Polaris A09BG50AA User Manual
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Polaris A09BG50AA User Manual

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Specifications
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Tap Drill Charts
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Decimal Equivalent Chart
Unit of Measure Conversion Table
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Specs
1.2
1.2
1.3
1.3
1.3
1.4--1.5
1.6
1.7
1.7
1.8
1.9--1.10
1.1

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Summary of Contents for Polaris A09BG50AA

  • Page 1: Table Of Contents

    GENERAL INFORMATION Specs Model Identification ..... . . Serial Number Location ....Replacement Keys .

  • Page 2: General Information

    GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 9 B G 5 0 A A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation ENGINE DESIGNATION NUMBERS EH500PLE...

  • Page 3: Replacement Keys

    4010278 PUBLICATION NUMBERS Year Model Model No. Owner’s Manual Parts Manual 2009 Scrambler 500 4x4 A09BG50AA, FA 9921777 9921778 2009 Scrambler 500 2x4 A09BA50FA 9921777 9921778 When ordering service parts be sure to use the correct parts manual. PAINT CODES FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147.
  • Page 4 GENERAL INFORMATION 2009 SCRAMBLER 500 MODEL: ..MODEL NUMBER: A09BG50AA, FA / A09BA50FA ( 4x4 / Intl’ ) (2x4 Intl’) ENGINE MODEL: EH50PLE Category Dimension / Capacity Length 75 in./190.5 cm Width 46 in./116.8 cm...
  • Page 5 Lubrication Pressurized Dry Sump Front Suspension / Shock A- -arm / MacPherson Strut Oil Requirements / Capacity Polaris 0W- -40 2 qt. / 1.9 ltr Front Travel 8.2 in. / 20.83 cm Exhaust System Single Pipe Rear Suspension / Shock...

  • Page 6: Standard Torque Specifications

    GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections. Bolt Size Threads/In Grade 2...
  • Page 7 GENERAL INFORMATION SAE TAP DRILL SIZES DECIMAL EQUIVALENTS 1/64 ....0156 Thread Size/Drill Size Thread Size/Drill Size 1/32 ... .0312 .

  • Page 8: Conversion Table

    GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft.lbs. kg-m x 7.233 = ft.

  • Page 9: Glossary Of Terms

    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.
  • Page 10 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.
  • Page 11 Pre-Ride Inspection ..... . Pure Polaris Products for Your ATV ..Lubrication Charts .

  • Page 12: Periodic Maintenance Chart

    Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.) E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING: Improperly performing the procedures marked with a could result in component failure and lead...

  • Page 13: Maintenance And Lubrication

    (if equipped) Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly " " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.
  • Page 14 Inspect routing, condition " (1000) Valve clearance 100 H 12 M Inspect; adjust (1000) " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.
  • Page 15 Auxiliary brake Inspect daily; adjust as needed " Headlight aim Adjust as needed " Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) J Have an authorized Polaris dealer perform these services.
  • Page 16 MAINTENANCE POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description Part No. Description Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc. 2870791 Fogging Oil (12 oz. Aerosol) 2874275 Loctitet Primer N, Aerosol 2871281 Engine Oil (Quart) Premium 4 Synthetic...

  • Page 17: Pre-Ride Inspection

    MAINTENANCE PRE-RIDE / DAILY INSPECTION Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. Tires - check condition and pressures Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank All brakes - check operation (includes auxiliary brake) Throttle - check for free operation Headlight/Taillight/Brakelight - check operation of all indicator lights and switches...
  • Page 18 MAINTENANCE POLARIS LUBES/FLUIDS FOR SCRAMBLER 500 MODELS Pure Polaris Lubricants and Maintenance Kits can be purchased at your local Polaris dealer. 2873554 -- ATV Oil Change Kit - - Oil Filter & 3 Qts. of 0W- -40 oil - - Reservoir Gasket...
  • Page 19 Fill to bottom of fill hole. Approx. 32 Change annually © Gearcase Lubri- cant Brake Fluid Polaris DOT 3 Fill master cylinder reservoir to in- As required. Change fluid every 2 years. Brake Fluid dicated level inside reservoir. Drive Chain...
  • Page 20 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) © More often under severe conditions (operating in water or hauling heavy loads) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or ¢ Mobilegrease Special...

  • Page 21: Lubrication Charts

    MAINTENANCE LUBRICATION / GREASE Be sure vehicle is level before proceeding. POINTS Check vent hose to be sure it is routed properly and unobstructed. As shown on Page 2.7, there are only five grease zerks on the Trail Blazer, two front ball joints, two on The correct gearcase lubricant to the swing are pivots, and one on the rear axle housing.

  • Page 22: Transmission Lubrication 4X4

    Torque to specification. Check vent hose to be sure it is 4. Remove fill plug. routed properly and unobstructed. 5. Add Polaris AGL Gearcase Lubricant (PN Follow instructions on following 2873602) to proper level as described above. pages...
  • Page 23 MAINTENANCE TRANSMISSION GEARSHIFT SHIFT LINKAGE LINKAGE ADJUSTMENT, ADJUSTMENT PRELIMINARY INSPECTION 1. Inspect shift linkage tie rod ends, clevis and pivot bushings and replace if worn or damaged. Linkage rod will rotate 2. Place gear selector in neutral. 1/8 -1/4 turn if rod ends 3.

  • Page 24: Throttle Operation / Choke Adjustment

    MAINTENANCE 5. Hold rod end parallel to mounting surface and PILOT SCREW tighten jam nuts securely. The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened. The fuel/air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet.

  • Page 25: Pilot Screw Adjustment

    MAINTENANCE PILOT SCREW ADJUSTMENT 6. Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM. Continue turning counterclockwise until idle RPM begins to drop. 7. Center the pilot screw between the points in Step 5 and 6. 8. Re adjust idle speed if not within specification. FRONT (Engine) IDLE SPEED ADJUSTMENT...
  • Page 26 MAINTENANCE THROTTLE CABLE / THROTTLE OPERATION ELECTRONIC THROTTLE To remove the ETC cover: CONTROL (ETC SWITCH) 1. Use a medium flat blade screwdriver and insert blade into the pockets of the cover starting on the ADJUSTMENT #1 position. 1. Slide the boots off inline cable adjuster sleeve. Loosen adjuster locknut.

  • Page 27: Fuel System

    MAINTENANCE CHOKE (ENRICHER) FUEL SYSTEM ADJUSTMENT WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 28: Vent Lines

    MAINTENANCE VENT LINES 1. Turn fuel valve to the off position. 2. Place a clean container beneath the bowl drain 1. Check fuel tank, oil tank, carburetor, battery and spigot or bowl drain hose. transmission vent lines for signs of wear, deterioration, damage or leakage.

  • Page 29: Compression Test

    MAINTENANCE COMPRESSION TEST BATTERY MAINTENANCE NOTE: This Polaris 4-Stroke engine is equipped with an automatic decompressor. Compression readings will vary in proportion to cranking speed during the WARNING test. Average compression (measured) is about 70- -90 psi during a compression test.
  • Page 30 MAINTENANCE SEALED LOW MAINTENANCE BATTERY CHARGING If battery voltage is 12.8 V or less, the battery may need recharging. When using an automatic charger, refer to the charger manufacturer’s instructions for recharging. When using a constant current charger, use the following guidelines for recharging. NOTE: Always verify battery condition before and 1-2 hours after the end of charging.

  • Page 31: Spark Plug

    MAINTENANCE SEALED LOW MAINTENANCE SPARK PLUG BATTERY INSPECTION/ 1. Remove spark plug high tension lead. Clean plug area so no dirt and debris can fall into engine REMOVAL when plug is removed. 2. Remove spark plug. The battery is located under the seat and right rear fender.

  • Page 32: Ignition Timing

    Ignition Timing: 30°±2° BTDC@5000RPM Antifreeze Hydrometer ENGINE-TO-FRAME GROUND A 50/50 or 60/40 mixture of Polaris Inspect engine-to-frame ground cable connection. Be Premium Coolant (PN 2871323) and sure it is clean and tight. distilled water will provide the optimum...

  • Page 33: Cooling System Pressure Test

    MAINTENANCE RADIATOR 2. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant (PN 2871323) or a mixture of antifreeze and distilled water as 1. Check radiator air passages for restrictions or required for freeze protection in your area.
  • Page 34 MAINTENANCE MAIN AIR FILTER CLEANING 4. Loosen clamp remove filter assembly. It is advisable to replace the filter when it is dirty. Cover However, in an emergency it is permissible to clean the main filter if you observe the following practices. Never immerse the filter in water since dirt can be transferred to the clean air side of the filter.

  • Page 35: Air Box Sediment Tube Service

    3. Reinstall drain plug. Filter Support BREATHER FILTER Air Box INSPECTION Polaris Four cycle ATV engines are equipped with a breather filter. The in-line filter is similar in appearance to a fuel filter, and is visible on the left side (Location A).

  • Page 36: Breather Hose

    MAINTENANCE BREATHER HOSE PVT DRAIN PLUG & DRYING 1. Be sure breather line is routed properly and NOTE: If operating the ATV in or through water, be secured in place. CAUTION: Make sure lines are sure to check the PVT cover and other components not kinked, pinched or has any sags that may for water ingestion.

  • Page 37: Oil Change/Filter

    7. Reinstall drain plug (B) and torque to 14 ft. lbs. (19 Nm). Recommended Engine Oil: 8. Loosen clamp (D) on oil hose. Polaris Premium 4 All Season Synthetic, 0W- -40, (PN 2871281) 9. Remove oil hose from screen fitting (C) on bottom of oil tank.
  • Page 38 20. Remove dipstick and fill tank with 2 quarts (1.9 L) Mark on Tank of Polaris Premium 4 Synthetic Oil (PN 2871844). 21. Place gear selector in Park and set parking brake. NOTE: Clamp or pinch off the vent line 2” from the oil tank as shown below in the Oil Pump Priming Procedure for the 500 engine.

