.
7. Turn handlebars from left to right through the entire turning
NOTE: Do not attempt to remove cover until all latch range. If idle speed increases, check for proper cable
points are released. routing. If cable is routed properly and in good condition,
repeat adjustment procedure.
Throttle Cable / Electronic Throttle Control
(ETC) Adjustment Choke Adjustment
1. Slide boot off throttle cable adjuster and jam nut. If the choke knob does not stay out when pulled, adjust the choke
2. Place shift selector in neutral and set parking brake. tension by tightening (clockwise) the jam nut under the rubber
3. Start engine and set idle to 1600 RPM. boot between the choke knob and nut. Firmly grasp the rubber
NOTE: Be sure the engine is at operating boot and tighten until the choke slides freely but stays out when
temperature. See Idle Speed Adjustment. pulled.
4. Loosen lock nut on in–line cable adjuster. Verify free play of 1/16-3/16” (1.6-4.76 mm) and smooth
operation of choke cable.
Lock Nut
If smooth choke operation is not obtainable, inspect choke cable
Boot Adjuster Sleeve Boot for kinks or sharp bends in routing.
Choke
Air Filter and Pre-filter Service

It is recommended that the air filter and pre-filter be inspected
frequently. When riding in extremely dusty conditions,
replacement is required more often.
2.13
MAINTENANCE
The pre filter should be cleaned before each ride using the Air Box Drain Tube
following procedure:
Periodically check the air box drain tube located on the bottom
1. Unlatch and remove the seat. side of the air box. Be sure the drain tube is not obstructed by
2. Release the two air box cover clips (A) and rotate the cover mud or sand. Whenever deposits are visible, clean out the tube.
rearward to remove it.
3. Remove the air filter retaining screw (B).
4. Loosen the filter clamp (C).
5. Remove the main air filter (D).
6. Remove the pre-filter (E) from the main filter element.
7. Remove the breather filter (F).
D
F
Drain Tube
B
NOTE: The drain tube will require more frequent

inspection if the vehicle is operated in severe
conditions.
Crankcase Breather Filter Inspection

Outlaw ATV engines are equipped with a crankcase breather
C filter in the air box. The filter is similar in appearance to a small
foam block, and is visible on the left side (See Illustration to the
left, Reference F).
A The air breather filter should be inspected or replaced whenever

the air filter is inspected.
Cleaning:
ENGINE AND TRANSMISSION
8. Wash the pre-filter (E) and breather filter (F) in soapy Engine Oil Level Check
water, then rinse and let dry.
Check the oil level before each use of the vehicle. The dipstick
9. Wash the main filter element (D) without removing it from is located on the left side of the ATV.
the internal filter cage. Rinse and let dry. When dry, apply
a commercially available foam filter oil thoroughly on the
element.
Installation:
Dipstick
10. Check the hoses for cracks, deterioration, abrasion, or Location
leaks. Replace as needed.
11. Reinstall crankcase breather filter, pre-filter and air filter Oil Level
into air box. Install the air filter retaining screw. Marks
12. Reinstall the air box cover and secure the cover with the two
clips.

MAINTENANCE
1. Position the ATV on a level surface. 8. Allow the oil to drain completely.
2. Start the engine and let it idle for one minute. 9. Replace the sealing washer and reinstall the plug. Torque
3. Stop the engine and remove the dipstick. Wipe it dry with to 14 ft. lbs. (19 Nm).
a clean cloth. 10. Place shop towels beneath the oil filter cover.
4. Reinstall the dipstick completely. 11. Remove the three cover bolts and remove the cover.
NOTE: The dipstick must be screwed completely in
to keep the angle and depth of the stick consistent. 2
5. Remove the dipstick and check the oil level. Maintain the
oil level in the safe range, between the full and add marks.
Do not overfill.
6. Reinstall the dipstick.
Engine Oil and Filter Service

IMPORTANT: Polaris PS-4 Engine Oil is
recommended for use in the Predator. PS-4 was 72–78 in. lbs.
specifically designed for the Predator’s engine and (8–9 Nm)
clutching system. Other oils do not contain the
needed additives to prolong engine life and provide NOTE: A spring located behind the filter may pop
proper lubrication to the Predator clutch and out as the filter is removed. The spring must be
transmission components. reinstalled with the new filter.
1. Place the vehicle on a level surface. 12. Pull out the oil filter.
2. Clean the area around the oil tank and crankcase drain plugs
with clean shop towels.
WARNING
Hot oil can cause serious burns to the skin.

Do not allow hot oil to contact skin.
3. Run the engine for two to three minutes until warm, then
stop the engine.
4. Place a drain pan beneath the oil tank and remove the drain Oil Filter
plug (1).
14 ft. lbs. (19 Nm)

2
1
5. Allow the oil to drain completely. Spring
6. Replace the sealing washer and reinstall the plug. Torque
13. Using a clean dry cloth, clean the filter sealing surfaces.
to 14 ft. lbs. (19 Nm).
NOTE: The sealing surfaces on drain plugs, oil tank
and crankcase should be clean and free of burrs,
nicks or scratches.
7. Place a drain pan beneath the crankcase and remove the

drain plug (2).
2.15
MAINTENANCE
14. Replace the gasket in the cover. 3. Shut off engine. Remove the vent line clamp. The oil pump
should now be properly primed and ready for field
Gasket 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.
Compression Test
NOTE: This engine has built-in decompression
15. Lubricate the gasket on the new filter with a film of fresh components. Compression readings will vary in
engine oil. proportion to cranking speed during the test.
16. Reinstall the spring and install the new filter with the open Average compression (measured) is about 85-90 psi
end facing outward. @ 400 RPM during a compression test.
17. Install the cover and torque the bolts to 72–78 in. lbs. (8–
9 Nm). A cylinder leakdown test is the best indication of engine
condition. Follow manufacturer’s instructions to perform a
NOTE: The long bolt must be placed in the forward
cylinder leakage test. (Never use high pressure leakage testers,
hole.
as crankshaft seals may dislodge and leak).
18. Remove the dipstick and fill the oil tank with 2.25 quarts
(1.9 l) of Polaris PS-4 Engine Oil (PN 2874414). Cylinder Compression w / decompression
Standard: 85-90 PSI @ 400 RPM
19. Place gear selector in neutral and set parking brake.
20. Start the engine and let it idle for one to two minutes. Stop Cylinder Leakdown
the engine and inspect for leaks. Service Limit: 10%
21. Re–check the oil level on the dipstick and add oil as (Inspect for cause if leakage exceeds 10%)
necessary to bring the level to the upper mark on the
dipstick.
Exhaust Pipe / Spark Arrestor
22. Dispose of used filter and oil properly.
Oil Pump Priming Procedure WARNING

NOTE: The oil pump priming procedure should be
• Do not perform clean out immediately after
performed as a safeguard against loss of pump the engine has been run, as the exhaust
prime when repairing oil tank, lines or engine. system becomes very hot. Serious burns
could result from contact with exhaust
1. Clamp or pinch off vent line approximately 2″ from oil components.
tank (P), between the end of oil tank vent fitting and the
vent line. • To reduce fire hazard, make sure that there
are no combustible materials in the area when
P purging the spark arrestor.
• Wear eye protection.
• Do not stand behind or in front of the vehicle
while purging the carbon from the spark
arrestor.
• Never run the engine in an enclosed area.
Exhaust contains poisonous carbon monoxide
gas.
• Do not go under the machine while it is
inclined. Set the hand brake and block the
wheels to prevent roll back.
Failure to follow these warnings could result in

2. Run engine for 5-10 seconds at IDLE. serious personal injury or death.

MAINTENANCE
Periodically clean the spark arrestor to remove accumulated arrestor is damage is found.
carbon.
Verify which type of spark arrestor your ATV is equipped with

and follow the appropriate cleaning procedure below: (A) or (B)
Inspect the screen
Procedure A - End Cap Spark Arrestor
1. Remove the three screws (1) and remove the arrestor (2)
2
from the end of the muffler.
2. Use a non-synthetic brush to clean the arrestor screen (3).
A synthetic brush may melt if components are warm.
If necessary, blow debris from screen with compressed air.
3. Inspect the screen for wear and damage. Replace the
arrestor is damage is found.
4. Remove and inspect the gasket (4). Replace if worn or
damaged. 4. Reinstall the arrestor and torque the bolt to 7 ft. lbs.
(9.5 Nm)
3 2 Engine Mount Locations

Inspect engine mounts and frame for cracks or damage.
Check engine fasteners and ensure they are tight.

1
Engine Mounting Locations
5. Reinstall the gasket and arrestor.

6. Torque screws to 50 in. lbs. (5.6 Nm).
Procedure B - Set Screw Type Spark Arrestor

1. Remove the bolt and remove the arrestor from the end of
the muffler.
LIQUID COOLING SYSTEM
Bolt
Cooling System Overview
The engine coolant level is maintained by the recovery
system.The recovery system components are the recovery
bottle, radiator filler neck, radiator pressure cap and connecting
hose.
As coolant operating temperature increases, the expanding

(heated) excess coolant is forced out of the radiator past the
Spark Arrestor
pressure cap and into the recovery bottle. As engine coolant
temperature decreases the contracting (cooled) coolant is drawn
back up from the tank past the pressure cap and into the radiator.
2. Use a non-synthetic brush to clean the arrestor screen. • Some coolant level drop on new machines is normal as
A synthetic brush may melt if components are warm. the system is purging itself of trapped air. Observe
If necessary, blow debris from screen with compressed air. coolant levels often during the break–in period.
3. Inspect the screen for wear and damage. Replace the
2.17
MAINTENANCE
• Overheating of engine could occur if air is not fully 2. Do not over–tighten hose clamps at radiator or radiator
purged from system. fitting may distort, causing a restriction or leak. Radiator
hose clamp torque is 36 in.lbs. (4 Nm).
• Polaris Premium 60/40 anti-freeze is premixed and
ready to use. Do not dilute with water. Radiator
Coolant Strength / Type 1. Check radiator external air flow passages for restrictions or
damage.
Test the strength of the coolant using an antifreeze hydrometer. 2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with compressed air or low
pressure water.
Recovery Bottle Coolant Level Inspection
Antifreeze Hydrometer WARNING
• A 50/50 or 60/40 mixture of antifreeze and distilled Never remove the radiator pressure cap when the
water will provide the optimum cooling, corrosion engine is warm or hot. Escaping stream and fluid can
cause severe burns. The engine must be allowed to
protection, and antifreeze protection. cool before removing the pressure cap.
• Do not use tap water. Tap water contains minerals and The recovery bottle, is located on the right side of the vehicle
impurities which build up in the system. Do not add under the front fender. The fluid level must be maintained
straight antifreeze or straight water to the system. between the FULL (A) and ADD (B) marks on the side panel
Straight water or antifreeze may cause the system to (when the fluid is cool).
freeze, corrode, or overheat.
Polaris 60/40 Anti-Freeze / Coolant Recovery Bottle

(PN 2871323)
Cooling System Hoses

Inspect all hoses for cracks, deterioration, abrasion or leaks.
Replace if necessary.
A
If coolant is not between the FULL and ADD marks, perform the
following steps:
1. Remove reservoir cap. Verify the breather foam is in place

and the inner splash cap vent hole is clear and open.
1. Check tightness of all hose clamps.

MAINTENANCE
2. Fill reservoir to upper mark with Polaris Premium 60/40 4. Squeeze the lever fully and release. Slightly squeeze the
Anti Freeze / Coolant (PN 2871323) or a mixture of lever again until a slight resistance is felt. Measure the
antifreeze and distilled water as required for freeze freeplay again. If necessary, repeat the adjustment
protection in your area. procedure until proper freeplay is attained.
3. Reinstall cap. 5. Replace the clutch perch pivot boot over the screw and lock
NOTE: If overheating is evident, allow system to ring.
cool completely and check coolant level in the
radiator. Inspect for signs of trapped air in system. Reverse Lock-Out Lever Inspection and
2
Cable Adjustment
Cooling System Pressure Test Check for smooth lever operation and ensure that the lever
See Chapter 3 for testing procedures. returns freely without binding (1).
Radiator Screen Removal

1. Remove the 4 screws retaining the radiator screen for
access to the radiator fins when cleaning.
Adjust the reverse cable freeplay to .08”-.12” by adjusting the

cable jam nuts (2).
Sprocket Inspection
Inspect the sprocket for worn, broken or bent teeth.
FINAL DRIVE
Clutch Adjustment
1. Measure clutch lever freeplay between the perch and the
lever (A). This distance should be 1/8” – 3/16” (3.1 mm –
4.7 mm)
CLUTCH LEVER FREEPLAY
C
B To check for wear, pull upward on the chain at the area indicated
A (arrow). Replace sprocket if chain movement exceeds 1/4”
2. If adjustment is required, slide the clutch perch pivot boot (.6 cm).
down the clutch cable to access the clutch adjustment screw
(B) and lock ring (C).
3. Loosen the lock ring and turn the screw in (clockwise) to
increase lever travel. Turn the screw out
(counterclockwise) to decrease lever travel. Tighten the
lock ring.
2.19
MAINTENANCE
Drive Chain Inspection / Replacement
If a gap is noticed between the outside edge
Inspect the drive chain for missing or damaged O–Rings, link of the master link and plate, back the plate out
plates, or rollers. Do not wash the chain with a high pressure and close the gap.
washer, gasoline or solvents; do not use a wire brush to clean the
chain as damage to the O–Rings may occur. Clean chain with Master Link
hot soapy water and a soft bristled nylon brush.
Polaris ATV drive chains are equipped with O–ring sealed Do not press
plate in too far
permanently greased pins and rollers.The sprockets and outer
rollers require periodic lubrication. Lubricate the chain with
Polaris Chain Lubricant (PN 2872073).
Never allow battery acid to contact the drive chain.

The chain must be replaced when it reaches 3% elongation.
1. Stretch the chain tightly in a straight line.
2. Measure the length of 21 pitches (pins) from pin center to
pin center, and compare to the specification. Replace the
chain if the length exceeds the wear limit.
Drive Chain Wear Limit, 21 Pitch Length:

Std: 12.5″(32 cm)
Drive Chain Tension
Wear Limit: 12.875” (32.7 cm)
CAUTION
3. When replacing or reinstalling drive chain, install the
closed end of the splice link clip as shown, with the closed Never adjust or operate the vehicle with the rear drive
end leading in forward operation. There should be a .003- chain too loose or too tight. Severe damage to the
transmission and drive components can result.
.005″ (.076-.127 mm) gap between the side plate of the
chain and the splice link clip. See illustrations below. BREAK-IN: It is extremely important to maintain proper chain
Proper Spacelink Clip Opening Position tension to ensure the best possible chain life. There is a chain
break–in period of approximately 100 miles or two (2) tanks of
.003 - .005″ fuel. During this time chain tension should be watched very
(.076- .127 mm) closely and loads to the chain should be kept light.
Gap after installation
CHECKING CHAIN TENSION:
Check the amount of chain slack by moving the vehicle slightly
forward to remove slack at the top side of the chain. At the
center point of the top side of the chain there should be 1/4” - 3/
8” (6-9 mm) deflection.
NOTE: The chain has a press-on master link. A

chain tool must be used if it’s necessary to remove
the chain for service.

MAINTENANCE
Drive Chain Adjustment Rear Driveshaft Boot Inspection
1. Loosen the upper and lower pivot mounting bolts (1). Before Operating
Inspect the boots before operating the vehicle. If a boot is torn,
punctured or leaking fluid, replacement is required.
2
OK
2. Thread the chain adjusting bolt (2) inward or outward to

adjust chain slack to the proper dimension.
After Operating
Inspect the boots after operating the vehicle. If a boot is bulging
or ballooned, perform the boot “burping” procedure.
2
1
3. Torque the pivot mounting bolts to 30 ft. lbs. (41 Nm).

4. Torque the chain adjusting bolt to 20 ft. lbs. (27 Nm).
2.21
MAINTENANCE
Rear Driveshaft Boot “Pressure Equalizing” ELECTRICAL AND IGNITION SYSTEM
1. Using a needle nose pliers or boot clamp removal tool,
Battery Maintenance
remove the small boot clamp (1) from the inboard boot.
NOTE: Do not use any tools that may damage the
boot. WARNING
Battery electrolyte is poisonous. It contains

sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get

prompt medical attention.
Batteries produce explosive gases. Keep

sparks, flame, cigarettes, etc. away. Ventilate
2. Slide the free end of the boot two inches toward the center when charging or using in an enclosed space.
of the vehicle and lift the boot away from the shaft to allow Always shield eyes when working near
excess air to escape. batteries. KEEP OUT OF REACH OF
CHILDREN.
The battery is located under the front cab at the front of the ATV.
NOTE: The Outlaw battery is a Low Maintenance
design and construction. Before placing the battery
into service, check the battery condition and charge
accordingly.
Use of Conventional Lead-Acid batteries is not
recommended.
New Batteries: Batteries must be fully charged before use or

battery life will be reduced by 10–30% of full potential.
Charge battery for 3-5 hours at a current equivalent of 1/10 of
the battery’s rated amp/hour capacity (i.e. 9 amp hr x.10 =.9
3. Wipe excess grease from the shaft before returning the boot amp charging). Do not use the alternator to charge a new bat-
to the boot groove. Use caution not to allow excess air back tery.
into the system when reinstalling the boot.
4. Reinstall the boot clamp. Maintenance-Free batteries are sealed at the factory. The use of
lead-calcium instead of lead-antimony allows the battery acid to
be fully absorbed by the plates. Therefore, a Maintenance-Free
battery case is opaque and the sealing caps are not removable,
since there is no need to check electrolyte level.
IMPORTANT: Never attempt to add electrolyte or

water to a Maintenance-Free battery. Doing so will
damage the case and shorten the life of the battery.

MAINTENANCE
Battery Inspection / Removal Off Season Storage
The battery is located under the front cab at the front of the ATV. To prevent battery damage during extended periods of non–use,
Removal of the front cab assembly is required to access the the following basic battery maintenance items must be
battery. Refer to “Chapter 5” for front cab removal. performed:
• Remove the battery from the machine and wash the

case and battery tray with a mild solution of baking
2
soda and water. Rinse with fresh water after cleaning.
NOTE: Do not get any of the baking soda into the

battery or the acid will be neutralized.
• Using a wire brush or knife, remove any corrosion from

the cables and terminals.
Battery
• Never add water to a sealed maintenance free
Location
battery.
• Charge at a rate no greater than 1/10 of the battery’s

To remove the battery: amp/hr capacity until the open circuit voltage is 12.9V
or greater.
1. Remove the front cab.
2. Disconnect holder strap. • Store the battery either in the machine with the cables
3. Disconnect battery negative (–) (black) cable first, disconnected, or store in a cool place.
followed by the positive (+) (red) cables.
Engine- To- Frame Ground
CAUTION
Inspect engine–to–frame ground cable connection. Be sure it is
clean and tight.
To reduce the chance of sparks: Whenever
removing the battery, disconnect the
negative (black) cable first. When reinstalling Charging Procedure
the battery, install the negative cable last. NOTE: Remote charging terminals have been
provided to allow for battery charging without
4. Remove the battery.
removal of the front cab.
5. Clean battery cables and terminals with a stiff wire brush.
Corrosion can be removed using a solution of one cup water 1. Attach the Positive battery charging cable to the Red
and one tablespoon baking soda. Rinse well with clean Charge Terminal (A); which is directly connected to the
water and dry thoroughly. Test battery for condition and positive battery terminal. It is located just above the front
charge accordingly. right shock mount.
6. If required, charge battery at 1/10 of its amp/hour rating.
Example: 1/10 of 14 amp battery = 1.4 amp 2. Attach the Negative battery charging cable to the free end
7. Reinstall battery, attaching positive (+) (red) cable first and of the Black Cable (B) under the right front cab (which is
then the negative (–) (black) cable. directly connected to the negative battery terminal).
8. Coat terminals and bolt threads with Dielectric Grease (PN
2871329).
9. Reinstall battery cover, holder strap and front cab.
Battery Terminals / Bolts

Ensure battery terminals are clean of corrosion. Use Polaris
corrosion resistant Dielectric Grease (PN 2871329) on battery
bolts.
2.23
MAINTENANCE
3. Charge with a charging output no larger than 1/10 of the 8. Remove spark plug. and inspect electrodes for wear and
battery's amp/hr rating. Charge as needed to raise the open carbon buildup. The insulator tip should be a light tan color,
circuit voltage to 12.9 V or greater. indicating good combustion. Look for a sharp outer
electrode edge with no rounding or erosion.
9. If needed, clean spark plug with electrical contact cleaner
or a glass bead spark plug cleaner only.
A NOTE: Wire brushes or coated abrasives should not
be used.
10. Measure gap with a wire gauge. Refer to specifications for

B proper spark plug type and gap. Adjust gap if necessary by
bending the side electrode carefully.
11. If necessary, replace spark plug with proper type.
CAUTION
Severe engine damage may occur if the

incorrect spark plug is used.
WARNING
12. Apply a small amount of anti–seize compound to the spark
plug threads.
To avoid the possibility of explosion or sparks,
connect positive (red) cable first and negative 13. Install spark plug and torque to specification. Reverse steps
(black) cable last. as needed for reassembly.
Spark Plug Inspection Recommended Spark Plug:
Spark Plug Removal and Replacement NGK DCPR8E
1. Turn the fuel valve to OFF. Spark Plug Torque:

2. Remove the side panels and front cab. 14 Ft. Lbs. (19 Nm)
3. Move the fuel valve hose clamp forward and gently remove
the hose (1) from the fuel valve fitting on the gas tank.
Spark Plug Gap
2 3
1
.035″ (0.9mm)
4. Remove the vent hose (2) from the instrument panel, taking
Ignition Timing
note of the hose routing for reinstallation. Timing is non-adjustable. Refer to Chapter 7 for ignition timing
5. Remove the tank mounting bolt (3) at the rear of the gas inspection.
tank.
STEERING AND SUSPENSION
6. Move the tank rearward and upward over the engine.
Slowly remove the tank, being careful not to catch any Steering
hoses, wires or other components. Place the tank on a stable
surface or work bench to protect the valve from The steering components should be checked periodically for
contamination or damage. loose fasteners, worn tie rod ends, ball joints, and damage. Also
7. Remove spark plug high tension lead. Clean plug area so check to make sure all cotter pins are in place. If cotter pins are
no dirt and debris can fall into engine when plug is removed, they must not be re–used. Always use new cotter pins.
removed.

MAINTENANCE
Replace any worn or damaged steering components. Steering Wheel Alignment
should move freely through entire range of travel without
binding. Check routing of all cables, hoses, and wiring to be sure One of two methods can be used to measure toe alignment. The
the steering mechanism is not restricted or limited. string method and the chalk method. If adjustment is required,
refer to following for procedure.
NOTE: Whenever steering components are
replaced, check front end alignment. Use only
genuine Polaris parts.
METHOD 1: USING A STRAIGHTEDGE OR STRING
2
WARNING
WARNING
Severe injury or death can result from improper toe
Due to the critical nature of the procedures outlined in alignment and adjustment.
this chapter, Polaris recommends steering component
repair and adjustment be performed by an authorized 1. Position the vehicle on a level surface.
Polaris MSD certified technician when replacing NOTE: Always measure toe alignment on a flat
worn or damaged steering parts. ground surface.
Use only genuine Polaris replacement parts. 2. Place the handlebars in a straight-ahead position. Use tie
straps to secure the handlebars to the rear grab bar so they
Controls can’t move.
3. Place stands (1) in front of the vehicle, perpendicular to the
Check controls for proper operation, positioning and rear tires. See illustration below.
adjustment.
Handlebars
2
If desired, the handlebars can be adjusted for rider preference.
WARNING
Improper adjustment of the handlebars or incorrect

torquing of the adjuster lock bolts can cause limited
steering of the handle bars, which could result in
loss of control and serious injury or death.
1. Loosen the four bolts and adjust the handlebar to the

desired height. Be sure the handlebars do not contact the
gas tank or any other part of the machine when turned fully
to the left or right.
3
1
11 ft. lbs.
(15 Nm)
1
4. Tie an elastic string (2) around the stands, making sure the
2. Torque the rear two bolts to 11 ft. lbs. (15 Nm), then torque string just touches the side surface of the rear tires on each
the front two bolts. A gap of up to 1/8” will remain at the side of the vehicle and goes around the stands in front of
rear bolts. the vehicle.
2.25
MAINTENANCE
5. Measure the distance between the string in front of the rear • Repeat inspection for inner tie rod end on steering post.
tires (A) and in front of the front tires (B). If the two
measurements are not equal, adjust the string position until
the measurements are equal.
6. Measure the distance from the string to the rim at the front
and rear of the front rim (3). The difference between these
two measurements should be between 0” and 1/16” toe out.
METHOD 2: USING A CHALK LINE

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 post arm
“frog” can be used as an indicator of whether the handlebars
are straight. The frog should be centered with equal
clearance between the steering stops.
3. Place a chalk mark on the center line of the front tires as • Elevate front end of machine so front wheels are off the
close to the hub/axle center line as possible, or measure to ground. Check for any looseness in front hub / wheel
a specific distance from the floor. NOTE: It is important assembly by grasping the tire firmly at top and bottom
that the height of both marks be equally positioned in order first, and then at front and rear. Try to move the wheel
to get an accurate measurement. and hub by pushing inward and pulling outward.
4. Measure the distance between the marks and record the
• If abnormal movement is detected, inspect the hub and
measurement. Call this measurement “A”.
wheel assembly to determine the cause (possible loose
5. Rotate the tires 180o by moving vehicle forward or wheel nuts or loose front hub components).
backward. Position chalk marks even with the hub/axle
centerline or the specified floor measurement.
6. Again measure the distance between the marks and record.
Call this measurement “B”. Subtract measurement “B”
from measurement “A”. The difference between
measurements “A” and “B” is the vehicle toe alignment.
The recommended vehicle toe tolerance is 0 to 1/16” (0
to.0625 cm) toe out. This means the measurement at the
front of the tire (A) is 0 to 1/16” (0 to.0625 cm) wider than
the measurement at the rear (B).
Check for Loose Wheel or Hub
• Refer to the Body/Suspension Chapter 5 or Final Drive

Chapter for service procedures.
Chalk Line
Measurement ‘B’
Chalk Line Measurement ‘A’
Steering Inspection / Tie Rod Ends and Hubs

• To check for play in the tie rod end, grasp the steering
tie rod, pull in all directions feeling for movement.

MAINTENANCE
Toe Alignment Adjustment Suspension Spring Preload Adjustment
If toe alignment is incorrect, measure the distance between The front suspension preload may be adjusted to suit different
vehicle center and each wheel. This will tell you which tie rod conditions and operator weight.
needs adjusting.
NOTE: Be sure handlebars are straight ahead before WARNING

determining which tie rod(s) need adjustment. 2
Uneven adjustment may cause poor handling of the
ATV, which could result in an accident and serious
CAUTION injury or death. Always adjust both the left and right
spring preloads equally or have your Polaris
During tie rod adjustment, it is very important that dealer perform the adjustments.
the following precautions be taken when
tightening tie rod end jam nuts. Front Suspension Set-Up
If the rod end is positioned incorrectly it will not
pivot, and may break. 1. Position the vehicle on a level surface.
2. Stop the engine.
3. Elevate the front of the vehicle by placing a suitable stand
under the frame.
To adjust toe alignment:
NOTE: The tires should be barely touching the
• Hold tie rod end to keep it from rotating. ground and the suspension should be at full
rebound.
• Loosen jam nuts at both ends of the tie rod.
4. Measure the distance from the ground to the bottom of the
• Shorten or lengthen the tie rod until alignment is as lower front bumper bolt. Note this measurement for later
required to achieve the proper toe setting as specified in use.
Method 1 or Method 2.
• IMPORTANT: When tightening the tie rod end jam

nuts, the rod ends must be held parallel to prevent rod
end damage and premature wear. Damage may not be
immediately apparent if done incorrectly.
• After alignment is complete, torque jam nuts to

specification.
Hold Rod End Level While Nut Is Tightened

12–14 ft. lbs.
(16–19 Nm)
5. Remove the support stand and have a rider sit comfortably

on the seat with hands on the handlebars.
Correct Tie Rod End Incorrect Tie Rod End 6. Place the transmission in neutral and slowly roll the
machine forward and backward at least ten feet (3 m)
without lifting or pushing down on the suspension.
Camber and Caster 7. Turn the handlebars fully to the left and right.
The camber and caster are non–adjustable. 8. With the rider still on the vehicle, repeat the measurement
performed in step 4.
2.27
MAINTENANCE
9. Subtract the step 8 measurement from the step 4 Rear Suspension Set-Up
measurement. The difference should be between 3.75 and
4 inches (9.5 - 10.2 cm). 1. Position the vehicle on a level surface.
2. Stop the engine.
10. If the number is less than 3.75 inches (9.5 cm), decrease the
3. Elevate the rear of the vehicle by placing a suitable stand
front spring preload and repeat all steps (See “Front Spring
under the frame.
Preload Adjustment”). If the number is higher than 4 inches
(10.2 cm), increase spring preload and repeat all steps. NOTE: The tires should be barely touching the
ground and the suspension should be at full
Front Spring Preload Adjustment rebound.
1. Raise and safely support the front of the ATV off the 4. Measure the distance from the ground to the bottom of the
ground to allow the suspension to fully extend. rear lower control arm pivot bolt. Note this measurement
for later use.
Preload adjustment tool
is included in tool kit
Figure 2-27
2. Turn the adjusting ring (1) clockwise to increase preload or

counter-clockwise to decrease preload.
5. Remove the support stand and have a rider sit comfortably
on the seat with hands on the handlebars.
1
6. Place the transmission in neutral and slowly roll the
machine forward and backward at least ten feet (3 m)
Decrease Increase without lifting or pushing down on the suspension.
Preload Preload 7. Turn the handlebars fully to the left and right.
8. With the rider still on the vehicle, repeat the measurement
performed in step 4.
9. Subtract the step 8 measurement from the step 4
Ride-In measurement. The difference should be between 4 and 4.25
Spring
Spring inches (10.2 - 10.8 cm).
Spacer
10. If the number is less than 4 inches (10.2 cm), decrease the
rear spring preload on both shocks and repeat all steps. (See
“Rear Spring Preload adjustment”) If the number is higher
than 4.25 inches (10.8 cm), increase spring preload and
repeat all steps.
Rear Spring Preload Adjustment

• The rear suspension spring preload and shock
compression damping may be adjusted to suit different
riding conditions and operator weight.
1. Raise and safety support the rear of the ATV off the ground
to allow the suspension to fully extend.

MAINTENANCE
2. Turn the adjusting ring (1) clockwise to increase preload or
counter-clockwise to decrease preload. See Figure 2-27 on Rear Compression Adjustments
previous page.
Setting Compression Damping
1 Softest Position #1 - Full Counter-Clockwise
Factory Position #4 - 3 Clicks from #1 2
Decrease Increase Firmest Position #7 - 6 Clicks from #1
Preload Preload
BRAKE SYSTEM
Brake System Inspection
Spring Ride-In
Spring The following checks are recommended to keep the brake
Spacer system in good operating condition. Service life of brake system
components depends on operating conditions. Inspect brakes in
accordance with the maintenance schedule and before each ride.
• Keep fluid level in the master cylinder reservoir to the

indicated level inside reservoir.
• Use Polaris DOT 3 or DOT 4 Brake Fluid

Rear Shock Compression Adjustment
Parking Brake
The compression damping adjustment is located on the bottom Lock
of each rear shock.
Use a flat blade screwdriver to make adjustments. There are 7

positions of compression adjustment.
The softest adjustment is position #1. To obtain position #1,

turn the adjuster counter-clockwise until it stops.
The firmest adjustment is position #7. To obtain position #7,

start from position #1 and turn the adjuster clockwise 6 clicks. Sight
Front Master Cylinder
Glass
The factory setting is position #4 or 3 clicks clockwise from
position #1.
Softest - 1 7 Positions
Factory - 4 Position 1 - Full Counter-Clockwise.
Firmest - 7 Position 7 - 6 Clicks Clockwise from
Position 1.
Use a
screwdriver
to adjust
Rear Master Cylinder
Compression Adjustment • Check brake system for fluid leaks.

