1998 Polaris Sportsman 400, 500, Xplorer 500 4×4 Service Repair Manual.pdf

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1. CONTENTS
QUICK REFERENCE DATA . . . . .... •...• . •.. .. .... . . ....•.IX
CHAPTERONE .
GENERALINFORMATION
Manualorganization
Notes, cautionsandwarnings
Safetyfirst
Cleaningparts
Handling gasoline s
afely
Servicehints
Torquespedfication s
Fasteners
Lubricants
Threadlocking compound
RTV gasketsealant
CHAPTERTWO .....
TROUBLESHOOTING
Operatingrequirements
Troubleshootinginstruments
Starting the engine
Starting difficulties
Engineisdifficulttostart
Enginestartingsystem
Charging system
Ignitionsystem
Electronicthrottlecontrol
....... 1
Expendablesupplies
Serialnumbers
Warningandinformationlabels
Basichandtools
Precisionmeasuringtools
Special tools
Fabricatingtools
Mechanic'stips
Bearingreplacement
Seals
Storage
.. 36
Fuelsystem
Engineoverheating
Engine
Enginenoises
Cylinder leakdowntest
P
owertrain
Steering
Frame noise
Brakes

2. CHAPTERTHREE . ........ ..• .•...
LUBRICATION,MAINTENANCEAND TUNE-UP
Pre-ridecheck list
Tiresandwheels
Battery
Battery electricalcable connectors
Periodiclubrication
CHAPTER FOUR .
ENGINETOPEND
Eng ine principles
Enginecooling
Engine lubrication
Servicingthe enginein theframe
Exha ust syst em
Cylin
derhead cover
Rocker
annassembly
CHAPTERFIVE..• .
ENGINELOWER END
Engine
Flywheelandstatorplate
Recoilstarte r
Crankcase
Crankshaft inspection
Balancershaft inspection
CHAPTERSIX •.. ..
FUELSYSTEM
Ca rburetor operation
Carburetor
Carburetorcleaningand inspection
Carburetor testsandadjustments
Throttlecablereplacement
CHAPTE RSEVEN.... . . . . .•
COOLINGSYSTEMS
Polarisvariabletransmission( PVT)
aircooling system
Engine
coolingsystem
Safetyprecautions
Hosesandhose clamps
Enginegaskets/seals
......53
Perio dicmaintenance
Unsc heduledinspection
and maint
enance
Enginetune-up
............94
Camshaft
Cylinde r head
Valvesandvalvecomponents
Cylinderblock
Pistonand pistonrings
Camsha ftchai n andsprockets
Break-inproc
edure
. ..137
Sha nend float measurement
andshimselect ion
Oilpumr
Oilsystem one-way chec kvalve
Break -inproc
edure
175
Stallingenrichment(choke) cable
Fue l tank
Fuelshutoff valve
Airfilter airbox
Fu~lpllmp
....198
Coo lingsystem inspection
Radiator
Coolingfan
Coolantpump
Therm ostat
Temperature sensors

3. CHAPTEREIGHT .
CLUTCH/DRIVEBELTSYSTEM
Driveunit
Drivepulley
Specialtools
Drivenpulley
Drivebelt
CHAPTERNINE.
TRANSMISSION
Transmission
Transmissioninspection
Shiftshafts
Frontoutputshaft
CHAPTERTEN.. . . . . .
FRONT DRIVESYSTEM
Fronthuband Hillardclutch
Front driveaxle,bootsandCV
(constantvelocity) joints
CHAPTER ELEVEN ..
ELECTRICALSYSTEM
Basicinformat ion
Negative batt eryterminal
Chargingsystem
Alternatorstator
Voltageregulator/rectificr
Capacitordischargeignition
Ignitioncoil
Ignitionstatorcoils
CHAPTERTWELVE .
FRONTSUSPENSION ANDSTEERING
Front wheel
Fronthub
Frontstrut cartridge andspring
Frontstrut/spindle
Control arm
CHAPTERTHIRTEEN.
REARSUSPENSION
Rearwheels
Tirechanging and tire repairs
Shockabsorber
Rearhubandbearingcarrier
Rearaxles
Upper controlarm
...........213
Drivepulley
Drivenpulley
Clutchouter and inner cover
(all models)
..249
Transmission gearcase oilseal
inspectionand replacement
Shiftselector linkage
.........290
Front driveshaft
Frontdrive unit
..... 303
Electric startingsystem
Starterdrive gears
Startersolenoid
Lighting system
Electricalcomponents
Switches
Wiringdiagrams
. 337
Handlebar
Tierods
Steering shaft
Tires andwheels
. 362
Lowercontrol arm
Upperand lowercontrol
arminspection
Stabilizerlinkage
Stabilizersupport

4. CHAPTERFOURTEEN .
BRAKES
Discbrakes
Front
brakepadreplacement
Frontcaliper
Output
shaftbrakepad replacement
(1996-1997models)
Outputshallbrake caliper
(]
996-1997mode ls)
Output
shallbrake padrepl acement
(I998- onmodels)
Outputshaft brakecaliper
(I998-onmodels)
CHAPTERFIFTEEN
BODY
Seat
Frontrackandgrille
Sidep anels
Frontfender
Front bumper (modelsso equipped )
SUPPLEMENT .
2001-2003SERVICEINFORMATION
Startingtheengine
Ignition system
Periodicmaintena nce
Engine tUIlC-Up
Cylinderblock
Pistonandpistonrings
Engine
Flywheelandstator plate
C
arburetor(Sportsman500H.G.models)
Cleaningandinspection
Carburetortestsand adjustments
Drivebelt
Driven pulley(200 3modelsbuilt
after 07/08102)
INDEX .
WIRING DIAGRAMS .
.......382
Frontmaster cylinder
Rearmaster cylinder
Brakehosereplacement
Rearbrakepedal
Rembrakelever
(1996-1997 Swedenmodels)
Footbrake
(199 8-onSweden models)
Brakedisc
Bleedingthesystem
..........425
Radiator guard
Rearrack
Rearfender
Footv..'ells
Rearbumper(mode lssoequipped)
...........437
Transmission
Lighting system
Electricalcomponents
Steering
shall(2002-on models)
Rear huband bearingcarrier(2003models)
Rear
brakepadrep lacement
(2003 m
odels)
Rear calipers (200 3models)
Frontmastercylinder
Rear mast ercylinder(2003models)
Rearbrakedisc(200 3mode ls)
Brakehose replacemen t(2003models)
.470
.476

5. QUICKREFERENCEDATA
ATVINFORMATION
MODEL: YEAR: _
VIN NUMBER:, _
ENGINESERIALNUMBER: _
CARBURETOR SERIALNUMBEROR 1
.0.MARK: _
TIREINFLATIONPRESSURE(COLD)'
Model kPa PSI
Frontwheels 34.5 5
Rear
wheels 34.5 5
"Tlre
pressurefororiginalequipmenttires.AftermarkettiresmayrequiredifferentInflationpressure.
RECOMMENDED LUBRICANTS, FLUIDSANDCAPACITIES
Item
Engine011
Transmissionall
Front gear case
Fronthubs
Brakefluid
Coolant
Grease
Item
Engineall
Transmissionall
Frontgear case (allyears)
Fronthubs
Coolant
Lubricantorfluidtype
PolarisPremium4Synthetic10W/4Q
or10W/40motorall
Polarissyntheticgearcase011(partNo.2871478)
Polarisfrontgearcaselube(partNo.2871653),or
API GL5 80·90
gearlube
Polarisdemanddrivehubfluid(partNo. 2871654),
orATFTypeF.
DOT 3
brakefluid
50:50mixtureethyleneglycol·based
coolantcompoundedforaluminumradiators
andengines
Polarisallseasongrease,orequivalent
RECOMMENDED CAPACITIES
Quantity
1.89L (2 U.S. qts.)
946.3 cc (32 U.S. oz.}
96 cc (3.25U.S.oz.)
75 cc (2.5 U.S. oz.)
Approx.2.16L (2.25U.S. qts.)
IX

