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Ranger RZR 170

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100% found this document useful (2 votes)

1K views231 pages

Ranger RZR 170

Uploaded by

Shannon Marcum

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

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2012-2013 RANGER RZR® 170

SERVICE MANUAL
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at [Link].

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual/Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.

Publication Printed July 2012 (PN 9923983)

© Copyright 2012 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator,
bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the
vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-Vac, Registered Trademark of Neward Enterprises, Inc.

Torx, Registered Trademark of Textron

Some Polaris factory publications can be downloaded from [Link], purchased from [Link]
or by contacting the nearest Polaris dealer.

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GENERAL INFORMATION 1

MAINTENANCE 2

ENGINE / TRANSMISSION 3

FUEL SYSTEM 4

BODY / SUSPENSION / STEERING 5

BRAKES 6

CVT 7

ELECTRICAL 8

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GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
MODEL NUMBER DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
UNIT SERIAL NUMBER (VIN) AND EMISSIONS DECAL LOCATIONS . . . . . . . . . . . . . 1.3
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MODEL: 2012 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MODEL: 2012 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
MODEL: 2013 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
MODEL: 2013 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
MISCELLANEOUS SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

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GENERAL INFORMATION

MODEL NUMBER DESIGNATIONS

Model Number Designation
Example: R12VA17AA

MODEL
GROUP CHASSIS DRIVELINE ENGINE CATEGORY OPTION
YEAR

1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit**

12 Displacement in cc
R= RANGER V = RZR A = 2x4 Chain A = ORV A
13 (i.e. 17 = 170cc)

* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.

VEHICLE IDENTIFICATION NUMBER

VIN Number Designation
Example: RF3VA17A6BT012516

Vehicle Descriptors Vehicle Identifiers

Engine Modifier

Mfg. Location
Model Year *
Engine Size

Check Digit

World Mfg. ID
Category

Individual Serial No.

Driveline
Chassis

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
R F 3 V A 1 7 A 6 B T 0 1 2 5 1 6
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013

Engine Designation Number

S35C-Single Cylinder, Air/Oil Cooled, OHV 4 Stroke, Electric Start

Engine Serial Number Location

Whenever corresponding about an engine, be sure to refer to the engine
model number and serial number. This information can be found on the ENGINE SERIAL NUMBER
sticker applied to the clutch-side engine case.

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GENERAL INFORMATION
Unit Serial Number (VIN) and Emissions Decal Locations
The machine model information decal (A) and vehicle identification number (VIN) are important for identification. The 1
VIN number (B) is stamped on a portion of the front left frame rail close to the left front wheel.

The engine emissions decal (C) is attached to the frame support, accessible through the front right wheel well.

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GENERAL INFORMATION

VEHICLE INFORMATION
Publication Numbers

Model Model No. Owner’s Manual PN Parts Manual PN

2012 RANGER RZR 170 R12VA17AA 9923583 9923584

R12VA17AC
R13VA17AA
2013 RANGER RZR 170 R13VA17AB 9923980 9923981

NOTE: When ordering service parts be sure to use the correct parts manual.

NOTE: Polaris factory publications can be found at [Link] or purchased from

[Link].

Paint Codes

Painted Part Color Description Polaris Number

Frame / Bumpers / Racks Gloss Black P-067
Indy Red P-293
Plastic - Hood / Dash / Fenders
White P-133

Replacement Keys
Replacement keys can be made from the original key. Polaris offers replacement key blanks (0453013) that can be cut
to match the original. Should both keys become lost, ignition switch replacement is required.

P/N 0453013

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GENERAL INFORMATION
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other
tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when
1
servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation,
by phone at 1-800-328-6657 or on-line at [Link]

Select “SPX Website - Tools, diagnostics” from

the “Service and Warranty” drop down menu

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GENERAL INFORMATION
GENERAL SPECIFICATIONS

MODEL: 2012 RANGER RZR 170

MODEL NUMBER: R12VA17AA / R12VA17AC
ENGINE MODEL: S35C

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GENERAL INFORMATION
MODEL: 2012 RANGER RZR 170 Drivetrain

MODEL NUMBER: R12VA17AA / R12VA17AC Transmission Type

2.5 gal. (9.5 liters) 0-3000

Fuel Capacity / Requirement 102 100
87 Octane (minimum) (0-10000)
Electrical 3000+ 98
100
Alternator Max Output 80 Watts @ 3000 RPM (10,000+) #3 needle clip position

2 - Single Beam
Lights: Main Headlights Daytime Running Lamps CLUTCH CHART
(DRL)
Tail / Brake 5 Watts / 21 Watts Altitude
Meters Shift Weight
Starting System Electric Start
(Feet)
Ignition System CDI
0-3000
Ignition Timing Non-Adjustable 6 @ 17 grams
(0-10,000)
NGK CR6HSA
Spark plug / Gap *** 6 @ 15 grams
.024-.028 in. (0.6-0.7 mm) 3000+ (10,000+)
PN 0454619
GTX12-BS / Low Maintenance
Battery
12 Amp Hr. / 12 Volt
Fuses Main: 20 Amp

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GENERAL INFORMATION
MODEL: 2013 RANGER RZR 170
MODEL NUMBER: R13VA17AA / R13VA17AB
ENGINE MODEL: S35C

Category Dimension / Capacity

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GENERAL INFORMATION
MODEL: 2013 RANGER RZR 170 Drivetrain

MODEL NUMBER: R13VA17AA / R13VA17AB Transmission Type

Shift Type
Polaris Automatic CVT
In Line Shift - H / N / R
1
ENGINE MODEL: S35C
Transmission Oil Polaris AGL
Engine Requirements Main Gearcase 23.7 oz. (700 ml)
Single Cylinder, Air/Oil Cooled Drive Belt 0454497
Platform
4-Stroke Drive Chain - Type / # Links 520 / 30
Engine Model Number S35C Steering / Suspension
Engine Displacement 169cc Front Suspension Single A-arm
Number of Cylinders 1 Front Travel 5 in. / 12.7 cm
Bore & Stroke (mm) 61 x 57.8 mm Rear Suspension Dual Shock Swingarm
Compression Ratio 9.5:1 Rear Travel 5 in. / 12.7 cm
Compression Pressure 130-160 psi @ W.O.T. Shock Preload Adjustment Cam Adjustable
Engine Idle Speed 1700 ± 100 RPM Front / Rear (Factory Setting - Softest)
Engine Max Operating RPM 8000 ± 200 RPM Toe Out 1/8-1/4 in. / 3-6.35 mm
Lubrication Wet Sump Wheels / Brakes
Oil Requirements Performance Synthetic (PS-4) Front Tire Size 19 x 7 - 8
Extreme Duty Oil
Rear Tire Size 20 x 10 - 9
Oil Capacity 37 oz. / 1.1 liters
Bolt Pattern 110mm
Exhaust System Single Headpipe / Single
Silencer Tire Air Pressure - Front / Rear 3 psi (20.7 kPa)
Fuel System Foot Actuated - 4 Wheel
Brake - Front / Rear
Hydraulic Disc
Carburetor Type Keihin
Brake Fluid DOT 4
Pilot Jet 35
Main Jet 100 JETTING CHART
Air Screw 2 1/4 Turns Out (initial)
Jet Needle 2MKNN - #4 clip position Altitude Ambient Temperature
Fuel Delivery Fuel Pump Meters -30 to -10° F -15 to 5° F 0° F+
(Feet) (-34 to -23° C) (-26 to -15° C) (-17° C+)
Fuel Filters See Chapter 4
2.5 gal. (9.5 liters) Main Jet = 102 Main Jet = 100 Main Jet = 100
Fuel Capacity / Requirement 0-2400
87 Octane (minimum) Pilot Jet = 38 Pilot Jet = 38 Pilot Jet = 35
(0-8000)
Electrical Clip Position = 4 Clip Position = 4 Clip Position = 4
Alternator Max Output 80 Watts @ 3000 RPM Main Jet = 100 Main Jet = 98 Main Jet = 98
2400+
Pilot Jet = 38 Pilot Jet = 38 Pilot Jet = 35
2 - Single Beam (8000+)
Clip Position = 4 Clip Position = 4 Clip Position = 4
Lights: Main Headlights Daytime Running Lamps
(DRL) Shaded cell indicates factory setting.
Tail / Brake 5 Watts / 21 Watts
Starting System Electric Start CLUTCH CHART
Ignition System CDI
Altitude
Ignition Timing Non-Adjustable Meters Shift Weight
NGK CR6HSA (Feet)
Spark plug / Gap
.024-.028 in. (0.6-0.7 mm)
0-3000
GTX12-BS / Low Maintenance 6 @ 17 grams
Battery (0-10,000)
12 Amp Hr. / 12 Volt
6 @ 15 grams
Fuses Main: 20 Amp 3000+ (10,000+)
PN 0454619