Location
• Check brake for excessive travel or spongy feel.
• Check friction pads for wear, damage or looseness.
2.29
MAINTENANCE
• Check surface condition of the disc. Free Play:
• Inspect thickness of brake pad friction material. Free play of the brake pedal should be 1/8″ – 1/4″ (3.2 – 6.35
mm).
Hose / Fitting Inspection
If free play is excessive, inspect pedal (1), linkage, and master
Check brake system hoses and fittings for cracks, deterioration, cylinder (2) for wear or damage and replace any parts as needed.
abrasion, and leaks.Tighten any loose fittings and replace any
worn or damaged parts. Bleeding:
Brake Pad Inspection If free play is correct and brake pedal travel is still excessive, air
may be trapped somewhere in the system. Bleed the hydraulic
Pads should be changed when the friction material is worn to auxiliary brake system in a conventional manner, following the
3/64” (.1 cm), or about the thickness of a U.S. dime.
procedure outlined in the Brake Chapter.
WHEELS AND TIRES

Wheels
Inspect all wheels for runout or damage. Check wheel nuts and
ensure they are tight. Do not over tighten the wheel nuts.
Wheel, Hub, and Spindle Torque Table
3/64” (.1cm) Item Specification

Minimum Thickness Front Wheel Nuts 30-35 Ft. Lbs. (41-47 Nm)
Rear Wheel Nuts 30-35 Ft. Lbs. (41-47 Nm)
Brake Testing Front Spindle Nut 40 Ft. Lbs. (55 Nm)
Rear Hub Retaining Nut 90 Ft. Lbs. (108 Nm)
The foot brake should be checked for proper function.
Wheel Removal: Front or Rear

Wheel Removal
1. Stop the engine, place the transmission in gear and lock the
parking brake.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing a suitable stand
under the footrest frame.
4. Remove the wheel nuts and remove the wheel.
1 Wheel Installation
2
1. With the transmission in gear and the parking brake
locked, place the wheel in the correct position on the wheel
When applied, the brake power should be sufficient enough to hub. Be sure the valve stem is toward the outside and
stop the wheels under most conditions. rotation arrows on the tire point toward forward rotation.
2. Attach the wheel nuts and finger tighten them.
If brake operation is poor, two things must be examined:
3. Lower the vehicle to the ground.

MAINTENANCE
4. Securely tighten the wheel nuts to the proper torque listed Tire Tread Depth
in the table.
Always replace tires when tread depth is worn to 1/8″ (3 mm)
CAUTION or less.
Improperly installed wheels could affect vehicle WARNING

handling and tire wear. On vehicles with flange wheel
nuts, make sure flat of nut goes onto wheel.
2
Operating your ATV with worn tires, improperly
inflated tires, non - standard tires or improperly
installed tires will affect vehicle handling and could
cause an accident resulting in serious injury or death.
Maintain proper tire pressure as described on the ATV
decal and in the owner’s manual.
Always use original equipment size and type
when replacing tires.
Make sure the wheels are installed properly.
1/8″ (.3 cm)

Flat side against wheel
Tire Pressure
CAUTION
Maintain proper tire pressure. Refer to the warning

tire pressure decal applied to the vehicle.
Tire Pressure (PSI - Cold)

Front Rear
5 5
Tire Inspection
• Improper tire inflation may affect ATV
maneuverability.
• When replacing a tire always use original equipment

size and type.
• The use of non–standard size or type tires may affect

ATV handling.
2.31
MAINTENANCE
NOTES

ENGINE
CHAPTER 3
ENGINE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ES50PL ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ES50PL ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
ENGINE FASTENER TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3
COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
COOLANT TEMPERATURE SENSOR (THERMISTOR) . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
RADIATOR CAP / SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
CRANKSHAFT STRAIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ES50PL ENGINE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
OIL FLOW - ES50PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
ES50PL OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
ES50PL ENGINE EXPLODED VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
UPPER ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
CAM CHAIN TENSIONER INSPECTION AND REASSEMBLY. . . . . . . . . . . . . . . . . . . 3.14
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
AUTOMATIC COMPRESSION RELEASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 3.15
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CYLINDER AND PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
PISTON AND ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
LOWER ENGINE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CRANKCASE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
STARTER DRIVE GEARS REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . 3.19
FLYWHEEL / ONE-WAY STARTER CLUTCH REMOVAL AND INSPECTION. . . . . . . 3.19
CRANKSHAFT NUT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
CLUTCH COVER / CLUTCH REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . 3.20
SHIFTER COMPONENT REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 3.22
OIL PUMP REMOVAL AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CRANKSHAFT DRIVE AND CAM GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CAM CHAIN / TENSIONER BLADE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CRANKCASE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CRANKCASE BEARING INSPECTION / REMOVAL / INSTALLATION . . . . . . . . . . . . 3.25
TRANSMISSION AND CRANKSHAFT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
TRANSMISSION REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
TRANSMISSION MAIN SHAFT DISASSEMBLY / ASSEMBLY . . . . . . . . . . . . . . . . . . . 3.26
TRANSMISSION REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
CRANKSHAFT REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
CRANKSHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
3.1
ENGINE
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CAM CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
PRIMARY DRIVE GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
OUTLAW CAM TIMING EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CYLINDER HEAD SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
CYLINDER HEAD WARP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
CYLINDER HEAD VALVE GUIDE / VALVE SEAT INSPECTION . . . . . . . . . . . . . . . . . 3.36
VALVE GUIDE REMOVAL / INSTALLATION / REAM . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
ES50PL ADJUSTING PAD SELECTION MATRIX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
PISTON–TO–CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
CYLINDER HONE SELECTION AND HONING PROCEDURE. . . . . . . . . . . . . . . . . . . 3.43
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
OIL SEAL / MECHANICAL SEAL REMOVAL (ENGINE DISASSEMBLED) . . . . . . . . . 3.44
WATER PUMP MECHANICAL SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
MECHANICAL SEAL REMOVAL AND INSTALLATION (ENGINE ASSEMBLED) . . . . 3.45
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
SPARK PLUG FOULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48

ENGINE
SPECIFICATIONS
Torque Specifications
ES50PL
Fastener Thread ES50PL: Ft. Lbs. (Nm)
Blind Plug (Crankcase) 1/8 PT 6.6–11.1 (9–15 Nm)
Blind Plug (Oil Filter Cover) 1/4 PT 12.5–17 (17–23 Nm)
Bearing Stop Plates 6mm 8.1–9.6 (11–13 Nm)
Camshaft Chain Tensioner Blade Bolt
Camshaft Chain Tensioner
8mm
6mm
10–12.2 (13.5–16.5 Nm)
6.6–8.1 (9–11 Nm)
3
Camshaft Chain Tensioner Cap 6mm 6.6–8.1 (9–11 Nm)
Camshaft Support 8mm 6.6–7.5 (9–10 Nm)
Carburetor Adaptor 8mm 11.8–14.8 (16–20 Nm)
Crankcase Cover 8mm 6.6–8.1 (9–11 Nm)
Crankshaft Nut (Primary Drive Sprocket) 18mm 81–96 (110–130 Nm)
Crankshaft Nut (Ball Bearing at Crankshaft) 32mm 66–81 (90–110 Nm)
11mm Refer to Page 3.42
Cylinder Base / Head Bolts
6mm 6–8 (9–11 Nm)
Clutch Basket Nut 18mm 66–81 (90–110 Nm)
Clutch Cover 6mm 6.6–8.1 (9–11 Nm)
Drive Sprocket and Sprocket Cover 6mm 6.6–8.1 (9–11 Nm)
Flywheel (Apply engine oil to threads) 14mm 111–125 (150–170 Nm)
Neutral Indicator Switch 5mm 2.2–3.7 (3–5 Nm)
Oil Delivery Pipe 12mm 11.1–15.5 (15–21 Nm)
Oil Drain Bolt (Crankcase) 14mm 14–17 (19–23 Nm)
Oil Filter Cover Housing and Oil Pump Case 6mm 6.6–8.1 (9–11 Nm)
Oil Hose Fittings 8mm 8.1–10.3 (11-14 Nm)
One Way Valve Plug 11mm 11.1–15.5 (15-21 Nm)
One Way Clutch Screws 6mm 9.6–11.1 (13–15 Nm)
Pulser Coil (Apply PN2871557 to threads) 5mm 1.8–2.6 (2.5–3.5 Nm)
Pressure Plate Screws 6mm 6.6–8.1 (9–11 Nm)
Shift Cam 6mm 5.9–7.4 (8–10 Nm)
Shift Lever 6mm 6.6–8.1 (9–11 Nm)
Shift Detent Arm (Apply PN 2871557 to threads) 6mm 6.6–8.1 (9–11 Nm)
Stator Housing Cover 6mm 6.6–8.1 (9–11 Nm)
Stator Plate 5mm 4.1–5.8 (5.5–6.5 Nm)
Starter Motor 6mm 6.6–8.1 (9–11 Nm)
Spark Plug 12mm 11.1–14.8 (15–20 Nm)
Timing Cover Plug (Center) 32mm 7.4–8.8 (10–12 Nm)
Timing Cover Plug (Timing window) 14mm 2–4 (3–5 Nm)
Thermo Cover 6mm 5.2–6.6 (7–9 Nm)
Thermo Switch 3/8 NPT 23.6–28 (32–38 Nm)
Valve Cover 6mm 6.6–8.1 (9–11 Nm)
Water Pump Impeller 6mm 6.6–8.1 (9–11 Nm)
Water Pump Housing Cover 6mm 6.6–8.1 (9–11 Nm)
Radiator Thermistor -- 8 ±12 in.lbs. (0.8 ± 1.36 Nm)
3.3
ENGINE
ES50PL Engine Service Data
Cylinder Head / Valve ES50PL

Std 1.667–1.671” (42.35–42.45 mm)
In
Limit 1.655” (42.05 mm)
Cam lobe height
Std 1.667–1.671” (42.35–42.45 mm)
Ex
Limit 1.655” (42.05 mm)
Mag .9821–.9828” (24.946–24.963 mm)
Camshaft journal OD
Camshaft PTO .8652–.8655” (21.976–21.985 mm)
Mag .9842–.9851” (25.000–25.021 mm)
Camshaft journal bore ID
PTO .8657–.8661” (21.990–22.000 mm)
Mag .0014–.0029” (.037–.075 mm)
Camshaft Oil clearance PTO .0001–.0009” (.005–.024 mm)
Limit .004” (.10 mm)
Surface warpage limit .0020” (.05 mm)
Cylinder Head
Standard height 4.975” (126.4 mm)
Std 1.5255” (38.75 mm)
Contacting width In
Limit 1.5425” (39.18 mm)
Valve Seat **Measure valve stem
height Std 1.5255” (38.75 mm)
Ex
Limit 1.5377” (39.06 mm)
Inner diameter .2362- .2367” (6.0- 6.012 mm)
Valve Guide
Protrusion above head .535- .551” (13.6- 14.0 mm)
Std .039” (1.0 mm)
In
Limit .031” (.8 mm)
Margin thickness
Std .039” (1.0 mm)
Ex
Limit .031” (.8 mm)
In .2343–.2348” (5.950–5.965 mm)
Stem diameter
Ex .2341–.2346” (5.945–5.960 mm)
Valve In .0014–.0024” (.035–.062 mm)
Std
Stem oil clearance Ex .0016–.0026” (.040–.067 mm)
Limit .0059” (.15 mm)
In 4.031” (102.4 mm)
Overall length
Ex 4.059” (103.1 mm)
In .006” (.15 mm) +/- .0019” (.05 mm)
Valve Lash
Ex .010” (.27 mm) +/- .0019” (.05 mm)
Overall length Inner 1.575” (40.0 mm)
Limit = -.079” (-2.0 mm) Outer 1.650” (41.9 mm)
Valve Spring
Inner .067-” (1.7 mm)
Squareness
Outer .071” (1.8 mm)

ENGINE
ES50PL Engine Service Data
Cylinder / Piston / Connecting Rod / Crankshaft ES50PL

Surface warpage limit (mating with cylinder head) .002” (.05 mm)
Cylinder bore Std 3.9055–3.9062” (99.20–99.22 mm)
Taper limit .002” (.05 mm)
Cylinder
Out of round limit .002” (.05 mm)
Std .0018- .0025” (.046- .065 mm)
Piston clearance
Limit .0039” (.10 mm) 3
Outer diameter Std 3.9037- 3.904” (99.155- 99.170 mm)
Piston
Piston Pin Bore Standard I.D. .9055- .9057” (23.001- 23.007 mm)
Outer diameter Std .9053- .9055” (23.001 - 23.007 mm)
Piston pin to pin bore clearance .0002- .0004” (.001- .0011 mm)
Piston Pin
Piston Pin must be a push (by hand)
Degree of fit
fit at 68o F(20o C)
Top Std .0012–.0028” (.030–.070 mm)
Ring Limit .0059” (.15 mm)
Piston Ring to ring groove clearance
Second Std .0012–.0028” (.030–.070 mm)
Top Std .008–.012” (.20–.30 mm)
Second Std .014–.019” (.35–.50 mm)
Piston Ring installed gap
Std .004–.019” (.10–.50 mm)
Oil Ring
Limit .039” (1.0 mm)
Connecting rod small end ID .9058- .9063” (23.007- 23.020 mm)
Connecting rod small end radial Std .0003- .0009” (.007- .024 mm)
clearance Limit .0020” (.05 mm)
Connecting Rod Std .0035- .0196” (.09- .50 mm)
Connecting rod big end side clearance
Limit .0255” (.65 mm)
Connecting rod big end Std .0004- .0015” (.011- .038 mm)
radial clearance Limit Same as standard
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.
3.5
ENGINE
Special Tools GENERAL ENGINE SERVICE
PART NUMBER TOOL DESCRIPTION Piston Identification
Water Pump Mechanical
2872105 The piston may or may not have an identification mark for
Seal Puller
Valve Seat Reconditioning
piston placement. If the piston has an identification mark, follow
2200634 the directions for piston placement below. If the piston does not
Kit
have an identification mark, the direction for placement of the
2870390 Piston Support Block piston does not matter.
Cam Chain Tensioner
PA-45958 NOTE: Note the directional and identification marks
Assembly Tool
when viewing the pistons from the top. Identifying
PA-46075 Flywheel Puller marks such as “F”, “J”, “X“or Q must always be
MAG End Crankshaft Nut positioned to the flywheel side of the engine. Other
PA- 46076 marks are used for identification as to diameter,
Remover/Installer
length and design. Four stroke engine rings are a
PA-46087 Crankcase Separator
rectangular profile. See text for oil control ring rail
MAG End Crankshaft installation. Use the information below to identify
PA-46077
Installer pistons and rings:
Crankshaft/Water Pump
2871283
Seal Install Kit
5131135 Water Pump Install Kit Compression Test
PA-46502 Valve Spring Compressor NOTE: This engine has built-in decompression
components. Compression readings will vary in
Engine Fastener Torque Patterns proportion to cranking speed during the test.
Average compression (measured) is about 85-90 psi
Tighten cylinder head, cylinder base, and crankcase fasteners @ 400 RPM during a compression test.
following the sequence outlined below.
A cylinder leakdown test is the best indication of engine
condition. Follow manufacturer’s instructions to perform a
Cylinder Head & Cylinder Base cylinder leakage test. Never use high pressure leakage testers,
as crankshaft seals may dislodge and leak.
3 2 5 8 mm
Cylinder Compression w / decompression
1 4 6
Standard: 85-90 PSI @ 400 RPM
Cylinder Leakdown
Service Limit: 10%
8 5 (Inspect for cause if leakage exceeds 10%)
2
3
10
4 13
1
12
6
7
11 9

ENGINE
Coolant Temperature Sensor (Thermistor) Radiator Cap Pressure Test
1. Remove radiator cap and test using a cap tester
(commercially available).
2. The radiator cap relief pressure is 13 psi. for all models.
Replace if cap releases at less than 13 psi.
8-12 in. lbs.
(.9-1.3 Nm) Pressure test
From Thermostat Sensor here with cap
in place
3
To Water Pump
Cooling System
FLOW
Radiator
Coolant Flow Diagram
Cooling System Specifications

Thermostat Water Pump
Description Temperature
Fan Switch (Off) 150o F (65o C) ± 8o
Fan Switch (On) 180o F (82o C) ± 7o
Hot Light On 221o F (105o C)
Cylinder Cylinder System Capacity 2.25 Quarts (2.1 L)
Head Radiator Cap Relief
13 PSI
Pressure
Recommended Coolant Type

Use only high quality antifreeze/coolant mixed with distilled
WARNING water in a 50/50 or 60/40 ratio, depending on freeze protection
required in your area.
Never remove radiator cap when engine is
warm or hot. The cooling system is under IMPORTANT: Using tap water in the cooling system
pressure and serious burns may result. will lead to a buildup of deposits which may restrict
Allow the engine and cooling system to cool coolant flow and reduce heat dissipation, resulting in
before servicing. possible engine damage. Polaris Premium 60/40
Antifreeze / Coolant (PN 2871323) is recommended for
Radiator Cap / System Pressure Test use in all cooling systems and comes pre–mixed,
ready to use.
1. Remove recovery bottle hose from coolant filler neck.
2. Connect a Mity Vac™ (PN 2870975) to radiator and
pressurize system to 10 PSI. The system must retain 10 lbs
of pressure for five minutes or longer. If pressure loss is
evident within five minutes, check radiator, all cooling
system hoses and clamps, or water pump seal.
3.7
ENGINE
Accessible Components Engine Removal
The following components can be serviced or removed with 1. Thoroughly clean the ATV engine and chassis.
the engine installed in the frame: 2. Clean work area.
3. Support the ATV with jackstands under the footrests at a
• Flywheel height sufficient to raise the rear wheels off the floor at least
• Alternator/Stator 5 inches (12.7 cm).
4. Drain coolant and engine oil.
• Starter Motor/Starter Drive
5. Remove the following components:
• Water Pump / Water Pump Mechanical Seal*
• Seat
*Mechanical Water Pump Seal Removal Tool (PN 2872105) is
required to replace mechanical seal with engine in frame. • Side Panels
The following components require engine removal for • Front Cab (Refer to Chapter 5)
service: • Fuel Tank (Refer to Chapter 4)
• Counterbalance Shaft or Bearing(s) • RH footwell (Refer to Chapter 5)
• Connecting Rod 6. Disconnect battery cables, starting with the negative (–)
• Crankshaft cable first.
7. Remove air intake duct.
• Crankshaft Main Bearings
8. Remove carburetor. Caution: Fuel will leak if carb is
• Cylinder Head turned upside down. In most instances, the carburetor will
• Cylinder not have to be disconnected from the throttle cable, choke
cable and fuel line for engine removal. Insert a shop towel
• Piston/RIngs into the carburetor flange to prevent dirt from entering the
• Camshaft intake of the engine.
9. Disconnect all electrical connections to the engine (coolant
• Cams sensor, neutral switch, plug wire, starter cable, ground
• Cam Chain and Sprockets cable). Remove the magneto side cover, leaving the
electrical components attached, and secure out of the way.
• Transmission Gears and Bearings
10. Remove clutch and reverse cable linkage and secure out of
the way.
11. Remove fasteners from exhaust pipe and remove header
pipe.
12. Remove oil tank and hoses as an assembly. Disconnect vent
line and secure out of the way.
13. Loosen chain, disconnect and remove. An acceptable
alternative is to remove the transmission drive sprocket and
roll chain off.
14. Remove all engine mount nuts and engine mount plates,
starting at the rear with the combination engine / swing arm
pivot mount first. Using a suitable tool, push the bolt out
far enough to loosen the engine, but not drop the swing arm
pivot. Use a jack under the bearing carrier to relieve tension
from the pivot bolt for easier removal and installation.
15. With an assistant helping you, remove the engine by tilting
forward and turning to exit through left side of frame.
To reinstall the engine, reverse the procedures. Refer to engine

installation notes on Page 3.9.

ENGINE
Engine Installation Notes Engine Break In Period
After the engine is installed in the frame, review this checklist The break in period for a Polaris ATV engine is defined as the
and perform all steps that apply: first ten hours of operation, or the time it takes to use two full
tanks of gasoline. No single action on your part is as important
General Items as a proper break in period. Careful treatment of a new engine
will result in more efficient performance and longer life for the
• Torque Rear Engine Lower Mount to 90 ft. lbs. engine. Perform the following procedures carefully.
(122 Nm)
New and rebuilt engines require a break-in oil change at 1 hour
• Torque Front Engine Lower Mount to 27 ft. lbs. of engine run time.
(33 Nm)
• Torque Top Engine Mount to 22 ft. lbs. (30 Nm) OIL RECOMMENDATION 3
• Install previously removed components using new Polaris PS-4 All Season synthetic oil is specially
gaskets, seals, and fasteners where applicable. formulated for use with wet-clutch transmissions.
Never substitute or mix oil brands. Serious engine
damage and voiding of warranty can result.
• Perform checks on fluid levels, controls, and all
important areas on the vehicle as outlined in the daily For new or rebuilt engines, do not operate at full
pre–ride inspection checklist (refer to Chapter 2 or the throttle or high speeds for extended periods during the
Owner’s Manual). first three hours of use. Excessive heat can build up
and cause damage to close fitted engine parts.
• Verify clutch and lever freeplay according to
procedures in Chapter 2. 1. Fill fuel tank with unleaded fuel which has a minimum
pump octane number of 87= (R+ M)/2.
• Adjust chain tension according to procedures in
2. Check oil reservoir level indicated on dipstick. Add oil if
Chapter 2.
necessary.
Exhaust
• Replace exhaust gaskets. Seal connections with high SAFE ADD 8 OZ
temp silicone sealant if applicable.
• Verify all fasteners are in good condition and torqued

properly. 3. Drive slowly at first to gradually bring engine up to
operating temperature.
Bleed Cooling System 4. Vary throttle positions. Do not operate at sustained idle or
sustained high speed.
NOTE: Refer to Page 3.7 for hose routing. Bleeding
generally is necessary after repairs to purge any air 5. Perform regular checks on fluid levels, controls and all
that may remain in the system during filling. important areas on the vehicle.
6. Pull only light loads during initial break in.
1. Remove radiator cap and slowly add coolant to the bottom 7. Change break in oil and filter at 1 hour or 100 miles.
of filler neck.
2. Fill coolant reservoir tank to full mark.
3. Install radiator cap half-way and gently squeeze coolant
hoses to force any trapped air out of system.
4. Again, remove radiator cap and slowly add coolant to the
bottom of fill neck if required.
5. Start engine and observe coolant level in the radiator. Allow
air to purge and top off as necessary. Reinstall radiator cap
and bring engine to operating temperature. After engine is
cool, check level in reservoir tank and add coolant if
necessary.
NOTE: Should the reservoir tank become empty, it
will be necessary to refill at the radiator and repeat
the bleeding procedure.
3.9
ENGINE
Crankshaft Straightening 3. If the crank rod pin location is 180o from the dial indicator
(opposite that shown), it will be necessary to spread the
Lubricate the bearings and clamp the crankshaft securely in the crankshaft at position A as shown in the illustration below.
crankshaft alignment fixture. Refer to the illustrations below. When rebuilding and straightening a crankshaft, runout
must be as close to zero as possible.
Crankshaft Alignment Fixture HIGH .002 (.05 mm)
(PN 2870569) HIGH .005 (.13 mm)
A A
NOTE: The rod pin position in relation to the dial

indicator position tells you what action is required to
straighten the shaft.
1. To correct a situation like the one shown in the illustration,

strike the shaft at point A with a brass hammer.
HIGH .004 (.1 mm)

A
HIGH .004 (.1 mm)
NOTE: Maximum allowable runout is .0024”.
ES50PL Engine Lubrication

Oil Type:
Polaris PS-4 Synthetic (PN 2874414)
B
Capacity:
SUPPORT CRANKSHAFT HERE Approximately 2.25 U.S. Quarts (2.1L)
2. To correct a situation like the one shown in the illustration, Filter:

squeeze the crankshaft at points A. (Use tool from (PN 3088036)
alignment kit).
Drain Plug / Screen Fitting:
HIGH .002 (.05 mm)
14.8 - 17 ft. lbs. (20-23 Nm)
HIGH .005 (.13 mm) (If fitting is removed, follow oil pump priming procedure).
Oil Pressure Specification:

20 PSI @ 5500 RPM, Polaris PS-4 Synthetic
(Engine Hot)
Oil Pressure Test

1. Remove blind plug on front right oil filter cover.
A A 2. Insert a 1/8 NPT oil pressure gauge adaptor and attach the
gauge.
3. Start engine and allow it to reach operating temperature,
monitoring gauge indicator.
NOTE: Use only Polaris PS-4 Synthetic Engine
Lubricant (PN 2874414).
Oil Pressure at 5500 RPM (Engine Hot):

Standard: 20 PSI
Minimum: 12 PSI

ENGINE
Oil Pump Priming Procedure Oil Flow - ES50PL
NOTE: The oil pump priming procedure should be The chart on Page 3.12 describes the flow of oil through the
performed as a safeguard against loss of pump ES50PL engine. Beginning at the oil tank, the oil flows through
prime when repairing oil tank, lines or engine. 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
1. Clamp or pinch off vent line approximately 2” from oil
and into the crankcase oil gallery, pulling the oil through another
tank, between the end of oil tank vent fitting and the vent
passage to the one way valve. When the engine is off, the one
line.
way valve closes to prevent oil in the tank from draining into the
crankcase. Oil is then pumped to the oil filter. If the oil filter is
obstructed, a bypass valve contained in the filter allows oil to
bypass the filter element. 3
At this point, the oil is diverted in three directions. Oil is
supplied to the crankshaft through a PTO side oil passage,
lubricating the crank bearings, crank pin, piston, cylinder and
connecting rod bearings. A delivery pipe supplies oil to the top
of the cylinder head and the transmission main shaft. Oil is
delivered though the pipe and enters the camshaft through the
2. Run engine for 5-10 seconds at IDLE. cam support oil gallery. The camshaft journals are lubricated
through holes in the camshaft. Oil lubricates the cam chain
IMPORTANT: Do not raise rpm or run for more than 10
sprockets and cam lobes via an oil jet, which drains to the
seconds. Damage to tank may result.
crankcase.
3. Shut off engine. Remove the vent line clamp. The oil pump
Another oil path flows from the delivery pipe to the transmission
should now be properly primed and ready for field
main shaft. Here it passes through the oil gallery to lubricate the
operation.
transmission gears, clutch and bearings.
NOTE: If the system is primed properly you should
hear some air release. If you do not, the system has Residual oil from the lubrication of the crankshaft and
not primed. Repeat the process if necessary. connecting rod indirectly lubricates the cylinder wall, piston,
rings, connecting rod small end bearing, piston pin, oil/water
pump drive gears, cam chain, drive sprocket, and Magneto end
crankshaft main bearing.
A one–way valve is located on the right front (PTO) side of the

crankcase. This valve prevents oil in the tank from draining into
the engine crankcase 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 crankcase when the engine is off, inspect the valve sealing
surface for debris or damage. Inspect the return spring for
distortion or damage.
3.11
ENGINE
ES50PL Oil Flow Chart
Top of Oil Tank
Crankcase (Clutch Side) Oil Pump

Oil Tank Oil Hose Crankcase (Mag Side)
Oil Gallery (Scavenging)
Oil Gallery
Oil Hose Oil Strainer
Crankcase (Mag Side) Crankcase

Oil Gallery
Cylinder
Cam Chain
Piston Cam & Crank Sprocket
Crankcase (Clutch Side)
Oil Gallery
Indirect Connecting Rod

Lubrication
(Small End) Chain Room
Oil Pump
Prevents oil from (Feed)
draining into Ball Bearing
crankcase with (Mag Side)
engine off Large End Cam Lobe
Cam Shaft
Bearing Valve Lifter Journal
One Way Valve
Oil Jet
Cam Support
Bypass Oil Filter Crank Pin Oil Gallery
Delivery Pipe Crankshaft

Cylinder Head
Oil Gallery
Oil Shaft Gears
Indirect
Lubrication
Transmission
Gears & Clutch
Main Shaft
Transmission
Gears
Counter Shaft

ENGINE
ES50PL Engine Exploded Views
Crankcase / Transmission Cylinder / Cylinder Head
Crankshaft and Piston Valve Train
3.13
ENGINE
UPPER ENGINE DISASSEMBLY 6. If tensioner remains in place, tap lightly on tensioner body
with a soft face hammer and remove tensioner.
Disassembly
CAUTION
REFER TO PAGE 3.8-3.9 FOR ENGINE
REMOVAL / INSTALLATION NOTES
The assembly is under spring tension.
Maintain inward pressure while removing.
Cam Chain Tensioner Removal
7. For installation, retract the plunger using the special tool
1. Remove ignition timing inspection plug from recoil
and reverse the installation procedures using a new gasket.
housing.
Tighten bolts to specification. (Page 3.3)
To position crankshaft at Top Dead Center (TDC) on the
compression stroke: Cam Chain Tensioner Inspection and
Reassembly
2. Rotate engine slowly in the direction of rotation watching
intake valves open and start to close. NOTE: The cam tensioner assembly is not a
3. Continue to rotate engine slowly, watching for the camshaft serviceable item. Replace assembly if problems are
sprocket marks and the indicator mark in the timing found. Spring tension may be relieved using the
inspection hole. special tool prior to removal, but is not necessary.
A
TDC
Case Mark
B
A- Tool PN PA-45958
B- 10mm tensioner cap
TDC Line
1. When removed, the cam chain tensioner plunger should be
(Left of the “T”) extended outward to the end of its travel. Verify and
inspect the plunger for wear or damage.
4. Align the indicator mark on flywheel with the indent in the 2. Push on the plunger. The plunger should not move in and
inspection hole and the cam sprocket marks (facing out of the tensioner body.
upward) aligned with the dots at the 12 o’clock and 9 3. To release the plunger tension and prepare for reassembly,
o’clock positions. remove the 10mm plug and insert the Cam Chain Tensioner
NOTE: The cam lobes should be laying flat and the Tool (PA-45958), lodging the tip of the tool into the spring
valves have clearance at this point.
5. Remove the two 8 x 25 mm cam chain tensioner flange Tool PA-45958

bolts.
IMPORTANT
Maintain Clearance
while rotating tool

ENGINE
4. To retract the plunger, rotate the special tool clockwise 4. To free the cam assembly, lift one cam assembly and
while holding the tensioner stationary. You may also hold slightly rotate it while removing the chain from the cam
the special tool stationary and rotate the tensioner assembly gear. Repeat this procedure for the other cam.
counterclockwise if desired. NOTE: Do not allow cam chain to drop into the
IMPORTANT: Do not grind edges of key flange into engine if no other disassembly is being performed.
tensioner to prevent damage to the tool or locking
guides during plunger retraction. 5. Use a device to secure the cam chain, such as mechanic’s
wire or nylon line, to prevent it from falling into the engine.
5. Once retraction is complete, lock the tool into the tensioner 6. Inspect cam sprocket teeth for wear or damage. If damage
guides. This holds the spring and plunger in place for is found, replace the camshaft assembly.
reassembly. Use caution not to disturb the tool during
tensioner installation. 3
Inspect for Areas of Tooth

Wear or Damage
Automatic Compression Release Inspection

6. Reinstall the tensioner assembly, torquing the bolts to
specification (Page 3.3). Remove the special tool and NOTE: The automatic compression release
replace the tensioner cap. mechanism cannot be serviced. The components are
not replaceable. Replace the camshaft as an
assembly if any part of the compression release is
Tensioner Bolt Torque worn or damaged.
6.6- 8.1 ft lbs (9- 11 Nm)
C
Camshaft Removal
A
1. Remove the valve cover.
2. Remove the tensioner assembly. B
3. Remove the 8 bolts securing the cam tower assembly and
remove the cover.
Note: Cam and compression release are

an assembly and not serviceable.
1. Check release cam (A) for smooth operation throughout

the entire range of movement. The spring (B) should hold
the cam against the stop. In this position, the actuator (C)
will be held outward in the compression release mode.
2. Inspect lobe on end of release cam for wear. Replace cam
assembly if necessary.
3.15
ENGINE
Camshaft Inspection 5. Measure ID of camshaft journal bore.
1. Visually inspect each cam lobe for wear, chafing or

damage.
Camshaft Journal I.D.:
NOTE: Camshafts, gears and bearings are not
serviceable. Replace camshaft as an assembly if Mag End: .9842- .9851ð
problems are found. (25.00- 25.021 mm)
2. Inspect the cam bearings for excess play or noise during
NOTE: Replace camshaft as an assembly if
rotation.
damaged or if any part is worn past the service limit.
3. Measure height of each cam lobe using a micrometer.
Compare to specifications. 6. Calculate oil clearance by subtracting journal OD from
journal bore ID. Compare to specifications.
Camshaft Oil Clearance

Limit: .0039ð (.10 mm)
NOTE: Replace cylinder head if camshaft journal

bore is damaged or worn excessively.
Cylinder Head Removal

1. Remove the cam shafts.
2. Remove the two 8mm flange bolts (A) from cylinder head.
3. Loosen each of the four cylinder head bolts (B) with a
Camshaft Lobe Height 14mm 12-point socket, turning evenly 1/8 turn each time
in a criss–cross pattern until loose.
Limit: 1.6555ð (42.05 mm)
B
4. Measure camshaft journal outside diameter (O.D.) A
Check for wear

or roughness
Journal O.D.
4. Remove bolts (B) and tap cylinder head lightly with a soft-
face hammer until loose.
Camshaft Journal O.D.:
CAUTION
Mag End: .9821- .9828ð
(24.946- 24.963 mm) Tap only in reinforced areas or on thick parts of
cylinder head casting to avoid
damaging the head.
5. Remove cylinder head and head gasket.