6. MAINTENANCEANDTUNE·UP TORQ UE SPECIFICATIONS
Item N'm in...lb.
Crankcase oil drain plug 19
Cylinderhead coverscrews 8.2 72
Front gear case drain plug
9.4 83
Handlebarupperholderbolts 13·17 115-150
Oil
tankdrainplug 19
011tank screenand fitting 20
Valve adjuster locknuts 6-7 53-62
Whee/lugnuts
Front 21
Rear 21
MAINTENANC EANDTUNE·UPSPEC IF IC AT IO NS
ft.·lb.
14
14
15
15
15
Item
Disc brake pad thickness wear limit
2003Sportsman500 & 500H.O.
Rear brake
All other models and years
Frontand rear brakes
Valveclearance(cold)
Intakeand exhaust
Sparkplug
400cc
Heatr ange
Gap
500 ee
Heat range
1996-1997
1998-2001
2002
·on
Gap
1996 ·1998
1999-2000
2001
·on
Idlespeed
1996-1988 ,2001-on
1997·2000
Carburetorpilotair screw (34 mm)
1996
1997
·1998
1999-2000
2001
-on(400ee)
Carburetorpilot air screw (40 mm )
2001
2002-on
Item
Headlights
Grillmountedlights
1996
1997
1998-on
Taillight
Brakelight
Indicatorlights
1996
1997-on
Specification
4.6mm(0.180In.)
3.8 1 mm (0.150 In. )
0.15mm (0.006In.)
NGK BKR 5E
0.9mm (0.036in.)
NGKBKR5ES
NGK
BKR5E
NGK
BKR6E
0.6-0.7 mm (0.024-0.028in.
0.7mm(0.028In .)
0.9 mm (0.036 in .)
1100-1300rpm
1000-1400
rpm
1 1/2turnsout
2turnsout
25/8turnsout
23/4turnsout
21/2turns out
2turnsout
REPLACE MENTBULBS
Specificati on
12volt ,6 0/60wattHalogen
12 vo lt,37.5 watt(2)
12 volt,35 watt(2)
12 volt,27 watt
12volt,
8.26watt
12 volt, 6.9 watt
12volt,1.25 watt
12volt,l.0watt
x

7. CHAPTERONE
GENERALINFORMATION
Thisdetailed. comprehensive manualcoversthe
PolarisSportsman 400,500andXplorer 500 4 x4
from
I996-on.
Keepthisbookhandyinthetoolbox.Readin g
and usingitwillhelpto betterunderstand howthe
vehicleruns,lowerrepaircosts andgenerallyim­
provepersonal satisfactionwiththevehicle.
Thefollowing tables areincludedat the end of
this chapter:
Tahle1 listsmodelyearandnumber.
Tahle2 lists general dimensions .
Table3 listsvehicleweight(dry).
Table 4listsdecimaland metric equivalents.
Table5 lists generaltorquespecifications.
Table6 lists conversion tables.
Table7 liststechnicalabbreviations.
Table8listsmetrictap anddrillsizes.
Tables
1-8areattheendofthis chapter.
MANUALORGANIZATlO:'ll
All dimensionsand capacitiesare expresse din
Englishunits familiarto U.S. mechanics.aswellas
inmetricuni ts.
Thischapter provides general information and
discusses equipment and toolsusefulboth for pre­
ventivemaintenanceandtroubleshooting.
Chapter Twoprovides methodsandsuggestions
forthequick andaccuratediagnosisandrepair of
problems.Troubles hooting proceduresdiscusstyp-

8. 2
icalsymptomsandlogicalmethodstopinpoint the
t
rouble.
Chap
terThreeexplainsall perio diclubrication
and routinemaint enancenecessary to
keepthevehi­
clefunningwel l. ChapterThreealsoincl udesrec­
ommen ded
tUIlC-Upprocedu res,eli minatingthe
need toconstantlyconsultchaptersonthevarious
assemblies.
S
ubsequentchaptersdescribespecificsystems
suchas
theengine, clutch/drivebeltsystem,trans­
mission,exhaust,cooling, suspensionand brakes.
Eachchapterprovid esdisass embly,repairand as­
sem blyproceduresin asimplestep-
by-step form.
Ifarepairisimpracticalfor a homeme chanic.itis
soindicated. Itisusuallyfaster
amiless expensive
totake suchrepairstoa dealeror competent repair
shop.Specifications concerningaparticul ar system
arcincludedat the end ofthe appro priatechapter.
So
meoftheproceduresin this manualspec ify
s
pecialtools.Inmostcases,thetoolisillustrated ei­
ther
inactual use or alone.Well-equi ppedmechan­
ic smayfind they cansubstitutesim ilar tools
already on handor can fabricatethei rown.
NOTES,CAUTIONSANDWARNINGS
ThetermsNOTE, CA UT IO N and WARNING
havespecific
meaningsinthismanual.A NOTE
providesadd itiona linformationto
make a step or
procedureeasieror clearer.DisregardingaNOTE
couldcauseinconvenience, but wouldnot cause
equ
ipmentdamageorpersonal injury.
A
CAUTIONemphasize,
areaswhere equipme nt
da
magecouldresult.Di sregarding
aCAUT ION
could
causepermanent mechanica l damage ;hO\\I­
ever, personalinju ryisunlikely.
AWARNING emphasi ze sareaswherepe
rsonal
injuryoreven death
couldresult from negligence.
Mechanicaldamagemay also
occur.WARNING S
arefabetakenseriously. Insomecases ,seriousin­jut)'ordeathhas resultedfromdisregardingsimilar
warnings.
SA
rETYFIRST
Professional mechanicscanwo rk foryears and
neversustain aserio us injury.I fa fewrules ofcom­
monsenseandsafe tyarc observed.manysafehours
canbeenjoyedserv ic ing the ATY. Ignoringthese
CHAPTERONE
rules caninj ureso meonewor kingon the vehicle.or
dam agethe ATV.
I.Never lisegasoline or
anytypeoflowflashpoint
solve nt to cleanparts,SecCleanin g Parts andHan­
dlingGasoline Safety
in thischapterfor additional
i
nformat iononparts cleaning,gasolineusc and
safety.
NOTE
Theflashpointisthelowesttempera­
lureatwhichthe vaporsfromaco m ­
bustibleli quidwillign itewhenin
o
pen
ail:Alowjlashpointsolve ntwill
igniteat alowertemperaturethana
higlzjlashpointsolvent.
2.Never
smo keorusc a to rch in the vici nityof
flammableliquidsinope ncontain
ers,suc h as gaso­
lineor cleaningsolve nt.
3.lfwcldingor bra zin g
isrequired onthevehicle.
removethefuelrank,c
arburetor,andfront andrear
shoc ks to
asafe dist anceatleast50 feet (15m)
awa y.
4.Use thepropersizedwrenc hesto avoiddamage
tofasteners.
5.Whenlooseninga tightorstuck nut,be gui de d
by wha twould h
appenifthe wrenchslips.
6.Whe n replacing
afa sten er,mak e su re to uscone
with the same measu rem
ents andstreng th asthe old
one. Inco rrect or mism atch ed fastenerscan resultin
da
magetothe vehi cle
andpossibl epersonal inj ury.
Beware
offastene r kitsthat are filled withchea p
and p
oorlymad enuts.bolt s, washe rsandcotter
pins.R
eferto
Faste nersinthischapt erfor add i­
tion al
inform ation.
7.Keepallhandand powertool sin goodcondition.
Wipegreas y
andoilytoolsafter usingthe m.Dirty
toolsarcdiffi c ult to hold
andcancauseinjury.Re­
placeorrepair worn ordamagedtools.
8.Keepthe workareaclean anduncluttered.
9.
Wearsafetyg ogg lcsduringall operationsin­
volving
drilling, grind ing. theuseofa cold chisel,
u
sing che mica ls,
clea ningparts,whenu singco m­
pressedairoranytimethesa fe tyof eyesisin­
volved.
10.
Make su re to wear the correcttyp eofclothes
forthe
job. Longhairshould betied up orcovered
witha capsothaiitcanno t be caug ht
bya piece of
mo ving equipme nt or tool.