  • Page 39: Valve Clearance

    MAINTENANCE 5. Remove timing inspection plug from recoil housing. CAUTION: Failure to position the crankshaft at TDC (A) Vent Hose to Air Box on compression stroke will result in improper valve adjustment. Oil Lines 6. Rotate engine slowly with recoil rope, watching To Engine the intake valve(s) open and close.

  • Page 40: Exhaust Valve Clearance Adjustment

    Polaris Dealer. Only a qualified technician should replace worn or damaged steering parts. Use only genuine Polaris replacement parts. One of two methods can be used to measure toe alignment.

  • Page 41: Camber And Caster

    MAINTENANCE Replace worn steering WHEEL ALIGNMENT components. Steering should move METHOD 1: freely through entire range of travel without binding. STRAIGHTEDGE OR STRING Be sure to keep handlebars centered. See notes below. NOTE: String should just touch side sur- face of rear tire on each side of machine. Elevate front end of machine so front wheels are off the ground.
  • Page 42 MAINTENANCE should always point straight back from the To adjust toe alignment: steering post. Hold tie rod end to keep it from 3. Place a chalk mark on the center line of the front rotating. tires approximately 10″ (25.4 cm) from the floor or Loosen jam nuts at both end of the tie as close to the hub/axle center line as possible.

  • Page 43: Exhaust Pipe

    Exhaust contains poisonous car- the 4 or 8 o’clock position. bon monoxide gas. 5. Add Polaris Demand Drive Hub Fluid until fluid G Do not go under the machine while it is trickles out. NOTE: Do not force the fluid into the inclined.

  • Page 44: Brake Pad Inspection

    Keep fluid level in the master cylinder cm), or about the thickness of a dime. reservoir to the indicated level inside reservoir. HOSE/FITTING INSPECTION Use Polaris DOT 3 Brake Fluid (PN 2870990). Check brake system hoses and fittings for cracks, Sight Parking Brake deterioration, abrasion, and leaks.
  • Page 45 SPROCKET INSPECTION exceeds the wear limit. 3. When replacing or reinstalling drive chain, install Polaris ATV drive chains are equipped with O-ring the closed end of the splice link clip as shown, with sealed permanently greased pins and rollers. The the closed end leading in forward operation.
  • Page 46 MAINTENANCE DRIVE CHAIN ADJUSTMENT, CONCENTRIC SWINGARM CAUTION: Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result. Break-In: It is extremely important to maintain proper chain tension to ensure the best possible chain life.

  • Page 47: Rear Axle

    MAINTENANCE ADJUSTMENT PROCEDURE - CONCENTRIC SWINGARM Alternate Adjustment Method -- Pin Punch (Step 5 and 6) REAR AXLE Loosen Eccentric clamp bolts (Step 2) 6. Roll the vehicle ahead or back to adjust chain slack to the proper dimension. 7. Tighten the eccentric clamp bolts to specification. Loosen (2) caliper CAUTION: OVER-TIGHTEN...

  • Page 48: Suspension Spring Preload Adjustment

    MAINTENANCE Eccentric Clamp With Hitch Chain Guide Torque to 40 ft.lbs. (54 Nm) With Trailer Hitch SUSPENSION SPRING 8. Remove the pin punch. PRELOAD ADJUSTMENT 9. 2004 Models -- Tighten caliper mounting bracket bolts 10-12 ft. lbs. (14 - 17 Nm). Operator weight and vehicle loading affect suspensionspringpreloadrequirements.

  • Page 49: Cv Shaft Boot Inspection

    Refer to Chapter 7 for CV boot replacement, or Rear Wheel Nuts 50 Ft. Lbs. (68 Nm) have you Polaris dealer replace the boot. Front Spindle Nut Refer to procedure listed in Chapter 7 Rear Hub Retaining Nut 80 Ft.

  • Page 50: Wheel Removal / Installation

    MAINTENANCE WHEEL INSTALLATION Tread Depth 1/8I (3 mm) 1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.
  • Page 51 ENGINE Torque Specifications ......EH50PL Service Data ......3.3-3.4 Special Tools .
  • Page 52 ENGINE TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Size EH50PLE Ft. Lbs. (Nm) Blind Plug (Oil Pressure) 1/8 Pipe 6.5-11 (9-15 Nm) Thread Camshaft Sprocket 5-6.5 (7-9 Nm) Camshaft Chain Tensioner Lever 5-6.5 (7-9 Nm) Camshaft Chain Tensioner 5-6.5 (7-9 Nm) Camshaft Chain Tensioner Cap 11mm 14-19 (20-25 Nm) Carburetor Adaptor...
  • Page 53 ENGINE EH50PLE ENGINE SERVICE DATA Cylinder Head / Valve EH50PLE10 Rocker Arm Rocker arm ID .8669-.8678″ (22.020-22.041 mm) Rocker shaft OD .8656-.8661″ (21.987-22.0 mm) Rocker shaft Oil Clear- .0008-.0021″ (.020-.054 mm) ance Limit .0039″ (.10 mm) Camshaft Cam lobe height 1.2884-1.2924″...
  • Page 54 ENGINE EH50PLE ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod EH50PLE10 Cylinder Surface warpage limit (mating with .0020″ (.05 mm) cylinder head) Cylinder bore 3.6221-3.6228″ (92.00-92.02 mm) Taper limit .0020″ (.050 mm) Out of round limit .0020″ (.050 mm) Piston clearance .0006-.0018″...

  • Page 55: Piston Identification

    ENGINE SPECIAL TOOLS PISTON IDENTIFICATION PART NUMBER TOOL The piston may have an identification mark or the DESCRIPTION piston may not have an identification mark for piston placement. If the piston has an identification 2872105 Water Pump Mechanical Seal mark, follow the directions for piston placement Puller below.
  • Page 56 3. Always add coolant to the radiator first, filling to the top of Remote Filler Cooling System the neck to replace air that has been purged from the system. Polaris Premium Antifreeze Fill the reservoir only after you have completely filled the cool- 2871534 Quart ing system at the radiator filler neck.

  • Page 57: Cooling System Specifications

    Vent hole inside cap reduce heat dissipation, resulting in possible engine liner must be clear. damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems, and comes pre-mixed and ready to use.
  • Page 58 ENGINE ACCESSIBLE COMPONENTS 12. Remove center drive and driven sprocket bolts and remove chain and sprockets as an assembly. The following components can be serviced or 13. Refer to PVT System to remove outer clutch removed with the engine installed in the frame: cover, drive belt, drive clutch, driven clutch, and inner cover.

  • Page 59: Honing To Oversize

    4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation, or 2 full tanks of fuel. 1. Use only Polaris Premium 4 All Season synthetic EXAMPLE OF CROSS HATCH PATTERN oil, or API certified “SH” oil. Never substitute or mix oil brands.

  • Page 60: Crankshaft Straightening

    *Oil Pressure Specification . . . 20 PSI @ 5500 RPM, Polaris 0W--40 Synthetic (Engine Hot) 2. To correct a situation like the one shown in the illustration at right, squeeze the crankshaft at point A. (Use tool from alignment kit).
  • Page 61 The oil NOTE: Use Polaris Premium 4 Synthetic Engine is pumped through a delivery pipe to the oil filter. If the Lubricant (PN 2871281).

  • Page 62: Eh50Pl Oil Flow Diagram

    ENGINE EH50PL OIL FLOW DIAGRAM Internal passage to camshaft (front left head bolt) Oil filter Oil feed to filter From filter to crankshaft One way valve Top fitting is oil Bottom fitting is oil feed or intake exhaust or return from bottom of Oil Tank to tank...
  • Page 63 ENGINE EH50PL ENGINE EXPLODED VIEW Crankcase Cylinder/ Cylinder Head Crankshaft Valve Train and Piston 3.13...

  • Page 64: Engine Disassembly

    ENGINE ENGINE DISASSEMBLY should have clearance at this point. REFER TO PAGE 3.7 FOR ENGINE REMOVAL / INSTALLATION NOTES. CAM CHAIN TENSIONER/ROCKER ARM/CAMSHAFT REMOVAL 1. Remove ignition timing inspection plug from recoil housing. 5. Remove cam chain tensioner plug, sealing TDC “T”...

  • Page 65: Cam Chain Tensioner Inspection

    ENGINE CAM CHAIN TENSIONER ROCKER ARM/SHAFT INSPECTION INSPECTION 1. Pull cam chain tensioner plunger outward to the 1. Mark or tag rocker arms to keep them in order for end of its travel. Inspect teeth on ratchet pawl (A) assembly. and plunger teeth (B) for wear or damage.

  • Page 66: Camshaft Removal

    ENGINE ROCKER ARM/SHAFT INSPECTION, CONT. Rocker Shaft Oil Clearance: Std: .0008-.0021I (.020-.054 mm) Limit: .0039I (.10 mm) 5. Measure I.D. of both rocker arm shaft supports and visually inspect surface. Compare to specifications. 6. Subtract rocker shaft O.D. from rocker arm & shaft support I.D.
  • Page 67 ENGINE 3. Loosen three camshaft sprocket bolts. 7. Slide camshaft inward to allow removal of cam sprocket and remove sprocket from camshaft and chain. 8. Secure cam chain with a wire to prevent it from falling into the crankcase. Sprocket Teeth 4.

  • Page 68: Camshaft Inspection

    ENGINE If Camshaft Is Removed From Engine: 3. Turn the camshaft until the actuator ball is in the lowest position and install the release lever shaft. If Camshaft Is Installed In The Engine: 4. Use a small magnet to draw the actuator ball outward, or rotate the engine until the cam lobes face upward and install release lever shaft.

  • Page 69: Cylinder Head Removal

    ENGINE 3. Measure height of each cam lobe using a CYLINDER HEAD REMOVAL micrometer. Compare to specifications. 1. Remove the two 6mm flange bolts (A) from cylinder head. See next exploded view on next Journal O.D. page to view item A. 2.
  • Page 70 ENGINE CYLINDER HEAD EXPLODED VIEW, EH50PL EH50PL 3.20...