ENGINE
Cylinder and Piston Removal 4. Rock cylinder forward and backward and lift it from the
crankcase, exposing the piston and connecting rod. Support
NOTE: Follow engine disassembly procedures to piston with Piston Support Block (PN 2870390).
remove valve cover, camshafts and cylinder head.
5. Remove dowel pins from crankcase.
Removal of clutch basket is required for this
procedure.
Piston Removal
1. Using a 9/32” (7mm) Allen wrench, remove the rear cam 1. Remove circlip. Note piston directional aid that is pointing
chain tensioner blade from the cylinder. toward the left (stator) side of engine.
Directional Aid
3
2. Loosen the 3 oil pipe banjo bolts, remove the bolts and 2. Remove piston circlip and push piston pin out of piston. If
sealing washers. Remove the pipes. necessary, heat the crown of the piston slightly with a
propane torch to aid removal.
IMPORTANT: Do not apply heat to the piston rings.
The ring may lose radial tension.
3. Tap cylinder lightly with a plastic hammer in reinforced

areas until loose.
3. Remove top compression ring:

*Using a piston ring pliers: Carefully expand ring and lift
it off the piston.
*By hand: Placing both thumbs as shown, spread the ring
open and push up on the opposite side. Take care to not
scratch the ring lands.
IMPORTANT: Do not expand the ring more than the
amount necessary to remove it from the piston, or the
ring may break.
3.17
ENGINE
4. Repeat procedure for second ring. 3. Measure piston ring to groove clearance by placing the ring
5. The oil control ring is a three piece design consisting of a in the ring land and measuring with a thickness gauge.
top and bottom steel rail and center expander section. Replace piston and rings if ring–to–groove clearance
Remove the top rail first followed by the bottom rail, then exceeds service limits.
remove the expander. For installation, refer to Page 3.31.
Piston
Piston and Rod Inspection Ring
1. Measure piston pin bore.
Feeler Gauge
Piston Pin Bore
Piston Ring-to-Groove Clearance

Piston Pin Bore:
.9055- .9057″ (23.001- 23.007 mm) Top Ring Limit: .0059″ (.15 mm)
Second Ring Limit: .0059″ (.15 mm)
2. Measure piston pin O.D. Replace piston and/or piston pin

if out of tolerance. 4. Measure connecting rod small end ID.
Piston Pin Measurement Locations
Piston Pin O.D. Small End I.D. :
.9053- .9065″ (22.994- 23 mm) Std: .9058- .9063″ (23.007- 23.020 mm)

ENGINE
LOWER ENGINE DISASSEMBLY 5. Measure the ID of the bushing in the stator housing (A) and
the crankcase and record. Measure in two directions 90°
Crankcase Disassembly and Inspection apart to determine if cover is out of round. Replace cover
if clearance is determined to be excessive.
NOTE: The starter motor, starter drive gears,
flywheel, stator, cam chain and sprockets can be
serviced with the engine in the frame.
NOTE: Crankcase and transmission components

cannot be serviced in the frame. Upper engine
components, with the exception of the starter and
stator removal, must be disassembled prior to
performing these procedures.
A 3
Starter Drive Gears Removal and Inspection
1. Remove the starter.
2. Remove the 12 bolts holding the stator cover assembly.
6. Inspect gear teeth on starter drive gears. Replace gears if
gear teeth are cracked, worn, or broken.
7. Installation: Reverse the removal procedures and install
with a new gasket. Do not use sealant. Torque the bolts in
a criss-cross pattern to 80–97 in. lbs. (9–11 Nm).
Flywheel / One-Way Starter Clutch

Removal and Inspection
1. Remove flywheel nut and washer.
2. Install Flywheel Puller (PA-46075) and remove flywheel.
IMPORTANT: Thread the puller onto the flywheel fully
or flywheel threads may be damaged.
3. Inspect the drive gears and shafts for wear or damage and
replace if necessary.
4. Measure the OD of the starter drive shafts on both ends and

record. Measure in two directions 90° apart to determine if
components are out of round. Replace if components are
worn or damaged.
3.19
ENGINE
3. Removing the flywheel exposes the starter drive main gear Crankshaft Nut Removal
and one way clutch, which is mounted on the flywheel.
Inspect the main gear and bearing for wear, broken teeth or 1. Remove the stator-side crankshaft nut using MAG End
other damage. Inspect the one-way clutch for wear or Crankshaft Nut Remover/Installer (PN PA-46076) while
damage to the rollers, springs, etc. Replace one-way using a suitable holding fixture to keep the crankshaft from
assembly if excessive wear or damage is found. turning.
PA
-46
07
6
2. To reinstall, use a suitable holding fixture and MAG End

Crankshaft Nut Remover/Installer (PN PA-46076) to
4. To replace the one-way starter clutch, remove the 8 screws torque the nut to 66-81 ft. lbs. (90–110 Nm).
(A) holding the assembly to the flywheel. Reinstall the
screws and torque to 155-133 in. lbs. (13-15 Nm) in a criss- Clutch Cover / Clutch Removal and
cross pattern. Inspection
1. Remove the 12 screws holding the clutch cover.
5. Installation: For installation of flywheel and starter gears,

reverse the removal procedures. When installing the 2. Remove the gasket. Clean the gasket surfaces prior to
flywheel, apply engine oil to the crankshaft threads and reassembly.
torque the flywheel nut to 111-125 ft. lbs. (150-170 Nm).

ENGINE
3. Inspect or replace the crankshaft oil seal anytime the clutch 6. Remove the clutch plates and friction discs, keeping them
cover is removed for service. Install with the seal lip in order. Inspect the pressure plates for wear and warpage.
pointed in toward the cover. Inspect the friction plates for wear or damage to friction
material. If either are damaged or worn excessively, replace
the components as a set.
NOTE: Replace clutch pack if measured thickness
of friction material is less than .110” (2.8mm). The
top plate has slightly different friction pads and
should always be installed on top.
NOTE: Top Clutch Plate Aligns In Basket Towers
Top 3
4. Remove the 6 screws holding the clutch pressure plate.
NOTE: The top clutch plate should rest in the
towers.
CAUTION
Assembly is under spring pressure. Wear safety

glasses during removal.
7. To remove the clutch basket, remove the plunger from the
center of the clutch and de-stake the nut to avoid damaging
NOTE: Top Clutch Plate Aligns In Basket Towers the threads upon removal.
NOTE: Nut is staked on flat of transmission shaft
5. Remove and inspect the clutch pressure plate for wear,

cracks, etc. Check bearing for wear and smooth rotation. 8. Installation: Reverse the procedures. Using a new nut,
Replace either component if found to be damaged or worn. torque the clutch basket retaining nut to 66-81 ft. lbs. (90-
110 Nm). Stake the nut at the flat on the transmission shaft.
Install the clutch plates in order of removal. Reinsert the
plunger into the shaft. Reinstall the cover, pressure plate
screws and springs. Torque the screws to 80–97 in. lbs.
(9–11 Nm).
3.21
ENGINE
Shifter Component Removal and Inspection 3. Inspect the ratcher pawls (F), pawl plungers (G), plunger
springs (H), shifter collar (J), shifter drum (K) and guide
1. With the clutch basket removed, remove the shift shaft plate (L) for wear or damage. Replace if wear or damage
assembly (A), guide plate (D), pawl assembly (B), and is evident.
stopper arm / detent spring assembly (C).
J
CAUTION F
Stopper arm (C) is under spring pressure. G

Use care during removal. H
L
K
A 4. Installation: Reverse the procedures, paying close attention

to the orientation of the ratcher pawls (F) during
B installation, as the surface must be flat when the pawls are
D installed correctly. The guide plat (L) should be installed
with the “dot” facing upward. Torque the guide plate bolts,
the detent spring assembly bolt and the shifter pin bolt (E)
C to 80–97 in. lbs. (9–11 Nm).
2. Remove the shift cam by loosening the shifter pin bolt (E).
E
L
Correct for installation - Flat Surface
Correct for installation

ENGINE
Oil Pump Removal and Inspection NOTE: Dowel pins for the inner pump body are
loose and may become lost. Keep pins in a secure
1. Remove the circlip holding the oil pump gear and remove location.
the gear.
3
2. Remove the 3 bolts holding the oil pump cover. Inspect the
inside of the cover for wear or scoring.
5. Replace any component that is found to be damaged or

worn.
OIL PUMP CLEARANCE

Limits are same as Standard
Body Feed / Scavenge .006-.008” .15 - .21mm
Less than
Rotor Tip Feed / Scavenge Less than .006”
.15 mm
Rotor Side Feed .0007-.003” .02 - .08mm
Scavenge .002-.006” .05 - .16mm
3. Remove the outer pump rotor assembly. Inspect for signs
of scoring or excess wear. 6. Installation: Reverse the procedures. Use assembly lube or
clean engine oil to coat the parts before assembly. Tighten
NOTE: Cross pins for the pump rotors are loose and
the cover bolts to 80–97 in. lbs.(9–11 Nm). Verify the pump
may become lost. Keep pins in a secure location.
turns freely during and after torquing bolts.
Crankshaft Drive and Cam Gear Removal

1. Remove the crankshaft nut, washer and drive gear. Note
and white-mark the double spline on both gears and shaft
for ease of reassembly.
Double Spline
4. Remove the inner pump chamber and pump rotor assembly.

Inspect these components for wear or scoring.
3.23
ENGINE
2. Remove the cam gear and thrustwasher from the crankshaft Crankcase Separation
for inspection. Replace if damage or excessive wear is
present to the gear teeth or splines. 1. Remove the 13 flange bolts. 12 from the magneto side and
1 from the clutch side of the crankcase evenly in a criss–
3. Installation: Reverse the procedures and torque nut to 81–
cross pattern.
96 ft. lbs. (110–130 Nm).
Cam Chain / Tensioner Blade Removal

1. Remove bolt (A) securing tensioner pivot blade to
crankcase . Inspect for cracks, wear, or damage.
2. Remove the shifter assembly and shift cog that is attached

to the shift drum (Items A-E).
2. Remove cam chain (B). Inspect chain for wear, missing A

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 B
(pin) section of chain. Replace if worn past service limit.
D
C
B
Chain Service Limit:

5.407” (13.7 cm)
3. Installation: Reverse the procedures and torque the pivot

blade bolt to 10–12.2 ft. lbs. (13.5–16.5 Nm).
4. See Page 3.32 for Cam Timing.

ENGINE
3. Separate crankcase by tapping with a soft faced hammer in NOTE: Due to extremely close tolerances and
reinforced areas. Watch the gap along the crankcase mating minimal wear, the bearings must be inspected
surface, making sure to separate the crankcase evenly. It visually, and by feel. Look for signs of discoloration,
may also be necessary to tap the clutch side of the scoring or galling. Turn the inner race of each
crankshaft lightly to help separate the crankcase. 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 with minimal side to side movement and no
detectable up and down movement.
Bearing Removal:
NOTE: To ease bearing removal, warm the bearing 3

area, but not the bearing itself, until hot to the touch
to expand the bearing cavity.
CAUTION
4. The crankshaft is designed to slip out of the PTO side upon Wear the appropriate safety equipment during the
disassembly. Once the crankcase halves are split apart, heating and removal process.
orientate the components into the stator side of the
crankcase containing the crankshaft, balancer, oil gallery, 1. Support the crankcase and drive or press the main bearings
the transmission gears and shift components for ease of out of each crankcase.
service and reassembly. 2. To remove balancer shaft bearings and pump shaft bearing,
use a blind-hole bearing puller.
Crankcase Inspection NOTE: Bearings are stressed during the removal
process and should not be re–used!
1. Remove all traces of gasket sealer from the crankcase
mating surfaces. Inspect the surfaces closely for nicks, Bearing Installation:
burrs or damage.
2. Check the oil pump and oil passage mating surfaces to be NOTE: For ease of bearing installation, warm the
sure they are clean and not damaged. Verify the oil pump crankcase until hot to the touch to expand the
screen is clean. bearing cavity. Place the bearings in a freezer. This
shrinks the bearing outer diameter slightly.
Crankcase Bearing Inspection / Removal /
Installation
CAUTION
1. Inspect the crankshaft main bearings, balancer shaft
bearings, output shaft, and pump shaft bearings. Wear the appropriate safety equipment during the
heating and installation process.
1. Install the bearings so the numbers are visible.

2. Drive or press new bearings into the crankcases, using the
proper driver.
IMPORTANT: Press only on outer race of bearing to
prevent bearing damage.
3.25
ENGINE
TRANSMISSION AND CRANKSHAFT 3. Inspect the shaft support bearings in the crankcase halves.
SERVICE Replace if any roughness or wear is felt. See page 3.25 for
crankcase bearing inspection / removal.
Transmission Removal and Inspection 4. To reassemble, reverse the procedures using the photos for
reference.
1. Remove the shift fork tubes, spring, shift forks, and shift
drum from the transmission assembly. Transmission Main Shaft Disassembly /
Assembly
CAUTION
These procedures require the use of a heat

source and hydraulic press to remove and install
components. Wear the proper protective and
safety gear to prevent injury.
1. Attach a bearing splitter to the reverse gear ONLY as

2. Remove the main and output transmission shaft assemblies shown. DO NOT apply a load to 4th gear, as damage will
and disassemble, keeping the parts in order for ease of result. Place the assembly into a hydraulic press and using
reassembly. Inspect the shift forks, shift drum, shift dogs, a suitable driver, press off the gear.
gear teeth and shaft splines for damage. If the mating
surfaces on any of the components are found to be rounded,
worn, or otherwise damaged, they must be replaced.
Main Shaft Assembly
Output Shaft Assembly 2. Remove the parts from the shaft, keeping them in order for
ease of reassembly. Inspect all the main shaft components
for signs of damage or wear. If the mating or rolling
surfaces on any of the components are found to be rounded,
worn, or otherwise damaged or rough, they must be
replaced.

ENGINE
3. To reassemble the main shaft, install the components in the 1. Insert the output shaft assembly, minus the outer gear into
order removed. the stator side casehalve. Do not insert outer gear or shift
4. Before pressing the reverse gear onto the main shaft, heat fork pins at this time.
the reverse gear in an oil bath if desired. This will expand
and ease pressing of the gear to the specified dimension.
CAUTION
This procedure requires the use of a heat source and

hydraulic press to install components. Wear the
proper protective and safety gear to prevent injury.
3
5. Support the mainshaft as shown with flat blocks. Press
ONLY on the reverse gear until the total width of the gear
set measures 120.4 ± .2mm (4.74 ± .008″) as shown.
2. Insert the reverse gear shaft assembly. Verify the alignment

pin (A) has seated into the casehalf.
Main Shaft Gear Set Width

120.4 + .2 mm (4.74 + .008″)
Transmission Reassembly
NOTE: Installation of the transmission assemblies
can be facilitated by constantly rocking or moving
them to reduce binding during assembly.
NOTE: Do not to allow transmission parts to fall

from their assemblies during installation. Parts that
are out of alignment will cause improper casehalf
mating, resulting in transmission binding. Use of
assembly lube to “stick” parts together for ease of
installation is recommended.
3.27
ENGINE
3. Install the main shaft assembly. The outer gear can now be 5. Insert and rotate the shift drum so the alignment pin is
installed. Verify the shallow side of the outer gear is facing approximately at the 5 o’clock position. Insert the fork pins
out during installation. into their respective cam followers, installing each fork
shaft as they are assembled. Lifting of forks and gears will
be required to align pins into the shift drum.
Pin Position
NOTE: The output fork shaft contains a spring that

must be inserted before assembly. See Photo.
Spring
4. Install the shift forks. Verify that each fork pin is pointed
toward the shift drum.

ENGINE
Crankshaft Removal / Installation 6. Using MAG End Crankshaft Installer (PA-46077), draw
the crankshaft into the bearing assembly by sliding the
To remove crankshaft: collar and thrustwasher over the crankshaft end, threading
1. Remove the crankshaft retaining nut using Crankshaft Nut the inner puller onto the crankshaft end. Turn the outer nut
Remover / Installer (PA-46076). clockwise while holding the inner to pull the crankshaft into
2. Remove the crankshaft bearing retainer screws using a the bearing.
impact driver at location (A). PA-46077
NOTE: Screw threads contain locking agent. Inner Puller
Heating of screws is required for removal. Use
caution and wear the proper safety equipment while Outer Puller
performing this procedure.
PTO side shown for clarity
Thrust Washer 3
Collar
A
Crankshaft Inspection
NOTE: Larger than standard readings indicate
3. Support the stator side crankcase in a stand to press the
excessive wear.
crankshaft out. Use care not to damage the crankcase
mating surface or connecting rod. Applying heat to the NOTE: Crankshaft components are press-fit and are
crankcase bearing area to ease removal is acceptable. serviceable.
4. Attach Crankcase Separator (PA-46087) to the casehalve.
Turn the inner shaft clockwise while holding the outer shaft 1. Inspect the crankshaft connecting rod bearing journal for
to press the crankshaft and bearing as an assembly out of scoring and abnormal wear.
the case. 2. Use a feeler gauge to measure the connecting rod big end
Verify that all bolts are side clearance.
PA-46087
fully threaded to avoid
damage to the case
To install crankshaft:
5. Press the bearing into the crankcase at the outer edges with
Connecting Rod Big End Side Clearance:
an appropriate driver. Insert the bearing retainers and new
screws, which have a pre-applied locking agent. Torque the Limit: .0256″ (.65 mm)
screws to 8.1–9.6 ft. lbs. (11–13 Nm).
3.29
ENGINE
3. Place the crankshaft in a truing stand or V–blocks and 3. Reassemble the crankcase halves. This is best
measure the runout on both ends with a dial indicator. See accomplished with the stator side casehalve settled in a
Crankshaft Straightening on Page 3.10. suitable fixture that allows it to lay flat. This allows easier
installation without parts falling out of position. Make sure
the oil gallery tube is oriented correctly and the balancer
shaft groove aligns with the water pump shaft. Refer to
photos.
NOTE: Some light tapping with a soft faced mallet
may be required to bring the casehalves together. If
for any reason the cases fail to mate, DO NOT
FORCE. Reverify the transmission assemblies are
fully seated in their respective case half and are not
binding.
Align balancer
shaft and water
pump shaft grooves
Max Runout: .0012″ (.03 mm)
4. Measure the connecting rod big end radial clearance.
Big End Radial Clearance:
Limit: .0004- .0015″ (.011- .038 mm)
5. Measure the connecting rod small end radial clearance.
Small End Radial Clearance:
Limit: .0020″ (.05 mm)

Pin
6. Measure the connecting rod small end I.D.
Small End I.D. :
Std: .9058- .9063″ (23.007- 23.020 mm)
ENGINE REASSEMBLY
Verify pin is aligned with notch in case
Crankcase Reassembly
1. Apply a thin layer of Crankcase Sealer (PN 2871557) to all 4. Reinstall the (12) stator side and (1) clutch side flange bolts,
sealing surfaces of the PTO case half, being careful not to tightening in a criss-cross pattern. Stop occasionally and
over apply, as excessive sealant may clog oil passages or check that all rotating assemblies turn freely. Torque the
drip into the crankcase. Allow the sealer to set for a few flange bolts to 80–97 in. lbs. (9–11 Nm).
minutes before assembling the two halves together.
2. Align the crankshaft and balancer timing marks and insert
the components into the stator-side case halve. Then install
the oil tube and transmission assemblies.

ENGINE
Piston Installation Piston Ring Installation
1. Clean the gasket surfaces on the cylinder and crankcase. NOTE: Apply clean engine oil to all ring surfaces
Remove all traces of old gasket material. and ring lands. Always check piston ring installed
2. Make sure the cylinder mounting bolt holes are clean and gap before rings are installed on piston. If the piston
free of debris. has been in service, clean any accumulated carbon
from the ring grooves and oil control ring holes.
1. Place the oil control ring expander in oil ring groove with
the end gap facing forward. The expander has no up or
down marking and can be installed either way. The ends
should butt squarely together and must not overlap. Install
the bottom and top rails. 3
2. Install the second ring with the mark facing up.
3. Install the top ring with the mark facing up.
Gap should face up or down Ring Profile
3. Install a new circlip on one side of the piston with the end Top - Chrome
gap facing up or down.
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. Install with mark facing up
Severe engine damage may result if circlips are
re–used or deformed during installation.
4. Apply clean engine oil to the piston rings, ring lands, piston
pin bore, piston pin, and piston skirt. Lubricate the
connecting rod (both ends), balancer drive gear, and
crankshaft main bearing area.
Top Side of Piston
Second - Cast
Identification Mark 4. Check to make sure the rings rotate freely in the groove
Stator Side when compressed.
5. Orientate the rings for installation by rotating until the end-
gaps are 120 degrees apart.
5. Install the piston on the connecting rod with the

identification mark facing the stator end of the crankshaft.
The piston pin should be a push fit in the piston.
6. Install the other circlip with the gap facing up or down. (see
Caution with Step 3 above). Push the piston pin in both
directions to make sure the clips are properly seated in the
groove.
3.31
ENGINE
Cylinder Installation Cam Chain Installation
1. Place the dowel pins in the crankcase and install a new NOTE: The camshafts, crankshaft sprocket and
cylinder base gasket. clutch basket must be removed to perform this
procedure.
1. Install the cam chain by dropping it down through the

chain room and over the crankshaft sprocket.
PN 2870390
2. Position the Piston Support Block (P/N 2870390) beneath

the piston skirt to support the piston during cylinder
installation.
3. Apply clean engine oil to the ring compressor and install
the compressor according to the manufacturer’s 2. Use a suitable device to hold the chain in place to keep it
instructions. from dropping through the chain room, such as wire or a
hammer handle.
IMPORTANT: Verify all ring end gaps are correctly
located.
Camshaft Timing
CAUTION
Serious engine damage will result if the camshaft

is not properly timed to the crankshaft.
IMPORTANT: CAMSHAFT TIMING NOTE

The Top Dead Center (TDC) mark is used to time the
camshaft to the crankshaft. Follow the procedures
outlined. Refer to the diagram.
1. Apply engine oil or assembly lube to the camshaft main

journals, cam lobes and the automatic compression release
4. Apply clean engine oil liberally to the cylinder bore and mechanism.
tapered area of the sleeve. Install the cylinder with a slight 2. Install the crankshaft cam sprocket onto the shaft. Note the
rocking motion until the rings are captive in the sleeve. double spline for ease of installation. The alignment mark
5. Remove the ring compressor and support block. should face outward.
6. Push the cylinder downward until fully seated on the base
gasket.
7. Rotate the crankshaft and position the piston at TDC.
NOTE: If cam chain is installed, hold it up while
rotating the engine to avoid damage to the chain,
drive sprocket teeth, or tensioner blade.

ENGINE
3. If not already at Top Dead Center, Loosely hold the cam 6. Re-check all cam timing marks to verify proper cam timing,
chain and rotate the crankshaft until the crankshaft cam and install the cam tower. Tighten the bolts evenly in a
sprocket timing mark is aligned with the Top Dead Center criss-cross pattern to specification. Do not rotate engine
(TDC) mark on the crankcase (see photo). Position the until the tensioner has been installed to avoid chain slip
chain for correct timing by aligning the bottom cam timing and loss of timing reference.
mark with the brass colored bottom chain link. Keep 7. Install the tensioner assembly. (raefer to Page 3.14). Verify
tension on the chain so as to not lose chain alignment at the timing by rotating the crankshaft two full revolutions (720
crankshaft sprocket during cam installation. degrees), checking for valve-to-piston interference which
Align Brass Colored Link and Sprocket would indicate a problem with cam timing. If interference
Mark with Top Dead Center (TDC) Mark is noted, immediately stop rotation and reverify cam
timing.
NOTE: Rotating the engine during verification will 3
cause the timing alignment marks to rotate out of
phase, and will take as many as 20 revolutions to
come back into phase. To maintain alignment of the
marks if needed, rotate the engine backward the
same number of turns as forward.
8. With timing procedure completed, install the primary drive

sprocket, washer and nut onto the crankshaft. Torque to
specification.
4. Install the camshafts one at a time. First, install the exhaust Primary Drive Gear Installation
cam by looping the chain over the cam gear. At the same
time, position the cam chain for correct timing by aligning 1. Install the cam sprocket with alignment mark outward.
the brass colored chain link with the 12 o’clock dot on the 2. With chain in place and cam timing having been performed,
cam sprocket. The sprocket secondary mark should be at install the primary drive sprocket, washer and nut onto the
the 9 o’clock position. Keep tension on the chain so as to crankshaft. Torque to 81–96 ft. lbs. (110–130 Nm).
not lose chain alignment at the crankshaft sprocket.
5. Next, install the intake cam, positioning the upper cam
chain for correct timing by aligning the remaining brass
colored chain link with the 12 o’clock dot on the cam
sprocket. Timing is in phase when all three brass colored
cam chain links align with all three sprocket timing marks
and the secondary cam gear marks are at approximately the
9 o’clock position, with the exhaust cam timing mark
slightly advanced. Refer to the diagram on Page 3.34.
NOTE: Failure to align marks in this fashion will
cause valve-to-piston interference, resulting in
engine damage.
Align Brass Colored Link and Sprocket
Mark with Top Dead Center (TDC) Mark
Note exhaust cam is slightly advanced
3.33
ENGINE
Outlaw Cam Timing Exploded View

ENGINE
CYLINDER HEAD SERVICE Cylinder Head Disassembly
Cylinder Head Inspection

WARNING
Wear eye protection during cylinder head

disassembly and reassembly.
1. Remove the valve buckets (A).

NOTE: Keep all parts in order with respect to their
location in the cylinder head. Use care not to mar or
damage the buckets upon removal. 3
A
1. Thoroughly clean cylinder head surface to remove all

traces of gasket material and carbon.
CAUTION
Use care not to damage sealing surface.
Cylinder Head Warp

1. Lay a straight edge across the surface of the cylinder head 2. Under each bucket is a valve shim (B). Record and keep
at several different points and measure warp by inserting a these shims oriented to each valve disassembled.
feeler gauge between the straight edge and the cylinder
head surface. If measurement exceeds the service limit,
replace the cylinder head.
B
3. Using Valve Spring Compressor (A) (PA-46502),

compress the valve springs and remove the split keepers.
Cylinder Head Warp Limit:
.002″ (.05 mm)
3.35
ENGINE
NOTE: To prevent loss of tension, do not compress NOTE: Replace seals whenever the cylinder head is
the valve springs more than necessary. disassembled. Hardened, cracked or worn valve
seals will cause excessive oil consumption and
carbon buildup.
A
4. Remove spring retainer, inner and outer springs and spring

washer.
Spring Washer Located Cylinder Head Valve Guide / Valve Seat
Below Assembly Inspection
Inspect valve seats in cylinder head for pitting, burnt spots,
roughness, and uneven surface. If any of the described
conditions exist, the valve seat must be reconditioned. If the
valve seat is cracked the cylinder head must be replaced.
B
NOTE: Servicing the valve guides and valve seats
requires special tools and a thorough knowledge of
reconditioning techniques. Follow the instructions
provided in the cylinder head service tool kit.
NOTE: The valve springs should be positioned with CAUTION

the tightly wound coils against the cylinder head (B).
Wear the proper safety equipment when
5. Push valve out, keeping it in order for reassembly in the performing cylinder head service. Valve guide
same guide. replacement will require heating of the cylinder
6. Measure free length of the inner and outer springs with a head. Wear safety gloves to prevent burns.
Vernier caliper. Check springs for squareness. Compare to
specifications. Replace inner and outer springs as a set if Valve Guide Removal / Installation / Ream
either measurement is out of specification.
1. Remove all carbon deposits from the combustion chamber,
valve seat and valve guide area before attempting to
remove valve guides.
IMPORTANT: Carbon deposits are extremely
abrasive and may damage the valve guide bore when
guides are removed.
2. Place new valve guides in a freezer for at least 15 minutes

while heating cylinder head.
3. Heat cylinder head in an oven or use a hot plate to bring
Inner 1.575” (40.0 mm) cylinder head temperature to 212° F (100° C).
Outer 1.650” (41.9 mm)
7. Remove the valve seals.

ENGINE
IMPORTANT: Do not use a torch to heat cylinder head Valve Seat Reconditioning
or warpage may result from uneven heating. Head
temperature can be checked with a pyrometer or a 1. Follow the manufacturers instructions provided with the
welding temperature stick. Valve Seat Reconditioning Kit (P/N 2200634). Abrasive
stone seat reconditioning equipment can also be used.
4. When thoroughly heated, place cylinder head on blocks of Keep all valves in order with their respective seat.
wood which will allow the old guides to be removed.
Valve Seat Wear Patterns
5. 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.
6. Place cylinder head on cylinder head table.
NOTE: Be sure cylinder head is still at 212° F (100° 3
C) before installing new guides.
Too Uneven Good Too
7. Place a new guide in the valve guide installation tool and Wide Narrow
press guide in to proper depth. Check height of each guide
above the cylinder head (A). NOTE: Valve seat width and point of contact on the
valve face is very important for proper sealing. The
valve must contact the valve seat over the entire
circumference of the seat, and the seat must be the
proper width all the way around. If the seat is
uneven, compression leakage will result. If the seat
is too wide, seat pressure is reduced, causing
carbon accumulation and possible compression
loss. If the seat is too narrow, heat transfer from
Valve Guide Installed Height valve to seat is reduced and the valve may overheat
and warp, resulting in burnt valves.
Valve Guide Height: 2. Install pilot into valve guide.
.689- .709” (17.5 - 18.0 mm) 3. Apply cutting oil to valve seat and cutter.
NOTE: The guide can also be inserted to the proper

depth using a driver. Inspect the guide closely for
cracks or damage if a driver is used.
8. Allow the cylinder head to cool to room temperature. Apply

cutting oil to the reamer. Guides should be reamed from the
valve spring side of the cylinder head. Ream each guide to
size by turning the reamer clockwise continually. Continue
to rotate reamer clockwise during removal of the tool.
4. Place 46° cutter on the pilot and make a light cut.