9. GENERALINFORMATION
11. Keepanapprovedfireextinguisher nearby.Be
sureit is rated fur gasoline(ClassB)andelectrical
(Class
C)fires.
12. When dryingbearings orotherrotat ing paris
withcompressedair, neverallowthe airjet to rotate
thebearing orpari.Theair jetiscapab le ofrotating
them at speeds
ta rin excessofthosefor whichthey
were designed .The bearin gorrotatingpart isvery
likely todisintegrate andcauseserious injuryand
damage.Topreventbearingdamagewhen using
compressedair,hold theinnerbearingrace byhand.
WARNING
Theimproper
useofcompressed air is
velJ'dangerous.Usingcompressed
airto
tlUSIoffclothes, theATVor
workbench
cancausejly ingparticles
to be blown into eyesorskill.Never
direct or blow compress
edair in/a
skinor through any bodyopening (in­
cluding cuts) asthiscancause
severe
injury ordeath.Compressedair must
beused care /idly; never allowchil­
drentoliseor playwithall)'com­
pressedair equipment orhoses.
13. Never work onthe upperpart ofthevehicle
whilesomeone is working underneath
it.
14.Whenputtingthe vehicle on astand,make sure
thevehicleissecurebeforewalking awayfrom
it.
15.Nevercarry sharptoolsin clothingpockets.
16. Thereis alwaysa right andwrong wayto use
tools.Learn tousethemtherightway.
17.Do notstartandrun theATV inan enclosed
area,The
exhaust gasesconta incarbonmonox ide,a
colorless,odorless,poisonousgas.Carbon monox­
idelevelsbuildquicklyin asmall closedareaand
cancauseunconsciousnessand death in a short
time.
When
itisnecessaryto startand runthevehi­
cle duringa service procedur e,alwaysdoso out­
side,orin
aservice
areaequip pedwithaventilating
system.
CLEANINGPARTS
Cleaning
partsisoneofthemoretediousanddif­
ficultservicejobs
performedinthehome garage.
Whilethereareannmber
ofchemicalcleaners
and
solvents available for homeandshoplise,most arc
poisonousandextremelyflammable. To prevent
chemicaloverexposure, vapor buildup,tireandsc-
3
riousinjury.obse rveallmanufact urer 'sdirect ions
andwarningswhilenotin gthefollowing,
I.Readtheentireproductlabel befor eusingthe
chemical.Observetheprecautionsandwarningson
thelabel.Alwaysknowwhat type
ofchem icalisbe­
ing used.
2.If thechemicalproduct mustbemixed,measure
theproperamountaccording tothedirection s.
3.Alwaysprovidesufficientventilationwhen
workingwithsolvents or otherchemicals.If a
chemicalcan be sme lled,thereis some vapor in the
air.Thestrongerthe smell,
thestrongerthe vapor
concentration.
4.If a prod uctislisted as combustible, flammable
or an extremelyflammable
Iiquid, thedangeroffire
increasesasthevaporcollects and buildsup in the
shop.
5.lf aprodu ctislisted asapoison,thevaporispoi­
sonous as
wellasthe liquid.
o.Topreventskinexposure, wearprotective
gloveswhencleaningparts. Selectapair ofchemi­
cal-resistan t glovessuitablefor the type ofcherni­
cals thatwillbeused. Replace the gloveswhcnthey
becomethin,damaged,change
COIOf, orswell.
7.Wear safety goggles whenusing chemicalsand
cleaning parts.
8.Do notlisemorethanone typeof cleaningsol­
vent at
alime.
9.If
apanmustbeheated toremove abearing,
cleanitthoroughlytoremoveall oil, greaseand
cleaner residue.Thenwashwithsoapywater and
rinsewithclearwater,
10. Weararespirator if the instruction label saysto
doso.
II.Keepchemicalproductsout
ofreachofchil­
drenand pets.
12.Topreventsparks, usc
anylonbristlebrush
when clea ningparis.
13.Whenusingacommerc ialpariswasher,read
andfollowthe manufacturer 'sinstructions
lo rse­
lecting thetypeofsolventtousc.Parts washers
mustbe equippedwitha fusiblelink designedto
melt anddrop thecoverin theevent
offire.
14.Washbothhandsand arms thoroughlyafter
cleaningparts,
HANDLINGGASOLINE
SAFELY
Gasoline, avolatile flammableliquid,isone of
themost dangerou sitemsin theshop, However,be-
a

10. cause gasolineis used so often, many peopleforget
that itisa dangerousproduct.Gasolineshould be
used only as fuel for internal-combustion engines.
Neverusc
gasoline to
cleanparts,tools or to wash
hands.When workingonanATV.motorcycleor
any othertype
ofgasolineengine.gasoline willal­
waysbepresentin tbe fuel tank, fuelline andcarbu­
retor.Toavoid a disa strous accident whenw orking
aroundgasolineor on the fuelsystem, carefullyob­
serve the following
precautions:
I.
Neveruscgasolineto cleanparts.SeeCleaning
Parts in thischapterforadditionalinformation on
panscleaningandsafety.
2.Whenworkingon thefuelsystem,work outside
orin a well-ventilatedarea.
3.Do not add fuel tothefueltankorservice thefuel
systemwhilethe ATVisin thevicinityof open
flames, sparksorwheresomeoneissmoking.Gaso­
linevaporsarcactuallymoredangerousthanliquid
gasoline.Becausethesevapors are heavier thanair.
theycollectin lowareasandareeasilyignited.
4.Allowtheengineto
coolcompletely before
workingon
anyfuelsystem component.
5.Whendraining thecarburetor,catchthegasoline
inaplasticcontainerand thenpour it intoa
safety-approved
gas can.
6.Donot store gasolineinany type ofglass con­
tainer. If theglassshoold break.aserious explosion
or fire could occu r.
7.Wipe upspilled gasolineimmediatelywith dry
rags.Storethe ragsinametalcontainerwith alid
ontil theycan beproperlydisposed of. or put them
outsideina safeplacetodry.
8.Do
notpourwater onto a gasoline tire. Water
spreadsthe lire andmakesit more difficult to put
oot. UseaClassB. BC.or AIlCfireextinguisherto
smotherthe
namesand put the fireout.
9.Alwaystum theengine
offbeforerefuelin g.Usc
awide-mouthfunnelto
preventspillinggasoline
onto the engine. exhaustpipe or
muffler.Do not
overfill the fuel
tank.Leaveanairspace atthetopof
the fue ltank topreventfue lfrom spi lling out when
installing thecap.
10. AlwaysrefueltheATV while it isparkedout­
sideand
awayfromallopen flames andsparks.
II.WhentransportingtheATV inanothervehi cle.
keepituprightwiththefuelvalveturnedoiT.
12.Donotperformasparktest(asdescribedin
ChapterTwo) ifthereis anygasolineleakingfrom
the
fueltank,fuelline or carburetor.
CIIAI'TER
O~E
FRONT
REAR
SERVICEHINTS
~..Iostoftheservice p rocedures coveredare
straightforward andcan beperformedby any one
reasonablyhandywithtools. Itissuggested. how­
ever. that thepersonalcapabilitiesbe carefully eon ­
sidercd
beforeattemptingany operation involving
major disassembly oftheengine.
Taketime and do the jobright. Do not forgetthat
anewlyrebuiltenginemust bebroken inthesame
wayasa new one. Referto the
EngineBreak-Inpro­
ccdurelistedinChapterFourandChapterFive.
J.Front,asused in thismanual,referstothefront
of the vehicle; the frontofanycomponent istheend
closesttothefrontof thevehicle.Theleft and right
sidesreferto thepositionafthepartsasviewedbya
ridersitting 011theseatracingforward.Forexam­
ple,the throttlecontrol ison therightside. These
rulesaresimple. butconfusioncancausea majorin­
convenienceduring service. SecFigure 1.
2.Wheneverservicinganengineorsuspension
component,secure thevehicle ina safe manner.
3.Tag allsimilar internal partsforlocation and
markallmatingpartsfo rposition.Record number