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GENERAL INFORMATION
MISCELLANEOUS SPECIFICATIONS
AND CHARTS
Standard Bolt Torque Specification

Grade 2 Grade 5 Grade 8

Bolt Size
ft-lbs (Nm) ft-lbs (Nm) ft-lbs (Nm)
1/4-20 5 (7) 8 (11) 12 (16)
1/4-28 6 (8) 10 (14) 14 (19)
5/16-18 11 (15) 17 (23) 25 (35)
5/16-24 12 (16) 19 (26) 29 (40)
3/8-16 20 (27) 30 (40) 45 (62)
3/8-24 23 (32) 35 (48) 50 (69)
7/16-14 30 (40) 50 (69) 70 (97)
7/16-20 35 (48) 55 (76) 80 (110)
1/2-13 50 (69) 75 (104) 110 (152)
1/2-20 55 (76) 90 (124) 120 (166)

Metric Bolt Torque Specification

GRADE

Bolt Size 4.6 4.8 8.8/8.9 10.9 12.9

FT-LB/NM (DRY THREADS)

M3 .3/.5 .5/.7 1/1.3 1.5/2 1.5/2

M4 .8/1.1 1/1.5 2/3 3/4.5 4/5
M5 1.5/2.5 2/3 4.5/6 6.5/9 7.5/10
M6 3/4 4/5.5 7.5/10 11/15 13/18
M8 7/9.5 10/13 18/25 26/35 33/45
M10 14/19 18/25 37/50 55/75 63/85
M12 26/35 33/45 63/85 97/130 110/150
M14 37/50 55/75 103/140 151/205 177/240
M16 59/80 85/115 159/215 232/315 273/370
M18 81/110 118/160 225/305 321/435 376/510

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GENERAL INFORMATION
Conversion Table
Unit of Measure Multiplied by Converts to
1
ft-lbs x 12 = in-lbs
in-lbs x .0833 = ft-lbs
ft-lbs x 1.356 = Nm
in-lbs x .0115 = kg-m
Nm x .7376 = ft-lbs
kg-m x 7.233 = ft-lbs
kg-m x 86.796 = in-lbs
kg-m x 10 = Nm
in. x 25.4 = mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz.) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz.)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in)
Imperial pints (Imp pt.) x 0.568 = Liters (l)
Liters (l) x 1.76 = Imperial pints (Imp pt.)
Imperial quarts (Imp qt.) x 1.137 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.)
US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.)
US quarts (US qt.) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt.)
US gallons (US gal) x 3.785 = Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
p(3.14)xR2x H (height) = Cylinder Volume

°C to °F: 9/5(°C + 32) = °F

°F to °C: 5/9(°F - 32) = °C

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Metric Tap Drill Sizes

Tap Size Drill Size Decimal Nearest
Equivalent Fraction
3x.50 #39 0.0995 3/32
3x.60 3/32 0.0937 3/32
4x.70 #30 0.1285 1/8
4x.75 1/8 0.125 1/8
5x.80 #19 0.166 11/64
5x.90 #20 0.161 5/32
6x1.00 #9 0.196 13/64
7x1.00 16/64 0.234 15/64
8x1.00 J 0.277 9/32
8x1.25 17/64 0.265 17/64
9x1.00 5/16 0.3125 5/16
9x1.25 5/16 0.3125 5/16
10x1.25 11/32 0.3437 11/32
10x1.50 R 0.339 11/32
11x1.50 3/8 0.375 3/8
12x1.50 13/32 0.406 13/32
12x1.75 13/32 0.406 13/32

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MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4
2
30 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5
MAINTENANCE REFERENCES / SERVICE LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . 2.6
FRONT AND REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6
RH AND LH SIDE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7
LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . .2.8
MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
SHIFT CABLE INSPECTION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
SHIFT CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
CHOKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
CHOKE CABLE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
PILOT AIR SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
FUEL VALVE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
FUEL PUMP / FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
THROTTLE STOP SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
THROTTLE CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
ENGINE OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
ENGINE CRANKCASE VENTILATION SYSTEM INSPECTION . . . . . . . . . . . . . . . . . .2.21
ENGINE/TRANSMISSION MOUNT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
COMPRESSION / LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
INTAKE VALVE CLEARANCE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
EXHAUST VALVE CLEARANCE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
EXHAUST - SPARK ARRESTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
TRANSMISSION SPECIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
TRANSMISSION OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL, HUB, AND SPINDLE TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
DRIVE CHAIN LUBRICATION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

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MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
BATTERY CHARGING (MAINTENANCE FREE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING INSPECTION / TIE ROD ENDS AND HUBS . . . . . . . . . . . . . . . . . . . . . . . 2.31
TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
PARKING BRAKE CABLE FREEPLAY ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 2.34
PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36

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MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment
and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement 2
parts, use genuine Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of
approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

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

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.

= SEVERE USE ITEM -- See Above

E = Emission Control System Service (California).

NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

Improperly performing the procedures marked with acould

result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.

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MAINTENANCE
Pre-Ride - 25 Hour Maintenance Interval
Periodic Maintenance Chart

Maintenance Interval
Item (whichever comes first) Remarks
Hours Calendar Miles (KM)
Steering - Daily -
Front-Suspension - Daily -
Rear-Suspension - Daily -
Tires - Daily -
Brake Pedal Travel - Daily -
Brake Fluid Level - Daily -
Daytime Running Lights - Daily - Check each day before driving the vehicle.
Make adjustments as needed. See the Pre-
Drive Chain - Daily -
Ride Checklist in the Owner’s Manual.
Brake Lamp / Tail Lamp - Daily -
Throttle - Daily -
Wheels / Fasteners - Daily -
Frame Fasteners - Daily -
 Engine Oil Level - Daily -
E
Fuel Level - Daily -
 Air Filter (main element) - Daily - Inspect; clean often, replace as needed
E
Open CVT drain as needed, check often if
CVT Housing - Weekly -
operating in wet conditions
 Brake Pad Wear 10 H 1M 100 (160) Inspect regularly

Idle Speed 10 H 1M 100 (160) Check; adjust as needed

Choke 10 H 1M 100 (160) Check for proper operation
E
Engine Oil Change Perform a break-in oil change after the first 10
 (Break-In Period)
10 H 1M 100 (160)
hours of operation
Drive Chain Adjust and lubricate after the first 10 hours of
10 H 1M 100 (160)
(Break-In Period) operation
 Check clearance after the first 10 hours of
Valve Clearance 10 H 1M 100 (160)
E operation; Adjust to specification if required
Battery 25 H Monthly 250 (400) Check terminals; clean; test
 Transmission Oil 25 H 12 M 250 (400) Inspect level; change yearly

Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services.