5. Inspect the cut area of the seat:
• If the contact area is less than 75% of the circumference

of the seat, rotate the pilot 180° and make another light
cut.
• If the cutter now contacts the uncut portion of the seat,

check the pilot. Look for burrs, nicks, or runout. If the
9. Clean guides thoroughly with hot soapy water and a nylon pilot is bent it must be replaced.
brush. Rinse and dry with compressed air. Apply clean
engine oil to guides.
3.37
ENGINE
• 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.
Seat Contact
• If the contact area of the initial cut is greater than 75%,
Width
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.
Top 30o Seat 45o or 46o

Bottom 60o
or 75o
6. To check the contact area of the seat on the valve face, apply
a thin coating of Prussian Blue™ paste to the valve seat. If
using an interference angle (46°) apply black permanent
marker to the entire valve face (A).
7. Insert valve into guide and tap valve lightly into place a few NOTE: When using an interference angle, the seat
times. contact point on the valve will be very narrow, and is
8. Remove valve and check where the Prussian Blue™ a normal condition. Look for an even and continuous
indicates seat contact on the valve face. The valve seat contact point on the black marker, all the way
should contact the middle of the valve face or slightly around the valve face.
above, and must be the proper width (refer to the wear limits
for proper seat width). 9. Clean all filings from the area with hot soapy water, rinse,
and dry with compressed air.
• If the indicated seat contact is at the top edge of the 10. Lubricate the valve guides with clean engine oil, and apply
valve face and contacts the margin area it is too high on oil or water based lapping compound to the face of the
the valve face. Use the 30° cutter to lower the valve valve.
seat. NOTE: Lapping is not required with an interference
angle.
• If too low use the 60° or 75° cutter to raise the seat.
When contact area is centered on the valve face, 11. Insert the valve into its respective guide and lap using a
measure seat width. lapping tool or a section of fuel line connected to the valve
stem.
• If the seat is too wide or uneven, use both top and
12. Rotate the valve rapidly back and forth until the cut sounds
bottom cutters to narrow the seat.
smooth. Lift the valve slightly off of the seat, rotate 1/4 turn,
• If the seat is too narrow, widen using the 45° cutter and and repeat the lapping process. Do this four to five times
re–check contact point on the valve face and seat width until the valve is fully seated, and repeat process for the
after each cut. other valve(s).
13. Clean cylinder head, valves, and camshaft oil supply
passages thoroughly.
Valve Seat Width:
Intake Std: .028” (.7 mm)

Limit: .055” (1.4 mm)
Exhaust Std: .039” (1.0 mm)

Limit: .071” (1.8 mm)

ENGINE
Valve Inspection
1. Remove all carbon from valve with a soft wire wheel.
2. Check valve face for runout, pitting, and burned spots. To
check for bent valve stems, mount the valve in “V” blocks
and use a dial indicator.
3. Check end of valve stem for flaring, pitting, wear or damage

(A).
A
B
4. Inspect split keeper groove for wear or flaring of the keeper
seat area (B).
NOTE: The valves cannot be re–faced or end
ground. Valves must be replaced if worn, bent, or
damaged.
5. Measure diameter of valve stem with a micrometer in three

places and in two different directions (six measurements
total). Compare to specifications.
Measure valve stem in
several places
Valve Stem Diameter:
Intake: .2343- .2348″ (5.950- 5.965 mm)

Exhaust: .2341- .2346″ (5.945- 5.960 mm)
3.39
ENGINE
ES50PL Adjusting Pad Selection Matrix
1. Measure valve clearance at TDC (Compression Stroke) using thickness gauge with original adjusting pad installed.
2. Reference the measurement and the 3 digits marked on the existing adjusting pad on the matrix below.
3. Select a suitable adjusting pad from the matrix below and replace existing pad.
4. Measure and confirm that valve clearance is within the standard values.
5. If valve clearance is not within standard, reverify step#1 and repeat procedures again.
Example:
Intake- Valve clearance before adjusting: 0.23mm(.009”)
Existing adjusting pad mark: 177
From “Intake Adjusting Pad Selection Matrix”, a suitable adjusting pad would be 185
Exhaust- Valve clearance before adjusting: 0.35mm(.0137”)

Existing adjusting pad mark: 177
From “Intake Adjusting Pad Selection Matrix”, a suitable adjusting pad would be 185

ENGINE
Cylinder Head Assembly 6. Place spring retainer on and install valve spring compressor
(A). Compress springs only enough to allow split keeper
installation and prevent loss of spring tension. Install split
CAUTION keepers with the gap even on both sides.
Wear eye protection during assembly.

A
NOTE: Assemble the valves one at a time to
maintain proper order.
1. Install new valve seals on valve guides.

3
7. Repeat procedure for remaining valves.

8. When all valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the keepers.
9. Install the shims and buckets for each valve in the order they
were removed.
10. Check valve clearance with engine at Top Dead Center
2. Apply engine oil to valve guides and seats. (TDC).
3. Coat valve stem with assembly lube. NOTE: Repairs such as valve grinding or valve
4. Install valve carefully with a rotating motion to avoid replacement will require re-shimming for proper
damaging valve seal. valve clearance. Use the chart provided on page 3.40
to determine the appropriate shim thickness.
5. Install spring washers. Dip valve springs and retainer in
clean engine oil and install springs with closely spaced coils
(B) toward the cylinder head.
Spring Washer Located
Below Assembly
Valve Clearance (Engine Cold):
Intake: .006″ (.15 mm)
Exhaust: .010” (.27 mm)
+/- .0019″ (.05 mm)
3.41
ENGINE
Cylinder Head Installation CYLINDER SERVICE
Clean the gasket surfaces on the cylinder head and cylinder.
Cylinder Inspection
Remove all traces of old gasket material.
Refer to disassembly photos. 1. Remove all gasket material from the cylinder sealing
surfaces.
1. Install the cam chain tensioner guides. Be sure bottom end 2. Inspect the top of the cylinder for warp using a straight edge
of guide is located properly in crankcase. and feeler gauge.
2. Install the two dowels 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
1. Torque bolts to 22 ft. lbs. (30 Nm)
2. Torque bolts to 51 ft. lbs. (70 Nm)
Leave at this torque for 1 minute to allow Cylinder Warp

gaskets to seat for proper sealing.
.002″ (.05 mm)
3. Loosen bolts evenly 360o (1 turn)
4. Torque bolts to 29 ft. lbs. (35 Nm) 3. Inspect cylinder for wear, scratches, or damage.
1/2” Down From Top of Cylinder
5. From this point, tighten bolts evenly 90o
(1/4 turn) X Y
6. Finally, tighten another 90o (1/4 turn)
7. Install two 6 mm bolts and torque to 6 ft. Y

lbs. (8 Nm) X
4. Install the two 6 mm bolts and torque to specification.

Y
X
Cylinder 6 mm Bolt Torque:
1/2” Up From Bottom
6 ft. lbs. (8 Nm)
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in two
different directions, front to back and side to side, on three
different levels (1/2” down from top, in the middle, and
1/2” up from bottom).

ENGINE
5. Record measurements. If cylinder is tapered or out of round Cylinder Hone Selection and Honing
beyond specification, the cylinder must be replaced. Procedure
Cylinder Taper
Limit: .002″ (.05 mm) Max. CAUTION
Cylinder Out of Round A hone which will straighten as well as remove

Limit: .002″ (.05 mm) Max. material from the cylinder is very important.
Using a common spring loaded glaze breaker for
honing is not advised for nicasil cylinders.
Standard Bore Size: Polaris recommends using a rigid hone
3.9055- 3.9062″ (99.20- 99.22 mm)

or arbor honing machine. 3
Cylinders may be wet or dry honed depending upon the hone
manufacturer’s recommendations. Wet honing removes more
Piston–to–Cylinder Clearance material faster and leaves a more distinct pattern in the bore.
1. Measure piston outside diameter at a point 40 mm down IMPORTANT: Clean the Cylinder After Honing
from the top of the piston at a right angle to the direction
It is very important that the cylinder be thoroughly cleaned after
of the piston pin.
honing to remove all grit material. Wash the cylinder in a
Piston 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.
Honing To Deglaze
A finished cylinder should have a cross–hatch pattern to ensure
piston ring seating and to aid in the retention of the fuel/oil
Piston Pin mixture during initial break in. Hone cylinder according to hone
2. Subtract this measurement from the maximum cylinder manufacturer’s instructions, or these guidelines:
measurement obtained previously in Step 5.
• Use a motor speed of approximately 300–500 RPM, run
Piston to Cylinder Clearance: the hone in and out of the cylinder rapidly until cutting
tension decreases. Remember to keep the hone drive
Std: .0018- .0025″ (.046- .065 mm) shaft centered (or cylinder centered on arbor) and to
Piston O.D.: bring the stones approximately 1/2” (1.3 cm) above and
below the bore at the end of each stroke.
Std: 3.9037- 3.9040″ (99.155- 99.170 mm)
• Release the hone at regular intervals and inspect the
bore to determine if it has been sufficiently deglazed,
and to check for correct cross-hatch.
NOTE: Do not allow cylinder to heat up during

honing.
• After honing has been completed, inspect cylinder for

thinning or peeling.
3.43
ENGINE
If cylinder wear or damage is excessive, it will be necessary to 3. If the bottom installed gap measurement exceeds the
replace the cylinder. Hone only enough to deglaze the outer service limit, replace the rings. If ring gap is below
layer of the cylinder bore. specified limit, file ring ends until the gap is within the
specified range.
NOTE: Always check piston ring installed gap after
re–boring a cylinder or when installing new rings. A
re–bored cylinder should always be scrubbed
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with oil immediately
to prevent rust.
WATER PUMP SERVICE

Oil Seal / Mechanical Seal Removal
(Engine Disassembled)
Piston Ring Installed Gap
NOTE: The water pump mechanical seal can be
1. Place each piston ring inside cylinder using piston to push removed without removing the engine. Refer to
ring squarely into place. Water Pump Mechanical Seal Installation.
Replace the water pump mechanical seal whenever the

crankcase is disassembled.
Feeler Gauge
Cylinder
25-50 mm
Piston Ring
Piston Ring Installed Gap
Top Ring
Std: .008- .012″ (.20- .30 mm) 1. Remove the pump shaft bearings from the PTO (right
Limit: .027” (.7 mm) hand) side crankcase.
2. Drive the water pump mechanical seal out of the crankcase
Second Ring from inside to outside.
Std: .014- .019″ (.35- .50 mm) NOTE: The new mechanical seal must be installed
Limit: .031” (.8 mm) using special tools. See Mechanical Seal Installation.
Oil Ring Water Pump Mechanical Seal Installation

Std: .004- .019″ (.10- .50 mm)
Limit: .039” (1.0 mm) 1. Clean the seal cavity to remove all traces of old sealer.
2. Place a new mechanical seal in the seal drive collar, and
2. Measure installed gap with a feeler gauge at both the top install on the pump shaft.
and bottom of the cylinder. 3. Screw the guide onto the end of the pump shaft.
NOTE: A difference in end gap indicates cylinder 4. Install the washer and nut and tighten to draw seal into place
taper. The cylinder should be measured for until fully seated.
excessive taper and out of round. 5. Remove the guide adaptor using the additional nut as a jam
nut if necessary.

ENGINE
Mechanical Seal Removal and Installation 2. Slide the main puller body over the outer portion of the
(Engine Assembled) mechanical seal as shown in (Figure 3-45)and turn T–
Handle clockwise until it contacts water pump shaft.
The Water Pump Mechanical Seal Puller allows a technician to Continue rotating until outer portion of mechanical seal is
replace the seal on ES50PL engines without removing the separated from the metal seal body.
engine and splitting the cases.
NOTE: This removal process dismantles the seal,

making it unusable for reinstallation.
Water Pump Mechanical Seal

Puller: (PN 2872105) 3
Replacement T-Handle:
(PN 2872106)
Figure 3-45
CAUTION III 2
3. Insert the puller legs between the water pump drive shaft
and the remaining portion of the mechanical seal. Attach
Improper or careless use of this tool or procedure the puller legs to the main puller body. (Figure 3-46)
can result in a bent water pump shaft.Pump shaft
replacement requires engine removal and
crankcase separation. Use caution while Main Puller Body
performing this procedure. Make sure the puller
is parallel to the shaft at all times.
Do not place side loads on the water pump shaft
or strike the puller or shaft in any way.
Position the split
1. After the coolant has been drained, remove the water pump Seal 90° to opening
cover, impeller and the sealing washer. on main puller body
Mechanical Seal
Sealing Washer Figure 3-46

4. Ensure that the split between the puller legs are fully
Impeller supported by the main body of the tool (Figure 3-46).
5. Tighten the hex socket screws on the puller legs sufficiently
so the lip of the puller legs will grasp the mechanical seal
(Figure 3-47).
Hex Socket Screws
Puller Legs
Lip must grasp inside of mechanical seal.
Figure 3-47
3.45
ENGINE
6. Turn the puller T–Handle clockwise until it contacts the TROUBLESHOOTING
water pump shaft. Continue rotating until the remaining
portion of mechanical seal has been removed from the case. Engine
(Figure 3-48)
Engine Turns Over But Fails to Start
• No fuel
• Dirt in fuel line or filter
• Fuel will not pass through fuel valve
• Fuel pump inoperative/restricted
• Tank vent plugged
• Carb starter circuit

Figure 3-48
• Engine flooded
7. Water Pump Install Kit (PN 5131135) is required to install
• Low compression (high cylinder leakage)
the new mechanical seal. This tool is available separately
as well as included in Crankshaft / Water Pump Seal • No spark (Spark plug fouled)
Installation Kit (PN 2871283).
Engine Does Not Turn Over
• Dead battery
• Starter motor does not turn
• Engine seized, rusted, or mechanical failure
Engine Runs But Will Not Idle
• Restricted carburetor pilot system
• Carburetor misadjusted
• Choke not adjusted properly
• Low compression
• Crankcase breather restricted

ENGINE
Engine Idles But Will Not Rev Up Low Compression
• Spark plug fouled/weak spark • Decompressor stuck
• Broken throttle cable • Cylinder head gasket leak
• Obstruction in air intake • No valve clearance or incorrectly adjusted
• Air box removed (reinstall all intake components) • Cylinder or piston worn
• Incorrect or restricted carburetor jetting • Piston rings worn, leaking, broken, or sticking
• ETC switch limiting speed • Bent valve or stuck valve

3
• Reverse speed limiter limiting speed • Valve spring broken or weak
• Carburetor vacuum slide sticking/diaphragm damaged • Valve not seating properly (bent or carbon accumulated
on sealing surface)
• Incorrect ignition timing
• Rocker arm sticking
• Restricted exhaust system
Backfiring
Engine Has Low Power
• ETC or speed limiter system malfunction
• Spark plug fouled
• Fouled spark plug or incorrect plug or plug gap
• Cylinder, piston, ring, or valve wear or damage (check
compression) • Carburetion faulty – lean condition
• PVT not operating properly • Exhaust system air leaks
• Restricted exhaust muffler • Ignition system faulty:

Spark plug cap cracked / broken
• Carburetor vacuum slide sticking/diaphragm damaged Ignition coil faulty
Ignition or kill switch circuit faulty
• Dirty carburetor
Ignition timing incorrect
Piston Failure – Scoring Sheared flywheel key
• Poor connections in ignition system

• Lack of lubrication
• System wiring wet
• Dirt entering engine through cracks in air filter or ducts
• Valve sticking
• Engine oil dirty or contaminated
• Air leaks in intake
Excessive Smoke and Carbon Buildup
• Lean condition
• Excessive piston–to–cylinder clearance
• Wet sumping
• Worn rings, piston, or cylinder
• Worn valve guides or seals
• Restricted breather
• Air filter dirty or contaminated
3.47
ENGINE
Spark Plug Fouling • Restricted system (mud or debris in radiator fins or
restriction to air flow, passages blocked in radiator,
• Spark plug cap loose or faulty lines, pump, or water jacket)
• Choke cable adjustment or plunger/cable sticking • Lean mixture (restricted jets, vents, fuel pump or fuel
valve)
• Foreign material on choke plunger seat or plunger
• Fuel pump output weak
• Incorrect spark plug heat range or gap
• Restricted radiator (internally or cooling fins)
• Carburetor inlet needle and seat worn
• Water pump failure
• Jet needle and/or needle jet worn or improperly
adjusted • Cooling system restriction
• Excessive carburetor vibration (loose or missing needle • Cooling fan inoperative or turning too slowly (perform
jet locating pins) current draw test)
• Loose jets in carburetor or calibration incorrect for • Ignition timing misadjusted
altitude/temperature
• Low oil level
• Incorrect float level setting
• Spark plug incorrect heat range
• PVT system calibrated incorrectly or components worn
or adjusted incorrectly • Faulty hot light circuit
• Fuel quality poor (old) or octane too high • Thermostat stuck closed or not opening completely
• Low compression Temperature Too Low
• Restricted exhaust • Thermostat stuck open

• Weak ignition (loose coil ground, faulty coil, stator, or Leak at Water Pump Weep Hole
ETC switch)
• Faulty water pump mechanical seal (coolant leak)
• ETC switch adjusted incorrectly
• Restricted air filter (main or pre–cleaner) or breather • Faulty pump shaft oil seal (oil leak)
system
• Improperly assembled air intake system
• Restricted engine breather system
• Oil contaminated with fuel
• Restricted oil tank vent
Cooling System
Overheating
• Low coolant level
• Air in cooling system
• Wrong type of coolant
• Faulty pressure cap or system leaks

FUEL SYSTEM / CARBURETION
CHAPTER 4
FUEL SYSTEM AND CARBURETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
BSR 42 CARBURETOR EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
FUEL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
JETTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
CARBURETOR JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
MIKUNI JET PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
CV CARBURETOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
CARBURETOR FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
VENT SYSTEMS – CV CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
MIKUNI CV CARBURETOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
PILOT (IDLE AND SLOW) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
STARTER SYSTEM (CHOKE OR ENRICHMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
FLOAT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4
MAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
PILOT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
CARBURETOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
CARBURETOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FLOAT HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
NEEDLE AND SEAT LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL LEVEL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
FUEL PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
FUEL PUMP INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
FUEL STARVATION / LEAN MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
RICH MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
POOR IDLE / IDLE TOO HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
IDLE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
ERRATIC IDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
4.1
FUEL SYSTEM AND CARBURETION
BSR 42 Carburetor Exploded View
Ref Description Ref Description Ref Description Ref Description
1 Cover, Diaphragm 16 Guide, Cable 31 A-Float 46 Asm., Plunger
2 Spring 17 O-ring 32 Jet, Main 47 Spring
3 Diaphragm 18 Cover 33 Ring 48 Holder, Guide
4 Valve, Piston 19 Screw 34 Holder, Jet 49 Screw
5 Holder 20 A-Shaft, Throttle 35 Jet, Needle 50 Cover
6 Spring 21 Screw 36 O-ring 51 Spring
7 Washer 22 Bolt 37 Needle Guide 52 Asm., Diaphragm
8 Washer 23 Spring, Idle Adjust 38 Screw 53 Filter
9 Jet, Needle 24 O-ring 39 Screw 54 Jet, Pilot Air 2 (1.3)
10 O-ring 25 Screw, Adjust 40 Jet, Pilot 55 Jet, Pilot Air 1 (110)
11 Case 26 Pin, Float 41 Jet, Starter (42.5) 56 Jet, Main Air (120)
12 Spring 27 O-ring 42 Asm., Carburetor 57 Ring
13 Seal 28 Body, Float 43 Packing 58 E-ring
14 Ring 29 Screw 44 E-ring 59 O-ring
15 Valve, Throttle (105) 30 Screw 45 Cap 60 Screw
60 3
53
1
50
54 49
51
4 55 52
56
5 59
2
6 58
7
48
47
8 57 46
9 45
1 2 44
3 11 10 43
4 42 13
5 41
40
12 39
13
14
38
Jet Needle 37
36
15
“E” Clip 35
Position 16
23
34 27
17 22 24
18 28 30
21 25 33
20 32
31
26
29
19
Refer to Page 4.4 for Optional Jet Part Numbers

Fuel Tank Assembly
Tank Cap
Vent Line
Fuel Tank
Fuel Valve
Fuel Lines 4
Impulse Line
Fuel Pump
In-Line
Filter
FUEL FLOW
Fuel Tank Vent Fuel Tank
Fuel Screens
*Fuel Pump Fuel Valve

(Filter in Pickup)
Carburetor Vent
In-Line Filter Carburetor Engine
* Located on upper frame
4.3
Special Tools Polaris ATV carburetors are calibrated for an altitude of 0–6000
ft. (0–1800 meters) and ambient temperatures above +40o F
TOOL (+26o C). Carburetors must be re–calibrated if operated outside
PART NUMBER
DESCRIPTION this temperature and/or altitude range. The jetting installed in
production is not intended for all altitudes and/or temperatures.
2870975 Mity VacTM Pressure Test In addition, air screw / pilot screw adjustments may be required
Tool to suit operating conditions.
Carburetor Float
2872314 Carburetor Jetting
Adjustment Tool
CAUTION
WARNING
A main jet that is too small will cause a lean
Gasoline is extremely flammable and operating condition resulting in
explosive under certain conditions. 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. charts in the specifications section or in the
Owner’s Manual for each particular model.
Do not overfill the tank. The tank is at full
capacity when the fuel reaches the bottom IMPORTANT: The following guidelines must be
of the filler neck. Leave room for followed when establishing a main jet setting:
expansion of fuel.
1. Select the lowest anticipated temperature at which the
Never start the engine or let it run in an machine will be operated.
enclosed area. Gasoline powered engine 2. Determine the lowest approximate altitude at which the
exhaust fumes are poisonous and can machine will be operated.
cause loss of consciousness and death in
a short time. 3. Select the correct main jet from the specifications chart in
Chapter 1.
Never drain the float bowl when the
engine is hot. Severe burns may result. Mikuni Jet Part Numbers
Main Jets Pilot Jets
Do not smoke or allow open flames or
sparks in or near the area where refueling Jet Number Part Number Jet Number Part Number
is performed or where gasoline is stored. 130 3131537 25 3131538
132.5 3131536 27.5 3131539
If you get gasoline in your eyes or if you 135 3131535 30 3131540
should swallow gasoline, seek medical 137.5 3131534 32.5 3131541
attention immediately. 140 3131522 35 3131542
142.5 3131523 37.5 3131543
If you spill gasoline on your skin or 145 3131524 40 3131544
clothing, immediately wash with soap and 147.5 3131525 42.5 3131545
water and change clothing. 152.5 3131526 47.5 3131546
155 3131527 50 3131547
Jetting Guidelines 157.5 3131528 52.5 3131548
160 3131529 55 3131549
Changes in altitude and temperature affect air density, which is 162.5 3131530 57.5 3131550
essentially the amount of oxygen available for combustion. In 165 3131531 60 3131551
low elevations and cold temperatures, the air is more dense and 167.5 3131532 65 3131552
has more oxygen. In higher elevations and higher temperatures, 170 3131533 70 3131553
the air is less dense with reduced oxygen.

CV CARBURETOR SYSTEM Vent Systems – CV Carburetor
The carburetor float bowl vent lines supply atmospheric
Carburetor Function
pressure to the float bowl. The lines must be free of kinks,
restrictions and be properly routed. This allows fuel to flow in
Carburetor Component Function
the proper amount and prevents contaminants from entering the
Main Main Main carburetor.
System
Components Function Affect
Mikuni CV Carburetor Operation
Maintains specified
Inlet Pipe, Needle fuel level in float The constant velocity carburetor incorporates a mechanically
Float System All systems; all
and Seat, Float, chamber
(Level Control)
Float Pin (carburetor float
throttle ranges operated throttle plate and a vacuum controlled slide valve
bowl). (vacuum slide). The venturi cross–sectional area in the
carburetor bore is increased or decreased automatically by the
vacuum slide, which moves according to the amount of
Venting
Passages in
carburetor; vent
Supplies
atmospheric All systems; all
pressure to float throttle ranges.
negative pressure (less than atmospheric) present in the
venturi. 4
lines to frame.
chamber. A diaphragm attached to the top of the vacuum slide is sealed to
the slide and to the carburetor body forming two chambers. The
chamber above the diaphragm is connected to the venturi area
by a drilled orifice in the center of the vacuum slide. The
Choke Lever, Cable, All throttle chamber below the diaphragm is vented to atmospheric pressure
Plunger, Return Supplies additional ranges. by a passage on the air box side of the carburetor. A spring,
Starter
Spring, Carb fuel air mixture Greatest effect
(Choke / installed in the center of the vacuum slide, dampens the slide
Passages (Starter necessary for cold at low throttle
Enrichment)
Jet, Starter Bleed starting. settings and
movement and assists the return of the slide.
Pipe). idle.
Low Pressure
Diaphragm
From Venturi
Atmospheric
Pilot Jet / Passage- Pressure
ways, Pilot–Mixture
Screw with Spring Mainly idle to
Washer and Sealing Primarily supplies 1/4 throttle. Atmospheric
Pilot Air inlet
O–Ring, By-pass fuel at idle and low Minimal effect
(Idle System)
Ports (Behind throttle positions. after 1/2
Throttle Plate), Pilot throttle.
Air Jet, Pilot Outlet,
Throttle Plate. Vacuum
Slide
Throttle Plate
Venturi
Main Jet, Main Air
Jet, Main Air
Supplies fuel at
Passage, Needle 1/4 to full
Main System mid–range and high
Jet, Jet Needle, throttle.
throttle settings.
Vacuum Slide,
Throttle Plate.
= Air Flow = Low pressure
4.5
Mikuni CV Carburetor Operation, Continued..... Pilot (Idle and Slow) System
When the throttle plate is opened and engine speed begins to
increase, the pressure in the venturi, and therefore in the This system supplies fuel during engine operation with throttle
chamber above the diaphragm, becomes significantly lower valve closed (1) or slightly opened. The fuel from float chamber
than atmospheric. Atmospheric pressure in the chamber below (2) is metered by pilot jet (3) where it mixes with air coming in
the diaphragm forces the diaphragm upward, raising the slide through pilot air jet (4). The mixture then goes up through pilot
against spring pressure. When the pressure above and below the passage to pilot screw (5). A part of the mixture is discharged
diaphragm are nearly equal, the slide moves downward under into the main bore out of bypass ports (6). The remainder is then
spring pressure. Raising or lowering the slide increases or metered by pilot screw and discharged into the main bore
decreases the cross sectional area in the venturi, and therefore through pilot outlet (7).
the air velocity in the venturi is kept relatively constant. This
provides improved fuel atomization and optimum fuel/air ratio.
4
2
3
Note: Diagrams are for explanation of theory only, and are not true
representations of Mikini BST carburetor.

Starter System (Choke or Enrichment) Float System
When the choke cable (1) is activated, the starter plunger (5) is Fuel enters the float chamber (3) by means of the inlet pipe and
lifted off the seat. passage, through a screen on the back of the inlet needle seat (4),
8 and around the inlet needle (2). As the fuel fills the float
5 1 chamber, the float (1) rises and forces the inlet needle against the
seat, shutting off the orifice in the seat. When fuel level is up in
float chamber, floats are up and needle valve remains pushed up
against valve seat. Under this condition, no fuel enters the float
chamber. As the fuel level falls, floats go down and needle valve
7 6 unseats itself to allow fuel into the chamber. In this manner, the
needle valve releases and shuts off fuel alternately to maintain
4 a constant fuel level inside the float chamber.
3 4
Fuel is drawn into the starter circuit from the float chamber (2)
through the starter jet (3). Starter jet meters this fuel, which then
flows into starter pipe (4) and mixes with the air (7) coming from
the float chamber. The mixture, rich in fuel content, reaches
starter plunger and mixes again with the air coming through a
passage (8) extending from underneath the diaphragm. The rich
fuel/air mixture for starting is discharged through starter outlet
(6) in the main bore.
Inlet
Pipe
1 3
4 2
4.7
Main System Pilot Screw
As throttle valve (1) is opened, engine speed rises, and this The pilot system supplies fuel during engine operation with the
increases negative pressure in the venturi. Consequently the throttle valve closed or slightly opened. The fuel/air mixture is
vacuum slide (2) moves upward. The fuel in float chamber (3) metered by pilot screw and discharged into the main bore
is metered by main jet (4), and the metered fuel enters needle jet through the pilot outlet.
(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 CAUTION
discharged into the venturi (A). Mixture proportioning is
accomplished in needle jet (5); the clearance through which the The pilot screw is calibrated at the factory to meet
emulsified fuel must flow is determined ultimately by throttle EPA / CARB regulations for air quality standards
position and vacuum slide height. 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
1 repair shop to ensure air quality standards
are not exceeded.
Pilot Screw Location

A
6
Brass Plug Installed
3
5
Brass Plug Removed

Carburetor Disassembly 3. Remove inlet needle seat retaining screw along with plate,
and carefully remove needle seat.
Use the following disassembly, assembly, and inspection
techniques to service a CV carburetor. NOTE: Do not use a pliers to remove the seat or
permanent damage may occur.
1. Remove carburetor diaphragm chamber cover with a
ratchet style screwdriver. DO NOT use an impact driver to
remove the screws or carburetor may be permanently
damaged.
Remove Screw
4
4. Remove the pilot mixture screw, spring, flat washer, and O–
Ring. If an anti–tamper plug is installed over the pilot screw
cavity, it must be removed for access.
2. Remove float bowl. Remove the float pin screw. Then the
float and float pin can be removed.
O-Ring
Washer
Spring
Pilot Screw
NOTE: The starter jet is removable. Upon

Float Pin Remove Screw disassembly, place the parts in a container for safe
keeping.
Starter Jet
Pilot Screw
4.9
Carburetor Cleaning Carburetor Inspection
1. Inspect jet needle and needle jet for wear. Look for
WARNING discoloration, shiny spots, or an area that looks different
than the rest of the needle. The middle to upper portion of
Protect eyes from contact with cleaner. Take the needle contacts the needle jet and is the most likely
appropriate safety measures during these wear point. If jet needle shows signs of wear replace both
procedures. Safety glasses and chemical the needle and needle jet to prevent a rich condition.
resistant gloves are required. Should you get TIP: A worn needle jet is difficult to spot. To check, slide
cleaner in your eyes or if you swallow cleaner, a slightly larger new jet needle into the needle jet and hold
seek medical attention immediately. it to a light source. Light will be visible between the needle
and needle jet if it is worn.
Carburetor cleaners can be extremely caustic.
Jet Needle Needle Jet
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
equipment. Rubber parts must be cleaned with
mild detergent and hot water only.
1. Thoroughly clean the carburetor body, jets, and all

passages with carburetor cleaner or electrical contact Inspect this area
cleaner.
2. Inspect the inlet needle tapered surface for any sign of wear
2. If the carburetor is extremely dirty or contaminated with or damage. Be sure the spring loaded pin is free moving and
fuel residue and varnish, soak for short periods only in returns freely when pushed. The inlet needle and seat
carburetor cleaner, and rinse in hot water. should be pressure tested after assembly.
3. Replace the jets if they have a buildup of fuel residue or
bacterial growth that cannot be removed. Even a small Good Condition Worn, Deposits
amount of residue will reduce the flow characteristics of the
jet.
4. Verify all passages and jets are unobstructed by spraying
electrical contact cleaner through the passages.
IMPORTANT: Do not use wire or welding tip cleaners Seat
as the orifice size may be altered.
Wear areas
5. Use low pressure air to dry carburetor body and all
components.
Needle

Carburetor Assembly NOTE: The final pilot (idle) mixture must be adjusted
with the engine running. Refer to Chapter 2 for
Inspect the diaphragm (A) for holes, deterioration, or damage. procedure.
Make sure the diaphragm is pliable but not swollen. The
diaphragm should fit properly in the carburetor body. Replace
diaphragm assembly if diaphragm is damaged. Pilot Screw Base Setting
(Set at Factory)
A Factory Specification: 2.5 Turns Out
Float Height Adjustment

1. Place the throttle side of the carburetor on a level surface
to remove weight from float arm. In this position, the float
tongue will rest slightly outward.
Float Outward
E 4
B
C
Carburetor Level
1. Replace parts in proper order. The spring seat (B) is
stepped and must be placed on TOP of “E” Clip (C). 2. With the carburetor still resting on the level surface, use one
Spacer washer (D) must be installed below the E–Clip. hand to slightly tilt the carburetor back. The float will then
Refer to parts manual for more information. fall into the correct position, with the float tongue resting
lightly on the inlet needle valve pin without compressing
2. Be sure the tab (E) on outer edge of diaphragm is positioned the spring. The bottom of the float should be parallel with
properly in the carburetor body. the float bowl mating surface.
13-14 mm
Float parallel with float

bowl mating surface
3. Install the pilot mixture screw, spring, washer, and O–ring
as an assembly. Lubricate the O–Ring with oil or light
grease before installation.
IMPORTANT: Do not damage the O–ring during
installation. Turn the screw in until it lightly contacts
the seat. Then back it out the specified number of
turns.
4.11
3. If the float is past parallel with the mating surface, the FUEL DELIVERY
carburetor has been tilted back too far and the float tongue
is likely compressing the needle valve pin. Needle and Seat Leak Test
Float too far inward
1. Install the float bowl. Invert the carburetor and install a
Mity–Vac™ (PN 2870975) to the fuel inlet fitting. Apply
5 PSI pressure to inlet fitting. The needle and seat should
hold pressure indefinitely. If not, inspect needle and seat
and seat O–ring.
4. Measure the height from the float bowl mating surface to

the top of step of the float as shown in Illustration 2. Both
sides of float should be parallel to each other. The
measurement should be made at the mid–point on top of the
float using Float Adjustment Tool (PN 2872314) or a
vernier caliper. When measuring the height, be sure the
inlet needle valve spring is not compressed.
Mity VacTM (PN 2870975)
Float Bowl Height: 13-14 mm
Fuel Level test