11. GENERALINFO RM AnON
andthickness ofany shimsas they are removed.
Smallparts suchasboltscanbeidenti fiedbyplac­
ingthemin plastic sandwichbags(Figu r e 2).Seal
andlabelthem withmaskin g tape.
4.Tagdisconnectedwiresandcon nectors with
maskingtapeandamarkin gpen.Again,donot rely
onmemory alone.
5.Protectfinishedsurfacesfromphysicaldamage
orcorrosion.Keepgasolineandotherchemicals off
pain ted surfaces.
6.Use penetratingoil on frozen ortightbolts,then
strike the bolt head afew times witha hammerand
punch(usea screwdriveronscrews).Avoid using
heatwherepossible, asitcanwarp,meltor affect
thetemper ofparts.Heat alsoruinsfinishes, espe­
ciallypaintandplastics.
7. Whena partisa press fitor requiresaspecial
toolto remove it,the necessary informat ionor type
oftool iscalledoutinthe text.Otherw ise, ifa part is
difficult toremove orinstall,lind out whybefore
proceeding.
S.To preventsmall obj ectsandabrasivedust from
fallinginto theengine,coverallopenings after ex­
posingthem.
9.Read each proced ure comp lete lywhile looking
atthe actualpartsbefore startinga job.Makesure
theprocedu ral stepsarefullyunderstood,the nfol­
lowthe procedurestep by step.
10.Recommendationsareoccasionally madetore­
ferservice ormaintenanceto a Polarisdealershipor
a specialistin
aparticularfield.Inthesecases,the
work
willbedonemorequickly andeconomica lly
thanbythehome mechanic.
11.In procedural
steps,theterm replace meansto
discardadefective part andreplace
itwithanew or
rebuiltunit.
Overhaulmeansto remove, disassem-
5
ble,inspect,measure, repair and/orreplacepartsas
required.
12. Someoperations require theusc ofa hydraulic
press. Ifapressis not available,it is wisertohave
theseoperatio ns pe rformedbyashopequippedfor
such work, rather than totryto do the jobyourself
withmakeshiftequipmentthat maydamage the
ma­
chine.
13.Repairsgomuchfa ster andeasierifthe vehi­
cleisclean beforestartingonthejob.Thereare
manyspecial cleanersonthemarket, like Bel-Ray
Degrcascr,for washingtheengineandrelated
parts.Followthe manufact
urer'sdirectionson the
containerfor thebestresults.Cleanalloilyor
greasyparts withcleaningsolventas theyarere­
moved.
WARNING
Never
usegasoline tocleanpartsor
tools.11presentsallextremefirehaz­
ani.Besure 10workina
well-ventilatedarea when using
cleaningsolvent. Keep
afireextin­
guisher ratedforgasoline
firesnear
byinany
case.
CAUTION
If acarwashisusedto clean tileArv,
do1I0tdirecttirehigh-pressurewater
hoseatsteering hearings.carburetor
hoses, suspensioncomponents,wheel
bearings,or electrical components.
The waterwtllflusbgrease outofthe
bearingsordamagetheseals.
14.Muchofthelabor chargesfor repairsmadeby
dealershipsareforthetimeinvolved during there­
moval,disass embly, assembly,andreinstallation of
otherpartsin orderto reachthe defectivepart.
Whenposs ible, perform thepreliminaryoperations
and take thedefectiveunit tothedealer forrepairat
considerable savings.
15. Whenspecialtoolsarerequired,makear­
rangcmcntsto getthembeforestarting on thejob.
Itisfrustratingandtime-consuming to getpartly
intoajoband the nbeunable to completeit. When
specialtoolsare required,they willbe described
(includingpartnumber) atthebeginning ofa pro­
cedure.
16. Makediagramswhereversimilar-appearing
partsarcfound.For instance,crankcaseboltsarc
of­
ten not thesame length.Do not relyonmemory

12. 6
aloneto replacepartsin theirproperlocation.There
isalso
thepossibilityofbeing side trackedandnot
ableto return to workfor days or
evenweeks, dur­
ing
whic htimethe carefullylaidoutpartsmaybe­
comedisturbed.
17.Whenassemblingparts, makesure allshims
and washersarereinstalledexac tly astheycam e
out.
18.When everarotatingpartcontactsa stationary
part,look for a shimor wash er. Uscnew gas kets
if
thereis anydoubtaboutthe conditionof the old
ones.
Athincoating ofoilon n on-pressuretype gas ­
ketsmayhelpthem scalmorceffe ctive ly.
19.
Some componentsareheldinpl acewith
se lf-loc kingnuts.
Thelockingability ofthesenuts
islessenedevery time theyareinstalledor r
emoved .
Itisrecommendedthat theybereplaced every time
they areremoved.
20.Useco ldheavy greas e toholdsma ll parts in
place
ifthcytend to fall outduringassembly.How­
ever,keepgrease and oilaway fromelectrical and
brake components.
TORQUE SPECIFICAT IONS
Thematerialsusedinthe manufacture ofthePo­
larismaybe subj ectedtoun evenstressesifthefas­
tenersthatholdthesub-assembliesarenotinstall ed
andtightenedcorrectly.Looseormissing fasteners
can ca use thecylinder headto
warp. crankcase
leaks,andprematurebearing and seal failureand
suspension failurefromloose ormissingfa steners.
Therefore, usc an accuratetorquewrench(de­
scribed in thischapter) tog
etherwiththetorqu e
specifications listed attheend
ofmost chapters.
Torquespecifications throu
ghout thismanu al
nrc
given inNewton-mete rs (Nsm). foot-po unds
(f't.-lb.)and, w
here applicable, in inch-pounds
(in.-Ib.).
Existin gtorque wrenchescalibrated in meterki­
lograms can beused.
Movethe deci mal point one
placeto theright;for example, 3.5mkg
=35Nsm.
Theexact mathematicalconversion is 3.5mkg =
34.3Nsm.
To math ematicallyconvertfoot-po unds toNew­
tonmetersmultiply the foot
pounds spec ificationby
1.3558to achievea
Nsrnequiva le nt.For example
150ft.-lb. x1.3558
=203Nsrn.
RefertoTable 5for generaltorque spec ificati ons
forvarioussizescrews, boltsand nutsnotlisted in
CHA PT ER ONE
theresp ective chaptertables . To uscthetable,first
det
erminethe sizeofthe boltor nut. Useavern ier
caliper and
measurethe insid edi mension of the
threads ofthenul
(F igur e3)andacrossthe threads
for abolt
(Figure 4).
FAST ENERS
Themat erialsand design s ofthevariousfasteners
usedon the Polarisare
eachdesigned fe r a specific
purpose.Fastene rdesign de tennines:thetypeo ftoo l
requ iredtoworkwith thefastener. Faste ner mate­
rialis
carefu llyselec ted to decrease the possibility
of physical failure.
Nuts,bolts
andscrewsaremanufacturedina
wide range ofthreadpattern s. Tojoinanutand
bolt,thediameter ofthe bolt andthe diam eter of
theholein thenut must bethe same. Itisjust asim­
portantthat thethr eadson bothbeproperly
matched.

13. GENERALINFORMATION
Grade marking
Thebestway totellif two fasteners'threads
matchisto turnthe nut on the bolt(or theboltinto
the threadedholein a piece
ofequipment)with fin­
gers only.
Besure both piecesareclean.If excessive
force is required,checkthe threadcondition oneach
fastener.If thethreadcondi tionisgoodbut thefas­
tenersjam,thethread s arenot compatible. Athread
pitchgaugecan beused to determi ne pitch.Polaris
vehicles arcmanufacturedwith ISO(International
OrganizationforStandardization) metric aswellas
Americanfasteners. Thethreadsarecutdifferent ly
thanthose
ofAmericanfasteners.Allengine
fasten­
ers aremetricthreadswhiletheframe components
aresecuredwithAmerica n threads
Most threads are cutso that the fasten ermustbe
turnedclockwise to tighten
itThesearccalled
right-handthreads.Somefastenershaveleft-hand
threads;theymustbe turned
counterclockwiseto be
tightened.Left-handthreads areusedinlocat ions
wherenormalrotation
ofthe equipmentwouldtend
toloosen a right-handthreadedfastener.
ISO
MetricScrewThre ads
(Bolls,Nu tsandScrews)
ISO(InternationalOrganizationforStanda rdiza­
tion)metri cthreads
comeinthreestanda rdthread
sizes:coarse,fine and constantpitch. TheISO
coarse pitch isusedforalmost all commonfastener
applications. The finepitchthreadisusedoncertain
precisiontoolsandinstruments.Theconstantpitch
threadis
usedmainly onmachineparts
andnotfor
fasteners.The constant pitchthread,however,is
usedonall metric threadsparkplugs.
Metric screwsand bolts are
classifie dbylen gth
(L,
Figure5),nominaldi ameter(D) and distance
b
etweenthread crests (T).Thenumbers 8x
7
1.25-130identifies atypicalbolt.whichwouldin­
dicate thatthe bolt hasa nomin aldiametero
f8mm,
thedistan cebetweenthread crests is1.25
111mand
boltlength is
130mm.
1I;·IRNING
Donotinstallscreu-'sor boltswitha
lowerstrengthgradeclassification
thaninstalledoriginallyby themanu­
facturer.Doingsomaycaliseengine
orequipmentfailureand possible in­
jury.
Themeasurementacro sstwo fl atsontheheadof
thebolt indicatestheproperwrench size touse.Flg­
nrc4
ShO\\o'5howtodetermineboltdiameter.When
buyinga boll fromadealer or parts store, itisim­
portantto know howto spec ify bolt length .Thecor­
rect way
10measurebolt lengthisbymeasuringthe
len gth startingfromundernea ththe boltheadtothe
end
ofthe bolt.Alwaysmeasure boltlengthin this
mann erto avoidbuy ing boltsthat are
ofthe wrong
length.
MachineScrews
There aremanydiff erenttypesofmachin e
screws.The screw heads arc alsodesignedto pro­
trude above themetal(round) orslightly rece ssedin
the metal(flat).SeeF
igure6.
Nuts
Nutsare manu facturedinavariety of typesand
sizes. Most arehexagonal(6-sided)andfit onbolts,
screws andstudswith thesamediamete r and
pitch,
The co mmon nutisgenerally usedwith a
lock wa
sher. Self-locking nutshave anyloninsert
thatpreventsthe
nutfrom loosenin g;nolockwasher
isrequi red.Wingnutsaredesignedfor fastremoval
byhand.Wingnuts are usedforconvenience in
non-critica llocations.
Toindicatethe size ofametricnut.manufac turers
speci fythediameter oftheopening and the thread
pitch.Thisis sim ilartobolt spec ifications. but with­
out the length dimension.Themeasurement across
twoflats on thenut indicatestheproper wrenchsize
to
beused.