  • Page 71: Cylinder Head Inspection

    ENGINE CYLINDER HEAD CYLINDER HEAD INSPECTION DISASSEMBLY WARNING: Wear eye protection or a face shield during cylinder head disassembly and reassembly. NOTE: Keep all parts in order with respect to their location in the cylinder head. 1. Thoroughly clean cylinder head (A) surface to remove all traces of gasket material and carbon.

  • Page 72: Valve Inspection

    ENGINE to specifications. Replace spring if either indicator. measurement is out of specification 3. Check end of valve stem for flaring, pitting, wear or damage (A). 4. Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valves cannot be re-faced or end ground.

  • Page 73: Combustion Chamber

    ENGINE VALVE SEAT SERVICE Valve Seat Inspection Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. See Valve Seat Reconditioning, Page 3.25. If the valve seat is cracked the cylinder head must be replaced.
  • Page 74 ENGINE Reaming The Valve Guide Good Uneven Wide Narrow 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.
  • Page 75 ENGINE If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation and must be Valve Seat Width: replaced. Be sure the cylinder head is at the proper temperature and replace the Intake Std: .028I (.7 mm) guide.

  • Page 76: Cylinder Head Assembly

    ENGINE 1. Install new valve seals on valve guides. 2. Apply engine oil to valve guides and seats. 3. Coat valve stem with molybdenum disulfide grease. 4. Install valve carefully with a rotating motion to avoid damaging valve seal. 5. Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head.
  • Page 77 ENGINE EXHAUST VALVE CYLINDER/PISTON REMOVAL CLEARANCE ADJUSTMENT AND INSPECTION NOTE: Follow engine disassembly procedures to 500 Engine remove valve cover, camshaft and rocker arms, and cylinder head. Feeler Gauge for Both Valves NOTE: The exhaust valves share a common rocker arm, and must be adjusted using two feeler gauges.

  • Page 78: Piston Removal

    ENGINE 3. Loosen hose clamps and remove coolant inlet PISTON REMOVAL hose. 4. Remove the two 6 mm cylinder base bolts. 1. Remove circlip. Note piston directional arrow pointing toward the right (Mag) side of engine. 5. Loosen each of the four large cylinder base bolts 2.

  • Page 79: Cylinder Inspection

    ENGINE 3. Remove top compression ring. *Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the 2. Inspect the top of the cylinder for warpage using a ring more than the amount necessary to remove it straight edge and feeler gauge.
  • Page 80 ENGINE PISTON-TO-CYLINDER 1. Measure piston pin bore. CLEARANCE Piston 40 mm Piston Pin Measurement Locations Piston Pin Piston Pin O.D. 1. Measure piston outside diameter at a point 40 mm .9053-.9055I (22.994-23.0 mm) down from the top of the piston at a right angle to the direction of the piston pin.

  • Page 81: Piston Ring Installed Gap

    ENGINE PISTON RING INSTALLED STARTER DRIVE REMOVAL/INSPECTION 1. Place each piston ring inside cylinder using piston 1. Remove recoil housing bolts and remove to push ring squarely into place as shown at right. housing. Feeler Gauge Cylinder 25-50mm Piston Ring 2.
  • Page 82 ENGINE 5. Measure the ID of the bushing in the recoil 6. Remove oil passage O-Ring (B). housing (A) and in the crankcase and record. Measure in two directions 90° apart to determine if bushing is out of round. Calculate bushing clearance.

  • Page 83: Crankcase Separation

    ENGINE 3. Remove cam chain (B). Inspect chain for worn or missing rollers or damage. Stretch chain tight on a flat surface and apply a 10 lb. (4.53 kg) load. One Way Valve Spring Free Length: Measure length of a 20 pitch section of chain. Std: 1.450″...
  • Page 84 ENGINE OIL PUMP 4. Remove three oil pump retaining bolts and pump. REMOVAL/INSPECTION 5. Inspect mating surface of crankcase and oil pump. Check for nicks, burrs, or surface irregularities. 1. Remove pump shaft bearing (A) and thrust washer (B) from pump shaft. 6.

  • Page 85: Oil Pump Assembly

    ENGINE 5. Install inner feed rotor and feed chamber cover with screw. 9. Measure pump end clearance using a feeler 6. Tighten screw securely. gauge and straight edge. 7. Install screen on pump body. 8. Install oil pump on crankcase and torque bolts to 6 ft.
  • Page 86 ENGINE 2. Note the alignment dots on the balancer and CRANKSHAFT crankshaft gears, the marks must be aligned REMOVAL/INSPECTION during reassembly. 1. Remove the shim washer (A) from the crankshaft. 3. Turn the shaft until balancer counter weights clear the crankshaft and remove the balancer shaft 2.
  • Page 87 ENGINE 5. Measure the connecting rod big end radial PUMP SHAFT OIL SEAL/ clearance. WATER PUMP MECHANICAL SEAL REMOVAL (ENGINE Big End Radial Clearance: DISASSEMBLED) Std: .0004-.0015I (.011-.038 mm) Limit: .0020I (.05 mm) NOTE: The water pump mechanical seal can be removed without removing the engine.

  • Page 88: Bearing Installation

    ENGINE BEARING INSTALLATION NOTE: To ease bearing installation, warm the crankcase until hot to the touch. Place the bearings in a freezer. 1. Install the bearings so the numbers are visible. 2. Drive or press new bearings into the crankcases, using the proper driver.
  • Page 89 ENGINE 4. Measure the distance from the Magneto 7. Measure the width of the crankshaft at the crankcase mating surface to the main bearing bearing seats with a micrometer or dial caliper using the same method and record. and record. Crankshaft Width 8.

  • Page 90: Oil Pump Shaft End Play Adjustment

    ENGINE COUNTER BALANCER SHAFT END PLAY ADJUST. Counter Balancer Shaft End Play: .008″-.016″ (.02-.04 cm) Step 2 OIL PUMP SHAFT END PLAY ADJUSTMENT 1. Make sure the pump shaft bearing is firmly seated in the Magneto side crankcase. 1. Make sure all bearings are firmly seated in the crankcase.

  • Page 91: Pump Shaft Oil Seal Installation

    ENGINE difficult, install two nuts on the end of the threaded rod and tighten against each other. Pump Shaft End Play: 3. Install the proper shim on the magneto end of the crankshaft. .008″-.016″ (.02-.04 cm) 4. Place the balancer shaft in the PTO crankcase aligning the timing marks on the crankshaft and balancer gears.

  • Page 92: Water Pump Mechanical Seal Installation

    ENGINE 4. Install the crankcase flange bolts and tighten in 3 steps following the pattern on Page 3.2 to Sealing Washer specified torque. Sealing Washer (Copper or Aluminum) Crankcase Bolt Torque: Coolant Drain Bolt 14 ft. lbs. (19 Nm) Seal Impeller Crankcase Sealant: Mechanical Seal...
  • Page 93 ENGINE 4. Ensure that the split between the puller legs is ONE WAY VALVE fully supported by the main body of the tool (Ill 4). INSTALLATION Install the one way valve plunger, spring, and plug Hex Socket Screws using a new sealing washer. Puller Legs One Way Valve Plug Torque: 16 ft.

  • Page 94: Piston Ring Installation

    ENGINE TENSIONER BLADE 5. Install the top ring (chrome faced) with the “R” mark facing up and the end gap facing forward INSTALLATION (toward the exhaust). (See ILL. 1). 6. Check to make sure the rings rotate freely in the 1.

  • Page 95: Cylinder Installation

    ENGINE compress the new clip more than necessary upon 3. Apply clean engine oil to the ring compressor installation to prevent loss of radial tension. Severe (Snap Ont PN RCL30) and install the engine damage may result if circlips are re-used or compressor following manufacturers...

  • Page 96: Cylinder Head Installation

    ENGINE 9. Tighten the cylinder bolts in three steps in a criss cross pattern and torque to specifications. 10. Install the two 6 mm bolts. Cylinder Bolt Torque: 10mm - 46 ft. lbs. (62 Nm) Guide in 6mm - 6 ft. lbs. (8 Nm) recess CYLINDER HEAD INSTALLATION...
  • Page 97 ENGINE 1. Apply Polaris Premium Starter Drive Grease (PN 2871460) to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil. (To install the compression release mechanism, refer to Page 3.17). 2. Install the camshaft with the lobes facing downward and the sprocket alignment pin facing upward.
  • Page 98 ENGINE CAMSHAFT TIMING Crankshaft to Camshaft Centerline Dots Sprocket Alignment Pin Single TDC Mark Aligned TDC Mark Rotation Do Not Use Advance Marks 3.48...

  • Page 99: Cam Chain Tensioner Installation

    ENGINE CAM CHAIN TENSIONER 2. Install a new O-Ring in the oil passage recess in the crankcase. INSTALLATION 3. Apply 3 Bond 1215 (PN 2871557) or an equivalent sealer to the stator plate outer surface and install a new O-Ring. 1.

  • Page 100: Thermostat Installation

    ENGINE Starter Drive 5. Be sure the dowel pins are in place and install the rocker shaft assembly. 6. Apply a light film of engine oil to the threads of the bolts and tighten evenly. Rocker Shaft Support Tower Bolt Torque: 9 ft.

  • Page 101: Oil Pipes

    ENGINE OIL PIPES 11. Remove center bolt from recoil friction plate (A). Install the oil pipes with new sealing washers. Tighten NOTE - - Information only. all bolts evenly to specified torque. 2009 models not equipped. Oil Pipe Bolt Torque: 20 ft.