5. If adjustment is necessary, bend the tongue slightly. Be sure
float measurement is even on left and right side. A fuel level test can be performed on some models if the drain
hose fitting is accessible. Be sure to re–attach the bowl drain
Bend to adjust
hose after performing the test. A fuel level test allows you to
observe the height of the fuel in the float bowl without removing
the carburetor. The fuel level can be observed with the engine
either running or shut off, however, engine must run briefly to
allow fuel level to stabilize.
1. Attach a clear line to drain fitting. Be sure line fits tightly

on fitting. Position hose along side of carburetor as shown.
Float arms even
1.5 mm
.060 in.
Bowl Mating
Surface

2. Open bowl drain screw by turning counterclockwise Fuel Pump Inspection / Assembly
approximately two turns. Start and run engine for 3 to 5
seconds to allow fuel level to stabilize in the line. If level 1. Inspect inlet and outlet check valves for cracks, warpage or
is out of specification, remove carburetor and inspect inlet damage. Inspect the diaphragms for cracks, holes or
needle and seat, float height, passages, etc. swelling.
2. To clean the valves or pump body, remove the set screw and
NOTE: If a line was removed to perform this
washer. Remove the valve and wash with soap and water.
procedure, it must be replaced.
Carburetor cleaner may be used to clean the pump body
when the check valves are removed.
Fuel Pump
IMPORTANT: Some carburetor cleaners are very
This 500cc is equipped with a pressure regulated fuel pump caustic and should not be used to clean the non–
(1–3 PSI). The pump is located in the front fender cavity of the metal parts of the fuel pump.
machine.
3. Check the sealing surfaces of the pump body and covers.
To test the fuel pump: Carefully remove all traces of old gasket and check the
1. Turn fuel off. surfaces for damage. Replace diaphragms and gaskets as a
set.
4
2. Remove the front cab to access the fuel pump if needed.
4. Reassemble the pump in the reverse order of disassembly.
3. Disconnect impulse line from pump. Tighten all screws evenly.
4. Connect Mity–Vac™ (PN 2870975) to the impulse line
fitting on the pump. TROUBLESHOOTING
5. Apply 5 inches (Hg) vacuum to the pump fitting. The
diaphragm should hold vacuum indefinitely.
Fuel Starvation / Lean Mixture
If fuel is present in the impulse line or vacuum chamber of the Symptoms: Hard start or no start, bog, backfire, popping
pump, the diaphragm is ruptured. The pump diaphragms must through intake / exhaust, hesitation, detonation, low power,
be replaced. spark plug erosion, engine runs hot, surging, high idle, idle
speed erratic.
Fuel Pump
• No fuel in tank
• Restricted tank vent, or routed improperly
• Fuel lines or fuel valve restricted
• Fuel filter plugged
• Carburetor vent line(s) restricted
Impulse Line • Plugged or restricted inlet needle and seat screen or

inlet passage
• Clogged jets or passages
Fuel Pump Disassembly • Float stuck, holding inlet needle closed or inlet needle
stuck
1. Remove the screws from the pump diaphragm cover. Note
the location of the two longer screws. • Float level too low
2. Remove the diaphragm cover gasket, diaphragm, and valve
• Fuel pump inoperative
body gasket.
3. Remove the outlet check valve cover, diaphragm, and • Air leak at impulse line
gasket.
• Restricted impulse line (kinked, pinched)
• Intake air leak (throttle shaft, intake ducts, airbox or air

cleaner cover)
4.13
• Ruptured vacuum slide diaphragm, vacuum slide stuck Idle Too Low
closed or sticky
• Choke cable bending or incorrectly adjusted
• Improper spring
• Idle speed set incorrectly
• Jet needle position incorrect • Idle mixture screw adjusted incorrectly or damaged
• Incorrect pilot screw adjustment • Belt dragging
• Ignition timing incorrect
Rich Mixture
• Worn jet needle/needle jet
Symptoms: Fouls spark plugs, black, sooty exhaust smoke,
rough idle, poor fuel economy, engine runs rough/ misses, poor • Plugged or restricted idle jet
performance, bog, engine loads up, backfire.
Erratic Idle
• Air intake restricted (inspect intake duct) • Choke cable bending or incorrectly adjusted
• Air filter dirty/plugged • Throttle cable incorrectly adjusted
• Choke plunger sticking, incorrectly adjusted choke • Air leaks, dirty carburetor passages (pilot circuit)
• Choke cable binding or improperly routed • Pilot mixture screw damaged or adjusted incorrectly
• Incorrect pilot air/fuel screw adjustment • Tight valves
• Faulty inlet needle and seat • Ignition timing incorrect
• Faulty inlet needle seat O–Ring • Belt dragging
• Float level too high • Dirty air cleaner
• Poor fuel quality (old fuel) • Engine worn
• Loose jets • Spark plug fouled
• Worn jet needle/needle jet or other carburetor parts • Idle speed set incorrectly (speed limiter)
• Dirty carburetor (air bleed passages or jets) • Worn jet needle/needle jet
• Weak or damaged vacuum piston return spring • Plugged or restricted idle jet
• Fouled spark plug
Poor Idle / Idle Too High

• Idle adjusted improperly / idle mixture screw damaged
• Sticky vacuum slide
• Throttle cable sticking, improperly adjusted, routed
incorrectly
• Choke cable sticking, improperly adjusted, routed
incorrectly
• Plugged or restricted idle jet

BODY / STEERING / SUSPENSION
CHAPTER 5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
SEAT / SIDE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
TANK COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
HEEL POCKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
REAR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
STEERING ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
STEERING KNUCKLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
BALL JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5
FRONT HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
HUB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
HUB DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
FRONT SUSPENSION EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
FRONT A-ARM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
A-ARM REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
A-ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
REAR SUSPENSION EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
REAR A-ARM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
A-ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
A-ARM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
A-ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
REAR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
HOUSING REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
HOUSING DISASSEMBLY / SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
REAR BEARING CARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
CARRIER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
REAR DRIVE (CV) JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
CV JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
CV JOINT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
CV BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
CV JOINT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
5.1
FRONT SHOCK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32
RYDE FX™ FRONT SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32
REAR SHOCK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
RYDE FX™ REAR SHOCK (COMPRESSION ADJUSTABLE) . . . . . . . . . . . . . . . . . . . 5.33
RYDE FX™ SHOCK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34
SHOCK SPECIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34
PISTON ORIENTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34
RYDE FX™ SHOCK REBUILD PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35

GENERAL INFORMATION COMPONENT TORQUE VALUE
SERVICEABLE COMPONENTS
COMPONENT TORQUE VALUE Rear Pivot Housing 30 ft. lbs.

Mounting Bolts (41 Nm)
FRONT SUSPENSION 26 ft. lbs.
Rear Sprocket Bolts
(35 Nm)
33 ft. lbs. Brake Disc 18 ft. lbs.
Front A–Arm Attaching Bolts
(45 Nm) Caliper Mounting Bolts (25 Nm)
Front A–Arm Ball Joint 40 ft. lbs. 25 ft. lbs.
Stud Nut (54 Nm) Wheel Nuts
(34 Nm)
40 ft. lbs. Rear Pivot Housing 17 ft. lbs.
Front Spindle Nut
(54 Nm) Mount Plate (23 Nm)
15 ft. lbs. 33 ft. lbs.
Tie Rod End Jam Nut Foot Peg
(20 Nm) (45 Nm)
33 ft. lbs.
Tie Rod End Attaching Nut
(45 Nm) Special Tools
Shock Bolts 33 ft. lbs.
(top & bottom) (45 Nm) PART NUMBER TOOL DESCRIPTION 5
STEERING Rear Drive Hub Removal /
PA - 48282
Installation Tool
45–55 in. lbs. Ball Joint Replacement
Master Cylinder Mount Bolts
(5.2–6.3 Nm) 2870871
Tool
9 ft. lbs.
Handlebar Adjuster Block PS-45259 Gas Fill Tool
(12 Nm)
35 ft.lbs. IFP Positioning /
Steering Post Nut PS-45261
(47 Nm) Extraction Tool
17 ft. lbs.
Steering Post Bushing Nuts PA-48282 Rear Hub Tool
(23 Nm)
17 ft. lbs.
Steering Post Retainer Nuts
(23 Nm)
33 ft. lbs.
Centerlink - Steering Post Arm
(45 Nm)
33 ft. lbs.
Centerlink - Idler Arm
(45 Nm)
REAR SUSPENSION
33 ft. lbs.
Rear A–Arm Attaching Bolts
(45 Nm)
90 ft. lbs.
Rear Hub Nut
(122 Nm)
30 ft. lbs.
Rear Hub Carrier Bolts
(41 Nm)
33 ft. lbs.
Upper Torsion Bar Bolts
(45 Nm)
Shock Bolts 33 ft. lbs.
(top & bottom) (45 Nm)
Torsion Bar Pivot 9 ft. lbs.
Plate Bolts (12 Nm)
5.3
BODY ASSEMBLY
Exploded View
A. Seat I. Grab Bar
B. Seat Release Latch J. Fuel Tank Cover
C. Rear Cab K. Frame
D. Side Panel L. Foot Peg
E. Front Cover M. Rock Guard
A F. Front Cab N. Front Bumper
G. Heel Pocket O. Rear Cab Support
H. Heel Support
O O
B C
D
I
J
G
L
K
F
M
N
L
M

BODY COMPONENT REMOVAL 2. Remove the 2 torx head screws holding the lower front
portion of the front cab.
Seat / Side Panel
1. Remove the seat by lifting up on the releasing latch and
slide the seat towards the rear of the ATV.
2. Remove the 2 torx head screws from the side panel.
3. Disconnect the 16 pin connector to completely remove the

front cab assembly.
3. Carefully unhook the locking tabs at the rear portion of the

5
side panel and then slide the panel towards the rear of the
ATV to completely disengage the side panel locking tabs
4. Reverse the removal steps to reinstall the side panel.
Front Cab
1. Remove the 4 torx head screws and the 2 (6mm) bolts
holding the rear portion of the front cab.
4. Reverse the removal steps to reinstall the front cab.
Tank Cover
1. Remove the 4 (6mm) bolts (A) retaining the fuel tank
cover.
5.5
2. Remove the fuel tank cap to allow the cover to be removed. Rear Cab
Once removed reinstall the fuel tank cap.
1. Remove the 2 bolts from the lower portion of the rear cab
on each side as shown below.
3. Reverse the removal steps to reinstall the tank cover.

2. Push both seat grommets (C) through the rear cab, remove
Heel Pocket screws (D) and completely remove the rear cab.
1. Remove the 2 bolts from the upper portion of the heel
pocket.
C
3. Reverse the removal steps to reinstall the rear cab. It may

be necessary to lubricate the rubber grommets to aid the
2. Remove the 3 screws (A) from the lower portion and reassembly.
remove the heel pocket.
3. Reverse the removal steps to reinstall the heel pocket.

STEERING ASSEMBLY EXPLODED VIEW
A. Handlebar
9 ft. lbs
B. Block Clamps
(12 Nm)
A C. Steering Bushings
D. Steering Post
B E. Zerk Fitting
F. Cotter Pin
G. Tie Rod Assembly
H. Sealed Ball Bearing
I. Ball Bearings
J. Foam Spacer
K. Tube Spacer
L. Steering Knuckle
M. Centerlink Asm.
N. Steering Idler Asm.
D
33 ft. lbs.
(45 Nm)
5
C E
L
17 ft. lbs.
(23 Nm)
33 ft. lbs. 17 ft. lbs.

(45 Nm) (23 Nm)
F
J
15 ft. lbs.
(20 Nm)
N K I
33 ft. lbs. H
(45 Nm)
NOTE: APPLY ANTI-SEIZE COMPOUND

ONTO SPINDLE BEFORE HUB INSTALLATION
35 ft. lbs. (47 Nm)
5.7
STEERING KNUCKLE 4. Tap down on the lower A-arm to move the lower ball joint
from the steering hub.
Removal
Installation
1. Follow the steps in the “FRONT HUB REMOVAL”
section to remove the hub, if needed. 1. Before installation check the condition of the ball joints.
2. Remove the upper and lower ball joint cotter keys and castle Joints should move freely and have no axial play.
nuts. 2. Place the upper and lower A-arms into the steering hub.
3. Install the castle nuts onto the upper and lower A-arms.
Torque the nuts to 35 ft.lbs. (47 Nm).
4. Install new cotter pins into the castle nuts and ball joints.
BALL JOINT SERVICE

Removal
1. The A-arm must be removed to perform this procedure,
Refer to “A-ARM REPLACEMENT” on Page 5.13.
Ball Joint
3. Carefully tap on the upper A-arm near the top ball joint
while lifting up on the upper A-arm.
Upper A-arm
Retaining Ring
2. Remove the retaining ring from the ball joint.
Upper A-arm Shown

3. A driver must be used for the removal of the ball joints. Use Installation
the dimensions below to fabricate or locate the correct size
driver to use in the following process. 1. Place the A-arm in the correct position for ball joint
installation. Face the A-arm end flat on top of the driver.
Driver Dimensions
1.375 in. Carefully drive the ball joint into place until the ball joint
(3.49 cm) is properly installed.
3 in.
(7.62 cm)
Press into the A-arm

1.75 in in this direction
(4.45 cm)
* Outside diameter of driver cannot be any larger than

1.75 in. Inside diameter cannot be any smaller than
1.375 in. Driver must be 3 in. or taller.
4. Use a press and correct size driver to remove the ball joint
from the A-arm.
Upper A-arm Shown
Press out of the A-arm
in this direction 2. After the new ball joint is installed into the A-arm, install
a NEW retaining ring. Upon A-arm installation onto the
5
steering hub, install a NEW cotter key.
Nut & Washer
NEW NEW Cotter Key

Retaining Ring
Lower A-arm
Upper A-arm Shown
NOTE: The driver must fit the inside diameter of the

A-arm. This will allow the ball joint to be properly Ball Joint
pressed out of the A-arm without damaging the A-
arm.
Correct
Driver Placement
Ball Joint
The driver must fit the inside

diameter of the A-arm end.
Upper A - arm
Lower A-arm Shown
NEW
Retaining Ring
Nut & Washer
NEW Cotter Key
5.9
FRONT HUB
Exploded View
12 15 19
10 11 13
8
5 6
4 14 18
3
2
17 16
1
Ref. Qty. Description

1. 2 Nut, Castle
2. 2 Pin, Cotter
3. 2 Washer
4. 2 Spacer, Outer
5. 2 Seal
6. 2 Bearing, Ball, Sealed
7. 2 Hub, Wheel, Front, Indy Red
8. 8 Stud
9. 2 Spacer, Tapered
10. 2 Bearing, Ball
11. 2 Seal
12. 2 Disc, Brake
13. 2 Spacer, Inner
14. 8 Bolt
15. 2 Rim, Front
16. 2 Valve, Rim
17. 8 Nut, Flange
18. 2 Tire, Front, 21x7–10
19. 2 Guard, Disc, Outer
Hub Removal 5. Remove outer brake disc guard, cotter pin, front spindle
nut, and washer.
1. Elevate front end of ATV and safely support machine
under footrest / frame area.
CAUTION
Serious injury may result if machine tips or falls.

Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
2. Check bearings for side play by grasping tire / wheel firmly

(top and bottom, side to side) and checking for movement.
It should rotate smoothly without binding or rough spots.
6. Remove the outer spacer from the spindle. Inspect outer

spacer for wear, replace if needed.
Outer Spacer
5
3. Remove wheel nuts and wheel.
4. Remove the two brake caliper bolts and the brake caliper.
Use mechanic’s wire or other suitable material to support 7. Remove the hub from the spindle. Remove the inner spacer
the caliper assembly. Do not allow caliper assembly to from the spindle. Inspect the inner spacer for wear, replace
hang by the brake line! if needed.
Inner Spacer
Brake Caliper
Bolts
8. Rotate each bearing inside the hub by hand and check for
smooth rotation. Visually inspect bearing for moisture, dirt,
or corrosion. Replace bearing if moisture, dirt, corrosion,
or roughness is evident.
5.11
Hub Disassembly Hub Assembly
1. Place a shop towel on hub to protect surface. Carefully pry 1. Drive or press one new bearing into hub using a bearing
seal out of hub. driver.
Seals (2)
Seal Hub
Tapered Spacer
Bearings (2)
2. Using a brass drift, tap bearing spacer to one side to expose

inner bearing race. Drive bearing out using a drift through CAUTION
opposite side of hub and discard.
Tap Spacer to Do not drive on the inner race of the bearing.
the side
Premium All- Season Grease
(PN 2871322) (3 oz. Tube)
(PN 2871423) (14 oz. Tube)
2. Coat bearing spacer with grease and install into hub. Drive
or press the other bearing into hub until seated against
spacer.
3. Install seal into hub (with numbers facing out) until flush
with end of seal bore.
3. Remove spacer. Drive other bearing out and discard.

4. Clean hub and spacer thoroughly. Seal
5. Inspect spacer for wear or damage. Measure the tapered
spacer for wear, replace as needed.
Tapered Spacer
.774 + .005
.797 + .005

Hub Installation 7. Rotate hub. It should rotate smoothly without binding,
rough spots or side play.
1. Apply anti-seize compound to spindle area, this will aid in
easier removal of the wheel in the future. 8. Install brake caliper. Tighten bolts to 18 ft.lbs. (24 Nm).
2. Inspect spindle and bearing surface for wear or damage.
Install the inner spacer.
Inner Spacer
18 ft. lbs. (24 Nm)
Apply anti-seize compound

9. Install the brake disc guard.
3. Install hub on spindle. Install the outer spacer. 10. Install the wheel and four wheel nuts finger tight. Lower the
ATV and torque the wheel nuts to 30-35 ft. lbs.
(41-47 Nm).
5
Outer Spacer
4. Install the washer and spindle nut. Torque the spindle nut
to 40 ft. lbs. (54 Nm).
Front Wheel Torque
Front Wheel Nuts (4)

30-35 ft. lbs.
(41-47 Nm)
Front Spindle Nut

40 ft. lbs. (54 Nm)
5. Install a new cotter pin. Tighten nut slightly if necessary to

align cotter pin holes.
6. Bend both ends of cotter pin around end of spindle in
different directions.
5.13
FRONT SUSPENSION EXPLODED VIEW
Use new cotter pins upon reassembly.

Install with open end toward rear of machine.
C
H
C E D
L G
33 ft. lbs. B
(45 Nm)
F
L
D B
A
J 40 ft. lbs.
(54 Nm)
M I K
A
40 ft. lbs.
(54 Nm) A. Springs
B. IFP Shock
C. Upper A-Arm
D. Lower A-Arm
E. A-Arm Shaft
F. Bushings
G. Bolt
33 ft. lbs. H. Flange Nut
(45 Nm)
I. Steering Knuckle
J. Ball Joints
K. Cotter Pins
L. Retainer Rings
M. Inner Disc Guard

FRONT A-ARM REPLACEMENT 6. Examine A–arm shafts (I). Replace if worn. Discard
hardware.
A-arm Removal and Inspection
1. Elevate and safely support vehicle. Remove the front
wheel(s).
2. Remove the upper and lower ball joint cotter pins (A) from
the ball joint studs (B & C) at wheel end of A–arm. Remove
the ball joint nuts until the nuts are flush with end of the ball
joints studs.
3. Push up on the upper A-arm (D) to remove the A-arm from I

the steering knuckle (E). Push down on the lower A-arm (F) H
to remove the A-arm from the steering knuckle (E).
D
5
E
A-arm Installation
A
1. Insert A–arm shaft (I) into the new A–arm (D & F).
2. Install new A–arm assembly onto vehicle frame (upper and

lower). Torque bolts to 33 ft. lbs. (45 Nm).
3. Attach upper A-arm (D) and lower A–arm (F) to steering

knuckle (E). Attach shock with bolts (G). Tighten all
fasteners to 33 ft. lbs. (45 Nm). If ball joint cotter pin holes
are not aligned, tighten nut slightly to align. Install a new
cotter pin with open ends toward rear of machine (upper and
lower). Bend ends in opposite directions around nut.
4. Locate grease fittings at the end of each A–arm tube and

F pump A–arm ends full of grease.
C
WARNING
4. Remove the lower shock bolt (G) from the lower A-arm and
remove the shock from the A-arm. Upon A–arm installation completion, test vehicle at low
speeds before putting into regular service.
5. Loosen two bolts on the A–arm tubes (H) (upper and lower
A-arms) until A–arm can be removed.
A-arm Attaching Bolt Torque:
Ball Joint Stud Nut Torque:
Front Shock Bolt Torque:
33 ft. lbs. (45 Nm)
5.15
REAR SUSPENSION EXPLODED VIEW
C
33 ft. lbs.
(45 Nm) J
I
30 ft. lbs. D
(41 Nm)
E
I
33 ft. lbs.
(45 Nm)
F B
F
J 9 ft. lbs.
(12 Nm)
A
D
J
E
K
33 ft. lbs.
(45 Nm)
I H
J G
B
30 ft. lbs.
(41 Nm) 33 ft. lbs.
(45 Nm)
A. Hub Carrier Assembly

B. Torsion Bar Assembly
C. Upper A-Arm
D. Lower A-Arm
E. Guard
F. Bushings
G. Bolt
H. Flange Nut
I. Needle Bearing
J. Bearing Seals

REAR A-ARM REPLACEMENT NOTE: Rear A-arm mounts contain needle bearings
A-arm Removal
1. Elevate and safely support vehicle. Remove the rear
wheel(s).
2. Loosen the upper and lower hub carrier bolts at the wheel
end of A–arms (A)(C).
E
D I
C H
F E E
D H G I
D G
E 5
B
A-arm Inspection
A 1. Disassemble, clean and inspect the upper A-arm bushings
and shaft. Replace components as required.
3. Remove the lower shock bolt from the lower A-arm hole
(B) and remove the shock from the A-arm.
4. Remove bolt (A) on the lower A–arm tube and pry the hub
carrier up and away from the A-arm.
5. Remove bolt (C) on the upper A–arm tube and pry the hub
carrier down and away from the A-arm.
6. Remove remaining bolts (D) from A-arms and remove A-
arms from frame.
7. Examine A–arm shafts (E), needle bearings (F), seals (G),
thrust washers (H) and bushings (I). Replace if worn or
damaged.
5.17
2. Disassemble, clean and inspect the lower A-arm thrust NOTE: Apply grease to the inside of the needle
washers, needle bearing, seals and shaft. Replace bearings before inserting shaft.
components as required.
A
Inspect A
6. Insert A–arm shafts, seals and thrust washers into the A–

arm mounting bores.
3. Inspect needle bearing performance by rotating the shaft
inside the bearing (circled). If replacement is required,
press the bearings out from opposite sides using a drift
punch or other suitable tool.
4. Press needle bearings (A) from the A-arms using a drift
punch or other suitable tool. Do not re-use bearings once
they have been removed.
A-arm Installation
1. Install A–arm assemblies onto vehicle frame (upper and
lower). Torque bolts to 33 ft. lbs. (45 Nm).
2. Attach upper A-arm and lower A–arm to hub carrier. (E).
Tighten both fasteners to 33 ft. lbs. (45 Nm).
5. Press new needle bearings (A) into the A-arms, centering 3. Locate grease fittings at the upper and lower A-arm
bearing in the bore. Press only on the outside diameter of bushings and pump full of grease.
the bearing. Verify that an equal amount of space remains
on each side to allow for seal installation. WARNING
Upon A–arm installation completion, test vehicle at low
speeds before putting into regular service.

REAR HOUSING
Exploded View
G H
F
E
A
D
B
C
I
B
D
5
A
CV Ball/Cage Assembly
Individual Parts Not Available - Order Hub Assembly
A. CV Boot Retaining Ring

B. Inner CV Boot
C. Sprocket Hub
D. Bearing (2)
E. Rear Axle Housing
F. O-Ring
G. Rear Brake Disc Hub
H. Brake Hub Retaining Ring
5.19
Housing Removal 9. Remove brake disc and drive sprocket from rear housing.
This provides the necessary clearance for housing removal.
1. With ATV on the ground, loosen wheel nuts and hub nuts.
2. Safely lift and support the rear of the ATV under the main
frame.
3. Remove both rear wheels and hubs.
4. Loosen rear housing mounting bolts and chain adjustment.
5. Remove drive chain.
6. Remove rear caliper and secure out of the way.
NOTE: Do not allow the caliper to hang by the brake
line. Brake line damage may result.
7. Remove both upper carrier bolts and secure upper a-arms

out of the way.
10. Remove rear housing mounting bolts and chain adjustment

components.
A
8. Tilt each hub carrier outward while pulling rear CV shaft
end from carrier assembly.
11. Lift and rotate rear housing and angle out of the ATV frame,
exiting the frame from either side.
NOTE: Removal of rear shock may be necessary to
gain adequate clearance for rear housing removal.

Housing Disassembly / Service 6. Using a flat blade screwdriver, carefully pry the retaining
rings from both CV ball cages.
1. Place housing in a suitable holding fixture.
2. Remove both boot clamps from their locations.
3. Using a flat blade screwdriver, carefully pry the retaining
ring from each boot.
7. Remove the CV ball cage retaining rings from the housing.
4. Remove the retaining rings from both inner boots of the rear
housing. 5
8. Remove the inner CV joints and shaft assemblies from the

carrier housing.
5. Remove both inner boots by pulling outward on boot. A

blunt prying tool may be required to break the sealing area.
NOTE: Inner CV joint parts are not

replaceable. Order new hub assembly if
damaged beyond serviceable condition.
NOTE: Inner CV boots are sealed to housing. Use
caution during removal. Boot damage may result.
5.21
9. To disassemble the inner CV joint, place the CV end on a 11. To reassemble the inner CV joint, use special Hi Temp CV
vise and use a punch to tap the driveshaft out. joint grease to allow the rollers to “stick” to the cage. Insert
the rollers into the outer cage, then insert the inner joint
sideways 180 degrees into the cage assembly and turn the
inner joint to capture the rollers. The chamfered end should
be facing toward the drive shaft.
12. Using a soft faced hammer, tap the drive shaft into the
chamfered end of the inner CV assembly until it locks in
place. Lubricate the inner CV assembly liberally with joint
grease before housing reassembly.
13. Before pressing the brake and sprocket hubs apart, remove
the sprocket hub snap ring.
IMPORTANT: Note the orientation of the parts for

reassembly. Inner CV joint parts are not replaceable.
Replace hub assembly if joints are damaged
NOTE: Drive shaft inserts into chamfered end
14. Using Special Tool PN PA-48282, press the rear hub

assembly apart to access the carrier bearings.
10. The inner CV joint can be disassembled by rotating the

inner joint approximately 180 degrees and pulling out.
Clean and inspect the joint and rollers for cracks or rough
surfaces. Replace the hub assembly if damage is found.
Brake Hub Assembly
180°
Rear Hub Tool

PA - 48282

15. Using a suitable holding fixture, press or tap the carrier 3. Using Special Tool PN PA-48282, press the rear hub
bearings out the opposite end of each housing. assembly together. Verify o-ring is seated properly during
NOTE: Do not reuse the bearings if removed. reassembly.
Bearing
Assembly
1.Using a suitable holding fixture, press or tap the carrier
Rear Hub Tool
bearings into the housing.
NOTE: Do not reuse the bearings if removed.
PA - 48282 5
4. Install the sprocket hub snap ring.
Bearing
2. Apply sealant to the sprocket hub splines before assembly.

Sprocket Hub Assembly
O-ring
5.23
5. Pack the housing assembly and inner boots with a total of 8. Clean and apply a thin coat of sealant to both the boot and
8.75 oz. of Hi-Temperature CV joint grease. Distribute sealing surface before installing inner boots. Install
grease evenly. retaining rings.
Apply sealant before assembly
CV GREASE
NOTE: Use Special Hi-Temp CV Grease

8.75 oz. (248.05 grams)
9. Install boot clamps.
Rear Housing Hi-Temp CV Grease NOTE: Before tightening boot clamp on inboard
Capacity: 8.75 oz. (248.05 grams) joints, make sure any air pressure which may have
built up in joint boot has been released using the
boot ‘burping’ process. The air should be released
6. Install the inner CV ball cage and retaining rings.
after the plunging joint has been centered properly.
Tighten boot clamps using boot clamp pliers.
7. Ensure the retaining ring is seated properly in the rear

housing groove.
Installation
1. Reverse the steps described in the Removal/ Disassembly
procedure.
2. Attach the rear housing mounting bolts, chain adjustment
components and brackets. Torque brackets to 17 ft.lbs. (23
Nm). Do not tighten chain adjustment or housing bolts
until chain adjustment has been completed.
3. Attach the brake disc and drive sprocket to rear housing.
4. Install and torque the brake disc bolts to 18 ft.lbs. (25 Nm).
5. Install and torque the drive sprocket bolts to 26 ft.lbs. (35
Nm).
6. Install each rear CV shaft end into hub carrier from and
attach the upper a-arm to the hub carrier.

7. Insert and torque the a-arm mount bolts to 30 ft.lbs. (41 Carrier Disassembly / Inspection
Nm).
1. Remove outer snap ring.
2. From the back side, tap on the outer bearing race with a drift
Carrier Bolt Torque: punch in the reliefs as shown.
30 ft.lbs. (41 Nm)
8. Follow chain adjustment procedures. 5

9. Torque remaining rear housing fasteners to 30 ft.lbs. (41
Nm) after completion of chain adjustment.
10. Install rear hubs, cone washer and nut. Verify cone washer
domed side faces outward. Torque hub nut to 90 ft.lbs. (122
Nm) and install cotter pin.
REAR BEARING CARRIER

Carrier Removal
1. Remove rear wheel and hub. NOTE: Drive bearing out evenly by tapping on outer
2. Remove upper carrier bolt and secure upper A-arm out of race only. Once bearing is at bottom of casting,
the way. Tip hub carrier outward and remove shaft end from support casting on outer edges so bearing can be
carrier. Remove lower carrier bolt. removed.
3. Inspect bearing.
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
outer race.
4. Inspect bearing housing for scratches, wear or damage.

Replace housing if damaged.
5.25
5. Disassemble, clean and inspect the upper A-arm bushings Carrier Assembly
and shaft. Replace components as required.
1. Assemble and install the upper A-arm bushings and shaft.
6. Disassemble, clean and inspect the lower A-arm thrust

2. Install needle bearings by pressing the bearings into the
washers, needle bearing, seals and shaft. Replace
housing using a suitable tool.
components as required.
Thrust
Washer
Seal
Shaft
Needle Bearing
Bearing Installation
3. Apply grease and install the shaft. Install the lower A-arm
7. Inspect needle bearing performance by rotating the shaft
seals.
inside the bearing. If replacement is required, press the
bearings out from opposite sides using a drift punch or other
suitable tool. Thrust
Washer
Seal
Shaft
Bearing Removal

4. Support bottom of bearing carrier housing and start bearing 4. Lift bearing carrier until top aligns with upper control arm.
in housing Install and torque upper control arm bolt and torque to
specification. Torque lower control arm bolts to
specification. Apply grease to zerk.
5. Press bearing into place until outer race bottoms on

housing.
Lower Control Arm Bolt Torque:

33 ft. lbs. (45 Nm)
Upper Control Arm Bolt Torque: 5
33 ft. lbs. (45 Nm)
5. Pull drive shaft outward and install hub onto driveshaft

splines.
6. Install cone washer domed side facing outward.
7. Install retainer nut, wheel and wheel nuts.
8. Remove jackstand and torque hub nut and wheel nuts to
specification.
CAUTION
Use an arbor press only on the outer race.