14. 8
MACHINESCREWS
CHAPTERONE
Hex Flat Oval Fillister Round
Self-LockingFasteners
Severaltypesofbolts,scr
ewsand nutsincorpo­
rateasystem thatdevelopsinterference betweenthe
bolt,screw, and nut orlappedholethreads. Interfer­
enceisachievedin variousways:bydis torting
threads,coatingt hreadswith dryadhesive ornylon,
disto
rtingthe topofanall-metalnut, usinga nylon
inse
rtin thece nterorat the topofanut.
Self-lockingfasteners off ergrea ter holding
strength and
bettervibrationresistance.The
self-locking
fasteners usedon the Polaris ATV can­
notbe
reused.Others,likethenyloninsert nut,form
aninitiallocking condition whenLitenutisfirstin­
stalled;the nylonforms close ly 10the boltthread
pattern,thus reducing anytendencyfor the nut to
loosen.Alwaysdiscard
andreplaceself
Clocking
fasteners after removal.
Washers
Therearc two basictypes of wash ers:Ilatwas h­
ersandlockwashers.Flatwashers are simplediscs
withaholeto fita screw or bolt. Lockwashers are
designedtopreventa fastener fromworkingloose
dueto vibration.expansion andcontraction.
\Vashers canbe
usedinthefollowingfunctions:
I.As spacers.
2.Topreventgalling ordamage ofthe equipment
by thefastener.
3.Tohelp distributefastenerloadduring tightening.
4.As seals.
Note thatflat washersarc oftenusedbetween
a
lockwasher andafastenertoprovide a smoothbear­
ingsurface.This
allowsthe fastener tobeturned
easilywith a tool.
NOTE
As
muchcareshouldbegivento the
selection andpurchase
of
washersas
thatgivento bolts,nuts andother/as­
teners.Beware ofwashers that are
made0/thinandweakmaterials.
Thesewilldeformandcrush tilefirst
lime theyare usedinahigh-to rque
application.
CotterPins
Incertainapplications.a fastener mustbe secured
so itcannotpossiblyloosen. Therearhub on an
ATVisone of'theseapplications.Forthispurpose,a
cotterpinand
slotted orcastellated nulisoftenused.
Touse a cotter pin.firstmake sure thepin fits
snugly, butnot toolight.Thenalignthe slot in the
fastenerwiththc holeintheb
ahoraxlc.
Insertthecotterpin thro ugh thenuland bolt or
axleand bendthe endsovertosecurethe cotter pin
tightly.
Iftheholesdonot align. tightenthe nutjust
enoughtoobtain the proper alignment.Unlessspe­
cificallyinstructedto
doso. neverloosen thefas­
tcner10align thc slot andthehole.Becausethe
cotter pin isweakened
afterinstallation andre­
moval,neverreuseacotterpin.Cotter pins are
availableinseveralstyles. lengths
anddiameters.
Measur ethecotterpinlength fromthebottom ofits
headto thelip
ofthcshortes tpron g.
Circlips
Circlips
canbeinternalor exte rnal in design.
They areused
toretainitemsonshafts(exte rnal
type ) orwithin lubes(internaltype).Insomeappli­
cations.circlipsofvarying thicknessesareused to
control the
endplay ofassemblies. These are often

15. GENERA LII\'FORMATION
CD
Full
'~~=;1;'7 Tsupport
I" areas
j
_
.... Rounded edges
1..tf111h Sharp edges
If:~'\ I
.~ m.,"ru"
callcdselectivecirclips.Circlipsshould bcreplaced
duringinstallation.asremovalweakensandde­
formsthem.
Two basic styles
ofcirclipsare available:machined
and stampedcirclips.Machinedcirclips(Figure7)
canbeinstalledineither direction(shaftor housing)
becausebothfacesare ma chined.thus creatingtwo
sharp edges.Stampedeirclips (Figure 8) aremanu­
facturedwithone sha rpedge
andonerou ndededge.
Wheninstalling sta mpedcirclipsin athrust situation
asontransmission shafts. the sharpedge mustface
awayfromthe part producingthethrust. Wheninstall­
ing circlips,observethe followin g:
I.Compressorexpandcircli psonlyenough toin­
stall them.
2.After thecirclipisinstalled,make sure itiscom­
pletelyseated within its groove.
3.
Transmission circlips become WOntwith lise anti
increase sideplay.For thisreason. always in stallnew
circlips whenever atransmissionisreassembled.
9
LUBRICANTS
Periodi clubricationassureslong Iifcforanyt ype
ofequipme nt. Thetype oflubricant used is just as
importantasthelubricationservice itself,although
inanemergencythewrong type
oflubricant
is
bellerthannone atall.The followin gparagraphs
describe thetypes
oflubricantsmost oftenusedfor
ATVs.Besure to follow themanufacturer'srecom­
mendationsfor l
ubricant
types.
Generallyallliquidlubricantsare called oil.They
maybemineral-based (includingpetroleumbases),
natural-based (vege table andanimalbases).syn­
thetic-based oremulsions(mix tures ).Greaseis oil
towhicha thickeningbasehasbeenadded so that
the end prod uctis semi-solid.Greaseisoften classi­
fiedbythetype
ofthiekcneradded;lithiumsoap is
commonly used,
EngineOil
Engineoilisclassifiedbytwo standards: the
American PetroleumInstitute(API)
serviceclassi­
fication andtheSocietyofAutomotiveEngineers
(SAE) viscosityrating. Thisinformationison the
oilcontain
erlabel.Two leitersindica tetheAPIser­
viceclassification. Thenumberorsequenceof
numbers and leit er( IOW-4 0for example} isthe oi l's
viscosityrating.TheAPI service classificationand
theSAE viscosity index are not indications
ofoil
quality.
Theservice classification indicatesthatthe oil
meets specific lubricationstandards.The first leiter
in the classificationSindicates thatthe oil isfor gas­
oline engines.
The second leiterindicatesthe stan­
dard theoilsatisfies.Theclassificat ion startedwith
the leiter
Aandiscurrent lyat theletter 1.
Alwayslise anoil
witha classificationrecom­
mended bythe
manufacturer.Usingan oil witha
classification different than that recommendedcan
causeenginedamage.
Viscos ity is an indication
ofthe
oil'sthickness.
Thinoils have alow ernumberwhilethick oils have
a highernumber.Engineoils fall into the5-to
50- we ight rangefor single-g radeoils.
Mostmanufacturersrecommend mu ltigradeoil.
Theseoils
performefficientlyacross a wide range
ofoperatingconditions.Multigradeoilsareidenti­
fied by a
IVafter thefirstnumber, whic hindicates
thelow-temperature viscosity.