  • Page 102: Recoil Assembly

    ENGINE To reinstall an old spring: 1. Hook outer tab in place in recoil housing and wind spring in a counterclockwise direction one coil at a time while holding the installed coils in place. 2. Lubricate the spring with light lubricant such as Premium All Season Grease (PN 2871423).
  • Page 103 ENGINE SPARK PLUG FOULING Dead battery Starter motor does not turn Spark plug cap loose or faulty Engine seized, rusted, Choke cable adjustment mechanical failure plunger/cable sticking Engine Runs But Will Not Idle Foreign material on choke plunger Restricted carburetor pilot system seat or plunger Carburetor misadjusted Incorrect spark plug heat range or...
  • Page 104 ENGINE Cylinder head gasket leak Ignition timing misadjusted valve clearance incorrectly Low oil level adjusted Spark plug incorrect heat range Cylinder or piston worn Faulty hot light circuit Piston rings worn, leaking, broken, or Thermostat stuck closed or not opening sticking completely Bent valve or stuck valve...
  • Page 105 FUEL SYSTEM/CARBURETION Exploded View, Mikuni BST 40 Carburetor . . . Fuel Tank Asm. Exploded View ... . Fuel Flow Diagram ..... . . Special Tool &...
  • Page 106 FUEL SYSTEM/CARBURETION BST 40 CARBURETOR EXPLODED VIEW 1. Cover, Diaphragm 2. Spring 3. Spring Seat 4. “E” Clip 5. Spacer 6. Jet Needle 7. Diaphragm Assembly 8. Throttle Valve 9. Cable Guide 10. Spring 11. Adjuster Cable 12. Drain Plug 13.

  • Page 107: Fuel Flow Diagram

    FUEL SYSTEM/CARBURETION FUEL TANK ASSEMBLY Forward Fuel tank mounted valve FUEL FLOW Fuel Tank Fuel Tank Vent Fitting Screens Fuel Pump Filter Fuel Valve Carburetor Vent Engine Carburetor L Located Above Oil Tank...

  • Page 108: Jetting Guidelines

    Never start the engine or let it run in an Polaris ATV Carburetors are calibrated for an altitude enclosed area. Gasoline powered engine 0-6000 ft. (0-1800 meters) and ambient exhaust fumes are poisonous and can temperatures between +40 and +80°...

  • Page 109: Carburetor Jetting

    FUEL SYSTEM/CARBURETION / pilot screw adjustments and PVT adjustments may be required to suit operating conditions. CARBURETOR JETTING CAUTION: A main jet that is too small will cause a lean operating condition resulting in serious engine damage. Select the correct main jet carefully for elevation and temperature according to the charts Chapter 1 specifications or in the Owner’s Safety and Maintenance Manual for each...

  • Page 110: Cv Carburetor System Function (4 Cycle)

    FUEL SYSTEM/CARBURETION CV CARBURETOR SYSTEM VENT SYSTEMS - CV FUNCTION CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl. The lines Carburetor Component Function must be free of kinks, restrictions and be properly System Main Main Main routed.
  • Page 111 FUEL SYSTEM/CARBURETION CARBURETOR OPERATION CONT’D When the throttle plate is opened and engine speed begins to increase, the pressure in the venturi (and therefore in the chamber above the diaphragm) becomes significantly lower than atmospheric. Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward, raising the slide against spring pressure.

  • Page 112: Float System

    FUEL SYSTEM/CARBURETION FLOAT SYSTEM and vacuum slide height. Fuel enters the float chamber (3) by means of the inlet pipe and passage, through a screen on the back of the inlet needle seat (4), and around the inlet needle (2). As the fuel fills the float chamber, the float (1) rises and forces the inlet needle against the seat, shutting off the orifice in the seat.

  • Page 113: Carburetor Cleaning

    FUEL SYSTEM/CARBURETION 2. Remove float bowl and carefully remove the keeping. pressed float pin. Support Here Pilot Screw Starter Jet NOTE: Be careful not to damage the float pin tower during the float pin removal. Support the float pin CARBURETOR CLEANING tower while removing the float pin.

  • Page 114: Carburetor Inspection

    FUEL SYSTEM/CARBURETION CARBURETOR INSPECTION CARBURETOR ASSEMBLY 1. Inspect jet needle and needle jet for wear. Look Inspect the diaphragm (A) for holes, deterioration, or for discoloration, shiny spots, or an area that damage. Make sure the diaphragm is pliable but not looks different than the rest of the needle.
  • Page 115 FUEL SYSTEM/CARBURETION 5. Install the pilot mixture screw, spring, washer, and BST 40 O-ring as an assembly. Lubricate the O-Ring with oil or light grease before installation. CAUTION: Do not damage the O-ring during installation. Turn the screw in until it lightly contacts the seat. Back out the specified number of turns.

  • Page 116: Needle And Seat Leakage Test

    FUEL SYSTEM/CARBURETION NEEDLE AND SEAT LEAKAGE TEST 1. Install the float bowl. Invert the carburetor and install a Mity-Vact (PN 2870975) to the fuel inlet fitting. Apply 5 PSI pressure to inlet fitting. The needle and seat should hold pressure indefinitely. If not, inspect needle and seat and seat O-ring.

  • Page 117: Fuel Pump Service

    FUEL SYSTEM/CARBURETION FUEL PUMP DISASSEMBLY 1. Remove the screws from the pump diaphragm cover. Note the location of the two longer screws. 2. Remove diaphragm cover gasket, diaphragm, and valve body gasket. 3. Remove the outlet check valve cover, diaphragm, 1.5 mm and gasket.
  • Page 118 FUEL SYSTEM/CARBURETION FUEL PUMP EXPLODED 1. Fuel Pump Assembly 2. Diaphragm, Gasket Set VIEW 3. Screw and Washer Assembly 4. Screw and Washer Assembly Fuel Pump Exploded View at Right 5. Screw and Washer Assembly 6. Pressure Regulator 7. Fuel Inlet 8.

  • Page 119: Troubleshooting

    FUEL SYSTEM/CARBURETION TROUBLESHOOTING Loose jets Worn jet needle/needle jet or other FUEL STARVATION/LEAN MIXTURE carburetor parts Dirty carburetor (air bleed Symptoms: Hard start or no start, bog, backfire, passages or jets) popping through intake / exhaust, hesitation, Weak or damaged vacuum piston detonation, low power, spark plug erosion, engine return spring runs hot, surging, high idle, idle speed erratic.
  • Page 120 FUEL SYSTEM/CARBURETION NOTES 4.16...
  • Page 121 BODY / STEERING / SUSPENSION Torque Specifications and Special Tools ....Body Assembly, Exploded View ..... Steering Assembly, Exploded View .
  • Page 122 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS COVER/PANEL REMOVAL To Remove: Perform These Steps: Item Specification Seat ....Pull release lever at left rear Front A-Arm Attaching Bolt 30 ft.

  • Page 123: Body Assembly Exploded View

    BODY / STEERING / SUSPENSION BODY ASSEMBLY EXPLODED VIEW Seat Release Latch Rear Cab Assembly Mud Flap Front Cover Panel or Headlight Cover Front Cab Assembly Front Cab Mud Flap...

  • Page 124: Steering Assembly, Exploded View

    BODY / STEERING / SUSPENSION STEERING ASSEMBLY, EXPLODED VIEW NOTE: Apply Loctitet 242 to To avoid damage to tie rods and other steering the bolt threads. components, be sure to install tie rod end bolts in the proper direction. The steering post arm bolt (B) points up; the rod end bolts (A) point down.

  • Page 125: A-Arm Replacement

    BODY / STEERING / SUSPENSION A-ARM REPLACEMENT Vehicle Frame Apply Loctitet 242 to the bolt threads. Bolt 30 ft. lbs. (41 Nm) Bolt 30 ft. lbs. (41 Nm) Ball Joint Stud A-Arm Tube 8 ft. lbs. A-Arm Shaft (11 Nm) 25 ft.

  • Page 126: Concentric Swing Arm Removal

    BODY / STEERING / SUSPENSION CONCENTRIC SWING ARM REMOVAL (2) Washer (3) Two-piece bushing (1) Nut (8) Pivot Bolt (4) Pivot Bushing, Right (7) Pivot Bushing, Left Place flats of pivot bushing in vise to hold while removing nut (5) Pivot Bolt (8) Pivot Bolt Retainer Refer to Maintenance section for chain adjustment information...

  • Page 127: Concentric Swing Arm Assembly/Installation

    BODY / STEERING / SUSPENSION CONCENTRIC SWING ARM ASSEMBLY/INSTALLATION 150 ft. lbs. (207 Nm) (1) Nut 120 ft. lbs. (163 Nm) (2) Washer (8) Pivot Bolt (3) Two-piece bushing (7) Pivot Bushing, Left (4) Pivot Bushing, Right Place flats of pivot bushing in vise to hold while removing and installing nut 150 ft.
  • Page 128 BODY / STEERING / SUSPENSION STRUT ASSEMBLY - AWD (4X4) 15 ft. lbs. Strut Bumper (21 Nm) Spring Retainer Washer Spacer Rubber Clamp 18 ft. lbs. Upper Pivot Ball (25 Nm) 15 ft. lbs. (21 Nm) Wire retainer Washer Bolt Spacer Lower Pivot Ball Spring Retainer...
  • Page 129 BODY / STEERING / SUSPENSION STRUT ASSEMBLY - - 2X4 15 ft. lbs. (20 Nm) Spring Retainer Strut Bumper Spring Spring Retainer Strut Tie--Rod Bolt 15 ft. lbs. (21 Nm) Jam Nut 45 ft. lbs. 14 ft. lbs. (61 Nm) (19 Nm) Hub Nut 40 ft.
  • Page 130 BODY / STEERING / SUSPENSION FRONT STRUT CARTRIDGE BALL JOINT REPLACEMENT REPLACEMENT REFER TO ILLUSTRATION ON PAGE 5.8 1. Loosen front wheel nuts slightly. REFER TO ILLUSTRATION ON PAGE 5.8 2. Elevate and safely support machine under 1. Hold strut rod and remove top nut. footrest/frame area.
  • Page 131 BODY / STEERING / SUSPENSION Apply grease to extension cap and NOTES threads of puller bolt to ease removal. Thread bolt (D) with nut (C) onto ball joint stud as shown. Hold bolt (D) and turn nut (C) clockwise until ball joint is removed from strut housing.