Bearing damage may occur.
6. Install snap ring into groove.
Carrier Installation
1. Insert bearing carrier on drive shaft.
2. Align bottom of carrier housing and lower control arm.
Grease and slide lower control arm bushings into place,
securing corner housing.
3. Install both lower control arm bolts.
Hub Nut Torque:
90 ft.lbs. (122Nm).
Wheel Nut Torque:

30-35 ft.lbs. (41-47 Nm).
5.27
9. Install a new cotter pin. Tighten nut slightly to align holes 2. Photo below is shown without shaft for clarity. Wipe
if required. grease away from recess in CV joint inner hub and locate
snap ring
REAR DRIVE (CV) JOINT Snap Ring Located in Recessed Area
CV Joint Removal
1. Remove rear wheel and hub.
Snap Ring
2. Remove upper carrier bolt and secure upper A-arm out of
the way. Tip hub carrier outward and remove shaft end from
carrier.
NOTE: CV joint service can be performed with
driveshaft attached to rear carrier housing.
3. Open the snap ring using a snap ring pliers or small needle
nose pliers. Tap CV housing off shaft with a soft faced
hammer while holding snap ring open.
Spread ends of snap ring

to remove joint from shaft
CV Joint Service
1. Remove clamps from rubber boot(s) using the CV Boot Tap CV housing
Clamp Pliers (PN 8700226) (A). off shaft
4. Place a new snap ring in the groove of the CV joint inner

hub, with tabs facing the shaft as shown.

CV Boot Replacement
1. Remove CV joint from end of shaft.
Tabs face shaft 2. Remove boot from shaft.
NOTE: When replacing a damaged boot, check the
grease for contamination by rubbing it between two
fingers. A gritty feel indicates contamination. If the
grease is not contaminated, the boot can be
replaced without cleaning the CV joint. Use the
recommended amount of grease for boot
replacement only (see below). Proceed to Boot
Installation.
3. Thoroughly clean and dry the CV joint and inspect ball

tracks and cages for wear, cracks or other damage.
5. Refit CV joint on interconnecting shaft by tapping with a
NOTE: Shiny areas in ball tracks and on the cage
plastic hammer on the joint housing. Take care not to
spheres are normal. Do not replace CV joints
damage threads on the outboard CV joint. The joint is fully
because parts have polished surfaces. Replace CV
assembled when the snap ring is located in the groove on
joint only if components are cracked, broken, worn
the interconnecting shaft.
or otherwise unserviceable.
Tap joint onto shaft
5
6. Install and tighten large boot clamp with boot clamp pliers. 4. Add the recommended amount of grease for CV joint
7. Remove excess grease from the CV joint's external surfaces cleaning to the joint as required. Be sure grease penetrates
and position joint boot over housing, making sure boot is all parts of the joint.
seated in groove. Position clamp over boot end and make 5. Refit CV joint on interconnecting shaft by tapping with a
sure clamp tabs are located in slots. plastic hammer on the joint housing. Take care not to
NOTE: NOTE: Before tightening boot clamp on damage threads on the outboard CV joint. The joint is fully
inboard joint, make sure any air pressure which may assembled when the snap ring is located in the groove on
have built up in joint boot has been released. The air the interconnecting shaft.
should be released after the plunging joint has been 6. Add grease through large end of boot.
centered properly. Tighten boot clamp using boot
7. Install a new boot onto the axle shaft and fill the CV joint
clamp pliers.
and boot with the correct type and amount of grease.
5.29
8. While pulling out on the CV shaft, fully extend the CV joint CV Joint Installation
and slide a straight O-ring pick or a small slotted screw
driver between the small end of the boot and the shaft. This 1. Slide shaft assembly into bearing carrier hub.
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.
2. Apply anti-seize compound to splines of shaft.

3. Install a new lock ring and install the shaft.
4. Lift bearing carrier into place and install bolt to upper
control arm. Torque bolt to 33 ft. lbs. (45 Nm).
9. Install the small clamp on the boot.

10. Be sure to use only the Constant Velocity Joint grease
supplied with boot service kit. IF CV JOINT WAS
CLEANED, add the required amount of grease to the joint
in addition to the grease pack supplied with boot kit.
NOTE: CV Joint Grease Capacity:
5. Install hub, flat washer, domed washer (domed side out)

and nut. Torque center hub nut to 90 ft. lbs. (122 Nm).
Install new cotter pin and hub cap.
Boot Capacity -
30 Grams
CV Joint Grease
Outboard Joints - 3.5 oz. (99.2 grams)
each

6. Install rear wheel and torque wheel nuts to specification. DECALS
90 ft.lbs. (122 Nm)
Replacement
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.
Be sure the area to be flame treated is clean and
free of gasoline or flammable residue.
The side panels, front and rear fender cabs are plastic
polyethylene material. Therefore, they must be “flame treated”
prior to installing a decal to ensure good adhesion. A bonus of
Refer to Chapter 2 for the flame treating procedure is it can be used to reduce or
Wheel Nut Torque. eliminate the whitish stress marks that are sometimes left after
a fender or cab is bent, flexed, or damaged.
To flame treat the decal area: 5

1. Pass the flame of a propane torch back and forth quickly
over the area where the decal is to be applied until the
surface appears slightly glossy. This should occur after just
a few seconds of flame treating. Do not hold the torch too
close to the surface (2-3 inches from the flame tip is
recommended). Keep the torch moving to prevent damage.
2. Apply the decal on one edge first. Slowly lay down
remainder of the decal while rubbing lightly over the decal
surface to eliminate any air bubbles during the application.
5.31
FRONT SHOCK EXPLODED VIEW
RydeFX™ FRONT SHOCK
5
1 2
11
8
9
10 3
13 1
12 2
Ref. Description Ref. Description

1. Bushing 8. Nut
2. Sleeve 9. IFP
3. Spring Retainer Nut 10. IFP O-Ring
4. Compression Bumper 11. Cylinder Head Asm
5. Upper Mount 12. Pressure Valve
6. Shaft 13. Valve Screw
7. Piston / Wear Band / Top-Out & Bottom-Out Washers

REAR SHOCK EXPLODED VIEW
RydeFX™ REAR SHOCK (Compression Adjustable)
6
11
3
10
12
13 2
Ref. Description Ref. Description

1. Bushing 8. Nut
2. Sleeve 9. IFP
3. Spring Retainer Nut 10. IFP O-Ring
4. Compression Bumper 11. Cylinder Head Asm
5. Upper Mount 12. Pressure Valve
6. Shaft 13. Valve Screw
7. Piston / Wear Band / Top-Out & Bottom-Out Washers
5.33
RYDE FX™ SHOCK SERVICE Changing oil on RydeFX™ Shocks is recommended annually
and should NOT be performed during end of season storage
Shock Specification Chart preparation.
Shown below is an example of how valving stacks are arranged. For competition use, shocks should be disassembled and
serviced more frequently.
NOTE: Direction of the valve piston before
disassembly. The side with the greater number of Piston Orientation
slots should face the IFP (nut end of the shaft).
NOTE: Orifice must be drilled to required size on

replacement valve pistons.

RydeFX™ Shock Rebuild Procedure NOTE: Before unscrewing pre-load springs,
measure the compressed length of the installed
Required Tools spring and mark position for reinstallation.
• RydeFX Gas Charge Tool (Inflation Needle)

CAUTION
• RydeFX I.F.P Extraction / Locator Tool
• Adjustable Wrench When removing the spring from a shock that
utilizes a fixed lower retainer; the use of a proper
• 5/64” Hex Key spring compressor should be used to avoid
• Slotted Head Screwdriver risk of bodily injury. 5
• Torque Wrench 3. Wash the shock body in parts cleaner; then dry with
• Vernier Caliper or Micrometer compressed air to remove sand and dirt.
WARNING
• Rod Thimble
• Rod Blocks
• Pic Tool When using compressed air to dry components,
protective eye wear should be worn to
• Shock Spring Compressor avoid risk of injury.
• Nitrogen Regulator
4. Remove bearing, sleeve and/or bushings from lower shock
DISASSEMBLY mount eyelet. Secure the lower mount of the shock in a
vise. The use of soft jaws is recommend to prevent damage
or marks to the shock.
WARNING
Before servicing a gas shock it is important that

all the gas pressure be discharged from the unit.
Refer to the instructions listed below for the
proper procedure of discharging the gas
pressure from a shock. Protective eye wear
should be worn to avoid risk of injury while
servicing RydeFX™ gas charged
mono-tube shocks.
1. Remove the shock from the vehicle.

2. If shock incorporates a spring; remove spring and collateral CAUTION
retainers.
It is important that the gas shock be retained in
the vise by the lower mount. Any other method
of securing the shock body during these
procedures may deform the shock body cylinder.
5.35
5. Remove the small button head screw from the pressure 7. Remove the pressure valve assembly from the lower end
valve assembly. mount. Account for an O-ring.
6. Using a slotted screwdriver, loosen the pressure valve 8. With an adjustable wrench, loosen and remove cylinder
assembly counter-clockwise two full revolutions allowing head assembly.
the gas pressure to fully escape past the pressure valve
assembly O-ring.
9. Pour the oil out of the shock body. Discard old oil into an
approved storage container and dispose appropriately.
Never reuse damper oil during shock rebuild.
WARNING
Nitrogen gas is under extreme pressure. Use

caution when releasing nitrogen gas from
shock. Protective eye wear should be worn to
avoid risk of injury.
CAUTION
Allow all the gas pressure to escape before

proceeding with the removal of the pressure
10. Using the I.F.P extraction tool, thread the tool into the I.F.P
valve assembly. Pressurized gas and shock oil
and pull upwards, removing the I.F.P from the shock body.
could eject the valve assembly from the cylinder
Account for wear band and an O-ring.
resulting in bodily injury.

11. Clean the inside of the shock body using clean parts- ASSEMBLY
cleaning solvent and blow dry using compressed air.
1. Place the piston rod upper mount into the vise.
12. Place the shock piston rod upper mount in bench vise, begin Reassemble damper rod assembly in the reverse order of
piston and valve removal. Arrange parts removed in the disassembly. Pay special attention to the order of the
sequence of disassembly. Rebound and Compression disc (shim) stacks, ensuring
Front Shock Part# 7043259 that they are in the same order prior to disassembly.
Tighten the lock nut to15-20 ft. lbs. (20-27 Nm) of torque.
Rear Shock Part# 7043260
CAUTION
5
DO NOT OVER-TORQUE.
If excessive torque is applied, damage to the
piston and valves will occur.
2. Secure the shock body by its lower mount in vise. The use
of soft jaws is recommended to prevent damage or marks
to the shock.
Items to inspect:
• Piston rod for straightness, nicks or burrs.
• Cylinder Head Assembly / DU Bearing - clean, inspect,
or replace.
• Inside of shock body for scratches, burrs or excessive

wear.
• Teflon piston and I.F.P wear band for cuts, chipped or

nicked edges, or excessive wear.
• O-rings for nicks, cuts, or cracks.

CAUTION
• Cap and rod seals for nicks, cuts or cracks.
• Valve discs for kinks or waves. It is important that the gas shock be retained in
• Compression bumpers for chipping, cracking or being the vice by the lower mount. Any other method
missing. of securing the shock body during these
procedures may deform the shock body cylinder.
Should any of these items be in question replacement is
recommended.
5.37
3. Thread the positioning head onto the I.F.P locator tool and 7. Screw the pressure valve assembly into the valve port by
adjust the top of the value indicator to the appropriate hand with a slotted head screwdriver. Tighten to 100-110
measurement. in. lbs. (11-12 Nm) of torque.
NOTE: Depending on which shock absorber is being 8. Fill the shock body with shock oil to the bottom of the
worked on, adjust the piston location tool to the threads within the cylinder.
specified depth indicated in the shock specification
chart, located on the bottom of Page 5.34.
4. Apply a thin film of oil onto the floating wear band and O-
ring and install the floating piston into the top of the shock
body, positioning it below the counterbore.
NOTE: After filling the shock body with oil, allow a

couple of minutes for all air bubbles to rise to the
top.
Polaris Gas Shock Oil - P/N 2870995
5. Using the tool as a handle, push the floating piston down 9. With the cylinder head assembly pushed down against the
into the shock body, being careful not to damage I.F.P wear piston, carefully, insert the piston rod and assembly into the
band and O-ring, until the value indicator knob comes in cylinder; Slightly oscillating the piston rod to allow piston
contact with the shock body. The piston should now be to enter shock body bore. A light coating of oil on the piston
located correctly. wear band will ease installation.
6. Apply a light film of grease to the pressure valve port 10. Slowly push the piston rod and assembly into shock body
counterbore through 360º, where the pressure valve until the cylinder head assembly bottoms on the cylinder
assembly O-ring meets. counterbore. Slight up and down movement may be
required to allow all air to pass through piston assembly.

NOTE: During installation, some shock oil will 13. Using a flat head screw driver, turn the compression
overflow. Wrap a shop cloth around shock body to adjusting cam clockwise to ensure there is positive
catch possible oil overflow. engagement of the internal adjusting rod with the surface
of the adjusting cam. Only applicable for the rear shock
NOTE: Fast installation of the piston rod and absorber P/N: 7043260.
assembly may displace the floating piston from its
original position. This must not occur if the damper
is expected to perform as designed
11. Using an adjustable wrench tighten cylinder head securely

into the shock cylinder.
14. Install the small button head screw in the pressure valve
assembly and tighten securely.
15. Reinstall sleeve and bushings in lower shock mount.
5
12. Pressurize the shock through the pressure valve with
nitrogen gas to the specified pressure.
Nitrogen Gas Pressure - 200 psi
NOTE: After being compressed, the piston rod

should fully extend from the shock body once the
shock has been pressurized.
5.39
NOTES

BRAKES
CHAPTER 6
BRAKES
BRAKE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
BRAKE CALIPER EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
REAR BRAKE CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
FRONT BRAKE CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
BRAKE SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
FRONT BRAKE SYSTEM - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
REAR BRAKE SYSTEM - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
HYDRAULIC SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BRAKE FLUID REPLACEMENT AND BLEEDING PROCEDURE. . . . . . . . . . . . . . . . . . 6.8
MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
CALIPER REMOVAL AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
CALIPER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
6
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
PAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
DISC REMOVAL / REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
REAR CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
REAR BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
DISC REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
BRAKES SQUEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24
POOR BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24
LEVER VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24
BRAKES LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24
6.1
BRAKES
BRAKE SPECIFICATIONS
General Specifications
FRONT BRAKE CALIPER

Item Standard Service Limit
Brake Pad Thickness .298″ / 7.6 mm .180″ / 4.6 mm
Brake Disc Thickness .158” / 4.013 mm .140″ / 3.556 mm
Brake Disc Thickness Variance
– .002″ / .051 mm
Between Measurements
Brake Disc Runout – .010″ / .254 mm
RH Handle Bar Master Cylinder I.D. – .551” / 14 mm
REAR BRAKE CALIPER
Item Standard Service Limit
Brake Pad Thickness .298″ / 7.6 mm .180″ / 4.6 mm
Brake Disc Thickness .158” / 4.013 mm .140″ / 3.556 mm
– .002″ / .051 mm
Between Measurements
Brake Disc Runout – .010″ / .254 mm
Master Cylinder I.D. – Aux. Rear .500” / 12.7 mm
TORQUE TORQUE
ITEM
(ft. lbs. except where noted) (Nm)
Front Caliper Mounting Bolts 18 24
Rear Caliper Mounting Bolts 18 24
Rear Master Cylinder Mounting Bolts 8 11
Front Master Cylinder Reservoir Cover Bolts 11 (in. lbs.) 1.24
Brake Line Banjo Bolts 15 20
Brake Disc Mounting Bolts 18 24
Wheel Mounting Nuts 25 34
Front Master Cylinder Clamp Bolts 85 (in. lbs.) 9.6
Rear Caliper Bleed Screws 27 (in. lbs.) 3.1
Front Caliper Bleed Screws 47 (in. lbs.) 5.3
Rear Caliper Slide Bolts 33 45
Rear Caliper Anvil Bolts 16-18 22-24
Rear Hub Nut 90 122
Upper A-arm Bolt 30 41
NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures
are used when torquing certain bolts and fasteners.
Special Tools
Part Number Tool Description

2870975 Mity Vac™

BRAKES
BRAKE CALIPER EXPLODED VIEWS
Rear Brake Caliper Assembly
16-18 ft.lbs. A
(22-24 Nm)
C
Apply Polaris DOT 3 or DOT 4 brake fluid D
to component. E
33 ft.lbs. G B
(45 Nm) H 27 in lbs.
(3.1 Nm)
I
A. Anvil Bolts
K F B. Bleed Screws
C. Washers
D. O-rings
E. Rear Housing
J F. Seals
M
G. Piston
H. Slide Pins
I. Bushings
J. Seal
K. Bracket
N L L. Pad
M. Front Housing
6
N. Retaining Clips
Front Brake Caliper Assembly
A Apply Polaris DOT 3 or DOT 4

Brake Fluid to Component
Apply Polaris All Purpose

Grease
B
E
47 in lbs.
(5.3 Nm)
G
H
C
A. Socket Set Screw

B. Bleeder Screw D
C. Caliper Assy. F
D. Boot
E. Square O-ring
F. Piston
G. Caliper Mount
H. Brake Pads
6.3
BRAKES
BRAKE SYSTEM OVERVIEW
Front Brake System - Exploded View
A. Master Cylinder
B. Brake Line
C. Mechanical Brake Switch
D. Wheel Hub
E. Banjo Bolt & Washers
F. Caliper
G. Caliper Mount Bolt C
15 ft. lbs.
(20 Nm)
85 in. lbs.
(9.6 Nm)
B
A
B
18 ft. lbs.
(24 Nm)
15 ft. lbs.
(20 Nm)
E
D

BRAKES
Rear Brake System - Exploded View
18 ft. lbs.
(24 Nm)
H
15 ft. lbs.
C
(20 Nm)
J
B
D
I
15 ft. lbs.
C
(20 Nm)
F
B
K
A
L
6
G
M
A. Caliper
B. Sealing Washer
C. Banjo Bolt Q
D. Brake Line
E. Clevis Pin O
F. Master Cylinder Asm.
G. Cotter Pin R
N
H. Rear Brake Reservoir O
I. Hose Clamp S
J. Reservoir Hose P
K. Brake Switch
L. Brake Switch Bracket
M. Switch Spring
N. Washer
O. Bushing
P. Torsion Spring
Q. Foot Brake
R. Large Washer
S. Screw
6.5
BRAKES
Service Notes
Disc brake systems are light weight, low maintenance, and perform well in the conditions ATVs routinely encounter. 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.
• Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment
• Do not over-fill the master cylinder fluid reservoirs.
• Make sure the brake levers return freely and completely.
• Check and adjust master cylinder reservoir fluid levels after pad service.
• Make sure atmospheric vent on reservoirs are unobstructed.
• Test for brake drag after any brake system service and investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins.
• Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.
• Perform a brake burnishing procedure after installing new pads to maximize service life.
CAUTION
Use only DOT 3 or DOT 4 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 Troubleshooting

Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning
does not reduce the occurrence of brake noise, check the backing of each pad for worn spots allowing metal to metal contact. See
table below:
Brake Noise Troubleshooting

Possible Cause Remedy
Spray disc and pads with a non–flammable aerosol brake
Dirt, dust, or imbedded material on pads or disc cleaner only! Remove pads and/or disc hub to clean imbedded
material from disc or pads.
Pad(s) dragging on disc (noise or premature pad wear)
Improper adjustment Adjust pad stop (front calipers)
Insufficient lever or pedal clearance Check position of controls & switches
Master cylinder reservoir overfilled Set to proper level
Master cylinder compensating port restricted Clean compensating port
Master cylinder piston not returning completely Inspect. Repair as necessary
Caliper piston(s) not returning Clean piston(s) seal
Operator error (riding the brake / park brake applied) Educate operator
Loose wheel hub or bearings Check wheel and hub for abnormal movement
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
If noise does not change when brake is applied check other
Noise is from other source (chain, axle, hub, disc or wheel)
sources. Inspect and repair as necessary
Wrong pad for conditions Change to a softer or harder pad

BRAKES
Hydraulic System Operation
C
F
A B
D
G
Typical Hydraulic Brake System
The Polaris brake system consists of the following components or assemblies: brake lever; master cylinder; hydraulic hose; brake
calipers (slave cylinder); brake pads; and brake discs, which are secured to the drive line.
When the hand activated brake lever (A) is applied it contacts a piston (B) within the master cylinder. As the master cylinder piston
moves inward it closes a small opening (compensating port) (C) within the cylinder and starts to build pressure within the brake
system. As the pressure within the system is increased, the piston (D) located in the brake caliper moves outward and applies pressure 6
to the moveable brake pad. This pad contacts the brake disc and moves the caliper in its floating bracket, pulling the stationary side
pad into the brake disc. The resulting friction reduces brake disc and vehicle speed. As the lever pressure is increased, the braking
affect is also increased.
The friction applied to the brake pads will cause the pads to wear. As these pads wear, the piston within the caliper moves further
outward and becomes self adjusting. Fluid from the reservoir fills the additional area created when the caliper piston moves outward.
Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause the brakes to feel
spongy. Too much fluid could cause brakes to drag due to fluid expansion.
Located within the master cylinder is the compensating port (C) which is opened and closed by the master cylinder piston assembly.
The port is open when the lever is released and the master cylinder piston is outward. As the temperature within the hydraulic system
changes, this port compensates for fluid expansion (heated fluid) or contraction (cooled fluid). 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. If the reservoir is over filled or the diaphragm vent is plugged the expanding
fluid may build pressure in the brake system leading to brake failure.
When servicing Polaris ATV brake systems use only Polaris DOT 3 or DOT 4 Approved High Temperature Brake Fluid.
WARNING
Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial
bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture. This causes the boiling temperature of
the brake fluid to drop, which can lead to brake fade and possible loss of control.
6.7
BRAKES
Brake Fluid Replacement and NOTE: Do not remove brake lever when reservoir
Bleeding Procedure fluid level is low.
NOTE: When bleeding the brakes or replacing the

fluid always start with the caliper farthest from the
master cylinder.
CAUTION
Always wear safety glasses during

these procedures.
CAUTION
5. Add brake fluid to the upper level mark on reservoir.
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact
with finished surfaces. Polaris DOT 3 or DOT 4 Brake Fluid
NOTE: This procedure should be used to change 6. Begin bleeding procedure with either front caliper. Install
fluid or bleed brakes during regular maintenance. a box end wrench on the caliper bleeder screw. Attach a
clean, clear hose to fitting and place the other end in a clean
Front Brake Caliper Bleeding
container. Be sure the hose fits tightly on fitting.
1. Clean reservoir cover thoroughly. Bleeder Screw
2. Remove screws, cover, and diaphragm from master
cylinder reservoir.
NOTE: Fluid may be forced from compensation port

when brake lever is pumped. Place diaphragm in
reservoir to prevent spills. Do not install cover.
3. Inspect vent slots in the cover and remove any debris or
blockage. 7. Slowly pump brake lever until pressure builds and holds.
4. If changing fluid, remove old fluid from reservoir with a 8. While maintaining lever pressure, open bleeder screw.
Mity Vac™ (PN 2870975) or similar tool. Close bleeder screw and release brake lever.
NOTE: Do not release lever before bleeder screw is
tight or air may be drawn into caliper.

BRAKES
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. Reservoir Cover Torque
CAUTION 11 in. lbs. (1.2 Nm)
Maintain at least 1/2” (1.27 cm) of brake fluid in Rear Brake Caliper Bleeding
the reservoir to prevent air from entering
the master cylinder. 1. Clean rear brake fluid reservoir cover thoroughly.
2. Remove the cap and diaphragm from the reservoir.
10. Tighten bleeder screw securely and remove bleeder hose.
Torque bleeder screw to 47 in. lbs. (5.3 Nm).
11. Repeat procedure Steps 5-9 for the remaining front caliper.
12. Add brake fluid to the proper level
Rear Brake Reservoir
3. If changing fluid, remove old fluid from reservoir with a

Mity Vac™ (PN 2870975) or similar tool.
4. Using a funnel, add brake fluid to the MAX level mark on
reservoir. 6
Master Cylinder Fuild Level:
Add to MAX level inside reservoir.

Sight glass must look dark, if sight glass
is clear, fluid level is too low
13. Install diaphragm, cover, and screws. Torque the screws to

11 in.lbs. (1.2 Nm).
Polaris DOT 3 or DOT 4 Brake Fluid
6.9
BRAKES
5. Install a box end wrench on the upper rear caliper bleeder 11. Field test machine at low speed before putting into service.
screw. Attach a clean, clear hose to fitting and place the Check for proper braking action and lever reserve. With
other end in a clean container. Be sure the hose fits tightly lever firmly applied, lever reserve should be no less than
on fitting. 1/2” (1.3 cm) from handlebar.
12. Check brake system for fluid leaks and inspect all hoses and
lines for wear or abrasion. Replace hose if wear or abrasion
is found.
Bleeder Screws
MASTER CYLINDER
Removal
1. Clean master cylinder and reservoir assembly. Make sure
you have a clean work area to disassemble brake
components.
2. Place a shop towel under brake line connection at master
cylinder. Loosen banjo bolt (A); remove bolt and sealing
washers.
6. Slowly pump foot brake lever until pressure builds and
holds.
7. While maintaining lever pressure, open bleeder screw.
Close bleeder screw and release brake lever.
NOTE: Do not release lever before bleeder screw is
tight or air may be drawn into caliper.
8. Repeat procedure until clean fluid appears in bleeder hose A B

and all air has been purged. Add fluid as necessary to
maintain level in reservoir.
9. Tighten bleeder screw securely and remove bleeder hose.
Torque bleeder screw to 27 in. lbs. (3.1 Nm).
10. Using a funnel, add brake fluid to the MAX level mark on
reservoir.
CAUTION
Brake fluid will damage finished surfaces.

Do not allow brake fluid to come in contact
with finished surfaces.
3. Loosen the master cylinder clamp bolts (B) on the

handlebar side of the master cylinder.
Rear Reservoir Fuild Level:
Add to MAX level shown on the outside

of the rear reservoir.

BRAKES
4. Remove master cylinder from handlebars. Installation
1. Install master cylinder on handlebars. Torque mounting
Master Cylinder bolts to 85 in. lbs. (9.6 Nm). Torque the top bolt first.
15 ft. lbs.
(20 Nm)
Front Brake Line
85 in. lbs.
Banjo Bolt (9.6 Nm)
15 ft. lbs.
(20 Nm)
15 ft. lbs.
Retainer Banjo Bolt (20 Nm)
Caliper NOTE: To speed up the brake bleeding procedure

Mount Bolt the master cylinder can be purged of air before
18 ft. lbs. Caliper brake line is attached. Fill with DOT 3 or DOT 4 Brake
(24 Nm)
Fluid and pump lever slowly two to three times with
finger over the outlet end to purge master cylinder of
air.
2. Place new sealing washers on each side of banjo brake line. 6

Install the brake line into the master cylinder. Torque the
Master Cylinder Assembly brake switch bolt to 15 ft.lbs. (20 Nm).
Banjo Bolt
15 ft. lbs. (20 Nm)
Brake Line
Sealing Washers
Torque to 15 ft. lbs.

(20 Nm)
Cover Screws
11 in. lbs. (1.24 Nm)
Master Cylinder Mounting Clamp
Clamp Bolts
85 in. lbs. (9.6 Nm)
Bolt Torque: 85 in. lbs. (9.6 Nm)
Banjo Bolt Torque:

15 ft. lbs. (20 Nm)
6.11
BRAKES
3. Fill reservoir with DOT 3 or DOT 4 Brake Fluid. 4. Loosen pad adjuster screw 2-3 turns.
5. Remove the upper and lower caliper mounting bolts and

remove the caliper assembly from the caliper mount.
Polaris DOT 3 or DOT 4 Brake Fluid
4. Follow bleeding procedure. Check all connections for leaks

and repair if necessary.
FRONT CALIPER SERVICE

Caliper Removal and Disassembly
1. Clean caliper area before removal.
2. Elevate and support front of machine. Remove the front
wheel.
CAUTION
6. Push upper pad retainer pin inward and slip brake pads past
edge.
Use care when supporting vehicle so that it
does not tip or fall.
Severe injury may occur if machine tips or falls.
3. Using a line wrench, loosen and remove brake line to

caliper. Place a container under caliper to catch fluid
draining from brake line.

BRAKES
7. Remove mounting bracket, pin assembly and dust boot. Caliper Inspection
1. Inspect caliper body for nicks, scratches or wear. Measure
bore size and compare to specifications. Replace if damage
is evident or if worn beyond service limit.
8. Remove dust seal and piston seal.
Caliper Piston Bore I.D.:

Std:. 1.188” (30.2 mm)
Service Limit: 1.193” (30.30 mm)
2. Inspect piston for nicks, scratches, wear or damage.

Measure diameter and replace if damaged or worn beyond
service limit.
6
9. Clean the caliper body, piston, and retaining bracket with
brake cleaner or alcohol.
Clean Components
3. Inspect the brake disc and pads as outlined for brake pad
replacement in this section. See “Brake Pad Inspection”
earlier in this chapter.
NOTE: Be sure to clean seal grooves in caliper

body.
6.13
BRAKES
Caliper Reassembly 4. Compress the mounting bracket and make sure the dust
seals are fully seated. Install the brake pads. Clean the disc
1. Install new O-rings (A) in the caliper body (B). Be sure and pads with brake parts cleaner or denatured alcohol to
groove is clean and free of residue or brakes may drag remove any dirt, oil or grease.
upon assembly.
C
B
A
Caliper Installation
2. Coat piston with clean Polaris DOT 3 or DOT 4 Brake Fluid 1. Install caliper and torque mounting bolts.
(C). Install piston (D) with a twisting motion while pushing 18 ft. lbs
inward. Piston should slide in and out of bore smoothly, (24 Nm) 15 ft.lbs. (20 Nm)
with light resistance.
3. Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install the rubber
dust seal boots.
2. Install brake line and tighten securely with a line wrench.

Torque the banjo brake lines to the proper torque
specification.
3. Install the adjuster screw and turn until stationary pad
contacts disc, then back off 1/2 turn.
4. Perform brake bleeding procedure as outlined earlier in this
chapter.
5. Install wheels and torque wheel nuts to specification.

BRAKES
FRONT BRAKE PADS 5. Push mounting bracket inward and slip outer brake pad
past edge. Remove inner pad.
Pad Removal
1. Elevate and support front of ATV.
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 screw 2-3

turns.
6. Measure the thickness of the pad material. Replace pads if

worn beyond the service limit.
6
3. Remove caliper from mounting bracket.
NOTE: When removing caliper, use care not to
damage brake line. Support caliper so to avoid
kinking or bending brake line.
4. Push caliper piston into caliper bore slowly using a

C-clamp or locking pliers with pads installed.
Measure Pad
Front Brake Pad Thickness

New : .298”/ 7.6 mm
Service Limit: .180” / 4.6 mm
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
6.15
BRAKES
Pad Assembly 3. Install caliper on spindle hub and torque mounting bolts.
1. Lubricate mounting bracket pins with a light film of 18 ft. lbs

Polaris Premium All Season Grease (PN 2871423), and (24 Nm)
install rubber dust boots.
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.
2. Compress mounting bracket and make sure dust boots are 5. Install the adjuster screw and turn clockwise until
fully seated. Install pads with friction material facing each stationary pad contacts disc, then back off 1/2 turn
other. (counterclockwise).
1/2 Turn
6. Verify fluid level in reservoir is up to MAX line inside

reservoir and install reservoir cap.
WARNING 7. Install wheels and torque wheel nuts.
NOTE: Front Wheel Nut Torque: Refer to Torque
If brake pads are contaminated with grease, oil, or Table at beginning of chapter.
liquid soaked do not use the pads.
Use only new, clean pads. 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 warping may result. Repeat this procedure 10
times.