16. 10
Engineoilsan:1110 Stcommonly mine ral(petro­
leum)based; howeversyntheticandsemi-synthetic
typesareused more
frequently. Whenselectingen­
gineoil,follow themanufacturer'srecommenda­
tion
for
type,classificationandviscosity.
Grease
TheNationalLubricatingGrease
Institute
(N LG I)
gradesgreases.Grease sarcgradedbynum­
beraccording to the consistency of the grease;these
range fromNo. 000 to No. 6,withNo. 6beingthe
most solid. Typicalmultipurposegrease
isNLGI
No
.2.Forspecifi capplications,equipme nt manu­
facturers mayre quire grease withan additive such
asmolybd enum disulfide.
TH R EA Il LOCKI:'oIGCO M P OU:'oIIl
A threadloc kingcompoundshouldbeusedto
helpsecure many ofthe fastenersused 011the vehi­
cle.Athreadl ock compound will lockfasteners
against vibrationlooseningandseal againstleaks.
Thefollowin g thread lockin gc ompounds arerec­
ommendedfor many threadlock requirementsde­
scribed inthis m anual.
\. Thrcelsond TB1342 (blue): low-stren gth ,fre­
quentrepair.
2.Loctit e No. 242 (blue):low-strength,frequent
repair.
3.ThreeBondTB13 60 (green):medium-strength,
hightemp erature.
4.
Threels ondNo.1333B(red):medi um-strength,
bearing
andstudlock.
5.ThreeBondTB1303 (orange):high-strength ,in­
frequent repai r.
6.Locti te No.271(red): high- stren gth, infrequent
repair.
There are other qualitythrcadlockbrands
on
the
market.
RTVGASKETSEA LANT
Roomtemperature vulcanizing(RTV) sealant is
usedonsome preformedgasketsand tosealsome
components. RTVisasiliconegel suppliedin tubes
and is available atmotorcycle and automotivesup­
pliesstores andmajor hardware stores.
MoistureintheaircausestheRTVto cure.Al­
waysplacethe capon thetubeas soonaspossible
CHAPTERONE
whenusing RTV.RTVhasashelflifeof approxi­
matelyoneyearand willnotcureproperlywhen the
she lflifehas expired.Check the expirat ion dateon
theRTV tube priortopurchasing a new tubeandon
using the sealant.Keep
partiallyusedtubestightly
scaledanddiscard
themaftertheexpirationdate.
A(lIJlyingRTV Seala nt
Clcan alloldgasket residu efromallmating sur­
faces.RemoveallRTV gasket material fromblind
threaded holes;itcan cause ahydrauliclock
andaf­
fect bolttorque.leadingtothe boll not being ti ght­
ened to the co rrecttorquespecification. Finally,
spray thematingsurfaceswithanaerosol parts
cleanerandwipe with
alint-freecloth.
ApplyRTVsealant in
acontinuous bead 2-3 ITIm
(0.08-0.12 in.) thick . Circle all mountingholesun­
lessotherwi sespec ified.Donotallow anysealan t to
enter theseholes. Assemble andtighten thefasten­
ers
tothespecifiedt orquewithin10 minutes after
application.
EXP EN IlA BLESUPPLIES
Certainexpendablesupplies arerequired during
maintenance
andrepairwork .These includegrease,oil.andgasketcement,wiping ragsandcleaning
solvent.Askthedealershipforthe special locking
compounds. silicone lubricantsand otherp roducts,
which make vehiclemaintenance simpler andeas­
ier.Cleaning solventor keroseneisavailable at
some services
tations, paint or ha rdware stores.
Besureto
followthemanuf acturer'sinstructions
and w
arningslisted on thelabel ofthe productbeing
used ,Some cleaning suppliesarcvery
causticand
are dangerousifn otusedproperly.

17. GENERALINFORMATIOI'O II
WARNI NG
Ha ringastackofcleanshopragsOil
handisimportantwhenpel/arming
engine
and suspens ionservice
work.
Howe ver.a pileofsolvent-soaked
ragspresentsafire hazard. Store
theminasealed metal container /lI1­
tiltheycan be washed or properly
discarded.
NOTE
70preventsolvent and other chemi­
calsfrombeingabsorbedintothe
skin.
Il'earapairofpetro­
leum-resistant
gloveswhencleaning
parts.Thesecan bepurchased
throughindustrial supplyhouses01'
well-equippedhardwarestores.
SERIAL N
UMIlERS
Polarismakesfreq uentchangesduringamodel
year-someminor, somerelativelymajor.When
orderingparts fromthe dealershiporother partsdis­
tributor,alwaysorder by VIN andengineserial
numbers. The serialnumberlocations arcas
fol­
lows:
I.ModelandYIN number (Figure 9) is stamped
on theleftlower framerail neartherearportion
of
thefrontA-a rmmount.Onsomemodels.
adecal
with theYINnumber islocatedon thefront fender
cover (Figure 10).
2.Engineserialnumber(Figure
II)is stamped on
apadonthecentertopof thecrankcase beneaththe
cylindercoolant elbow,
3.The transmissionse rialnumberislocatedon top
of the
transmissioncasebelowtheshinbellc rank
andon alabel onthe rightside(Figure 12).
4.Thecarburetorserial number (Figure 13)islo­
catedon theleft sideof the carburetor body.
Enter thesenumberson thech artin theQuick
Refe renceData tableat thefrontof thisbookand
keepthem forreference . Compare new partstothe
old onesbeforehuyingthem.If theyarenot alike,
havethepartsmanagerexplainthe difference. Ta­
ble1liststhemodelnumbers for the modelscov­
ered in thismanual.

18. 12
WAR;;INGANDINFORMATION LABE LS
Anumberofwarninglabels(Figure14) arcat­
tachcdtothe Polaris. Theselabelsconta in informa­
tionthatisimpo rtantto personalsafety when
operating.transporting andstoring the vehicle.A lso
referto the informative labelsfastenedtothe vari­
ouscomponentson thevehicle.asthisinformation
is veryuseful.Refertothe owner 'smanual fora de­
scriptionand location ofeachlabel.If alabelis
missing,orderareplacementlabelfrom aPolaris
dealership.
BASI C
llANOTOOLS
Many of theproceduresin this manualcanbe car­
ried out withsimple hand toolsand test equipment
familiartothe homemechanic.Keep all tools
clean
andinatoolbox.Keepthem organized with the
sockets andrelated drivestogether,the open-end
combination wrenchestogether,etc.Afterusing a
tool,wipeoffdirtandgrease withacleanclothand
returnthetoolto
itscorrectplace.
Top quality toolsareessential; theyare alsomore
economicalin thelong run.Ifjuststarting tobuilda
tool collection, stay away fromtheadvertisedspe­
cials
featuredatsomep artshouses,discount stores
andchain drugstores. These are usuallypoor grade
toolsthatarc made ofinferiormaterial.andarc
thick,heavy and clumsyto use.Their rough
finish
makesthemdifficultto clean and theyusuallydo
notlastverylong.The wrenchesdo notfitthe heads
ofboltsand nuts correctly and maydamagethefas­
tener.
Quality toolsarcmadeofalloysteeland arc
heat-treated forgreaterstrength. They are lighter
andbetterbalancedthaninferiorones.Their surface
issmooth.makingthemapleasureto workwithand
easyto clean.The initialcost of good qualitytools
maybemore,
buttheyaremore economical in the
longrun.Donot try to buy everythinginallsizesin
thebeginning:buy a fewatatimeuntil allthe nec­
essarytools arcon hand.
Screwdrivers
Thescrewdriver is
avery basic tool,but ifused
improperlyitwill domore damagethangood.The
slot ona screwhas adefinitedimensionandshape.
Ascrewdriver must beselected to conform to t hat
CIIAPTERO;;E
shape.Use asmallscrewdriverforsmallscrewsand
alargeoneforlargescrews, or thescrew head will
bedamaged.
Twobasic types ofscrewdriversare r equired:
common (flatblade)screwdriversand Phillips
screwdrivers.
Screwdriversarc availableinsets that
oftenin­
cludean assortment ofcommonandPhillipsblades.
Ifpurchased individually,buyat leastthe follow­
ing:
I.Commonscrewdriver-5!16x6 in.blade.
2.Commonscrewdrive r-3/8x12in. blade.
3.Phillips screwdriver
-size 2 tip,6 in.blade.
4.Phillips screwdrive r-size 3 tip,6and 10 in.
blade.
Usescrewdriversonly fordrivingscrews.Never
usca screwdriver forp
ryingorchiselingmetal. Do
not
trytoremove a Phillipsor Allen head screw
witha commonscrewdriver (unlessthe screwhasa
combination headthatwillaccepteither type);ifthe
head isdamaged,thepropertoolwill beunableto
remove it. Keepscrewdrivers in the proper condi­
tion and they will lastlongerand p
erformbetter.Al­
wayskeepthetip ofacommonscrewdriverin good
condition.
Pliers
Pliers
come inawide rangeoftype sandsizes.
Pliersare useful forcutting,bending andcrimping.
Donotuscthemtocut h ardenedobjectsor totum
boltsor nuts.Eachtype ofpliershas a speciali zed
function.Slip-joint pliersare generalpurposepliers
and areusedmainly forholding thingsand for
bending.