  • Page 132: Steering Post Assembly

    BODY / STEERING / SUSPENSION STEERING POST ASSEMBLY 12 ft. lbs. (16 Nm) 12 ft. lbs. (16 Nm) NOTE: Steering post bearing is shown in ex- ploded view form. This bearing is attached to the post using a radial riveting method and is a non--serviceable item.
  • Page 133 CLUTCHING Service Tools and Supplies ....PVT System Operation ....PVT Maintenance/Inspection .

  • Page 134: Special Tools And Supplies

    (initial vehicle movement), clutch Tool Kit upshift and backshift. During the development of a Polaris ATV, the PVT system is matched first to the engine power curve; then to average riding conditions and the vehicle’s intended usage. Therefore,...

  • Page 135: Pvt Maintenance/Inspection

    CLUTCHING DRIVEN CLUTCH OPERATION CONT’D air ducts, as well as the inner and outer covers, must be properly sealed to ensure clean air is As engine RPM and horsepower increase, the load being used for cooling the PVT system. This also from the drive belt increases, resulting in the belt will prevent water and other contaminants from rotating up toward the outer diameter of the drive...
  • Page 136 10 seconds. PVT seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. Inspection/repair of clutch components should be performed by a certified Polaris MSD techinician.

  • Page 137: Pvt Disassembly

    CLUTCHING PVT DISASSEMBLY 8. Remove driven clutch retaining bolt and driven clutch. Use the Driven Clutch Puller (PN 2870913) if necessary. NOTE: Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. (See Page 6.6). Driven Clutch Puller (PN 2870913) 1.

  • Page 138: Pvt Assembly

    CLUTCHING PVT ASSEMBLY Inner Cover Bolt Torque (Rear): 12 ft. lbs. (16.6 Nm) Seal this edge to cover on engine side Driven Clutch Retaining Bolt Torque: 17 ft. lbs. (23.5 Nm) Drive Clutch Retaining Bolt Torque: 40 ft. lbs. (55 Nm) 1.

  • Page 139: Pvt Sealing And Ducting Components

    CLUTCHING PVT SEALING AND DUCTING COMPONENTS Outer Cover Seal Inner Cover Drain Inlet duct Plug Inlet Duct Inner Cover Seal Retainer Outer Cover Cover Bolts Exhaust Duct DRIVE CLUTCH EXPLODED VIEW Drive Clutch Teflont coated brass bushing Teflont coated brass bushing Mark with permanent marker before disassembly...

  • Page 140: Drive Clutch Spring Specifications

    CLUTCHING DRIVE CLUTCH SPRING SPECIFICATIONS FULL UPSHIFT NEUTRAL The drive clutch spring has two primary functions: ATV TRAVEL 1. To control clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM.

  • Page 141: Shift Weights

    CLUTCHING SHIFT WEIGHTS Shown below are the shift weights which have been designed for, or which may be used in the PVT system. These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.

  • Page 142: Shift Weight Inspection

    WASHER INSPECTION”, Page 6.12. clutch assembly! All PVT system maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual. Because of...

  • Page 143: Drive Clutch Disassembly/Inspection

    CLUTCHING DRIVE CLUTCH Inspect shaft DISASSEMBLY Mark “X” Mark 4. Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch 1. Using a permanent marker, mark the cover, assembly if worn or damaged. spider, moveable and stationary sheaves, and 5.

  • Page 144: Drive Clutch Assembly

    CLUTCHING Moveable Sheave Bushing Inspection the new pin during installation. 2. Inspect the Teflont coating on the moveable sheave bushing. 2. Rubber backed buttons can be used in all ATV clutches if the hollow roller pin is changed to the Teflont solid roller pin.

  • Page 145: Drive Belt Tension

    CLUTCHING c) “X”, or the marks that were made earlier, under weight Spacer washers Spider Torque: 200 ft. lbs. (276 Nm) 2. Install moveable sheave onto fixed sheave. Cover Screw Torque: 3. Install spider spacers. Use same quantity and 90 in. lbs. (10.4 Nm) thickness as were removed.

  • Page 146: Drive Belt Removal/Inspection

    CLUTCHING NOTE: Pinch the sheaves lightly together with clamp to prevent the belt from being pushed into the driven sheave. 1. Place a straight edge on top of the belt between drive and driven clutch. 2. Push down on drive belt until it is lightly tensioned. 3.

  • Page 147: Drive Belt Installation

    CLUTCHING 5. Inspect belt for loose cords, missing cogs, cracks, DRIVE BELT INSTALLATION abrasions, thin spots, or excessive wear. Replace if necessary. 6. Inspect belt for hour glassing (extreme circular wear in at least one spot and on both sides of the belt).

  • Page 148: Clutch Offset

    CLUTCHING 1. Remove belt and install the Clutch Offset CLUTCH OFFSET Alignment Tool (PN 2870654) as shown. 2. With tool touching rear of driven clutch inner Offset Alignment Tool sheave, the distance at point “A” should be 1/8″. (PN 2870654) If the distance is greater than 1/8″...
  • Page 149 CLUTCHING 2. Remove nut from puller rod and set aside. Drive Clutch Cover 5020629 Bushing Removal/ Installation Tool (all clutches) Piston Pin Puller (PN 2870386) P--90 Driven Clutch 5020631 Cover Bushing Re- moval Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633...
  • Page 150 CLUTCHING 6. Turn sheave puller barrel together DRIVE CLUTCH COVER - counterclockwise on puller rod until bushing is BUSHING REMOVAL removed. 7. Remove nut from puller rod and set aside. 8. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard. Piston Pin Puller (PN 2870386) DRIVE CLUTCH MOVEABLE...

  • Page 151: Driven Clutch Disassembly/Inspection

    CLUTCHING 2. With the Main Puller Adapter (#8) (PN 5020632) 5. Turn clutch cover counterclockwise on puller rod on the puller, insert cover onto puller rod, placing until bushing is removed. outside of cover toward vise. 6. Remove nut from puller rod and set aside. 3.
  • Page 152 CLUTCHING 6. Inspect ramp buttons in the moveable sheave and replace if worn. NOTE: The ramp buttons are secured by Torxt screws (T20). Belt deflection adjustment washers 1. Apply and hold downward pressure on the helix, or place driven clutch in the Clutch Compression Tool (PN 8700220).

  • Page 153: Driven Clutch Assembly

    CLUTCHING DRIVEN CLUTCH ASSEMBLY Driven Spring Driven Clutch Scrambler 500 Driven Spring Placement: 1--1 Ill. 2 Moveable Spring Example: Helix Sheave Tension - - 1 Heavy Spring/ - - 2 Align boss spline Position - - 1 to install helix - - 3 - - 2 - - 3...
  • Page 154 CLUTCHING DRIVEN CLUTCH MOVEABLE SHEAVE - BUSHING REMOVAL NOTE: Bushings are installed at the factory using Loctitet. In order to remove the bushing it will be necessary to apply heat. A press can be used to remove and install some of the bushings. Be sure to support the sheave or cover as close as possible to Clutch Bushing the bushing bore when using a press.
  • Page 155 CLUTCHING 6. Install sheave onto puller. 2. Start new bushing evenly in moveable sheave. Apply Loctitet 680 (PN 2870584) to the back 7. Install nut onto puller rod and tighten by hand. side of new bushing. Turn puller barrel for further tension if needed. 8.
  • Page 156 CLUTCHING 5. Turn clutch sheave counterclockwise until bushing is seated. 6. Remove nut from puller rod and set aside. 7. Remove installation tool and clutch sheave from puller. 8. Repeat installation procedure for other moveable bushing. 6.24...

  • Page 157: Troubleshooting

    CLUTCHING TROUBLESHOOTING Situation Probable Cause Remedy Engine RPM -Wrong or broken drive clutch spring. -Replace with recommended spring. below specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application. range, although engine is prop- -Driven clutch spring broken or installed in -Replace spring;...
  • Page 158 CLUTCHING TROUBLESHOOTING Situation Probable Cause Remedy Belt slippage -Belt worn out -Replace belt. -Water ingestion -Inspect and seal PVT system. -Belt contaminated with oil or grease -Inspect and clean. Belt burnt, thin -Abuse (continued throttle application when -Caution operator to operate machine within guidelines. spots vehicle is stationary, excess load) -Dragging brake...
  • Page 159 FINAL DRIVE AWD Front Hub Exploded View ..Final Drive Torque Specifications ..AWD Operation Overview ... 7.3--7.4 AWD Front Hub Removal .

  • Page 160: Final Drive

    FINAL DRIVE AWD FRONT HUB EXPLODED VIEW Garter Spring Brake Disc Armature Plate Seal Detail Bearing (1.000″ I.D.) DETAIL A Spacer Bearing Race Front Hub Clutch Front Hub Clutch Bearing (1.000″ I.D.) Cotter Pin ¡ Castle Nut (Use new cotter pin) O-Ring Bearing Race Washer...

  • Page 161: Awd Operation Overview

    FINAL DRIVE WHEEL AND HUB TORQUE With the Polaris All Wheel Drive System activated (AWD selected), the machine operates as a 2 wheel TABLE drive vehicle until the rear wheels lose traction. If the rear wheels lose traction the front wheel rotational...
  • Page 162 FINAL DRIVE engagement offers an advantage over mechanical 3. Remove the two brake caliper attaching bolts. systems. When the AWD button is switched Off the CAUTION: Do not hang the caliper by the brake ATV is in 2 wheel drive. When AWD button is On All hose.