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MAINTENANCE
30 - 100 Hour Maintenance Interval
Periodic Maintenance Chart

Maintenance Interval
Item (whichever comes first) Remarks

 Oil Change
Hours
30 H
Calendar
6M
Miles (KM)
300 (480) Lubricate all grease fittings, pivots, & cables
2
Clean filter at every oil change; clean annually
 Oil Pre-Filter Screen 30 H 6M 300 (480)
if operated less than 10 hours
General Lubrication 50 H 3M 500 (800) Lubricate all grease fittings, pivots, & cables
Check clearance; adjust to specification if

Valve Clearance 50 H - 500 (800) required; perform break-in adjustment after the
E
first 10 hours of operation
Carburetor Float Bowl 50 H 6M 500 (800) Drain bowl periodically and prior to storage
 Throttle Cable /
50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary
E TRS Switch

Choke Cable 50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary
E
Carburetor Air Intake Ducts
E 50 H 6M 500 (800) Inspect for proper sealing / air leaks
/ Flange
Shift Cables 50 H 6M 500 (800) Inspect; lubricate; adjust
 Brake Pad Wear 50 H 6M 500 (800) Inspect; replace as needed
Drive Belt 50 H - 500 (800) Inspect; replace as needed
 Check for leaks at tank cap, lines, fuel valve,
Fuel System 100 H 12 M 600 (1000)
E filter, carburetor, replace lines every two years

Fuel Filter 100 H 12 M 600 (1000) Replace yearly
E
Engine Mounts 100 H 12 M 600 (1000) Inspect
 Exhaust Emissions / Inspect secondary air system filter and exhaust
100 H 12 M 600 (1000)
E Muffler / Pipe - clean as required

Ignition Timing 100 H 12 M 600 (1000) Inspect
E
 Spark Plug 100 H 12 M 600 (1000)
Clean; check condition; adjust gap;
E replace as needed
Inspect for wear, routing, security; apply
Wiring 100 H 12 M 600 (1000) dielectric grease to connectors subjected to
water, mud, etc.
CVT Clutches / Drive Belt
 100 H - 600 (1000) Inspect;clean; replace worn parts
(Drive and Driven)
 Wheel / Axle Bearings 100 H 12 M 600 (1000) Inspect; replace as needed
Spark Arrestor 100 H 12 M 600 (1000) Clean
Inspect periodically; adjust when parts are
 Toe Adjustment - - -
replaced
Idle Speed - - - Adjust as needed

 Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services.

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MAINTENANCE
MAINTENANCE REFERENCES / SERVICE LOCATIONS
Front and Rear View

Daytime Running
Lamps
Grease Steering Pivots

Grease A-arm Pivots

Inspect Brake Pads

Tail / Brake Lamp

Inspect Exhaust

Inspect / Replace Air Filter

Clean / Lubricate Chain Inspect Brake Pads

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MAINTENANCE
RH and LH Side Views

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MAINTENANCE

LUBRICANTS / SERVICE PRODUCTS NOTE: Each item can be purchased separately at

your local Polaris dealer.
Polaris Lubricants, Maintenance and Service
Products Part No. Description
Additives / Sealants / Thread Locking Agents / Misc.
Part No. Description
2870585 Loctite™ Primer N, Aerosol, 25 g
Engine Lubricant
Loctite™ Thread Sealant 565
2870791 Fogging Oil (12 oz. Aerosol) 2871956
(50 ml.) (6 Count)
Performance Synthetic (PS-4) Extreme Loctite™ Threadlock 242
2878920 2871949
Duty Oil (Quart) (50 ml.) (10 Count)
Performance Synthetic (PS-4) Extreme Loctite™ Threadlock 242
2878922 2871950
Duty Oil (2 Quart) (6 ml.) (12 Count)
Performance Synthetic (PS-4) Extreme Loctite™ Threadlock 262
2878919 2871951
Duty Oil (Gallon) (50 ml.) (10 Count)
Gearcase / Transmission Lubricants Loctite™ 518 Gasket Eliminator / Flange
2870587
Sealant (50 ml.) (10 Count)
AGL Plus - Synthetic ATV Gearcase
2878068
Lubricant (1 Qt.) (12 Count) Premium Carbon Clean
2871326
(12 oz.) (12 Count)
AGL Plus - Synthetic ATV Gearcase
2878069
Lubricant (1 Gal.) (4 Count) 2870652 Fuel Stabilizer (16 oz.) (12 Count)
AGL - Synthetic ATV Gearcase Lubricant Black RTV Silicone Sealer
2873604 2871957
(2.5 Gal.) (2 Count) (3 oz. tube) (12 Count)
ATV Angle Drive Fluid Black RTV Silicone Sealer
2871653 2871958
(8 oz.) (12 Count) (11 oz. cartridge) (12 Count)
ATV Angle Drive Fluid 2872189 DOT 4 Brake Fluid (12 Count)
2872276
(2.5 Gal) (2 Count)
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
Premium Demand Drive Fluid LT
2871654 2872893 Engine Degreaser (12oz.) (12 Count)
(1 Qt.) (12 Count)
2870465 Oil Pump for 1 Gallon Jug NOTE: The number count indicated next to each
Grease / Specialized Lubricants part number in the table above indicates the number
of units that are shipped with each order.
2871312 Grease Gun Kit
Premium All Season Grease
2871322
(3 oz. cartridge) (24 Count)
Premium All Season Grease
2871423
(14 oz. cartridge) (10 Count)
2871460 Starter Drive Grease (12 Count)
2871329 Dielectric Grease (Nyogel™)
Chain Lubricant, Aerosol
2872348
(16 oz.) (12 Count)

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MAINTENANCE
MAINTENANCE REFERENCES
Item Ref. Rec. Lube / Fluid Method Frequency*
Change after 10 hrs, and
then every 50 hours, 6

Engine Oil Page 2.7

Performance Synthetic
(PS-4) Extreme Duty Oil
Add oil to proper level on
dipstick.
months or 100 hours
thereafter; Change more 2
often in extremely dirty
conditions, or short trip
cold weather operation.
Fill reservoir between Fill as required. Change
Brake Fluid Page 2.7 DOT 4 (PN 2872189)
MAX and MIN lines. brake fluid every 2 years.
AGL Plus Synthetic Add lube to bottom of fill
Transmission Page 2.7 Gearcase plug threads. 24 oz. (710 Change annually***
Lubricant (PN 2873602) ml)
Front A -Arm Polaris Premium All
Locate grease fittings and
and Steering Page 2.6 Season Grease (PN Semi-annually**
grease with grease gun.
Pivot Bushings 2871423)

* More often under severe use, such as operated in water or under severe loads.

**Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)

***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)

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MAINTENANCE

GENERAL VEHICLE INSPECTION 1. Locate the shift cable in the rear wheel well area.
AND MAINTENANCE
Pre-Ride / Daily Inspection Shift Cables

Perform the following pre-ride inspection daily, and when Dust Boot
servicing the vehicle at each scheduled maintenance.

• Tires - check condition and pressures

• Fuel tank - fill to proper level Shift Cable
Mount
• All brakes - check operation and adjustment
• Throttle - check for free operation and closing
• Running lights/Taillight/Brakelight - also check
operation of all indicator lights and switches Clevis Pin
• Ignition switch - check for proper function
• Wheels - check for tightness of wheel nuts and
axle nuts; check to be sure axle nuts are secured 2. Inspect shift cable, clevis pin, pivot bushings, and dust
by cotter pins boot. Replace if worn or damaged.
• Air cleaner element - check for dirt; clean or
replace 3. If adjustment is required, loosen the lower jam nut and
• Steering - check for free operation noting any pull the cable out of the mount to move the upper jam
unusual looseness in any area nut.
• Loose parts - visually inspect vehicle for any
damaged or loose nuts, bolts or fasteners Upper
• Check all front and rear suspension components Jam Nut
for wear or damage.