19. GENERALINFORMATIO N 13
Circlip Pliers
Locking Pliers
Circlippliers(Figu re15) aremadefor removing
andinstalling circlips.Externalpliers(spreading)
are used toremovecirclips that fitontheoutside of
a shaft.Internalpliers (squeezing)are used tore­
move circlipswhich
fitinsideagearorhousing.
II
Box,O pen-EndandCombinationWrenches
An adjustablewrench(sometimescalledcrescent
wrench)can beadjustedtofit nearlyanynut orbolt
head thathas clearaccessaround itsentireperime­
ter.Adj ustablewrenchesare bestusedas abackup
wrench to keep a
largenut orboltfromturning
whiletheotherendisbeingloosencd ortightened
withabox-endor socketwrench,
Ad
justablewrenches
haveonly two gripp ingsur­
faceswhichmakethem more subject toslipping ofT
thefasteneranddamagingthepart and possibly
A
djustableWrenches
WARNING
Becausecirclipscallsometimesslip
amiflyof]whenremovingand install­
ingthem.alwayswearsafetyglasses
whenusingthem.
Open-e nd, box-endandcombinationwrenches
areavailable insetsorseparatelyin a varietyof
sizes.
Onopen andbox endwrenches, thenumber
stamped near the endreferstothe distancebetween
two parallel flatsonthehexheadboltornut. On
combinationwrenches,thenumber
isstampednear
thecenter.
Open-endwrenches(A,
Figure16)arespeedy
andwork best inareaswithlimitedoverheadac­
cess.
Their
wide,flatjawsmake themunstable for
situationswhere the
boltor nutislocated in abore
orcloseto the edge ofa casting.Thesewrenches
griponlytwo flats of a fasten er;ifeitherthefastener
heador thewrench jawsare worn,the wrenchmay
slip ofT.
Box-endwrenches(B,Figu re16)requireclear
overhead
accessto thefastenerbutcan workwellin
situations wherethefastenerhead isclosetoan­
otherpart.Theygriponallsix edges
ofa fastener
for a verysecure grip.Theyare availablein either
6-pointor 12-po int.The6-pointgivessuperior
holdingfloweranddurabilitybutrequiresa greater
swinging radius.The12-pointworksbetterinsitua­
tionswherethe swingingradiusislimited.
Combinationwrenches(C.Figur eJ6)have
open-endon one sideandbox-endontheotherwith
bothendsbeing thesame size.Professional me­
chanicsfavorthesewrenchesbecauseoftheirver­
satility.
o
:sK
~...~~~
A
®
oQ!
Lockingpliersareusedto hold objectsvery
tightly
like a vise.Butavoidusingthem unlessnec­
essarysincetheirsharpjaws
willperm anently scar
anyobjectsthatareheld.Lockingpliersareavail­
ableinmanytypesfor more specifictasks.
Needlcnoscpliersareused toholdorbendsmall
objects.Waterpumppliers can be ad
justedtohold
varioussizes ofobjects;thejaws remainparallel to
griparoundobjectssuchaspipe ortubing. Therearc
manymore typesofpliers.Theonesdescribedhere
aremostsuitable for vehiclerepairs.

20. 14
causinginjury.The fact that one jawis adjustable
only aggravatesthis shortcoming.
Thesewrenchesare directional:thesolid jaw
must be the onetransmittingthe force.If theadjust­
able
jawis used(0transmitthe force. itwillloosen
and possibly slipotT.
Socket
Wrenc hes
®
CHA PT ERONE
This typeofwrenchisundoubtedly the fastest,
safestandmostconvenientto use.Sockets.which
attac hto a ratchet handle. areavailablewith6-point
(A,
Figure17) or 12-point(B, Figure17) openings
(;;;\
and1/4,3/8.1/2 and 3/4in.drives.The drivesize~
indica tes the size ofthesquarehole whichmates
with theratchethandle.
Alle n
Wrenches
A B
Allenwrenchesare availableinsetsorseparately
in a variety
ofsizes.These setscome in SAE
and
metricsizes . Allenbolts arc sometimescalled
socket bolts. Sometimes thebolts are
difficult to
reachand it is suggestedthata
varietyorAllen
wrenches be purchased, suchasthe socketdriven.
T-handleandextensiontype.
TorqueWrench
Atorq ue \
...Tenchis usedwith asocketto measure
howtightly anut or bolt is installed.Theycome
witheither
1/4.318or1/2in. square drive(Fig ure
18).Thedrive sizeindicatesthe size ofthesquare
drivethatmateswith thesocket.
ImpactDriver
This tool might have beendesignedwith theATV
mechanicin mind.This tool makesremoval offas­
tenerseasyandeliminatesdamageto bolts and
screwslots.Impactdrivers(Figure19)andinter­
changeablebitsare availableat mostlargehard­
ware,vehicleor auto parts stores.Socketscan
also
be usedwith ahand impact
drive r;however,make
surethatthe socket isdesignedfor use withanim­
pactdriver or air tool.Donotuseregularhand sock­
ets, asthey1113yshatter duringuse.
Hammers
Thecorrecthammerisnecessaryfor certain re­
pairs. Ahammer withaface (orhead)
ofrubber or
plastic or asoft-facedtype tilled with buckshotis
sometimesnecessaryin enginedisassem bly.Never
usca metal-fa cedhammeron engineorsuspension
parts.asseveredamagewillresultin mostcases.
Thesameamo unt offorce can beproducedwith a
soft-facedhammer.Theshock
ofa metal-faced
hammer, however,isrequiredfor using
ahand im­
pactdriveror cold chisel.
Su
pportJacks
The correct type ofsupport
jackisnecessaryfor
manyroutineservice or major componentreplace­
mentprocedureson the vehicle.The centerstand
scissorjack
issuitable for mostserviceprocedures
onthis series ofvehicles.Itis adjustableand isvery
stableforusc withthe frame configurat ion
ofthis
vehicle.
Also,thestandard floor jackmay
beusedfor
some applications,Toprotect allengineandframe

21. GENERA L IN FORM AT IO N
®
surfaces,always place apiece ofwood betwe enthe
jack padand thesupportedcomponent.
PRECISION
l\IEASURl:O;GTOOLS
Measurementis anim portantpartofengineand
suspensionservice. When performing manyofthe
service procedures inthismanual, a number of
measurements arerequired.Theseincludebasic
checkssuchas enginecompressionandspark plug
gap.As shopexperienceprogressesintoengine
disassembly andservice. manymeasurements arc
requiredtodetermine the sizeandcondition ofthe
pistonandcylinderboreandcrankshaft runoutand
other complexmeasurement s. Whenmakingthese
measurements,thedegree ofaccuracywill dictate
which toolisrequired.Precision measuring tools
arc expensive.
Ifthis isthefirstexperienceaten­
gine orsuspension
service,it maybe more worth­
while tohavethe checksandmeasurements
performedby aPolaris dealership.a competent in­
dependent vehiclerepair shoporamachine shop.
However,as skillsandenthusiasmincreasefor do­
ingservice work,
itmaybe desirab le 10buysome
15
ofthesespecializedtools. Thefollowingis a
descriptionofthemeasuringtools required toper­
formtheserviceproceduresdescribed in
thevari­
ous chaptersin thismanual.
FeelerGa uJ.:c
Feelergaugescomein asso rtedsetsandtypes
(Figure 20).Thefeelergaugeismade ofeithera
piece o
fanator roundhardenedsteel ofaspec ified
thickness.Wire gauges are
usedtomeasure spark
plug gap.
Flatgaugesarcusedforother measure­
ments.Feeler gaugesare alsodesignedfor special­
izeduses.Forexample. the end
ofagaugecanbe
smallandangled to facilitatecheck ingvalveclear­
ances onmodelsrequiring adjustment.
VernierCaliper, DialCaliper and
DigitalE lectronicCaliper
These arcvaluable toolsforreadinginside, out­
sideanddepth measurements. Althoughthistype of
tool isnotasprecise
asa micrometer.itallowsrea­
sonable,non-closetole
rancemeasurements, typi­
callyto within0.025mrn(0.00 1 in.). Common uses
ofa verniercaliperarcmeasuring thelength ofthe
clutchsprings,thethickness
ofclutch plates. shims
and thrust washers,brakepador liningthicknessor
the dcpthof abearingborc.The
jawsofthecaliper
must be c1can andfrcc
ofburrsat all times toobtain
anaccuratemeasurement. There are severaltypes
ofvernier calipersavailable. Thestandardvernier
caliperhas ahighlyac curate graduatedscaleonthe
handl e (Fig
ure 21)inwhichthemeasurements
mustbe calculated,follow ing them
anufacturer's
instructions.Thedialindicator caliper is equipped
withasmalldial andneedlethatindicatesthemea­
surementreading;thedigital electronictypehasan
LCD display thatshowsthcmeasurement Oilthc
small display screen.Someve rniercalipersmustbe
ca
libratedpriorto
makingameasurementto ensure
accuracy.R
efertothemanufacturer'sinstructions
for thisprocedure.
Outside
l\l icrometcrs
An outsidemicrometer isa precisiontool used to
accuratelymeasurepartsusingthe decimal divi­
sionsoftheinch ormeter(Figu re 22).Whilethere
are manytypes andstylesofmicrometers.this sec-