BRAKES
FRONT BRAKE DISC
Brake Disc Runout
Disc Inspection
Service Limit .010” (.254 mm)
1. Visually inspect the brake disc for nicks, scratches, or
damage.
2. Measure the disc thickness at 8 different points around the Disc Removal / Replacement
pad contact surface using a 0–1” micrometer. Replace disc
1. Apply heat to the hub in the area of the brake disc
if worn beyond service limit.
mounting bolts to soften the bolt locking agent.
2. Remove bolts and disc.
3. Clean mating surface of disc and hub.
4. Install disc on hub.
CAUTION
Always use new brake disc mounting bolts.

The bolts have a pre–applied locking agent
which is destroyed upon removal.
5. Install new bolts and tighten to specified torque.
Brake Disc Thickness 18 ft. lbs.

New: .158” (4.013 mm) (24 Nm) 6
Service Limit: .140” / 3.556 mm)
Service Limit: .002” (.051 mm)

(difference between measurements)
3. Mount dial indicator as shown to measure disc runout.

Slowly rotate the disc and read total runout on the dial
indicator. Replace the disc if runout exceeds specifications.
Front Brake Disc Mounting Bolt Torque
18 ft. lbs. (24 Nm)
6.17
BRAKES
REAR CALIPER SERVICE 2. Remove the caliper slide bolts (B), mounting bracket (C),
and brake pads (D).
Caliper Removal
B D
1. Clean caliper area before removal.
2. Using a flare nut wrench, remove the brake line (A). Place
a container to catch brake fluid draining from brake line.
A
C
A
3. Remove the outside dust boot (E).

B
E
3. Remove the caliper mounting bolts (B) and remove the

caliper assembly from the caliper mount.
Caliper Disassembly
4. Remove the piston and seal (F).

F
1. Remove the c-clips (A) from the caliper sliding bolts.

BRAKES
5. Remove the caliper body bolts (G). Pull the caliper bodies 2. Inspect piston for nicks, scratches, wear or damage.
apart (if necessary). Replace if damaged or worn.
G Inspect Piston
6. Clean the caliper body, piston, and retaining bracket with 3. Inspect the brake disc and pads as outlined for brake pad
brake cleaner or alcohol. replacement this section.
Caliper Inspection Caliper Assembly

1. Inspect caliper body bore and o-rings for nicks, scratches 1. Reassemble the two caliper halves if previously
or wear. Measure bore for roundness. Replace if damage is disassembled. Torque the caliper body bolts to 18 ft.lbs.
evident. (24 Nm).
18 ft.-lb.
(24Nm)
6
O-rings
2. Install new O–ring (A) in the caliper body. Install the dust
NOTE: Be sure to clean seal grooves in caliper boot over the caliper and seat the dust boot into caliper
body. groove. Be sure groove is clean and free of residue or brakes
may drag.
B
A
6.19
BRAKES
3. Coat piston and inside of caliper body with clean DOT 3 REAR BRAKE PAD
or DOT 4 Brake Fluid. Install piston with a twisting motion
while pushing inward. Piston should slide in and out of bore Pad Removal
smoothly, with light resistance. NOTE: Be sure that the O-
ring does not bind when installing the piston. 1. Loosen both bolts and remove the rear brake mount bolt.
Tip the caliper and re-torque the remaining brake mount
4. Seat the dust boot securely onto the caliper body. bolt. This will allow access to the upper caliper slide bolt.
2. Loosen the caliper slide bolts with an Allen wrench before

5. Install the caliper mount (C), brake pads (D), caliper slide you remove the brake caliper.
bolts (E), and c-clips (F).
C
D
F
E
3. Remove caliper mounting bolts and lift caliper off of disc.
6. Torque the caliper slide bolts (E) to 33 ft.lbs. (45 Nm).
NOTE: When removing caliper, be careful not to

damage brake line. Support caliper so as not to kink
or bend brake line.

BRAKES
4. With pads installed, push caliper piston into caliper bore 7. Measure the thickness of the pad material. Replace pads if
(A) slowly using a C–clamp (B) or locking pliers. worn beyond the service limit.
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
Brake Pad Thickness

5. Remove the c-clips (C) on the ends of the caliper slide bolt.
New: .298” / 7.6 mm
Pad Installation
1. Install new pads (A) in caliper body. Slide the caliper slide
bolts (B) into the caliper and hand-tighten. 6
6. Remove caliper slide bolts (D) and brake pads (E).
D
B
A
2. Install the caliper assembly over the brake disc and onto the
caliper mount. Tip the caliper forward and install only the
forward bolt. This will allow both slide bolts to be torqued
to specification. TIP: Use a block or wedge to keep the
caliper stationary while tightening the slide bolts.
E Brake Caliper Mounting Bolt

Torque:
18 ft. lbs. (24 Nm)
6.21
BRAKES
3. Torque the caliper slide bolts to 33 ft.lbs. (45 Nm). NOTE: BRAKE BURNISHING: It is recommended
that a burnishing procedure be performed after
installation of new brake pads to extend service life
33 ft.-lb. and reduce noise. Start machine and slowly increase
(45Nm) speed to 30 mph. Gradually apply brakes to stop
machine. Repeat this procedure 10 times, allowing
brakes to cool sufficiently after each run.
REAR BRAKE DISC

Disc Inspection
1. Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident.
4. Install the caliper mounting bolts and torque both bolts to

18 ft. lbs. (24 Nm).
Rear Brake
Disc
Measure
Thickness
2. Use a 0–1” micrometer and measure disc thickness at 8

18 ft. lbs. (24 Nm) different points around perimeter of disc. Replace disc if
worn beyond service limit.
5. Install the c-clips (C) onto the ends of the caliper slide bolts.
Brake Disc Thickness

New: .158” (4.013 mm)

(difference between measurements)
C
3. Mount dial indicator and measure disc runout. Replace the
disc if runout exceeds specifications.
6. Slowly pump the brake levers 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 master cylinder. Brake Disc Runout
Auxiliary Brake Master Cylinder
Fluid Level
Between MIN and MAX lines

BRAKES
Disc Removal 7. Remove brake disc mounting bolts (4).
1. With ATV on the ground, loosen wheel nuts and hub nuts.
2. Safely lift and support the rear of the ATV under the main
frame.
3. Remove right rear wheel and hub.
4. Remove rear caliper and secure out of the way.
NOTE: Do not allow the caliper to hang by the brake
line. Brake line damage may result.
5. Remove right upper carrier bolt and secure upper a-arm out
of the way.
8. Lift and rotate disc, slipping it over the hub assembly and
off the driveshaft, exiting the frame from the side.
Disc Replacement
1. Install disc, slipping it over the over the drive shaft and hub
assembly. Disc mounting holes will be on the inside face
of the hub assembly for correct installation.
2. Install brake disc mounting bolts. Torque mounting bolts to
18 ft.lbs. (24 Nm).
6. Tilt right hub carrier outward while pulling rear CV shaft

3.
4.
Install CV shaft into hub carrier.
Install upper a-arm, bolt and nut on to hub carrier. Torque 6
end from carrier assembly. mounting bolt to 30 ft.lbs. (40.6 Nm).
5. Install wheel hub, domed washer and nut (dome of washer
facing out). Torque to 90 ft.lbs. (122 Nm). Install cotter pin.
6.23
BRAKES
TROUBLESHOOTING
Brakes Squeal
• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn disc splines
• Glazed brake pads
Poor Brake Performance

• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted lever
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Improper clearance between lever and switch
Lever Vibration
• Disc damaged
• Disc worn (runout or thickness variance exceeds
service limit)
• Caliper overheats (Brakes Drag)

• Compensating port plugged
• Pad clearance set incorrectly
• Auxiliary brake pedal incorrectly adjusted
• Brake lever or pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes
Brakes Lock
• Alignment of caliper to disc
• Fluid overfill of the reservoir
• Stuck caliper piston

ELECTRICAL
CHAPTER 7
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TIMING CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
LIGHTING AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
NEUTRAL / REVERSE POSITION INDICATOR SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
HEADLIGHT LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
HEADLAMP SWITCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
HEADLIGHT HOUSING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
TAILLIGHT / BRAKELIGHT LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
BRAKE LIGHT SWITCH TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
CLUTCH SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
INDICATOR LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
TETHER SWITCH TEST (ACCESSORY OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
ETC OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
IGNITION SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
CIRCUIT BREAKERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
CRANKING OUTPUT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
FLYWHEEL IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
DC / CDI IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
IGNITION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
COMPONENTS OF DC / CDI IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
FAN CONTROL CIRCUIT OPERATION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
COOLANT TEMPERATURE SENSOR TEST (HOT LIGHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
FAN CONTROL SWITCH BYPASS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
COOLANT FAN CONTROL SWITCH OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
FAN MOTOR CURRENT DRAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
CURRENT DRAW – KEY OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
ALTERNATOR TESTS (CHARGING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
BATTERY INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
BATTERY TERMINALS / BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
BATTERY TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
OCV – OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
STARTER SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
CLUTCH SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
NEUTRAL START DIODE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
STARTER VOLTAGE DROP TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
STARTER MOTOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
BRUSH INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
ARMATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
STARTER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
STARTER ONE-WAY CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
STARTER SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
7.1
ELECTRICAL
GENERAL INFORMATION Timing Check Procedure
1. The ignition timing inspection hole is located in the starter
Special Tools
/ magneto housing. Remove the check plug.
NOTE: Do not allow the engine to warm up. The
PART NUMBER TOOL DESCRIPTION timing may retard approximately 2° when the engine
PV-43568 Fluke™ 77 Digital Multimeter is warm.
2870630 Timing Light The ignition timing marks are stamped on the outer diameter of
2870836 Battery Hydrometer the flywheel. Ignition timing must be inspected with the engine
at room temperature (68° F / 20° C) to obtain the most accurate
2871745 Static Timing Light Harness reading.
Electrical Service Notes 2. With the transmission in neutral, start the engine and set
engine speed to 3500 ± 50 RPM.
Keep the following notes in mind when diagnosing an electrical
problem. 3. Direct the timing light at the ignition timing check hole and
check the ignition timing.
• Refer to wiring diagram for stator and electrical If the ignition timing is not within the specified range, test
component resistance specifications. ignition components for proper function.
• When measuring resistance of a component that has a Ignition timing is non-adjustable.
resistance value under 10 Ohms, remember to subtract
meter lead resistance from the reading. Connect the
leads together and record the resistance. The resistance
of the component is equal to tested value minus the lead
resistance.
• Become familiar with the operation of your meter. Be

sure leads are in the proper jack for the test being
performed (i.e. 10A jack for current readings). Refer to
the Owner’s Manual included with your meter for more
information.
Timing Inspection Hole
• Voltage, amperage, and resistance values included in
this manual are obtained with a Fluke™ 77 Digital
Multimeter (PV-43568). This meter is used for when Ignition Timing: Max 30o @ 3500 RPM
diagnosing electrical problems. Readings obtained with
other meters may differ.
TDC
• Pay attention to the prefix on the multimeter reading (K,
M, etc.) and the position of the decimal point.
Case Mark
• For resistance readings, isolate the component to be
tested. Disconnect it from the wiring harness or power
supply.
• Ignition timing is non-adjustable.

TDC Line
(Left of the “T”)

ELECTRICAL
LIGHTING AND CONTROLS 3. Apply dielectric grease to the light bulb socket before
installing the new bulb. Install the replacement bulb into
Neutral / Reverse headlight housing and rotate firmly.
Position Indicator Switch Test NOTE: The bulb must be positioned so the harness
installs into the lamp at the outer side.
4. Reinstall the connector to the back of the headlight.
Headlamp Switch Test

Probe the headlamp plug wires (Brown and Yellow) at back of
A B connector. Turn headlights on. Test for battery voltage across the
connections.
RED
• Low Beam - Brown and Yellow
BLK
• High Beam - Brown and Green
If no current is found, test for bad connections, switches, or

1. Shift the transmission into 1st gear. The ohm meter should broken wiring. Refer to the wire diagram for harness routing and
show no continuity or OL when testing at points A and B. connections.
2. Check for continuity at test points A and B while in reverse
and neutral. You should have continuity on one of the wires Headlight Housing Replacement
for each test at points A and B.
NOTE: If there is no continuity at either of the wire CAUTION
connections with the transmission in neutral or
reverse, remove the switch and inspect the shift
Do not service while headlight is hot. Serious
drum contact pin and spring for proper function. If
burns may result. Protect lamp during install.
no problems are found, inspect the wiring, bulb, and
harness connection. 1.
2.
Remove the wire harness connector from the headlights.
Remove the front cab. Position the cab upside down on a
7
Headlight Lamp Replacement
soft protective surface to prevent scratching.
1. Remove the wire harness connector from the back of the 3. Remove the small adjuster bracket (1) and install it on the
headlight. new lamp.
2. On the left headlamp, grasp the bulb housing and turn it
counterclockwise and pull outward (1) to remove the bulb.
On the right headlamp, turn the bulb housing clockwise and
pull outward (2) to remove the bulb.
2
2
1
4. Remove the large pivot bracket (2) and remove the

1 headlamp.
5. Install the new headlamp by inserting the outboard pivot
pin in the hole of the mounting tab on the cab.
7.3
ELECTRICAL
6. Install the adjuster bracket onto the inboard pivot pin of the 5. Loosen the pivot screw (1) and adjust the beam to the
headlamp. desired position.
7. Adjust for approximately 1/16” clearance between the
bracket and the edge of the headlight. Tighten the mounting
screws.
IMPORTANT: Be sure the bracket is 90 degrees to the
pivot pin so the lamp can move freely. 1
8. Install the adjusting screw, leaving it loose so the headlight
can be adjusted.
9. Reinstall the front cab and connect the wire harness to the
headlamp.
10. Adjust the lamps as needed, then tighten the adjuster screw.
6. Tighten the screw and torque to 27 in. lbs. (3 Nm).
Headlight Adjustment
The headlight beam can be adjusted to varied positions by using Taillight / Brakelight Lamp Replacement
the following procedures:
If the taillight / brakelight does not work the LED lamp
1. Place the vehicle on a level surface with the headlight assembly may need to be replaced.
approximately 25’ (7.6 m) from a wall.
25’ (7.6m)
Lamp Center Height
2” (5.1cm)
2. Measure the distance from the floor to the center of the Pinout Detail
headlight and make a mark on the wall at the same height
TAIL
3. Start the engine and turn the headlight switch to high beam. BRAKE GROUND
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.
1. From the rear of the taillight remove two screws holding

the assembly in place.
2. Remove the assembly and replace it with the recommended
lamp. Apply dielectric grease (PN 2871329) to the new
contacts.
3. Reinstall the assembly as in step 1.
4. Test the taillight / brakelight to see it is working.
ELECTRICAL
Brake Light Switch Tests Clutch Switch Test
Foot Brake Switch 1. Disconnect wire harness from switch.
1. Disconnect wire harness from switch.
2. Connect an ohmmeter across switch contacts. The circuit

should have an open line or infinity reading.
should have an open line or infinity reading. 3. Apply the clutch lever and check for continuity between
switch contacts. Replace switch if there is no continuity or
3. Apply foot brake and check for continuity between switch greater than .5 ohms resistance when the lever is applied
contacts. Replace switch if there is no continuity or greater with slight pressure.
than .5 ohms resistance when the brake is applied with
slight pressure.
Indicator Lamp Replacement
Hand Brake Switch
1. Gain access to the lamps by disconnecting the front cab
1. Disconnect wire harness from switch.
harness and removing the fasteners that attach the front cab
to the ATV.
2. Disconnect wire harness connector at indicator panel.
Remove indicator lamp from the panel by turning the
holder 1/4 turn with a screw driver (A).
7
A B

3. Apply front brake 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
3. Push a new lamp into holder assembly and insert into the
with slight pressure.
indicator panel. Turn holder 1/4 turn to lock in place (B).
Reconnect wiring and reattach the cab assembly.
7.5
ELECTRICAL
Tether Switch Test (Accessory Option) ETC Operation Test
1. Disconnect wire harness from switch. Remove throttle block cover by carefully releasing all 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
are closed in a fault
condition (throttle cable Switch contacts are open
2. Connect an ohmmeter across switch contacts. The circuit slack) during normal operation
3. Pull tether boot from switch and check for continuity
between switch contacts. Replace switch if there is no
continuity or greater than .5 ohms resistance.
Electronic Throttle Control (ETC) Switch

The Electronic Throttle Control (ETC) system is designed to
stop the engine of an ATV in the event of a mechanical problem
with the throttle mechanism. The ETC switch is mounted
independently of the throttle actuator lever inside the throttle
block assembly. This is a normally closed switch, and is held in
A
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 black wire
to ground, which prevents ignition spark. This is the same as
turning the key or engine stop switch “OFF”.
Test the ETC switch at the harness connector.

NOTE: Adjust throttle cable freeplay (ETC switch)
and make sure throttle mechanism is functioning
properly before testing the switch. Refer to
Maintenance Chapter 2 for cable adjustment
procedure.

ELECTRICAL
IGNITION SYSTEM Circuit Breakers
The circuit breaker panel is located underneath the front cab.
Ignition System Troubleshooting
Access can be gained by removing the cover. Removal of front
No Spark, Weak or Intermittent Spark cab may be required for better access.
• No 12 volt power or ground to CDI
• Spark plug gap incorrect
• Fouled spark plug
• Faulty spark plug cap or poor connection to high

tension lead
• Related wiring loose, disconnected, shorted, or 15 Amp - System Main

corroded 10 Amp - Fan
5 Amp - CDI
• Engine Stop switch or ignition switch faulty
• ETC switch misadjusted or faulty Cranking Output Tests

• Poor ignition coil ground (e.g. coil mount loose or The following tests will measure the amount of output directly
corroded) from each component.
• Faulty stator (measure resistance of all ignition related Test output from the CDI and pulse (trigger) coil and compare
windings) to the table. The following measurements are obtained when
cranking the engine with the electric starter and with the spark
• Incorrect wiring (inspect color coding in connectors plug installed. The starter system must be in good condition and
etc) the battery fully charged.
• Faulty ignition coil winding (measure resistance of 200 Watt 4 Stroke DC/CDI Ignition
primary and secondary)
• Worn magneto (RH) end Crankshaft bearings Connect

Reading
(Without Peak
7
Test
Meter Wires To: Reading Volt
• Sheared flywheel key meter)
• Flywheel loose or damaged Pulse (Trigger) White / Red and White 1.4 - 2.0 DCV
• Excessive crankshaft runout on magneto (RH)

end – should not exceed .005” CDI Output White / Blue and Ground 200 - 400 DCV
• Faulty CDI module
7.7
ELECTRICAL
Flywheel Identification
Flywheel Identification Stamp Location

The flywheel can be identified by the casting marks in location A. Refer to “I.D.” location in chart below.
Engine Application Type Stamp Comment I.D. Stamp
External IJ09 DC / CDI K1805

ES50PL
Trigger Ignition
DC / CDI Ignition
Some of the advantages of DC ignition are:
• Stronger, more consistent spark at low rpm for better performance
• Easier starts
• Simpler component design for ease trouble shooting and maintenance
Operation Overview:
The DC/CDI system relies on battery power for ignition function. Instead of generating DC voltage via magnetic induction, a 12
volt DC current is supplied directly to the CDI unit from the battery.
At the CDI, the supplied 12 volt DC current charges an internal capacitor to build up the initial ignition charge. A small AC signal
from the Pulse coil closes a thyristor (located in the CDI) at a point pre-determined in the crankshaft rotation by magnets on the
flywheel’s outer diameter. This signal releases the electrical charge which saturates the coil for ignition. DC/CDI systems have the
ability to ignite with as little as 6 volts of power.
NOTE: DC/CDI systems and components

are not interchangeable
with any other system.
Typical Timing Pattern Shown

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 red wire to CDI. Replace Spark Plug.
Disconnect the black wire from the 4 wire connector -Test the ignition switch, engine stop
attached to the CDI module to isolate the ignition switch, and speed limiter circuit for
from the kill system. Verify the CDI has a good Yes
ground path (brown) for operation. short to ground.
- Check connectors for moisture,
Does it have spark? wire color matching or corrosion.
No
Disconnect the pulse (trigger) coil connector from

the CDI module. Measure the resistance of the
trigger coil. Check reverse signal coil. Refer to the Inspect connectors, wiring and
exploded view or the wiring schematic for meter grounds to the component in ques-
connections and specifications. No tion. Replace the component if a
Compare results to the specifications. wiring problem cannot be found.
Is it within specification?
Yes
Check coil ground connection between engine and coil

mount using an ohmmeter. The coil mount should No
Clean coil mounting area.
Repair ground wire connections.
7
have good continuity to ground on the engine (0 - .3 Ω).
Yes
Disconnect and check the secondary coil.

Resistance values should be:
Primary Side - Primary wire tab to engine ground
(on coil mount or engine): .3 to .5 Ohms
No Replace the ignition coil.
Secondary Side High Tension wire to engine ground
Cap installed - 11,300Ω
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.
7.9
ELECTRICAL
Components of DC / CDI Ignition
Note: DC/CDI components are not compatible with any other type of ignition.
Refer To Wiring Diagrams For Specified Stator Coil Resistance
Primary
Resistance
Ω High Tension
Meter Lead
Ignition Kill Wire
.3 Ω (Black)
12 Volt DC
Supply Wire
(Red)
Ignition Coil
Resistor
Cap
Ω CDI Box
Meter
11.3kΩ
Ω
Secondary
Resistance Ω Meter
Reverse Signal Coil
Meter
(Located in stator) 190Ω
.089Ω
Starter
Solenoid Pulse Coil (Trigger)
Air Gap: .016 - .030”
(.4 - .75mm)
Stator
Refer to Page 7.8 for

Flywheel identification.
One way starter clutch
Starter Drive gear

ELECTRICAL
COOLING SYSTEM Coolant Temperature Sensor Test (Hot Light)
With the ignition switch (and engine stop switch) “ON”, power
Fan Control Circuit Operation / Testing
is delivered to the hot light via the Red / White wire.
The fan switch is located on the radiator. Power is supplied to the The Blue / White wire (ground) out of the light socket is
fan switch via the Red / Black wire when the ignition key is connected to the coolant temperature switch on the cylinder
“ON”. When the fan switch reaches the specified temperature, head. In normal operating conditions, the temperature switch is
it becomes conductive and sends power to the fan motor through non–conductive (open). If engine coolant reaches the specified
to the Orange / Black wire. The ground path for the fan motor temperature, the switch becomes conductive completing the
is through the Brown harness wire. 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 (mega-ohms).
Hot Light On 221o F (105o C)

7
Fan Control Switch Bypass Test
1. Disconnect harness from fan switch on radiator.
2. Place a jumper wire between the Red / Blk and Org / Blk
wires in the connector.
CAUTION 3. With the parking brake on, turn the ignition key (and engine
stop switch) “ON”. The fan should start running.
Keep hands away from fan blades during this
4. If the fan runs with the jumper wire installed, check the fan
procedure. Serious personal
control switch and connector terminals. If the fan does not
injury could result.
run or runs slowly with the jumper wire installed, check the
The fan switch may not function or operation may be delayed if fan motor wiring, ground, and motor condition (refer to Fan
coolant level is low or if air is trapped in the cooling system. Motor Current Draw). Repair or replace as necessary.
Verify the cooling system is full and purged of air. Refer to
Maintenance Chapter 2 for cooling system information.
7.11
ELECTRICAL
Coolant Fan Control Switch Operation Test 6. During start-up, the amperage should peak then decline
rapidly. If the motor continues to draw more amperage than
1. Place switch in a liquid bath and submerse it to the base of the fan circuit breaker rating during start-up, replace the
the threads. Do not allow threads to contact container or an motor.
inaccurate reading will result.
7. If the fan motor draws more than 6.5 Amps during continual
2. Heat the liquid slowly and monitor the temperature with a running, check for debris blocking the fan, or replace the
thermometer or Fluke™ meter pyrometer. The switch motor.
should be closed (conductive) at the “ON” temperature
indicated in the chart, and stay conductive until the “OFF”
temperature is reached. Fan Motor Current Draw:
Less Than 6.5 Amps
Refer To Parts Manual For Fan Switch Application
Continuity No Continuity
CHARGING SYSTEM
Fan Switch Type
(On) (Off)
Current Draw – Key Off
Off / On o o o o
180 F (82 C) ± 150 F (65 C)
Thermistor 3 oF ± 8 oF CAUTION
Fan Motor Current Draw Do not connect or disconnect the battery cable
A current draw test will provide a good indication of fan motor or ammeter with the engine running.
condition. A worn or damaged fan motor will draw more Damage will occur to electrical components.
current, which causes a reduction in blade speed and reduced Connect an ammeter in series with the negative battery cable.
cooling. Check for current draw with the key off. If the draw is excessive,
loads should be disconnected from the system one by one until
1. Turn key off. Disconnect harness from fan switch on
the draw is eliminated. Check component wiring as well as the
radiator.
component for partial shorts to ground to eliminate the draw.
2. Place a jumper wire between the Red / Blk and Org / Blk
wires in the fan switch connector.
Current Draw Inspection
3. Disconnect the fan and place a jumper wire between the Key Off
brown wires in the connectors. This will provide a ground
path to the fan. Use caution as to not damage the wire
terminals.
4. Place a DC ammeter in series as shown in the Illustration.
Verify fan blade is free to rotate.
Connect ammeter leads to

each service tool terminal
Current Draw - Key Off:

Maximum of .01 DCA (10mA)
Connect BRN Wires
5. Turn ignition key and engine stop switch to “RUN”

position. Read the current draw on ammeter with fan
running.

ELECTRICAL
Charging System “Break Even” Test Alternator Tests (Charging System)
Three tests can be performed using a multimeter to determine
CAUTION the condition of the stator (alternator).
TEST 1: Resistance Value of Each Stator Leg

Do not allow the battery cables to become
1. Measure the resistance value of each of the three stator
disconnected with the engine running.
legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3. Each should
Follow the steps below as outlined to reduce
measure 0.49 ohms.
the chance of damage to electrical
NOTE: If there are any significant variations in ohms
The “break even” point of the charging system is the point at readings between the three legs; it is an indication
which the alternator overcomes all system loads (lights, etc.) that one of the three stator legs may be weak or
and begins to charge the battery. Depending on battery condition failed.
and system load, the break even point may vary slightly. The
battery should be fully charged before performing this test.
TEST 2: Resistance Value of Stator Leg to Ground
WARNING 1. Measure the resistance value of each of the stator legs to
ground: Y1 to Ground, Y2 to Ground, Y3 to Ground.
Never start the engine with an ammeter NOTE: Any measurement other than Infinity (open)
connected in series. Damage to the meter or will indicate a failed or shorted stator leg.
meter fuse will result. Do not run test for
extended period of time. Do not run test with
1. Connect a tachometer to the engine. TEST 3: Measure AC Voltage Output of Each Stator
2. Using an inductive amperage metering device, (set to DC Leg at Charging RPM with a Voltmeter set to Volts AC.
amps) connect to the negative battery cable.
1. Set the voltmeter to read AC Voltage.
3. With engine off and the key, kill switch, and lights in the
“ON” position, the ammeter should read negative amps 2. Start the engine and let it idle.
(battery discharge). Reverse meter lead if a positive reading 3. Separately test each ’leg’ of the stator by connecting the
is indicated. meter leads to the wires leading from the alternator (Y1 to
Y2, Y1 to Y3, Y2 to Y3). Alternator Output Readings
7
4. Shift transmission into Park and start the engine. With the
should be no less than 30-40V AC above 2000 RPM on
engine running at idle, observe meter readings.
each ’leg’.
5. Increase engine RPM while observing ammeter and NOTE: If stator leg AC output varies significantly
tachometer. from the specified value, the stator may need to be
6. Note RPM at which the battery starts to charge (ammeter replaced.
indication is positive).
7. With lights and other electrical loads off, the “break even”
point should occur at approximately 1500 RPM or lower.
8. With the engine running, turn the lights on and engage
parking brake lock to keep brake light on.
9. Repeat test, observing ammeter and tachometer. With
lights on, charging should occur at or below 2000 RPM.
7.13
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- Remove the battery and properly ser-
sure the battery open circuit voltage (See No vice. Reinstall the fully charged battery
page 7.12). It should be 12.5 volts or more. or a fully charged shop battery.
Is it?
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 Yes Check Key off Current Draw.
multitester. Readings should increase to be-
tween 13.0 and 14.6 V D.C. Are they?
No
Check for owner modification, and
Meter Setting: DC Amps discuss operating habits. The battery
Perform system “Break Even Amperage” will continually discharge if operated
test outlined on Page 7.13. Yes below the “Break Even” RPM. Con-
tinued problems would call for battery
Does charging occur as specified? inspection.
No
Ohm stator (Y) wires. If failed, replace, if good, Inspect the wiring harness be-
continue with alternator output test. tween the panel and the stator for
Meter Setting: AC Volts damage. If no damage is found,
Disconnect the Yellow wires from the regu- remove the recoil and flywheel.
lator/rectifier. Using a multitester, perform No
Inspect the flywheel magnets, sta-
an Alternator Output Test. See tor coils and stator wire harness
test procedure on Page 7.13 for procedure.
Does output meet specification? for damage. Repair or replace
any damaged components.
Yes
Meter Setting: DC Volts

Reconnect the alternator wires. Note: Red Check regulator/rectifier connections
wire must be connected to harness. Battery and ground, battery connections, cir-
No cuit breaker and connecting wires.
voltage must be present on red wire terminal
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
voltage regulator.

ELECTRICAL
BATTERY SERVICE Battery Inspection / Removal
Battery Maintenance The battery is located under the front cab at the front of the ATV.
Removal of the front cab assembly is required to access the
battery. Refer to Chapter 5 for front cab removal.
WARNING
Battery electrolyte is poisonous. It contains

sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
Battery
Location
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
To remove the battery:
Batteries produce explosive gases. Keep 1. Remove the front cab.
sparks, flame, cigarettes etc. away. Ventilate
when charging or using in an enclosed space. 2. Disconnect holder strap.
Always shield eyes when working near 3. Disconnect battery negative (–) (black) cable first,
batteries. KEEP OUT OF REACH OF followed by the positive (+) (red) cables.
CHILDREN.
All Outlaw ATV batteries are Maintenance-Free design CAUTION

and construction. Before placing the battery into
service, check the battery condition and charge To reduce the chance of sparks: Whenever
accordingly. Use of Conventional Lead-Acid batteries removing the battery, disconnect the 7
is not recommended. negative (black) cable first. When reinstalling
the battery, install the negative cable last.
New Batteries: Batteries must be fully charged before
use or battery life will be reduced by 10–30% of full 4. Remove the battery.
potential. Charge battery for 3-5 hours at a current
5. Clean battery cables and terminals with a stiff wire brush.
equivalent of 1/10 of the battery’s rated amp/hour
Corrosion can be removed using a solution of one cup water
capacity (i.e. 9 amp hr x .10 = .9 amp charging). Do not
and one tablespoon baking soda. Rinse well with clean
use the alternator to charge a new battery.
water and dry thoroughly. Test battery for condition and
Maintenance-Free batteries are sealed at the factory. charge accordingly.
The use of lead-calcium instead of lead-antimony 6. Reinstall battery, attaching positive (+) (red) cable first and
allows the battery acid to be fully absorbed by the then the negative (–) (black) cable.
plates. Therefore, a Maintenance-Free battery case is
opaque and the sealing caps are not removable, since 7. Coat terminals and bolt threads with Dielectric Grease (PN
there is no need to check electrolyte level. 2871329).
NEVER attempt to add electrolyte or water to a 8. Reinstall the holder strap.