Frame, Nuts, Bolts, and Fasteners

Periodically inspect the torque of all fasteners in
accordance with the maintenance schedule. Check that all
cotter pins are in place. Refer to specific fastener torques
listed in each chapter.
Lower
Jam Nut
Shift Cable Inspection / Adjustment
Shift cable adjustment may be necessary if symptoms
include: 4. Adjust the shift cables so there is an equal amount of
lever travel when shifting past the Neutral detent into
• Ratcheting noise on deceleration HIGH (H) and REVERSE (R).
• Inability to engage into a gear
5. Thread the upper jam nuts as required to obtain
• Excessive gear clash (noise)
proper cable adjustment without binding. There are
• Gear selector moving out of desired range
adjusters on the cables:

• If adjustment cannot be obtained, the adjusters on

the trans case should be set to center, and the
adjusters on the cables should be used to set the
adjustment
• The adjusters on the trans case can be used again
for subsequent adjustments
NOTE: This procedure may require a few attempts to
obtain the proper adjustment.

6. Once the proper adjustment is obtained, tighten the

lower jam nut against the mount.

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MAINTENANCE
7. Start engine and shift through all gears to ensure the 6. Loosen the lower and upper jam nuts and remove the
shift cable is properly adjusted. If transmission still cables.
ratchets after cable adjustment, verify the idle RPM is
set correctly, otherwise the transmission may require
service.

Shift Cable Replacement 2

Shift cable replacement may be necessary if symptoms
include: Upper
Jam Nut
• Inability to engage a gear
• Inability to adjust cables for proper operation
• Gear selector moving out of desired range

1. Locate the shift cables in the rear wheel well area. Lower
Jam Nut
2. Loosen the lower and upper jam nuts and remove the
cables. 7. Inspect shift lever assembly. Replace parts as
required if worn or damaged.
Upper
Jam Nut 8. Raise the vehicle and support it with jack stands in
order to access the underside to remove the cables.

IMPORTANT: It is important for reassembly to

document location of cable ties and routing prior to
removal.
9. Install new cables and adjust for proper operation and
lever travel without binding.

IMPORTANT: Do not allow cables to hang below

Lower vehicle frame.
Jam Nut 10. After installation, lower the vehicle, and then start the
engine and shift through all gears to ensure the shift
3. Inspect shift cable arm. Replace if worn or damaged. cables are properly adjusted. If transmission still
ratchets after cable adjustment, verify the idle RPM is
4. Remove the shift knob to prepare for seat panel set correctly, otherwise the transmission may require
removal. Refer to Chapter 5. service.

5. Refer to Chapter 5 for console cover removal in order 11. Reassemble the console cover, seats and shift knob
to access the shift cable mount on the lever assembly. as outlined in Chapter 5.

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MAINTENANCE

FUEL SYSTEM AND AIR INTAKE 4. Clean the air box and remove any sediments/
contaminants.
Air Filter Service
5. Apply a small amount of commercially-available
It is recommended that the air filter be inspected as part of chassis lubricant to the inner lip seal of the new air
pre-ride inspection. If riding in extremely dusty conditions, filter. Install the filter and tighten the gear clamp.
apply a small amount of grease to the seal under the air
APPLY LUBRICANT TO INNER LIP
box cap. In extremely dusty conditions, air filter cleaning
will be required more often.

NOTE: Service the filter more frequently if vehicle is

operated in wet conditions, dusty conditions or at
high throttle openings for extended periods.

1. Move or remove the storage bag. Remove the four

(4) access cover fasteners, and then remove the
access cover.

6. Reinstall the air box cover and secure the spring clips.

7. Reinstall the access cover and storage bag.

ACCESS PANEL

2. Release the air box cover spring clips and remove the
cover. Verify the cover seal is not damaged.

3. Loosen the air filter gear clamp and remove the filter.
Discard the filter.

AIR FILTER

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MAINTENANCE
Choke Cable Adjustment 3. Remove the retaining screws and pull the choke
assembly out at the dash.
With the choke knob pushed in, verify the choke linkage is
not engaged at the carburetor. Pull the choke knob out and
verify there is 3/16" cable freeplay before the choke
linkage engages.
Decrease 2
Choke Cable Bracket

Increase

No Adjustment Past This Point 4. Raise the vehicle and support it with jack stands in
order to access the underside.

IMPORTANT: It is important for reassembly to

document location of cable ties and routing prior to
removal.
Free play adjustment is made by loosening the choke
cable bracket at the carburetor and moving the cable 5. Pull the cable out from under the dash and the
barrel up or down in the bracket. underside of the vehicle.

IMPORTANT: Do not adjust the cable barrel higher 6. Route the new cable from front-to-back, through the
than flush with the bottom of the choke cable bracket. retainers at the bottom of the frame, following the
routing noted during disassembly. Place cable ties at
After adjusting choke cable, pull choke knob out to full the appropriate locations.
choke position. Verify knob does not pull out of cable. If
knob pulls out of cable, decrease choke cable free play. IMPORTANT: Do not allow cable to hang below
vehicle frame.
Choke Cable Replacement 7. Reinstall the choke assembly into the dash. Hand-
The choke cable is replaced as an assembly. tighten fasteners sufficiently, using care not to over-
tighten.
1. With the engine off, place the vehicle in neutral and
apply the parking brake. 8. Reinstall the choke cable onto the carburetor.

2. Remove the cable end from the carburetor. 9. Adjust cable to desired freeplay.

If smooth choke operation is not obtainable, inspect for

kinks, sharp bends in the routing or a linkage obstruction.

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MAINTENANCE
Idle Speed Adjustment Stop turning at this point and note the screw setting.

1. Start engine and warm it up thoroughly.

2. Adjust idle speed by turning the slide adjustment

screw in (clockwise) to increase or out
(counterclockwise) to decrease RPM. (Refer to PILOT AIR SCREW
illustration).

Increase
Idle Speed
Screw
IDLE SPEED Decrease

Decrease

Increase Pilot Air Screw Base Setting:

2.25 turns out (initial)

Special Tool:
PA-47361

3. Slowly turn mixture screw counterclockwise until idle

speed returns to Idle RPM. Continue turning
Idle Speed counterclockwise until idle RPM begins to drop. Stop
1700 ± 100 turning at this point and note the screw setting

4. Center the mixture screw between points in Step 2 and

NOTE: Always check throttle cable freeplay after 3.
adjusting the idle speed and readjust if necessary.
5. Readjust idle speed if not within specification.
Pilot Air Screw Adjustment

CAUTION

The pilot air screw is calibrated at the factory to

meet EPA / CARB regulations for air quality
standards. Cleaning of the pilot circuit must be
performed by a certified repair shop to ensure
air quality standards are not exceeded.

1. Start the engine and verify (using a portable

tachometer) the idle speed is set to specification.
Always check throttle cable freeplay after adjusting
idle speed, and adjust if necessary.

2. Using ‘D’-shaped screwdriver Special Tool PA-47361

adjust the pilot air screw setting, turn the screw
clockwise until engine idle RPM begins to decrease.

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MAINTENANCE
Vent Lines Fuel Filter
1. Check fuel tank, crankcase, carburetor and The fuel filter should be replaced in accordance with the
transmission vent lines for signs of wear, “Periodic Maintenance Chart” or whenever sediment is
deterioration, damage or leakage. Replace every two visible in the filter.
years.
Fuel Filter Location - Located in-line between fuel
2. Verify vent lines are routed properly and secured with pump and carburetor inlet. 2
cable ties.

Fuel System

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.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately. To service the fuel filter:
If you spill gasoline on your skin or clothing,
1. Turn off fuel supply at fuel valve.
immediately wash it off with soap and water
and change clothing. 2. Remove line clamps at both ends of the filter.
Never start the engine or let it run in an enclosed
area. Engine exhaust fumes are poisonous and 3. Remove fuel lines from filter.
can result loss of consciousness or death
in a short time. 4. Install new filter and clamps onto fuel lines.
Never drain the fuel when the engine is hot.
5. Turn fuel valve to ‘ON’.
Severe burns may result.
6. Start engine and inspect for leaks.