  • Page 163: Awd Front Hub Bearing Adjustment

    6. Reinstall hub cap. 7. Remove fill check plug and rotate hole to either 4:00 or 8:00 position. 8. Fill with Polaris Premium Demand Drive Hub Fluid or Type F Automatic Transmission Fluid until fluid trickles out. NOTE: Do not force the oil into the hub under pressure.

  • Page 164: Awd Hub Seal Replacement

    It is very important that the brake disc be free of any oil or solvents. 6. Reinstall the brake disc using genuine Polaris OEM bolts that have a pre-applied locking agent. Do not substitute bolts or use old ones.
  • Page 165 FINAL DRIVE MAGNETIC COIL REMOVAL 4. Press on the seal sleeve until even with the inner pole. See Page 7.17 for additional information. 1. Remove the front drive axle as described later in Once the seal sleeve is properly positioned, a this chapter.

  • Page 166: Awd Armature Plate Inspection

    FINAL DRIVE 6. Without removing the garter spring, inspect the replacement spring part number by referring to coils for consistency. If coils are distorted or the appropriate parts manual. uneven, cut the old spring with a side cutter to 8. Current electro-mechanical spring, remove it, and replace it.

  • Page 167: Awd Front Drive Axle Removal

    FINAL DRIVE cage. If the unit is driven with the armature plate out of position, it will cause roller clutch damage. AWD FRONT DRIVE AXLE REMOVAL 7. Remove cotter pin and nut. 8. Remove hub, bearings, hilliard assembly, and armature plate. 1.

  • Page 168: Awd Front Drive Axle Installation

    FINAL DRIVE 10. Using Roll Pin Remover (PN 2872608), remove disassembly or potential damage to the the roll pin at front housing. driveshaft joints. S Over-angling of joints beyond their Roller Pin Removal Tool (PN 2872608) capacity could result in boot or joint damage.
  • Page 169 FINAL DRIVE 2. Remove cotter pin and castle nut from A-arm ball 5. Remove clamps from rubber boot using the joint. proper boot clamp pliers. 3. Disconnect A-arm from ball joint using a tie rod fork. Retaining ring Pull shaft to remove from CV joint 6.
  • Page 170 FINAL DRIVE the boot kit. DO NOT use a substitute grease and DO NOT overfill or underfill the CV joint. CV Joint Grease - 30g (PN 1350046) 9. Slide the new clamp and boot (small end first) over the splined shaft, then slide (tap) the CV joint CV Boot Clamp Pliers: into the splines of the axle.

  • Page 171: Awd Front Drive Axle Exploded View

    FINAL DRIVE AWD FRONT DRIVE AXLE EXPLODED VIEW Front Drive Axle Components Boot Drive Axle CV Joint Assy Clamps Circlip Yoke U--Joint Assy Front Prop Shaft Components O-Ring Propshaft Assembly Prop Shaft Cross and Bearing Kit Yoke, Propshaft to Transmission Spring Pin Yoke, Front Gearcase 7.13...
  • Page 172 FINAL DRIVE AWD STRUT CASTING BEARING REPLACEMENT FRONT DRIVE AXLE SEAL NOTE FOR FRONT DRIVE REPLACEMENT AXLE AND FRONT HUB NOTE: The front axle bearings have a larger I.D. (1.0625″) than the hub bearings (1.000″). Be sure to install the bearings with the larger I.D. in the strut housing, and the bearings with the smaller I.D.

  • Page 173: Awd Front Prop Shaft Removal

    FINAL DRIVE Hub Seal Sleeve Replacement New front drive axle CV joint assemblies and drive axle assemblies have the seal sleeve installed from the factory. Seal Sleeve Not Unusual To See (Outer Two Wear Rings Magnet Pole) Inner Magnet Pole (Fixed) Coil Max.

  • Page 174: U-Joint Disassembly

    FINAL DRIVE U-JOINT DISASSEMBLY 4. Force U-joint cross to one side and lift out of inner yoke. CAUTION: Always wear eye protection. 1. Remove internal or external snap ring from all U-JOINT ASSEMBLY bearing caps. NOTE: If yoke or bearing is removed, cross bearing must be replaced.

  • Page 175: Awd Front Housing Removal

    FINAL DRIVE 3. Install snap ring to contain bearing cap just 3. Elevate support machine under installed. Repeat procedure for other side. footrest/frame area. CAUTION: Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.

  • Page 176: Awd Front Housing Assembly

    FINAL DRIVE 2. Remove bolts and output shaft cover. 6. Unscrew fill plug and remove pinion shaft assembly. Inspect pinion gear for chipped broken or missing teeth. NOTE: Pinion shaft assembly will not clear the fill plug unless it is backed out. AWD FRONT HOUSING ASSEMBLY 1.
  • Page 177 FRONT HOUSING INSTALLATION 1. To install housing, reverse removal procedure. Use new roll pins in drive shafts. 2. Add Polaris ATV Angle Drive Fluid to front housing. Check drain plug for proper torque. Fill Plug Cover Bolts Torque 14 ft. lbs. (19 Nm) 6.

  • Page 178: Awd Front Housing Exploded View

    FINAL DRIVE AWD Front Housing Exploded View Vent Bushing Seal Output Shaft Pinion Shaft Pinion Cover Bearing Retaining Ring O-Ring Shim Output Cover Bearing O-Ring Thrust Button Seal Shim Seal 7.20...

  • Page 179: Rear Axle Removal

    FINAL DRIVE CONCENTRIC SWINGARM REAR AXLE REMOVAL 1. Securely support rear of machine with rear wheels off the floor. Remove rear wheels. 2. Removing the cotter pin, hub nut, and washer, Pull off the left side hub. 6. Loosen the hex screw (A) to loosen the axle nut.. 3.
  • Page 180 FINAL DRIVE 11. Remove the O--rings from left side of the axle. Brake Disc 9. Remove the three bolts that secure the sprocket 12. Slide the axle out the right side of the axle guard (C) on the other side of the axle. housing.
  • Page 181 FINAL DRIVE should still be visible under the axle nut from an angle. Torque to 8- -10 ft.lbs. (11--14 Nm) 16--19 ft.lbs. NOTE: The chain maybe installed at this point or later in the procedure. 7. Torque the axle nut pinch bolt to 50 in.lbs. (6 Nm). 3.
  • Page 182 Rear Hub Nut 80 ft. lbs. (108 Nm) 15. Lubricate the axle housing through the grease fitting with Polaris All Season Grease (PN 2871423). 12. Apply Anti--Seize lube to the axle splines. Install the rear wheel hubs on both sides.
  • Page 183 FINAL DRIVE REAR HOUSING CONCENTRIC SWINGARM DISASSEMBLY/BEARING REAR HOUSING SERVICE INSTALLATION 1. Remove seals from housing. 1. Re--install the housing (A) into the swing arm mounts. Re--install the brake caliper mounting bracket (B) onto the housing. Seal Bearing Swing arm Seal Bearing Race 2.
  • Page 184 FINAL DRIVE CONCENTRIC SWINGARM REAR AXLE ASSY, EXPLODED VIEW 11 12 1 Ring, Retaining 1 Housing, Axle, Rear 1 Screw 1 Fitting, Lubrication 1 Nut, Axle 1 Link, Connector, 520 3 Nut, Nylok 1 Axle, Rear 1 Disc, Brake 1 Chain, 520 O-Ring 1 Hub, Brake Disc 6 Nut, Nylok 3 Screw...
  • Page 185 TRANSMISSION Torque Specifications ..... Transmission Removal / Installation ..Transmission Exploded View ....Transmission Disassembly .

  • Page 186: Torque Specifications

    TRANSMISSION TORQUE SPECIFICATIONS 2. Remove right side shield and auxiliary brake master cylinder and reservoir. 3. Remove PVT outer cover, both drive and driven Item Specification clutch, and inner PVT cover (refer to Clutch Chapter Transmission Case Bolts 12 Ft. Lbs. (16.5 Nm) Bell Crank Nut 12 Ft.

  • Page 187: Transmission Disassembly

    TRANSMISSION TRANSMISSION EXPLODED VIEW - 4X4 TRANSMISSION DISASSEMBLY - 4X4 1. Remove gear position switch. Tap with soft face hammer Gear Position Switch (3 places) 6. Remove snap ring from front drive input shaft. CAUTION: Switch damage will occur if not removed prior to disassembly.
  • Page 188 TRANSMISSION 7. Remove output shaft and gear assembly along with sprocket and chain, by tapping on shaft with a soft faced hammer, from the back side of the gear case. 10. Inspect shift fork surface for wear or damage. Replace if necessay. 8.
  • Page 189 TRANSMISSION 12. Inspect reverse shaft gear, sprocket, needle bearings and engagement dog for wear or damage. Replace if necessary. Reverse Shaft Assembly Reverse Shaft Engagement Dog Gear Needle Bearing E--Rings Sprocket 17. Remove front drive input shaft bearing retainer Needle Bearing plate.

  • Page 190: Transmission Reassembly

    TRANSMISSION 19. Mark orientation of bellcrank to the shift fork shaft. protect O-ring during assembly. 23. Clean all components in a parts washer and 20. Remove bellcrank. Use a small puller if inspect for wear. necessary. 24. Inspect engagement dogs of gears and replace if edges are rounded.
  • Page 191 3 steps to 18 ft. lbs. (25 Nm). 13. Install drain plug with a new sealing washer. Torque drain plug to 14 ft. lbs. (19 Nm). 14. Install transmission and add Polaris AGL Gearcase Lubricant (PN 2873602) in the recommended amount. Refer to Maintenance Chapter 2.

  • Page 192: Troubleshooting

    TRANSMISSION TROUBLESHOOTING CHECKLIST Check the following items when shifting difficulty is encountered. Idle speed adjustment Transmission oil type/quality Transmission torque stop adjustment Engine torque stop adjustment Drive belt deflection Loose fasteners on rod ends Loose fasteners on shifter Worn rod ends, clevis pins, or pivot arm bushings Linkage rod adjustment and rod end positioning...
  • Page 193 BRAKES Special Tools/Specifications/Torques ... Brake System Operation ....Brake System Service Notes .
  • Page 194 BRAKES SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2870975 Mity Vact Test Tool SPECIFICATIONS Front Brake Caliper Item Standard Service Limit .298 ± .0073″ (7.6mm ± .185 mm) Brake Pad Thickness .180″ (4.6mm) Brake Disc Thickness .150--.165” (3.81mm 4.191 mm) .140″ (3.556mm) Brake Disc Thickness Variance Between .002″...