Maintenance-Free battery. Doing so will damage the 9. Reinstall the battery caps.
case and shorten the life of the battery.
10. Charge battery at 1/10 of its amp/hour rating. Example: 1/
10 of 14 amp battery = 1.4 amp
11. Reinstall the battery after testing.
7.15
ELECTRICAL
Battery Terminals / Bolts Load Test
Use Polaris corrosion resistant Dielectric Grease (PN 2871329)
on battery bolts. CAUTION
Battery Testing To prevent shock or component damage,
remove spark plug high tension leads and
Whenever a service complaint is related to either the starting
connect securely to engine ground
or charging systems, the battery should be checked first. before proceeding.
Following are tests which can easily be made on a maintenance-
free battery to determine its condition: The OCV Test and Load NOTE: This test can only be performed on machines
Test. with electric starters. This test cannot be performed
with an engine or starting system that is not working
OCV – Open Circuit Voltage Test properly.
Battery voltage should be checked with a digital multitester. A battery may indicate a full charge condition in the OCV test
Readings of 12.6 volts or less require further battery testing and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system.
and charging. See charts and Load Test.
For this reason, a battery capacity or load test should be
To perform an open circuit voltage test, set the digital meter to conducted whenever poor battery performance is encountered.
DC volts and place the tester leads on each battery terminal. To perform this test, hook a multi-tester to the battery in the
Minimum voltage should be 12.4 to 12.7 VDC for a known good same manner as was done in the OCV test. The reading should
battery. be 12.6 volts or greater. Engage the starter and observe the
battery voltage while cranking the engine. Continue the test for
OPEN CIRCUIT VOLTAGE 15 seconds. During cranking the observed voltage should not
drop below 9.5 volts. If the beginning voltage is 12.6 volts or
State of Charge Maintenance Free higher and the cranking voltage drops below 9.5 volts during the
100% Charged 12.6 V test, replace the battery and re-test. Continued low cranking
voltage with a known good battery may indicate excess current
75% Charged 12.4 V draw from one or more of the starting components.
50% Charged 12.1 V
Off Season Storage
25% Charged 11.9 V
0% Charged less than 11.9 V To prevent battery damage during extended periods of non–use,
the following basic battery maintenance items must be
Self Discharge vs. Temperature performed:
Temperature Days to 0% Charged • Remove the battery from the machine and wash the
104 F 300 case and battery tray with a mild solution of baking
soda and water. Rinse with lots of fresh water after
77 F 600 cleaning.
32 F 950 NOTE: Do not get any of the baking soda into the
battery or the acid will be neutralized.
• Using a wire brush or knife, remove any corrosion from

the cables and terminals.
• Never add water to a sealed maintenance free

battery.
• Charge at a rate no greater than 1/10 of the battery’s

amp/hr capacity until the open circuit voltage is 12.9 V
or greater.
• Store the battery either in the machine with the cables

disconnected, or store in a cool place.

ELECTRICAL
Charging Procedure STARTING SYSTEM
NOTE: Remote charging terminals have been
Starter System Troubleshooting
provided to allow for battery charging without
removal of the front cab. Starter Motor Does Not Turn
1. Attach the Positive battery charging cable to the Red • Battery discharged. Low specific gravity
Charge Terminal (A); which is directly connected to the
positive battery terminal. It is located just above the front • Loose or faulty battery cables or corroded connections
right shock mount. (see Voltage Drop Tests)
2. Attach the Negative battery charging cable to the free end • Related wiring loose, disconnected, or corroded
of the Black Cable (B) under the right front cab (which is
directly connected to the negative battery terminal). • Poor ground connections at battery cable, starter motor
or starter solenoid (see Voltage Drop Tests)
3. Charge with a charging output no larger than 1/10 of the
battery's amp/hr rating. Charge as needed to raise the open • Faulty key switch
circuit voltage to 12.9 V or greater.
• Faulty kill switch
• Faulty neutral diode

A • Faulty clutch switch
• Faulty starter solenoid or starter motor
B • Engine problem – seized or binding (Can engine be

rotated easily ?)
• NOTE: The Outlaw will not push start or key start if

the battery is disconnected or completely dead.
Starter Motor Turns Over Slowly

• Battery discharged
7
WARNING • Excessive circuit resistance – poor connections (see
Voltage Drop Test)
To avoid the possibility of explosion or sparks, • Engine problem – seized or binding (Can engine be
connect positive (red) cable first and negative rotated easily?)
(black) cable last.
• Faulty or worn brushes in starter motor
• Automatic compression release inoperative
Starter Motor Turns – Engine Does Not Rotate

• Faulty starter drive/one way clutch
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel
• Possible engine damage
7.17
ELECTRICAL
Clutch Switch Test Starter Motor Disassembly
Refer to “Clutch Switch Test” under the “Lighting and Use only electrical contact cleaner to clean starter motor parts.
Controls” section of this chapter. Problems with the clutch Some solvents may leave a residue or damage internal parts and
switch will cause the starter circuit to not operate. insulation.
Neutral Start Diode Test 1. Note the alignment marks on both ends of the starter motor
casing. These marks must align during reassembly.
1. Disconnect diode from harness.
2. Using an ohm meter, test for continuity each way. The diode
should only read continuity one direction if it is working
properly.
3. Should the diode test good and there is still a problem,

check the clutch switch, wiring, and harness connections.
Starter Voltage Drop Testing 2. Remove the two bolts, washers, and sealing O–Rings.
Inspect O–Rings and replace if damaged.
A Voltage Drop Test tests for bad connections. When
performing the procedure, 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.
Voltage should not exceed

.1 DC volts per connection
3. Remove brush terminal end of housing while holding other

two sections together.
4. Remove shims from armature shaft.

NOTE: All shims must be replaced during reassembly.

ELECTRICAL
Brush Inspection / Replacement 5. Inspect surface of commutator for wear or discoloration.
See Steps 3–6 of armature testing on Page 7.20.
6. Install a new carbon brush assembly in the brush housing.
Brush Set
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.
9. Remove the electrical tape and reinstall the two small
phenolic washers, the large phenolic washer, flat washer,
1. Using a digital multi-tester, measure the resistance and nut.
between the cable terminal and the insulated brush. The
reading should be .3 ohms or less.
Armature Testing
2. Measure the resistance between the cable terminal and
brush housing. Make sure the brush is not touching the case. 1. Remove armature from starter casing. Note order of shims
The reading should be infinite. on drive end for reassembly.
3. Remove nut, flat washer, large phenolic washer, two small 2. Inspect surface of commutator. Replace if excessively
phenolic washers, and O–Ring from brush terminal. Inspect worn or damaged.
the O–Ring and replace if damaged.
4. Remove brush plate and brushes. Measure length of

brushes and replace if worn past the service limit. Replace
springs if they are discolored or have inadequate tension.
Brush length
5/16” (.8 cm)
Brush Length Service Limit:

5/16” (.8 cm)
7.19
ELECTRICAL
3. Using a digital multitester, measure the resistance between 6. Install O–Ring on other end of field magnet casing. Make
each of the commutator segments. The reading should be sure it is in good condition and not twisted on the case.
.3 ohms or less.
7. Align casing marks and install housing, pushing back
brushes while installing shaft in bushing.
4. Measure the resistance between each commutator segment

and the armature shaft. The reading should be infinite (no
continuity). Starter One-Way Clutch Inspection
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 360o. If
hacksaw blade is drawn to armature on any pole, the Flywheel
armature is shorted and must be replaced.
One - way Clutch
Starter Reassembly
Drive Gear
CAUTION
1. Inspect the drive gear teeth, bearings and thrust surfaces
Use care when handling starter housing. Do not for excessive wear or damage.
drop or strike the housing as magnet damage is 2. Inspect the one way drive clutch rollers and springs for
possible. If magnets are damaged, excessive wear or damage.
starter must be replaced.
3. Proper function can be determined by rotating the drive
1. Inspect permanent magnets in starter housing. Make sure gear counterclockwise, which will engage the one-way
they are not cracked or separated from housing. clutch rollers and turn the flywheel. During engine rotation,
2. Reinstall starter motor housing bolts. Make sure O–Rings there should be no chattering or hanging of the drive gear
are in good condition and seated in groove. and one-way clutch. Should this occur, replace one or both
3. Place armature in field magnet casing. components and retest. Refer to Chapter 3 for the proper
4. Place shims on drive end of armature shaft with phenolic torque specifications and assembly procedures.
washer outermost on shaft. Engage tabs of stationary
washer in drive end housing, holding it in place with a light
film of grease.
5. Install case sealing O–Ring. Make sure O–Ring is in good
condition and not twisted on the case. Lubricate needle
bearing and oil seal with a light film of grease, and install
housing, aligning marks.

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 Remove battery and properly service.
lead on the battery positive. No Install fully charged shop battery to conti-
nue test.
Reading should be 12.5 VDC or greater.
Yes
Check voltage on both sides of circuit break-

Disconnect White/Red engagement coil wire from er, ignition switch/engine stop switch and
the starter solenoid. Connect tester black wire to starter button. The voltage on both sides
battery ground. Connect red tester lead to White/ should be the same. NOTE: The ignition
No
Red harness wire at solenoid.Turn on ignition switch must be on and the engine switch
switch and depress the starter button.Tester turned to “RUN”. Check the clutch and neu-
should read battery voltage. tral safety start circuits, as they supply the
ground path for solenoid operation. Replace
the defective component(s) or wiring.
Test starter solenoid coil by connecting an ohmmeter between the solenoid

Yes red wire and the solenoid mounting plate. Resistance should be 3.4Ω.
Check solenoid ground path by measuring resistance between mounting
Voltage Drop Testing plate and battery negative terminal (-).
See Page 7.16 for information
Reconnect the solenoid. Connect the tester black

lead to the battery positive and the red lead to the No
Clean the battery-to-solenoid cable ends or
replace the cables.
7
solenoid end of the battery-to-solenoid wire.Depr-
ess 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. Depre-
ss starter button. Reading should be less than
.1 V D.C.
Yes
Connect the black tester lead to solenoid end of

the solenoid-to-starter cable. Connect red tester Clean the solenoid-to-starter cable ends or
No
lead to the starter end of the same cable. Depress 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.
7.21
ELECTRICAL
NOTES

A Brake Pads, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
A-Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
A-Arm, Front Installation . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Brake Pads, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
Brake Pads, Rear Installation . . . . . . . . . . . . . . . . . . . . . 6.21 IX
Brake Pads, Rear Removal . . . . . . . . . . . . . . . . . . . . . . . 6.20
A-Arm, Front Removal and Inspection . . . . . . . . . . . . . 5.15
Brake Pads, Removal, Front . . . . . . . . . . . . . . . . . . . . . . 6.15
A-Arm, Rear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Brake Switch, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
A-Arm, Rear Installation . . . . . . . . . . . . . . . . . . . . . . . . 5.18
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
A-Arm, Rear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Brake System, Service Notes . . . . . . . . . . . . . . . . . . . . . . 6.6
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
Brakelight Lamp Replacement . . . . . . . . . . . . . . . . . . . . . 7.4
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
Brakes, Fluid Replacement and Bleeding Procedure . . . . 6.8
Anti-Freeze / Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Brakes, Hydraulic System Operation . . . . . . . . . . . . . . . . 6.7
Auxiliary Brake, Master Cylinder Fluid Level . . . . . . . . 6.22
Brakes, Inspection and Maintenance . . . . . . . . . . . . . . . . 2.29
B
C
Ball Joint, Removal and Installation . . . . . . . . . . . . . . . . . 5.8
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23, 7.17 Cam Timing Exploded View . . . . . . . . . . . . . . . . . . . . . . 3.34
Carburetor Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Battery Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
Carburetor Exploded View . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . 2.22, 7.15
Carburetor Pilot Screw . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
Battery Service . . . . . . . . . . . . . . . . . . . . . . .2.23, 7.15, 7.16 Carburetor, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 Carburetor, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Carburetor, Float Bowl Level Test . . . . . . . . . . . . . . . . . 4.12
Battery Terminal Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Carburetor, Float Height Adjustment . . . . . . . . . . . . . . . 4.11
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Carburetor, Function and Operation . . . . . . . . . . . . . . . . . 4.5
Battery, Off Season Storage . . . . . . . . . . . . . . . . . . . . . . 7.16
Carburetor, Jetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Body Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Carburetor, Needle and Seat Leak Test . . . . . . . . . . . . . . 4.12
Boot Burping, Rear Driveshaft . . . . . . . . . . . . . . . . . . . . 2.22
Carburetor, Pilot Screw Adjustment . . . . . . . . . . . . . . . . . 4.8
Boot Inspection, Rear Driveshaft . . . . . . . . . . . . . . . . . . 2.21
Carburetor, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4.13
Brake Burnishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
Brake Caliper Assembly, Front . . . . . . . . . . . . . . . . . . . 6.14
Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
Brake Caliper Exploded View . . . . . . . . . . . . . . . . . . . . . 6.3
Chain, Inspection and Replacement . . . . . . . . . . . . . . . . 2.20
Brake Caliper Inspection, Front . . . . . . . . . . . . . . . . . . . 6.13
Charging System Break Even Test . . . . . . . . . . . . . . . . . 7.13
Brake Caliper Installation, Front . . . . . . . . . . . . . . . . . . 6.14
Charging System Flow Chart . . . . . . . . . . . . . . . . . . . . . 7.14
Brake Caliper Removal, Front . . . . . . . . . . . . . . . . . . . . 6.12
Charging System Testing . . . . . . . . . . . . . . . . . . . . . . . . 7.14
Brake Caliper, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
Charging System, Alternator Tests . . . . . . . . . . . . . . . . . 7.13
Brake Caliper, Rear Mounting Bolt Torque . . . . . . . . . . 6.21
Charging System, Break Even Test . . . . . . . . . . . . . . . . . 7.13
Brake Caliper, Rear Removal . . . . . . . . . . . . . . . . . . . . . 6.18
Charging System, Current Draw-Key Off . . . . . . . . . . . . 7.12
Brake Caliper, Rear, Assembly . . . . . . . . . . . . . . . . . . . 6.19
Charging System, Exploded View . . . . . . . . . . . . . . . . . 7.10
Brake Caliper, Rear, Disassembly . . . . . . . . . . . . . . . . . 6.18
Choke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
Brake Caliper, Rear, Inspection . . . . . . . . . . . . . . . . . . . 6.19
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
Brake Disc Runout, Front . . . . . . . . . . . . . . . . . . . . . . . . 6.17
Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
Brake Disc Runout, Rear . . . . . . . . . . . . . . . . . . . . . . . . 6.22
Clutch Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
Brake Disc Thickness, Front . . . . . . . . . . . . . . . . . . . . . 6.17
Clutch Switch, Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
Brake Disc Thickness, Rear . . . . . . . . . . . . . . . . . . . . . . 6.22
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16, 3.6
Brake Disc, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
Brake Disc, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
Coolant Temp. Sensor Test . . . . . . . . . . . . . . . . . . . . . . . 7.11
Brake Disc, Inspection, Rear . . . . . . . . . . . . . . . . . . . . . 6.22
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Brake Disc, Mounting Bolt Torque . . . . . . . . . . . . . . . . 6.17
Cooling System Pressure Test . . . . . . . . . . . . . . . . . . . . . . 3.7
Brake Disc, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
Cooling System, Recovery Level Inspection . . . . . . . . . 2.18
Brake Disc, Removal, Rear . . . . . . . . . . . . . . . . . . . . . . 6.23
Cooling, Fan Control Operation . . . . . . . . . . . . . . . . . . . 7.11
Brake Disc, Replacement / Service . . . . . . . . . . . . . . . . 6.17
Cooling, Temperature Sensor Operation/Test . . . . . . . . . 7.11
Brake Disc, Replacement, Rear . . . . . . . . . . . . . . . . . . . 6.23
Crankcase Bearing Inspection . . . . . . . . . . . . . . . . . . . . . 3.29
Brake Front Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . 6.16
Crankcase Bearing Installation . . . . . . . . . . . . . . . . . . . . 3.25
Brake Lamp, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Crankcase Breather Inspection . . . . . . . . . . . . . . . . . . . . 2.14
Brake Light Switch Testing . . . . . . . . . . . . . . . . . . . . . . . 7.5
Cranking Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
Brake Pad Assembly, Front . . . . . . . . . . . . . . . . . . . . . . 6.16
Crankshaft Removal/Inspection . . . . . . . . . . . . . . . . . . . 3.29
Brake Pad Thickness, Front . . . . . . . . . . . . . . . . . . . . . . 6.15
Crankshaft Straightening . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Brake Pad Thickness, Rear . . . . . . . . . . . . . . . . . . . . . . . 6.21
IX.1
Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12 Fuel Tank Assembly, Exploded View . . . . . . . . . . . . . . . 4.3
CV Joint, Boot Replacement . . . . . . . . . . . . . . . . . . . . . .5.29 Fuel Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
CV Joint, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.30 Fuses, See Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . 7.7
CV Joint, Rear Removal . . . . . . . . . . . . . . . . . . . . . . . . .5.28 G
CV Joint, Rear Service . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
Gear Position Switch Test . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . .3.35
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Cylinder Leakdown Test . . . . . . . . . . . . . . . . . . . . . . . . .2.16
H
D
Headlamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Decals, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.31
Headlamp Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Decimal Equivalent Size Charts . . . . . . . . . . . . . . . . . . .1.10
Headlamp Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Drain Tube, Air Box . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
Headlamp Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . 7.3
E Headlight Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
E.T.C. Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13 Headlight Housing, Replacement . . . . . . . . . . . . . . . . . . 7.3
Electrical Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . .7.2 Headlight Lamp Replacement . . . . . . . . . . . . . . . . . . . . . 7.3
Electrical Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2 Heel Pocket, Remove and Install . . . . . . . . . . . . . . . . . . . 5.6
Engine Accessible Components . . . . . . . . . . . . . . . . . . . .3.8 Hub Carrier, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
Engine Bottom End Disassembly . . . . . . . . 3.17, 3.18, 3.29 Hub Carrier, Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5.25
Engine Break in Period . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9 Hub Carrier, Installation . . . . . . . . . . . . . . . . . . . . . . . . 5.27
Engine Designation Number . . . . . . . . . . . . . . . . . . . . . . .1.2 Hub Carrier, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
Engine Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . .3.13 I
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9 Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . .3.9
Ignition System Components . . . . . . . . . . . . . . . . . . . . . 7.10
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
Ignition System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
Ignition, Cranking Output Test . . . . . . . . . . . . . . . . . . . . 7.7
Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . .3.10
Ignition, DC/CDI Ignition Operation . . . . . . . . . . . . . . . . 7.8
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8
Ignition, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . 7.10
Engine Serial Number Location . . . . . . . . . . . . . . . . . . . .1.2
Ignition, Testing Flow Chart . . . . . . . . . . . . . . . . . . . . . . 7.9
ETC Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6
Ignition, Timing Check Procedure . . . . . . . . . . . . . . . . . . 7.2
ETC Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6
Indicator Lamp Replacement . . . . . . . . . . . . . . . . . .7.5, 7.18
ETC Switch, Operation and Testing . . . . . . . . . . . . . . . . .7.6
Indicator Lamp, Replacement . . . . . . . . . . . . . . . . . . . . . 7.5
Exhaust, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
J
F
Jet Part Numbers, Mikuni . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Fan Control Bypass Test . . . . . . . . . . . . . . . . . . . . . . . . .7.11
Jetting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Fan Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .7.11
Fan Control Switch Test . . . . . . . . . . . . . . . . . . . . . . . . .7.12 L
Fan Motor Current Draw . . . . . . . . . . . . . . . . . . . . . . . . .7.12 Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Fan Motor Current Draw Test . . . . . . . . . . . . . . . . . . . . .7.12 M
Front Brake Caliper Assembly . . . . . . . . . . . . . . . . . . . . .6.3 Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Front Brake System, Exploded View . . . . . . . . . . . . . . . .6.4 Maintenance Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
Front Cab, Remove and Install . . . . . . . . . . . . . . . . . . . . .5.5 Maintenance References . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Front Caliper, Piston Bore I.D. . . . . . . . . . . . . . . . . . . . .6.13 Master Cylinder, Installation . . . . . . . . . . . . . . . . . . . . . 6.11
Front Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11 Master Cylinder, Removal . . . . . . . . . . . . . . . . . . . . . . . 6.10
Front Hub, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
Front Hub, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .5.12
N
Front Hub, Exploded View . . . . . . . . . . . . . . . . . . . . . . .5.10 Neutral / Reverse Switch Test . . . . . . . . . . . . . . . . . . . . . 7.3
Front Hub, Installation . . . . . . . . . . . . . . . . . . . . . . . . . .5.13 Neutral Start Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
Front Hub, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11 O
Front Suspension, Exploded View . . . . . . . . . . . . . . . . .5.14 Oil and Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Fuel Line Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10 Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Fuel Pump, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13 Oil Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Fuel Pump, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .4.13 Oil Level, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Fuel Pump, Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13 Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Fuel System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .2.10 Oil Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Fuel System, Troubleshooting . . . . . . . . . . . . . . . . . . . . .4.13 Oil Pump Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
IX.2 RepairPro Service Manual

Oil Pump Priming Procedure . . . . . . . . . . . . . . . . . . . . . 2.16 Specification, Drive Chain Wear Limit . . . . . . . . . . . . . . 2.20
P
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Specification, Float Height . . . . . . . . . . . . . . . . . . . . . . . 4.12
Specification, Flywheel Nut Torque . . . . . . . . . . . . . . . . 3.20 IX
Specification, Handle Bar Fastener Torque . . . . . . . . . .2.25
Periodic Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . 2.3
Specification, Hub Carrier Fastener Torque . . . . . 5.25, 5.27
Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Specification, Hub Nut Torque . . . . . . . . . . . . . . . . . . . . 5.27
Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Specification, Idle Speed RPM . . . . . . . . . . . . . . . . . . . . 2.12
Piston Ring Installed Gap . . . . . . . . . . . . . . . . . . . . . . . . 3.44
Specification, Oil Filter Cover Bolt Torque . . . . . . . . . .2.16
Piston to Cylinder Clearance . . . . . . . . . . . . . . . . . . . . . 3.43
Specification, Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . 3.10
Piston/Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
Specification, Oil Tank Drain Plug Torque . . . . . . . . . .2.15
Pre-Ride / Daily Inspection . . . . . . . . . . . . . . . . . . . . . . 2.10
Specification, Pilot Screw Setting . . . . . . . . . . . . . . . . . . 2.12
Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Specification, Piston Ring Installed Gap . . . . . . . . . . . . . 3.44
Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Specification, Radiator Cap Pressure . . . . . . . . . . . . . . . . 3.7
R Specification, Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . 2.24
Radiator Cap Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . 3.7 Specification, Sparkplug Gap . . . . . . . . . . . . . . . . . . . . . 2.24
Radiator, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 Specification, Sparkplug Torque . . . . . . . . . . . . . . . . . . . 2.24
Rear Brake Caliper Assembly . . . . . . . . . . . . . . . . . . . . . 6.3 Specification, Tensioner Bolt Torque . . . . . . . . . . . . . . . 3.15
Rear Brake System, Exploded View . . . . . . . . . . . . . . . . 6.5 Specification, Thermistor Torque . . . . . . . . . . . . . . . . . . . 3.7
Rear Cab, Remove and Install . . . . . . . . . . . . . . . . . . . . . 5.6 Specification, Throttle Lever Freeplay . . . . . . . . . . . . . . 2.13
Rear Housing, Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5.23 Specification, Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . 2.31
Rear Housing, Disassembly . . . . . . . . . . . . . . . . . . . . . . 5.21 Specification, Tire Wear . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
Rear Housing, Exploded View . . . . . . . . . . . . . . . . . . . . 5.19 Specification, Valve Clearance . . . . . . . . . . . . . . . . . . . . 3.41
Rear Housing, Installation . . . . . . . . . . . . . . . . . . . . . . . 5.24 Specification, Valve Guide Installed Height . . . . . . . . . . 3.37
Rear Housing, Removal . . . . . . . . . . . . . . . . . . . . . . . . . 5.20 Specification, Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . 3.38
Rear Suspension, Exploded View . . . . . . . . . . . . . . . . . 5.16 Specification, Valve Spring Height . . . . . . . . . . . . . . . . . 3.36
Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Specification, Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . 3.39
Reverse Lock-Out Lever . . . . . . . . . . . . . . . . . . . . . . . . 2.19 Specification, Wheel and Hub Torque . . . . . . . . . . . . . . 2.30
S Specification, Wheel Nut Torque . . . . . . . . . . . . . . . . . . 5.27
Serial Number (VIN) Location . . . . . . . . . . . . . . . . . . . . . 1.2 Specifications, Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Shock Compression Adjustment, Rear . . . . . . . . . . . . . . 2.29 Specifications, Brakes Torque . . . . . . . . . . . . . . . . . . . . . . 6.2
Shock, Front, Exploded View . . . . . . . . . . . . . . . . . . . . . 5.32 Specifications, Cooling System . . . . . . . . . . . . . . . . . . . . . 3.7
Shock, Piston Orientation . . . . . . . . . . . . . . . . . . . . . . . . 5.34 Specifications, Detailed . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5
Shock, Rear, Exploded View . . . . . . . . . . . . . . . . . . . . . 5.33 Specifications, Engine Fastener Torques . . . . . . . . . . . . . 3.3
Shocks, Front / Rear Standard Valving . . . . . . . . . . . . . 5.34 Specifications, ES50PL Engine Data . . . . . . . . . . . . . . . . 3.4
Shocks, RydeFX Service Procedure . . . . . . . . . . . . . . . . 5.35 Specifications, Front Suspension Fastener Torque . . . . . . 5.3
Side Panel, Remove and Install . . . . . . . . . . . . . . . . . . . . 5.5 Specifications, General . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Sparkplug, Inspection and Torque . . . . . . . . . . . . . . . . . 2.24 Specifications, Piston and Rod . . . . . . . . . . . . . . . . . . . . 3.17
Special Tool, Rear Housing . . . . . . . . . . . . . . . . . . . . . . 5.22 Specifications, Rear Suspension Fastener Torque . . . . . . 5.3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6, 3.6, 4.4 Specifications, Steering Component Fastener Torque . . . 5.3
Special Tools, Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Sprocket Inspection, Rear . . . . . . . . . . . . . . . . . . . . . . . . 2.19
Special Tools, Detailed Listing . . . . . . . . . . . . . . . . . . . . 1.7 Starter Armature Testing . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
Special Tools, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
Special Tools, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 Starter Brushes, Inspection and Replacement . . . . . . . . . 7.19
Special Tools, Fuel System . . . . . . . . . . . . . . . . . . . . . . . 4.4 Starter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
Special Tools, Suspension . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Starter Motor Armature Testing . . . . . . . . . . . . . . . . . . . 7.19
Specification, A-Arm Fastener Torque . . . . . . . . . . . . . 5.15 Starter Motor Brush Inspection/Replacement . . . . . . . . . 7.19
Specification, Brake Lever Freeplay . . . . . . . . . . . . . . . 2.30 Starter One-Way Clutch Inspection . . . . . . . . . . . . . . . . 7.20
Specification, Brake Pad Thickness . . . . . . . . . . . . . . . . 2.30 Starter Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
Specification, Cam Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3.16 Starter System Flow Chart . . . . . . . . . . . . . . . . . . . . . . . 7.21
Specification, Chain Wear Limit . . . . . . . . . . . . . . . . . . 2.20 Starter System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
Specification, Crankshaft Nut Torque . . . . . . . . . . . . . . 3.20 Starter Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . 7.18
Specification, CV Joint Grease Amount . . . . . . . . . . . . . 5.30 Starting Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Specification, Cylinder Head Torque . . . . . . . . . . . . . . . 3.42 Starting System Troubleshooting . . . . . . . . . . . . . . . . . . 7.17
Specification, Cylinder Taper . . . . . . . . . . . . . . . . . . . . . 3.43 Steering Assembly, Exploded View . . . . . . . . . . . . . . . . . 5.7
Specification, Cylinder Warp . . . . . . . . . . . . . . . . . . . . . 3.42 Steering Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
IX.3
Steering Knuckle, Removal and Installation . . . . . . . . . . .5.8
Steering, Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
Steering, Toe Alignment . . . . . . . . . . . . . . . . . . . . . . . . .2.27
Suspension, Spring Preload Adjustment . . . . . . . . . . . . .2.27
T
Tail Lamp, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .7.4
Taillight Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . .7.4
Tank Cover, Remove and Install . . . . . . . . . . . . . . . . . . . .5.5
Tap / Drill Sizes, Metric . . . . . . . . . . . . . . . . . . . . . . . . .1.10
Tap / Drill Sizes, SAE . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
Temperature Sensor Operation/Test . . . . . . . . . . . . . . . .7.11
Tether Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6
Tether Switch, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6
Throttle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
Timing Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .7.2
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
Toe Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
Torque Patterns, Engine . . . . . . . . . . . . . . . . . . . . . . . . . .3.6
Torque Specifications, Standard . . . . . . . . . . . . . . . . . . . .1.3
Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
Troubleshooting, Brake Noise . . . . . . . . . . . . . . . . . . . . . .6.6
Troubleshooting, Brake System . . . . . . . . . . . . . . . . . . .6.24
Troubleshooting, Cooling . . . . . . . . . . . . . . . . . . . . . . . .3.48
Troubleshooting, Engine . . . . . . . . . . . . . . . . . . . . . . . . .3.46
Troubleshooting, Ignition System . . . . . . . . . . . . . . . . . . .7.7
Troubleshooting, Spark Plug Fouling . . . . . . . . . . . . . . .3.48
Troubleshooting, Starter System . . . . . . . . . . . . . . . . . . .7.17
U
Unit Model Number Identification . . . . . . . . . . . . . . . . . .1.2
V
Valve Shim Adjustment Matrix . . . . . . . . . . . . . . . . . . .3.40
Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2
Vehicle Identification Number (VIN) . . . . . . . . . . . . . . . .1.2
Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.18
W
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
Water Pump Seal Removal and Installation . . . . . . . . . .3.45
Water Pump Shaft Oil Seal . . . . . . . . . . . . . . . . . . . . . . .3.44
Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
Wheel Removal, Front or Rear . . . . . . . . . . . . . . . . . . . .2.30
IX.4 RepairPro Service Manual

WIRE DIAGRAM
OUTLAW 500
8.1
WIRE DIAGRAM
OUTLAW 500
8.2
RepairPro Service Manual
WIRE DIAGRAM
OUTLAW 500
8.3

2006 - 2007 Polaris Outlaw 500 Service Manual

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Fix it like a Pro

BODY / STEERING / SUSPENSION 5

Machine Model Number Identification

Basic Chassis Designation Engine Designation

Engine Designation Number

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 PAINTED PART COLOR POLARIS

SERIES # PART NUMBER

1.2 RepairPro Service Manual

1.4 RepairPro Service Manual

Main Jet 145 Turning Radius 67 in. / 170 cm

Float Height 13 mm (0.51") Rear

Instrument Cluster N/A

PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN

1.6 RepairPro Service Manual

Standard Tools and Engine Tools

PU-45432 - Caliper or A Basic Caliper

PA-46502 - Valve Spring Compressor PA-46077 - Mag End Crankshaft Installer

PV-43527 Oil Filter Wrench

5131135 - Water Pump Install Tool

2870390 - Piston Support Block

PA-45958 - Cam Chain Tensioner Tool

2871283 - Crank/Water Pump Seal Install Kit

2870305 - Stone Replacement Kit

PS-45261 - Shock IFP Positioning / Extraction Tool

PS-45259 - Gas Fill Tool

2870459 - Dial Indicator

PV-35667-A - Cylinder Leak down Tester

2872105 - Water Pump Seal Puller

1.8 RepairPro Service Manual

2870630 - Timing Light

2871745 - Static Timing Light Harness

PV-43568 - Fluke™ 77 Multimeter

2460761 - Hall Sensor Probe Harness

PV-39617 - Current Clamp

PV-39991 - Peak Reading Adapter

2870836 - Battery Hydrometer

PV-37453 - Christie™ Se-Sulfating

PV-63070 - Christie™ Multi-Battery Charger

1.10 RepairPro Service Manual

Unit of Measure Multiplied by Converts to

1.12 RepairPro Service Manual

2.2 RepairPro Service Manual

Severe Use Definition

Maintenance Chart Key

Recommended Pre-Ride Fluid Level Checks

 Oil Filter Change 10 H - 100 (160) Replace with oil change

Item Maintenance Interval Remarks

2.6 RepairPro Service Manual

3. Rear Drive Chain

Oil Filter Location

III. # Item Lube Rec. Method Frequency*

2.8 RepairPro Service Manual

LUBRICANTS AND SERVICE PRODUCTS

PART NO. DESCRIPTION

GENERAL VEHICLE INSPECTION FUEL SYSTEM AND AIR INTAKE

Frame, Nuts, Bolts, and Fasteners

1. Check fuel lines for signs of wear, deterioration, damage,

Make sure lines are not kinked or pinched.

2.10 RepairPro Service Manual

Vent Lines Carburetor Draining

Oil Filter Change 10 H - 100 (160) Replace with oil change