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MAINTENANCE
Fuel Valve Location 4. Tighten drain screw.

The fuel valve is located on the passenger side of the 5. Turn fuel valve to “ON” and check for fuel leaks.
vehicle below the gas cap. Always turn off the fuel when
the vehicle is not in use. 6. Start engine and re–check for leaks.

Fuel Pump / Fuel Lines

NOTE: Thoroughly clean the exterior of all fuel
related components before servicing.

The RZR170 fuel pump is located in the right rear wheel

well.

Turn knob to operate

the fuel valve

Carburetor Draining
The carburetor float bowl should be drained before
extended periods of storage, or periodically to remove
accumulated moisture or sediment from the bowl. 1. Check the fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary.
1. Turn fuel valve to the ‘OFF’ position.
2. Be sure fuel line is routed properly.
2. Place a container under the bowl drain hose.
IMPORTANT: Make sure line is not kinked or pinched.
3. Loosen drain screw and allow fuel in the float bowl and
3. Replace fuel lines every two years.
fuel line to drain completely.
NOTE: For all other information related to the fuel
System, refer to Chapter 4.

Open
Drain Screw

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MAINTENANCE
Throttle Pedal Inspection Throttle Stop Speed Control
If the throttle pedal has excessive play because of cable Use the following procedure to control how far the throttle
stretch or misadjustment, it will cause a delay in throttle opens.
response. In addition, the throttle may not open fully. If the
throttle pedal has no play, the throttle may be hard to IMPORTANT: This procedure should be performed
by consumers only when they determine that their
control, and the idle speed may be erratic.
child is capable of handling the additional speed. 2

Throttle Pedal

Jam Nut
Check the throttle pedal play periodically in accordance SPEED
with the Periodic Maintenance Chart and adjust if Stop Screw
necessary.
Decrease / Increase

1. Loosen the jam nut.

2. Turn the screw clockwise to increase speed or

counter-clockwise to reduce speed.

3. Tighten the jam nut after adjusting.

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MAINTENANCE
Throttle Freeplay Adjustment Throttle Cable Replacement
Inspection
WARNING
1. Place the transmission in the Neutral (N) position.

2. Start the engine and warm it up thoroughly. Follow the factory cable routing as installed to
prevent cable pinching, binding or damage.
3. Measure the distance the throttle pedal moves before
the engine begins to pick up speed. Freeplay should Do not allow cable to hang below vehicle frame.
be 1/16” - 1/8” (1.5 - 3 mm). Failure to install properly could result in loss of
vehicle control, resulting in severe injury or death.
Adjustment
1. Turn engine off, then place the vehicle in neutral and
1. The throttle cable adjuster is located at the throttle
apply the parking brake.
pedal housing, outside of the cab well.
2. Remove the foot pedal TRS cover screws and ONE
left-side housing mounting screw.

Throttle Cable
Adjuster

Pivot Bearing
2. Slide back the cable adjuster boot.

3. Using an open-end wrench, loosen the adjustment

NOTE: Pivot bearing inside the housing is a slip-fit
jam nut.
and will require some light prying to separate the
4. Using an open-end wrench, move the cable adjuster housing. Use caution.
until 1/16” to 1/8” (1.5 - 3 mm) of freeplay is achieved
3. Remove the cable from the housing and the ball-end
at the throttle pedal.
from the throttle pedal arm.
NOTE: While adjusting, lightly move the throttle
pedal in and out.

5. Re-tighten the jam nut.

6. Apply a small amount of grease to the inside of the

boot and slide it over the cable adjuster to its original
position.

4. Remove the carburetor slide assembly from the

carburetor body and disconnect the throttle cable.

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MAINTENANCE
5. Raise the vehicle and support it with jack stands in 12. Install the new cable onto the carburetor slide
order to access the underside of the vehicle. assembly and install the slide into the carburetor.
Hand-tighten the slide cap sufficiently.
IMPORTANT: It is important for reassembly to
document location of cable ties and routing prior to 13. Place the throttle cable end into the foot pedal
removal.
housing.
6. Remove the panduit straps retaining the throttle cable
to the frame and brake line. 14. Place a new gasket on the housing and install the 2
cover. Torque the retaining screws to specification.
7. Pull the throttle cable out through the back of the
vehicle and discard the cable.

8. Route the new cable from back-to-front, through the

retainers at the bottom of the frame, following the
routing noted during disassembly.

Pivot Bearing

=T
TRS Throttle Housing Screws:
8.5-10 ft-lbs (11.5-13.5 Nm)

9. Fasten the cable with cable ties at the same locations

they were previously removed. =T
10. Continue to route the cable towards the front of the Throttle Pedal Mounting Screws:
vehicle using the brake line routing as a general 16-20 ft-lbs (21-27 Nm)
guide.
15. Start the engine and allow it to warm up.

16. Measure the distance the throttle pedal moves before

the engine begins to pick up speed. Freeplay should
be 1/16" - 1/8" (1.5 - 3 mm).

• If freeplay is correct, proceed to step 21.

• If adjustment is required, refer to “Throttle
Freeplay Adjustment” procedure.

17. After reassembly and adjustment, field test vehicle to

ensure proper throttle operation.

11. Use cable ties to retain the throttle cable, using the
same locations they were previously removed.

NOTE: Be sure to route the throttle cable inside the

retainers.

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MAINTENANCE

ENGINE Engine Oil Change

1. Position the vehicle on a level surface.
Engine Oil Level
Maintain the oil level within the safe range on the dipstick. 2. Clean area around the drain plug.
Do not overfill.
3. Run engine until warm.
To check the oil level: 4. Stop the engine.
1. Position the vehicle on a level surface.

2. Remove the dipstick and wipe it dry with a clean cloth. CAUTION

Hot oil can cause serious burns to skin. Do not

allow hot oil to come in contact with skin.

5. Place a drain pan beneath the engine crankcase.

6. Remove the drain plug and pre-filter screen and allow

the oil to drain completely.

Dipstick

Safe Range
{

Drain Plug
Add Oil Full

3. Reinstall the dipstick completely.

4. Remove the dipstick and check the oil level.

7. Wash the oil pre-filter screen with solvent to remove
NOTE: Rising oil level between checks in cool any debris. Allow the screen to air dry.
weather driving, can indicate moisture collecting in
the oil reservoir. If the oil level is over the full mark,
change the oil.

5. Add the recommended oil as needed.

NOTE: Do not fill over the normal oil operating

range, because it could cause a mist of oil to enter
the air box. 8. Inspect the O-ring on drain plug, replace if needed.

6. Reinstall the dipstick. NOTE: The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks
or scratches.

9. Reassemble the pre-filter screen and spring to the

pre-filter plug.

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MAINTENANCE
10. Reinstall the drain plug, and torque to specification. Engine Crankcase Ventilation System
Inspection
=T The engine is equipped with a crankcase ventilation.
Follow the breather hoses from the airbox to the engine
Crankcase Drain Plug: and inspect the hoses for possible kinks or wear. The
hoses are form-fitted for a proper fit. 
18 ft-lbs (23 Nm)
2
11. Remove the dipstick. Add recommended oil making
sure not to overfill.

Recommended Engine Oil:

Performance Synthetic (PS-4)

Extreme Duty Oil

Capacity:

37 oz. (1.1 ltr)

12. Reinstall the dipstick.

13. Start the engine and allow it to idle for a short period.

14. Stop the engine and inspect for leaks. NOTE: Make sure lines are not kinked or pinched.
15. Check the oil level. Add oil as needed to bring the
level to the ‘Safe Range’ on the dipstick. Engine/Transmission Mount Locations
Periodically inspect engine/transmission upper and lower
IMPORTANT: Over-filling engine crankcase will result
mounts for cracks or damage.
in oil entering the air box. Maintain the recommended
oil level.