  • Page 195: Hydraulic Brake System Operation

    When servicing Polaris ATV brake systems use only Polaris DOT 3 High Temperature Brake Fluid (PN 2870990). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws.

  • Page 196: Brake System Main Components

    NOTES cause if brake drag is evident. Make sure caliper moves freely on Polaris disc brake systems are light weight, low guide pins (where applicable). maintenance and perform well in the conditions ATVs Inspect caliper piston seals for routinely encounter.

  • Page 197: Hydraulic Caliper Bleeding

    BRAKES separated by seals. The hand brake system applies Brake Noise Troubleshooting hydraulic pressure to both front calipers and only the Possible Cause Remedy outer diameter of the rear caliper pistons. Dirt, dust, or im- Spray disc and pads auxiliary (foot) brake applies pressure to the inner bedded material with CRC Brake Kleent portion of the rear caliper pistons.
  • Page 198 Bleeder Screw Torque 25- -30 in.lbs. (2.80 - -3.40 Nm) Polaris DOT 3 Brake Fluid 9. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add (PN 2870990) fluid as necessary to maintain level in reservoir.
  • Page 199 12. Repeat Steps 7-10 for the remaining caliper(s). 13. Add Polaris Dot 3 Brake Fluid (PN 2870990) to MAX level inside reservoir. Cap is Even 5 in. lbs. (0.56 Nm)

  • Page 200: Master Cylinder Removal

    There are different brake master cylinders for the different Polaris ATV models. Refer to your parts manual or guide for the correct parts. The master cylinder is not serviceable and is replaced as a unit.

  • Page 201: Front Pad Removal

    3. Fill reservoir with DOT3 Brake Fluid (PN FRONT PAD REMOVAL 2870990). 1. Elevate and support front of machine. Polaris DOT 3 Brake Fluid CAUTION: (PN 2870990) Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine 4.

  • Page 202: Front Pad Installation

    5. Install the adjuster screw and turn clockwise until stationary pad contacts disc, then back off 1/2 FRONT PAD INSTALLATION turn (counterclockwise). 1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. 9.10...

  • Page 203: Brake Burnishing

    BRAKES 6. Verify fluid level in reservoir is up to MAX line Brake Disc Thickness inside reservoir and install reservoir cap. .150-.164″ (3.810-4.166 mm) Service Limit .140″ / 3.556 mm Master Cylinder Fluid Up to MAX line inside reservoir Brake Disc Thickness Variance Service Limit: .002″...

  • Page 204: Front Caliper Removal

    BRAKES 2. Remove bolts and disc. FRONT CALIPER 3. Clean mating surface of disc and hub. DISASSEMBLY 4. Install disc on hub. 5. Install new bolts and tighten to specified torque. 1. Remove brake pad adjuster screw. Front Brake Disc Mounting Bolt Torque 18 ft.

  • Page 205: Front Caliper Inspection

    BRAKES 4. Remove piston, dust seal and piston seal. 2. Inspect piston for nicks, scratches, wear or damage. Measure diameter and replace if 5. Clean the caliper body, piston, and retaining damaged or worn beyond service limit. bracket with brake cleaner or alcohol. NOTE: Be sure to clean seal grooves in caliper body.

  • Page 206: Front Caliper Installation

    BRAKES 2. Coat piston with clean Polaris DOT 3 Brake Fluid (C). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance. 3. Lubricate the mounting bracket pins with Polaris Premium All Season Grease, and install the 15 ft.
  • Page 207 BRAKES FRONT BRAKE CALIPER EXPLODED VIEW APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT APPLY POLARIS ALL PURPOSE GREASE 35--60 IN. LBS. (4--6.5 NM) 1. Caliper Mount 2. Brake Pads 3. Piston 4. Brake Caliper Body 5. Boot Seal 6. Pin Bushing Seal 7.
  • Page 208 BRAKES REAR BRAKE PAD REMOVAL 1. Remove the snap ring (B) from the bottom slide pin (A). 5. Clean the caliper with brake cleaner or alcohol. 6. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. 2.
  • Page 209 BRAKES REAR BRAKE PAD 5. Install the snap ring. INSTALLATION 30--35 ft.lbs. (41--48 Nm) 1. Insert new brake pads into the caliper. NOTE: If pads are greasy, dirty, oily, or fluid soaked DO NOT use the pads, use only new clean pads. 6.

  • Page 210: Rear Caliper Removal/Inspection

    BRAKES REAR CALIPER Caliper REMOVAL/INSPECTION 1. Clean caliper area before removal. 2. Remove hand brake (inner) and auxiliary brake (outer) lines. Place a container to catch brake fluid draining from brake lines. 5. Remove the anvil bolts and separate caliper halves and remove pistons with piston pliers.

  • Page 211: Rear Caliper Assembly

    BRAKES 9. Inspect caliper piston bore for scratches, severe corrosion, or galling and replace if necessary. Inspect 16--18 ft.lbs. (22--25 Nm) Caliper Anvil Bolt Torque: 10. Inspect surface of caliper piston for nicks, scratches, or damage and replace if necessary. 16- -18 ft.
  • Page 212 BRAKES 4. Install caliper and tighten mounting bolts, then REAR BRAKE DISC torque mounting bolts to 18 ft.lbs (25 Nm). INSPECTION 1. Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. 2. Use a 0-1″ micrometer and measure disc 18 ft.lbs.

  • Page 213: Rear Caliper Exploded View

    BRAKES REAR CALIPER EXPLODED VIEW APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT 1. Snap Ring 2. Outboard Anvil Body 3. Slide Pin Bushing 4. Brake Pad 5. Caliper Bracket 6. Dust Boot 7. Dust Boot 8. Pin Sleeve 9. Piston Ring 10.
  • Page 214 BRAKES AUXILIARY BRAKE Rear Brake Master Cylinder Removal / Install REMOVAL / INSTALL 1. If necessary, remove the rear brake line from the master cylinder. Use a suitable container to catch Brake Pedal Removal / Install the brake fluid. Dispose of brake fluid properly. 1.

  • Page 215: Troubleshooting

    BRAKES TROUBLESHOOTING Brakes Squeal S Dirty/contaminated friction pads S Improper alignment S Worn disc S Worn disc splines Poor Brake Performance S Air in system S Water in system (brake fluid contaminated) S Caliper/disc misaligned S Caliper dirty or damaged S Brake line damaged or lining ruptured S Worn disc and/or friction pads S Incorrectly adjusted lever...
  • Page 216 BRAKES NOTES 9.24...
  • Page 217 ELECTRICAL 240 Watt Alternator, Exploded View . . . 10.2 Special Tools and Electrical Notes ..10.3 Timing Check Procedure ... . 10.3 PDM Operation ....10.4-10.9 Hot Light Operation .
  • Page 218 ELECTRICAL COMPONENTS OF EH500PLE / 240 WATT ALTERNATOR NOTE: CDI boxes may look the same but have different internal circuitry. Be sure to always use the correct CDI box part number. Refer To Wiring Diagrams For Specified Stator Coil Resistance Resistor Ignition Coil...

  • Page 219: Electrical Service Notes

    ELECTRICAL SPECIAL TOOLS TIMING CHECK PROCEDURE PART NUMBER TOOL 1. The ignition timing check hole is in the starter DESCRIPTION recoil/magneto housing. Remove the check plug. PV- -43568 Fluket77 Digital NOTE: The ignition timing marks are stamped on the Multimeter outside of the flywheel.
  • Page 220 PDM Control Circuit The Power Distribution Module (PDM) integrates Regulator these electronic features found on Polaris ATVs; The rectifier converts the the output of the 3--phase Rectifier/regulator, Solid- -state circuit breaker alternator (COIL 1,2,3) and applies it to the battery output, Starter Lockout output and Engine and the PDM loads.
  • Page 221 ELECTRICAL condition then the regulator will remain off, as the thermistor. A thermistor fault will cause the engine hot minimum battery requirement will not be met. The indicator and FAN output to activate. regulator will not turn on unless there exists battery voltage in excess of the minimum battery voltage Accessory Power: requirement.
  • Page 222 ELECTRICAL Connector 1 Signal Name Description Pin # IPS = Intelligent Power Switch J1--A STARTER Starter output provides ground path when active. J1--B BRAKE Brake input for starter lockout. Active high. J1--C PDM enable input. Connected to BAT_PROT via ignition and run switches.
  • Page 223 ELECTRICAL PDM SPECIFICATIONS Characteristic Parameter Unit Note Operating Temperature --40 to +55 Ambient temperatures at which module should remain within specified limits Storage Temperature --50 to +85 Ambient temperatures which should have no adverse ef- fects on module operation Characteristic UNIT Note Battery Voltage...
  • Page 224 ELECTRICAL Characteristic UNIT Note STARTER Output Current Current capability of the STARTER output TRANS Neutral Voltage BRAKE On Input Voltage Voltage on BRAKE input to activate the STARTER output REVERSE POLARITY PROTECTION Battery Reverse Current Max reverse leakage current when connected in reverse Reverse Bias Voltage --55...
  • Page 225 ELECTRICAL Characteristic UNIT Note STARTER Output Current Current capability of the STARTER output TRANS Park Voltage mVdc Current capability of the output Neutral Voltage 1.73 2.11 2.48 BRAKE On Input Voltage Voltage on BRAKE input to activate the STARTER output REVERSE POLARITY PROTECTION Battery Reverse Current Max reverse leakage current when connected in...