22. 16 CHAPTERONE
@ METRIC
VERNIERCALIPER
10.00 mm
+0. 50rom
10.50 mm
o
1.Reading onfixed scale:
2. Read ingon movablescale:
Totalreading:
'\10mm~F lxedscale
\:-----"ie
f----"==l-) s:=J=-..
2 J 4 5 :
'!I""I""I"uli'- IlIII!':·::.
I ililt'C:Jr
•,.\ ( Movablesc:',e
0.50mm
reads0.001in.(one one-thousandth)ofan inch.
Thus,each thimblemarkis equal to0.001in.
Every
fiftht himblemarkisnumberedtohelpwithread­
ing:0,5.15 and20.
Resetthe mi
crometer sothat the thimbl e
and
sleeveline zeromarksalign .Then tumthethimble
countercloc
kwiseonecomplete re volution and
alignthethimble ze ro markwiththefirstlinein the
sl
eeveline.The mi crometernowrea ds0.025in.
(twenty- five thou sand s)
of
aninc h.Thus, cach
sl
eevelinerepresents0.025inch.
N
owtumthethimbleco unterclockwi sewhile
co unting the sleevelincmarks.Everyfourth
mark
on the sleevelineismarkedwith a numberranging
from
one throu ghnine.M anufacturersusuall ymark
thelastmarkon the sleeve with aO.Thisindicat es
theendofthemicrome ter'smeasuringrange. Each
sleevenum berrepresents 0.1in.Forexample,the
numberI r
epresents0.1in.and the number9repre­
sents 0.9 inch.
Whenreadinga
sta ndardmicrometer.takethe
followi ngthreemea
surementsdescribedandadd
them togeth er.
Thesum ofthethreereadingswill
give themea
surem ent
inathousandthofan inch
(0.00 1in.).
Tor
eada micro me ter. perf ormthefollowing
stepsandreferto theexamplein Figure24.
Amicrometer'ssizeindicatestheminimum and
maximum size ofapartthat itcanmeasure.The
usual sizesare:0-1 in.(0-25mm),1-2in.(25-50
mm),2-3in. (50-75
mm)and3-4(7 5-100mm).
T
hesemicrometerslisefixed anvils.
Some mic
rometersusethesame fra mewith inter­
cha
ngeable anvils ofdifferentlengths.This
allows
theinstallation ofthecorrectlengthanviltorapar­
ti
cularjo b.F orexample,a0-4in. inter changeable
micrometeris equippedwithfourdifferent length
anvi ls.
Whilepurchasing oneor two microm etersto
coverarange from0-4in,or0-6inchesisless ex­
pensiv e,its overa llframesizemakesit less conve­
nien ttousc.
Thesta ndard inch micro meter isuccuratcto
one- tho usa ndth of
aninch (0.001in.) .The heart of
the micrometeris itsspindlescr ewwith40threads
perinch.Everytum
ofthethim ble willmovethe
s
pindle1/40of
aninch or0. 025inch.
B
eforelearn ing how10read amicrometer,study
themarki ngs
andpartnamesinFigure23. Tum the
micrometerthimbleuntil its zeromarkalignswith
thezeromarkon thesle
eveline. Nowtumthethim­
ble
counterclockwiseandalignthenext thimble
markwith
theslee veline.Themic rometernow
liondes
cribeshow tousc the outside mi crometer.
The outside mi
crometeristhe mos tcom mo n typ e of
micrometerused toservice a vehicle, Theoutside
micrometerisalsousedto measurethedimension
tak en bya smallhole gaugeor
atele scoping gauge
describ edlaterinthis section.
Ot
hertypesofmi crometersincludethedepthmi­
crometer andscrewthread micrometer. Figure23
illustratesthe vario usparis oftheoutsid emicrome­
ter
withitspartnamesand markingsidentified .
HowTo ReadaMicrometer
l\licromcterRange
Standardinchmicrometer
Whenreadingamicrometer, numbersaretaken
fromdiffere ntscalesandaddedtogether.The fol­
lowingsectionsdescribehowto r eadthe standard
inch mic rom
eter,thevernie r inchmicrom eter,the
standard metricmicrometerandthemetr ic vern ier
mi
crometer.

23. GE:'/ERALINFOR:\lATlON 17
DECIMALPLACEVALUES'
Indicates1110(onetenthof aninch
ormillimeter)
Indicates11100(oneone-hundrethof
an Inch ormillimeter)
Indicates
111,000(one one-thousandth
of aninchormillimeter)
0.001
0.1
0.010
@r--------==:::...:...=:=.::...=-=--------,
*Thls chartrepresentsthevaluesof figuresplacedto the rightof thedecimal point.Use itwhen
readingdecima ls fromone-tenthtooneone-thousandthof anInchormillimeter.ItIsnotacon­
versionchart(forexample:0.001 in.Is notequalto0.001 mm).
STANDARD INCHMICROMETER
LocknutSleeveline
Thimblemarks
1.Largestnumbervisible
onthesleeveline 0.200 In.
2.Numberon sleeve marksvisible
betweenthe numberedsleevemark
and the thimbleedge 0.025in.
3.Thimblemarkthatalignswith
sleevelineQ.QO§Jn,
Totalreading:0.231in.

24. 18 CHAPTERONE
VERNIERINCHMICROMETER
Vern ier scale
,
-0
•
'-
Vern ierscale
Th
imble
tvernier. scale
o
--"t-
'"--"t-
O>
,,__r-
o>- -.r-
",__-r--O
~==E
0--"""'--_20
o
1. Largest number visi ble
onsleeveline 0.100In.
2. Numberof sleevemarksvisible
betweenthe numbe redsleeve
mark and the
thimbleedge 0.050In.
3.ThimbleIs between O.D1Sand
0.019in.on thesleeveline 0.018 In.
4.Vernierline
coincidingwith
thimbleline 0.0003In.
Totalreading:0.1683In.
Sleeve Thimble
I.Readthe sleevelineto find the largestnumher
visible-eachsleeve number markequals 0.100
inch.
2.Count thenumber of
sleevemarksvisiblebe­
tweenthe numberedsleevemarkand thethimble
edge
-eachsleevemark equals 0.025 inch. Ifthere
isno visible
sleevemarks.continue toStep3.
3.Readthethimble mark that linesupwith the
sleeveline
-eachthimblemarkequals0.00Iinch.
NOTE
Ifa
thimblemarkdoesnot lineuper­
actlywiththesleeve linebut fallsbe­
tweentwolilies.estimate thefraction
a/decimalamount betweenthelines.

25. GENERALINFORMATION 19
®
Anvil
STANDARD METRICMICROMETER
LocknutSleeve line Thimble
Sleevemarks
4.Addingthemicrom eterread ingsinStepsI.2
and 3 givesthe actualmeasurement,
Vernierinchmicrometer
Avernier micrometer can accuratelymeasure in
ten-tho usandths ofan inch(0.00 01 in.).Whi le ithas
the same markings asthe standardinch micrometer.
a vernie rscalescribe don the s leeve(Figure25)
makesitunique.Thevernierscale consistsof
eleveneq uallyspace d Iinesmarked 0-9witha0on
eachend.Theselines runpara lle lonthe top ofthe
sleevewhere eachlineis eq ua l to0.0001inch.
Thus.the ve rnierscale dividesa thousa ndthof311
inch (0.001in.)intoten-thous andthsofan inch
(0.0001in.).
Toread theverniermic rometer,performthefol­
low ing stepsand r efertothe example in Fjuure26:
I.Readthe micrometerin the sameway as onthe
standard inchmi crometer.This isthe initialreading.
2.If
athimb le mark linesup exactlywith the sleeve
line.reading the vernierscaleis not necessary.I fa
thimble mark doesnotline exactly withthesleeve
line.readtheve rnierscalein Step3.
3.Readthe
vernierscaletofindwhichve rnier
marklinesup with theone thimblemark. The num­
ber
ofthatvernier mark is thenumberof
ten-thousandt hs ofan inch toadd to the initialread­
ing takeninStep I.
Metricmicrometer
TIlemetricmicrometeris verysimilarto thestan­
dardinchmicrometer. Thedifferencesare thegrad­
uations onthethimbleandsleeve asshown in
Figure27.
Thestandard metric micrometerisacc urateto
oneone-hund red thofan millimeter (0.0 I mm).On
the metricmicrometer.the spindlescrew isground
withathrea d pitch ofone-ha lf millimeter(0.5 mm).
Thus, everytum
ofthethimble willmovethespin­
dle0.5111111.
The sle eveline is
graduatedinmillimetersand
hal f millimeters.
Themarkson theupper side ofthe
sleevelinearcequal to 1.00 mru. Everyfifthmark
above the sleeve line ismarked withanumbe r.The
actual numbersdepend on thesize
ofthemicrome­
ter.For example,ona 0-25mmmicrometer.the
sleevemarksare n umbered 0,5,10 ,15.20and25.
Ona 25-50 nunmicrometer.the sleeve m arks are
numbered25,30,35,40,45and50.This numbering
sequencecontinueswith larger micrometers(50-75
and75-IOO).Each mark on thelower side ofthe
sleevelineis equalto0.5mm.

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