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MAINTENANCE
Compression / Leakdown Test Intake Valve Clearance Adjustment
IMPORTANT: Use of a compression tester adaptor 1. Remove the valve cover and secondary air pipe
that is too long WILL CAUSE DAMAGE to the cylinder assembly.
head. The adaptor length should be no longer than
the length of the spark plug threads (1/2” or 12.07mm). 2. Verify cam lobes are pointed down.
Compression tester adaptor threads
should not exceed spark plug threads. 3. Insert the correct thickness feeler gauge between end
1/2” (12.07mm)
of intake valve stem and adjuster screw.

4. When clearance is correct, hold adjuster screw and

tighten locknut securely.

5. Re-check the valve clearance.

6. Repeat adjustment procedure if necessary until

clearance is correct with locknut secured.
Cylinder Compression
Standard: 130 - 160 psi
= In. / mm.
Cylinder Leakage
Service Limit: 15% Valve Clearance:
Inspect if leakage exceeds 15% .003” (.07 mm)

Exhaust Valve Clearance Adjustment

1. Remove the valve cover and secondary air pipe
assembly.

2. Verify cam lobes are pointed down.

3. Insert the correct thickness feeler gauge between end

of exhaust valve stem and adjuster screw.

4. Loosen locknut and turn adjuster screw until there is

a slight drag on feeler gauge.

5. When clearance is correct, hold adjuster screw and

tighten locknut securely.

6. Re-check the valve clearance.

7. Repeat adjustment procedure if necessary until

clearance is correct with locknut secured.

= In. / mm.

Valve Clearance:
.003” (.07 mm)

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MAINTENANCE
Exhaust - Spark Arrestor

WARNING

Do not clean spark arrestor immediately after the

engine has been run, as the exhaust system
becomes very hot. Serious burns could result from
2
contact with the exhaust components. Allow
components to cool sufficiently before proceeding.
Wear eye protection and gloves.
Never run the engine in an enclosed area. Exhaust
contains poisonous carbon monoxide gas that can
cause loss of consciousness or death in a very
short time.

To remove accumulated carbon, clean the spark arrestor

at the interval recommended in the Periodic Maintenance
Chart.

1. Remove the retaining screws and remove the

arrestor from the end of the silencer.

2. Use a non-synthetic brush to clean the arrestor

screen. A synthetic brush may melt if components are
warm.

3. Inspect the screen for wear and damage. Replace if

required.

4. Reinstall the arrestor and torque the fasteners to

specification.

Silencer

Screen

Retaining Arrestor
Screws

=T
Spark Arrestor Fasteners:
7 ft-lbs (9.5 Nm)

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MAINTENANCE

TRANSMISSION
Transmission Specification Chart

FILL / LEVEL CHECK

GEARCASE LUBRICANT CAPACITY DRAIN PLUG TORQUE
PLUG TORQUE

AGL Plus - Synthetic

Transmission
ATV Gearcase 23.7 oz. (700 ml) 18 ft-lbs (24 Nm) 30-45 in-lbs (3-5 Nm)
(Main Gearcase)
Lubricant

Transmission Oil Change The fill plug is located on the side of the gearcase next to
the shift lever bell crank. The fluid level should be
NOTE: It is important to follow the transmission and maintained so it is even with the bottom of the fill plug hole.
gearcase maintenance intervals described in the
Periodic Maintenance Chart.

Transmission Specifications

Specified Lubricant:
AGL Plus Synthetic Gearcase Transmission Oil Fill/Check
Lubricant
(PN 2878068)

Approximate Capacity at Change:

23.7 oz. (700 ml)

Fill / Level Plug Torque:

30-45 in-lbs (3-5 Nm) • Be sure vehicle is positioned on a level surface
when checking or changing fluid.
Drain Plug Torque: • Check vent hose to be sure it is routed properly
18 ft-lbs (24 Nm) and unobstructed.

1. Position vehicle on a level surface.

Transmission Oil Level Check:
2. Remove the fill plug.

3. Add the recommended fluid through the fill plug hole

until it is even with the bottom of the check plug hole.

4. Reinstall the check/fill plug and torque to 30-45 in-lbs

(3-5 Nm) or tighten by hand sufficiently.

Transmission Oil Change:

1. Remove the level check plug (refer to “Lubricant

Level Check”).

2. Place a drain pan under the main gearcase drain plug.

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MAINTENANCE
3. Remove the drain plug and allow to drain completely. FINAL DRIVE / WHEEL AND TIRE
Wheel, Hub, and Spindle Torque Table

Item Nut Type Specification

Aluminum Wheels
Lug Nut
(#1)
30 ft-lbs (41 Nm)
+1/4 turn
2
Flange Nut
Steel Wheels 27 ft-lbs (37 Nm)
(#2)
Hub Retaining Nuts
- 40 ft-lbs (54 Nm)
(Front & Rear)

4. Clean the drain plug.

5. Reinstall the drain plug with a new o-ring and torque

to specification.

=T #1 #2

Transmission Drain Plug:

18 ft-lbs (24 Nm) Aluminum Steel Wheel
Wheel
6. Add the recommended fluid through the fill plug hole.
Maintain the fluid level even with the bottom of the fill
plug hole when filling. Do not overfill. NOTE: Do not lubricate the stud or the lug nut.

7. Reinstall the fill plug. Wheel Removal

8. Check for leaks. 1. Position the vehicle on a level surface.

9. Discard the used lubricant properly. 2. Place the transmission in gear and stop the engine.

3. Loosen the wheel nuts slightly. If wheel hub removal

is required, remove the cotter pin and loosen the hub
nut slightly.

4. Elevate the appropriate side of the vehicle by placing

a suitable jack and stand under the frame.

5. Remove the wheel nuts and remove the wheel.

6. If hub removal is required, remove the hub nut and

washers.

Wheel Installation
1. Verify the transmission is in gear.

2. Install the wheel hub, washers, and hub nut, if

previously removed.

3. Place the wheel in the correct position on the wheel

hub. Make sure the valve stem is toward the outside
and rotation arrows on the tire point toward forward
rotation.

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MAINTENANCE
4. Attach the wheel nuts and finger tighten them. Always replace tires when tread depth is worn to 1/8" (3
mm) or less.
5. Carefully lower the vehicle to the ground.
Tread
6. Torque the wheel nuts and/or hub nut to the proper Depth 1/8" (3 mm)
torque specification listed in the torque table at the
beginning of this section.

7. If hub nut was removed, install a new cotter pin after

the hub nut has been tightened.

Use a new
cotter pin
Note
Tire Rotation

Hub Nut

WARNING

Operating a RANGER 170 with worn tires will

increase the possibility of the vehicle skidding
easily with possible loss of control.
Valve stem
Wheel Nuts (4) facing outward
Worn tires can cause an accident.

CAUTION Always replace tires when the tread depth

measures 1/8", (.3 cm) or less.

If wheels are improperly installed it could affect

vehicle handling and tire wear. On vehicles with Tire Pressure
tapered rear wheel nuts, make sure tapered end
of nut seats properly into taper on wheel.
CAUTION
Tire Inspection Maintain proper tire pressure.
• Improper tire inflation may affect vehicle Refer to the warning tire pressure decal
maneuverability. applied to the vehicle.
• When replacing a tire always use original
equipment size and type. Tire Pressure Inspection (Cold)
• The use of non-standard size or type tires may
affect vehicle handling. Front Rear
3 psi (20.7 kPa) 3 psi (20.7 kPa)
Tire Tread Depth
Drive Chain Lubrication and Adjustment
Lubricate the drive chain with Polaris chain spray lube or
an approved chain lube at the interval specified in the
Periodic Maintenance Chart. Lubricate more often under
severe use, such as in dirty or wet conditions.