  • Page 226: Fan Motor Current Draw

    ELECTRICAL FAN MOTOR CURRENT TEMPERATURE SENSOR DRAW (THERMISTOR) OPERATION / TEST A current draw test provides a good indication of fan motor condition. Worn or damaged fan motors will The thermistor relays a power signal to the ECM draw more current, which causes a reduction in blade depending on engine coolant temperature.

  • Page 227: Etc Operation Test

    ELECTRICAL ELECTRONIC THROTTLE ETC OPERATION TEST CONTROL (ETC) SWITCH Remove throttle block cover by carefully releasing all tabs around edge of cover. The Electronic Throttle Control (ETC) system is Place transmission in neutral and apply parking designed to stop the engine of an ATV in the event of brake.
  • Page 228 ELECTRICAL IGNITION SYSTEM NOTES: TROUBLESHOOTING No Spark, Weak, or Intermittent Spark GSpark plug gap incorrect GFouled spark plug GFaulty spark plug poor connection to high tension lead GRelated wiring loose, disconnected, shorted, or corroded GEngine Stop switch or ignition switch faulty GETC switch misadjusted or faulty GConnections wet, corroded...
  • Page 229 ELECTRICAL FLYWHEEL IDENTIFICATION Flywheel Identification Stamp Location The flywheel can be identified by the stamp mark in location A. Refer to “I.D.” location in chart below. Do not use the cast mark to determine flywheel application. Engine Application Type Cast Stamp Comment I.D.
  • Page 230 ELECTRICAL IGNITION SYSTEM TESTING FLOW CHART Whenever troubleshooting an electrical problem, 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.
  • Page 231 ELECTRICAL CRANKING OUTPUT TEST LIMITER SPECIFICATIONS WITH PEAK READING VOLTMETER Speed Limiter Module LR The following peak voltage tests will measure the ID Number amount of output directly from each component. A peak reading voltmeter should be used to perform the CDI output test.
  • Page 232 ELECTRICAL REVERSE LIMIT SYSTEM 10.16...
  • Page 233 ELECTRICAL NO REVERSE SPEED LIMIT (4X4) KEY SWITCH=ON THIS TEST REQUIRES A OFF-RUN SWITCH=RUN “KNOWN GOOD” REVERSE INDICATOR LAMP SET PARKING BRAKE GEARCASE=REVERSE 1. FAULTY BATTERY 2. FAULTY CIRCUITY BREAKER 3. FAULTY IGNITION KEY SWITCH FIND WHY REVERSE LAMP ON? 4.
  • Page 234 ELECTRICAL NO AWD (4X4) IGNITION=ON OFF-RUN SW.=RUN GEARCASE=FORWARD 1. FAULTY BATTERY 2. FAULTY CIRCUIT BREAKER 3. FAULTY IGNITION SWITCH AWD LAMP ON? 4. FAULTY OFF-RUN SWITCH FIND WHY 5. FAULTY WHEEL COIL? 6. WIRING/CONNECTIONS? 7. MECHANICAL AWD FAULT? MEASURE DC VOLTS BRN/WHT WIRE TO REVERSE SPEED LIMIT MODULE SCRAMBLER 500 4X4 GROUND AT LR...
  • Page 235 ELECTRICAL NO AWD (SCRAMBLER 4X4 CONT.) NO AWD SCRAMBLER CONTINUED FROM PREVIOUS PAGE MEASURE DC VOLTS RED/WHT WIRE TO REVERSE SPEED LIMIT MODULE SCRAMBLER 500 4X4 GROUND AT LR MODULE. 1. FAULTY BATTERY 2. FAULTY CIRCUIT BREAKER 3. FAULTY IGNITION SWITCH 12 VOLTS DC? 4.
  • Page 236 ELECTRICAL FRONT HUB ENGAGEMENT LIMITER (SCRAMBLER 4X4) THIS TEST REQUIRES A “KNOWN GOOD” AWD INDICATOR LAMP KEY SWITCH=ON OFF-RUN SWITCH=RUN SET PARKING BRAKE REVERSE SPEED LIMIT MODULE SCRAMBLER 500 4X4 GEARCASE=FORWARD AWD SWITCH=ON START ENGINE 1. FAULTY BATTERY 2. FAULTY CIRCUITY BREAKER 3.
  • Page 237 ELECTRICAL CHARGING SYSTEM TESTING Whenever charging system problems are suspected, proceed with the following system check. Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage. It Remove the battery and properly ser- should be 12.4 volts or more. Is it? vice.

  • Page 238: Alternator Output Test

    ELECTRICAL CURRENT DRAW - KEY OFF 6. Note RPM at which the battery starts to charge (ammeter indication is positive). CAUTION: Do not connect or disconnect the battery 7. With lights and other electrical load off, the “break even” point should occur at approximately 1500 cable or ammeter with the engine running.
  • Page 239 ELECTRICAL BATTERY IDENTIFICATION INITIAL BATTERY ACTIVATION NOTICE: It is important to identify what type of battery you have installed in your ATV. Different types WARNING of batteries require different service procedures. Proper servicing and upkeep of your battery is very important for maintaining long battery life.
  • Page 240 ELECTRICAL Battery Check: SEALED LOW MAINTENANCE 1. Check the date label on the side of the battery to BATTERY CHARGING calculate when to check voltage. The battery should be checked every 3 months. If battery voltage is 12.8 V or less, the battery may 2.

  • Page 241: Battery Testing

    ELECTRICAL SEALED LOW MAINTENANCE BATTERY - - OCV - OPEN Battery Location CIRCUIT VOLTAGE TEST Battery voltage should be checked with a digital multitester. Readings of 12.8 volts or less require further battery testing and charging. See charts and Load Test. NOTE:Lead-acid batteries should be kept at or near a full charge as possible.
  • Page 242 ELECTRICAL SEALED LOW MAINTENANCE CONVENTIONAL BATTERY BATTERY OFF- -SEASON ACTIVATION/ SERVICE STORAGE To ensure maximum service life and performance from a battery, perform the following steps. To prevent battery damage during extended periods NOTE: This section contains information for both of non-use, the following basic battery maintenance Conventional Lead--Acid batteries and Sealed Low items must be performed:...

  • Page 243: Conventional Battery Installation

    BATTERY TERMINALS/TERMINAL BOLTS Use Polaris corrosion resistant Nyogelt grease (PN 1. Disconnect holder strap and remove covers. 2871329) on battery bolts. See Battery Installation. 2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable.

  • Page 244: Conventional Battery Testing

    ELECTRICAL from frame and body to prevent contact with CONVENTIONAL BATTERY electrolyte. Avoid skin contact with electrolyte, as LOAD TEST severe burns could result. If electrolyte contacts the vehicle frame, corrosion will occur. CAUTION: To prevent shock or component 5. Reinstall the holder strap. damage, remove spark plug high tension leads and connect securely to engine ground before CONVENTIONAL BATTERY...
  • Page 245 ELECTRICAL discharges. The chart below indicates freezing points OPEN CIRCUIT VOLTAGE by specific gravity. State of Conventional charge Lead-/ Acid Electrolyte Freezing Points 100% 12.60V Specific Gravity Freezing Charged 12.40V of Electrolyte Point 75% Charged 12.10V 1.265 -75° F 50% Charged 11.90V 1.225 -35°...

  • Page 246: Headlight Adjustment

    ELECTRICAL HEADLIGHT ADJUSTMENT The headlight beam can be adjusted up and down. 1. Place the vehicle on a level surface with the headlight approximately 25’ (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

  • Page 247: Brake Light Switch

    ELECTRICAL BRAKE LIGHT SWITCH INDICATOR LAMP REPLACEMENT 1. Disconnect wire harness from switch. Located on bulk head under front cover. 1. Remove retaining nuts holding choke and key 2. Connect an ohmmeter across switch contacts. switch. Reading should be infinite (∞). 2.

  • Page 248: Starter System

    ELECTRICAL STARTER SYSTEM 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.

  • Page 249: Voltage Drop Test

    ELECTRICAL STARTER SYSTEM VOLTAGE DROP TEST TROUBLESHOOTING The Voltage Drop Test is used to test for bad connections. When performing the test, you are Starter Motor Does Not Turn testing the amount of voltage drop through the connection. A poor or corroded connection will GBattery discharged - low specific gravity appear as a high voltage reading.

  • Page 250: Starter Motor Disassembly

    ELECTRICAL STARTER MOTOR DISASSEMBLY NOTE:Use electrical contact cleaner to clean starter motor parts. Some solvents may leave a residue or damage internal parts and insulation. 3. Remove brush terminal end of housing while holding other two sections together. 1. Note the alignment marks on both ends of the starter motor casing.
  • Page 251 ELECTRICAL BRUSH 4. Inspect surface of commutator for wear or discoloration. See Steps 3-6 of armature testing INSPECTION/REPLACEMENT on Page 10.36. 5. Install a new carbon brush assembly in the brush housing. NOTE: Be sure that the terminal bolt insulating washer is properly seated in the Brush Set housing, and the tab on the brush plate engages the notch in the brush plate housing.

  • Page 252: Armature Testing

    ELECTRICAL ARMATURE TESTING STARTER ASSEMBLY 1. Remove armature from starter casing. Note order of shims on drive end for reassembly. 2. Inspect surface of commutator. Replace if excessively worn or damaged. 1. Place armature in field magnet casing. 2. Place shims on drive end of armature shaft with phenolic washer outermost on shaft.

  • Page 253: Starter Drive

    Make sure the end washer is positioned properly so that it will hold the lock ring Armature in its groove. Polaris Premium Starter Drive Grease (PN 2871460) Rubber Rings Washer O-ring...
  • Page 254 ELECTRICAL NOTES 10.38...
  • Page 255 ELECTRICAL WIRING DIAGRAM - - 2009 SCRAMBLER 500...
  • Page 256 ELECTRICAL WIRING DIAGRAM - - 2009 SCRAMBLER 500...

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