IMPORTANT: Washing the drive chain with a high

pressure washer or solvents can cause premature
wear and chain failure. Do not use a high pressure
washer or gasoline to clean the drive chain. Operating
the vehicle with improper rear drive chain deflection
can result in severe damage to the transmission and

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MAINTENANCE
drive components. Always make sure the chain 7. Torque the chain adjuster locknuts. Hold the adjuster
adjusted within the stated specifications. stud securely while tightening the nut to avoid
breaking the stud.
1. Check the amount of chain slack by moving the
vehicle slightly forward to gain slack at the top side of
the chain. =T
2. Raise the rear of the vehicle and support securely
under the mainframe. Allow the swing arm to hang at
Chain Adjuster Locknuts: 2
18 ft-lbs (25 Nm)
full shock extension without touching the ground. This
establishes the tightest chain position. 8. Torque the four rear housing mount bolts.
3. Pull down on the chain tensioner to move it out of the
way, then measure chain deflection. It should have 1/ =T
4"-1/2" (6-12 mm) deflection.
Rear Housing Mounting Bolts:
43 ft-lbs (60 Nm)

4. Loosen the four rear housing mount bolts (two on each

end of axle).

5. Loosen the chain adjuster locknuts.

6. Turn the chain adjusters evenly to achieve 1/4"-1/2"

(6-12 mm) chain deflection.

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MAINTENANCE

ELECTRICAL AND IGNITION SYSTEM Battery Removal

1. Remove or pull the driver’s seat forward to access
Battery Maintenance
the battery.
Keep battery terminals and connections free of corrosion.
If cleaning is necessary, remove the corrosion with a stiff
Battery
wire brush. Wash with a solution of one tablespoon baking
soda and one cup water. Rinse well with tap water and dry
off with clean shop towels. Coat the terminals with
dielectric grease or petroleum jelly.

WARNING

Battery electrolyte is poisonous. It contains

sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. 2. Disconnect the black (negative) battery cable.
Follow with milk of magnesia, beaten egg, or 3. Disconnect the red (positive) battery cable.
vegetable oil. Call physician immediately.
4. Remove the rubber strap and lift the battery out of the
Eyes: Flush with water for 15 minutes and get vehicle.
prompt medical attention.

Batteries produce explosive gases. CAUTION

Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed To reduce the chance of sparks: Whenever
space. Always shield eyes when removing the battery, disconnect the black
working near batteries. (negative) cable first. When reinstalling the
KEEP OUT OF REACH OF CHILDREN. battery, install the black (negative) cable last.

NOTE: Batteries must be fully charged before use or Battery Installation

battery life will be reduced by 10-30% of full
potential. Charge battery for 3-5 hours at a current IMPORTANT: Using a new battery that has not been
equivalent to 1/10 of the battery’s rated amp/hour fully charged can damage the battery and result in a
capacity. Do not use the vehicle’s stator/alternator shorter life. It can also hinder vehicle performance.
to charge a new battery. Follow the battery charging procedure before
installing the battery.

1. Ensure the battery is fully charged.

2. Place the battery in the battery holder and secure with

rubber strap.

3. Coat the terminals with dielectric grease or petroleum

jelly.

4. Connect and tighten the red (positive) cable first.

5. Connect and tighten the black (negative) cable last.

6. Verify that cables are properly routed and reinstall the

driver’s seat.

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MAINTENANCE
Battery Off Season Storage State of Charge
Voltage Action
Whenever the vehicle is not used for a period of three Charge Time
months or more, remove the battery from the vehicle, At least 13
ensure that it's fully charged, and store it out of the sun in 11.5 - 12.0 hrs, verify
a cool, dry place. Check battery voltage each month 25% - 50% Needs Charge
VDC state of
during storage and recharge as needed to maintain a full
charge. 11.5 VDC or
charge
2
0% - 25% Needs Charge 20 hrs
less
NOTE: Battery charge can be maintained by using a
Polaris battery tender charger or by charging about
once a month to make up for normal self-discharge. Spark Plug Service
Battery tenders can be left connected during the 1. Clean plug area so no dirt or debris can fall into the
storage period, and will automatically charge the cylinder when the plug is removed.
battery if the voltage drops below a pre-determined
point.
WARNING
Battery Charging (Maintenance Free)
A hot exhaust system and engine can cause serious
The sealed battery is already filled with electrolyte and has
burns. Allow engine to cool or wear protective
been sealed at the factory. Never pry the sealing strip off
gloves when removing the spark plug.
or add any type of fluid to this battery.

The single most important thing about maintaining a 2. Remove the spark plug cap.
sealed battery is to keep it fully charged. Since the battery
is sealed and the sealing strip cannot be removed, you
must use a voltmeter or multimeter to measure the DC
voltage at the battery terminals.

1. Check the battery voltage with a voltmeter or

multimeter. The battery voltage should read 12.8
VDC or higher.

2. If the voltage is less than 12.8 volts, charge the battery

at 1.2 amps or less until battery voltage is 12.8 VDC
or greater.

NOTE: When using an automatic charger, refer to

the charger manufacturer’s instructions for battery
charging directions. When using a constant current
charger, follow the guidelines in the following table:

State of Charge 3. Remove spark plug.

Voltage Action
Charge Time
4. Inspect electrodes for wear or carbon buildup. Look
None, check for a sharp outer edge on the electrode, with no
12.8 - 13.0 None
100% again in 3 rounding or erosion.
VDC Required
months
May need Inspect electrode for
75% - 12.5 - 12.8 slight charge, wear or buildup
3 - 6 hrs
100% VDC check again in
3 months
12.0 - 12.5
50% - 75% Needs Charge 5 - 11 hrs
VDC

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MAINTENANCE
5. Clean with electrical contact cleaner or a glass bead STEERING
spark plug cleaner only. CAUTION: A wire brush or
coated abrasive should not be used. Steering Inspection
6. Measure gap with a wire gauge. Refer to The steering components should be checked periodically
specifications in the following illustration for proper for loose fasteners, worn tie rod ends, ball joints, and
spark plug type and gap. Adjust gap if necessary by damage. Also check that all cotter pins are in place. If
carefully bending the side electrode. cotter pins are removed, do not re–use, always use new
cotter pins.
Spark Plug Gap
Replace any worn or damaged steering components.
Steering should move freely through the entire range of
travel without binding. Check routing of all cables, hoses,
and wiring to be sure the steering mechanism is not
restricted or limited.
Gap - .024-.028" (0.6-.07 mm)
NOTE: Whenever steering components are
7. If necessary, replace spark plug with proper type. replaced, check front end alignment.
CAUTION: Severe engine damage may occur if the
incorrect spark plug is used. Steering Wheel Freeplay

8. Apply anti-seize compound to the spark plug threads. Check the steering wheel for specified freeplay and
operation.
9. Install spark plug and torque to specification.
1. Position the vehicle on level ground.

Recommended Spark Plug: 2. Lightly turn the steering wheel left and right.
NGK CR6HSA 3. There should be 0.8”-1.0” (20-25 mm) of freeplay.

Spark Plug Torque: 4. If there is excessive freeplay or the steering feels

11 ft-lbs (15 Nm) rough, inspect the following components.

• Tie Rod Ends

• Steering Shaft U-Joints
Engine To Frame Ground • Steering Gearbox
Inspect engine ground cable connection. Be sure it is
clean and tight. The ground cable runs from the engine
starter motor to the ground terminal location under the
driver’s seat.

U-Joints

Tie Rod Location

Ground
Terminal Location Gearbox

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MAINTENANCE
Steering Inspection / Tie Rod Ends and Hubs Toe Alignment Inspection
• To check for play in the tie rod end, grasp the 1. Place machine on a smooth level surface.
steering tie rod and pull in all directions feeling for
movement. 2. Set steering wheel in a straight ahead position and
secure the steering wheel in this position.

3. Place a chalk mark on the center line of the front tires

approximately 10” (25.4 cm) from the floor or as close
2
to the hub/axle center line as possible.

• Elevate front end of machine so front wheels are

off the ground. Check for any looseness in front
hub and wheel assembly by grasping the tire firmly
at top and bottom first, and then at front and rear. Measurement “B” Chalk Mark
Try to move the wheel and hub by pushing inward Measurement “A”
and pulling outward.
NOTE: It is important that the height of both marks
Check for Loose Wheel or Hub be equally positioned in order to get an accurate
measurement.

4. Measure the distance between the marks and record

the measurement. Call this measurement “A”.

5. Rotate the tires 180 by moving vehicle forward or

backward. Position chalk marks facing rearward,
even with the hub/axle center line.

6. Again measure the distance between the marks and

record. Call this measurement “B”. Subtract
• If abnormal movement is detected, inspect the hub measurement “B” from measurement “A”. The
and wheel assembly to determine the cause difference between measurements “A” and “B” is the
(possible loose wheel nuts or loose front hub vehicle toe alignment. The recommended vehicle toe
components). tolerance is 1/8” to 1/4” (.3 to .6 cm) toe out. This
• Refer to Chapter 5 for front hub service means the measurement at the front of the tire (A) is
procedures. 1/8” to 1/4” (.3 to .6 cm) wider than the measurement
at the rear (B).

= In. / mm.

Wheel Toe-Out:
(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)

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MAINTENANCE
Toe Adjustment SUSPENSION
If toe alignment is incorrect, measure the distance
Spring Preload Adjustment
between vehicle center and each wheel. This will tell you
which tie rod needs adjusting. The front and rear shock absorber springs are adjustable
by rotating the adjustment cam to change spring tension
NOTE: Be sure steering wheel is straight ahead preload.
before determining which tie rod(s) need
adjustment.
WARNING
CAUTION Uneven adjustment may cause poor handling of the
vehicle, which could result in an accident and
During tie rod adjustment, it is very important that serious injury or death. Always adjust all spring
the following precautions be taken when preloads equally.
tightening tie rod end jam nuts.
If the rod end is positioned incorrectly it will not Suspension Spring Adjustment
pivot, and may break.
1. Position the vehicle on a level surface and stop the
To adjust toe alignment: engine.

• Hold tie rod end to keep it from rotating. 2. Raise and safely support the front or rear of the
• Loosen jam nuts at both ends of the tie rod. vehicle off the ground to allow the suspension to fully
• Shorten or lengthen the tie rod until alignment is as extend.
required to achieve the proper toe setting as
specified in Toe Alignment Inspection. NOTE: The tires should not be touching the ground.
• IMPORTANT: When tightening the tie rod end jam
3. To adjust the shock spring preload, rotate the
nuts, the rod ends must be held parallel to prevent
adjustment cam clockwise to increase spring tension
rod end damage and premature wear. Damage
or counter-clockwise to decrease spring tension using
may not be immediately apparent if done
the supplied spanner wrench.
incorrectly.
• After alignment is complete, torque jam nuts to
specification. Keep tie rod parallel to the mounting
surface.

=T
Tie Rod Jam Nut:
12-14 ft-lbs (16-19 Nm)

Decrease Increase
Preload Preload

Special Tool:

Shock Spanner Wrench

4. Each notch of the adjustment will add 6% - 8% more

preload to the spring over the primary position.

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MAINTENANCE
BRAKE SYSTEM Brake Pad / Disc Inspection
1. Check the brake pads for wear, damage, or
Brake Fluid Inspection
looseness.
Always check the brake pedal travel and inspect the brake
fluid reservoir level before each operation. If the fluid level 2. Inspect the brake pad wear surface for excessive
wear.
is low, add DOT 4 brake fluid only.
3. Pads should be changed when the friction material is
2
Brake fluid should be changed every two years, anytime
the fluid becomes contaminated, the fluid level is below worn to .040” (1 mm).
the minimum level, or if the type and brand of the fluid in
the reservoir is unknown.

The brake fluid master cylinder reservoir can be accessed

through the left front wheel well.

1. Position the vehicle on a level surface with the engine

off.

2. Place the transmission in gear and lock the parking Measure Pad Material
brake. Thickness Service Limit:
.040" (1 mm)
3. View the brake fluid level in the reservoir. The level
should be between the MAX and MIN level lines.

4. If the fluid level is lower than the MIN level line, add 4. Check surface condition of the brake discs.
brake fluid until it reaches the MAX level line.
5. Measure the thickness of the front and rear brake
5. Install the reservoir cap and apply the brake pedal discs.
forcefully for a few seconds, then check for fluid leaks
around the master cylinder and brake caliper fittings. 6. The disc(s) should be replaced if thickness is less than
.170” (4.32 mm).

Measure Brake Disc Thickness

Rear Front
Disc Disc

Service Limit:
.170" (4.32 mm)

Brake Hose and Fitting Inspection

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

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MAINTENANCE
Parking Brake Cable Freeplay Adjustment
Use the in-line adjuster to adjust the parking brake cable
freeplay.

NOTE: Inspect the brake pads before adjusting

parking brake adjuster.

1. Verify the parking brake lever is down.

2. Inspect the freeplay between the cable end and

caliper bracket by pulling back on the cable.

3. Freeplay should be 1/16"-1/8" (1.5-3mm).

4. To adjust the cable freeplay, loosen the in-line adjuster

jam nut. Turn the adjuster nut outwards to decrease
cable freeplay. Turn the adjuster inwards to increase
cable freeplay.

5. After setting the correct amount of freeplay, tighten the

in-line adjuster jam nut against adjuster.

Inspect Freeplay Here

Inline Adjuster Nut

Jam Nut

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MAINTENANCE
Parking Brake Adjustment 9. Verify the park brake lever stays in the UP position
when brake is fully applied.
NOTE: Inspect the brake pads before adjusting
parking brake adjuster.

1. Place vehicle on a flat, level surface.

2. Shift transmission into Neutral. 2

3. Carefully lift rear tires off the ground with a stable
platform jack, or set vehicle on stable jack stands.
A
4. Loosen jam nut (A) on parking brake adjustment bolt.

5. While rotating the rear wheels by hand, tighten the

adjustment bolt (B) until significant brake drag is B
detected.

6. Back the adjustment bolt out 1/4 turn.

7. Hold adjustment bolt in place and tighten jam nut

securely against lever arm.

8. Check parking brake lever movement. Verify the rear

wheels rotate freely with the parking brake off (parking
brake lever is in the DOWN position), and that the
vehicle will not move when the parking brake is
applied (lever in the UP position).

Hold Adjuster Bolt While

Tightening Jam Nut

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MAINTENANCE

MAINTENANCE LOG

Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician

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ENGINE
CHAPTER 3
ENGINE
TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE PATTERNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
ENGINE SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
ENGINE SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
ENGINE SYSTEMS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
BREATHER / OIL SEPARATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
EMISSIONS SECONDARY AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
COOLING SHROUD REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
TOP-END DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
ENGINE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
FINDING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
CAM CHAIN TENSIONER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
ROCKER ASSEMBLY 
DISASSEMBLY AND INSPECTION3.15
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CYLINDER HEAD DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
CYLINDER HEAD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CAM CHAIN FOLLOWER / TENSIONER GUIDE REMOVAL . . . . . . . . . . . . . . . . . . . . 3.23
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CYLINDER HONE SELECTION / HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 3.25
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
BOTTOM-END DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
STARTER DRIVE GEAR REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 3.27
FLYWHEEL REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
CRANKSHAFT ONE WAY GEAR / DRIVE SPROCKET REMOVAL/INSPECTION . . . 3.29
STARTER DRIVE ONE-WAY CLUTCH REMOVAL AND INSPECTION . . . . . . . . . . . . 3.30
BALANCE SHAFT SPROCKET REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . 3.30
OIL PUMP REMOVAL / DRIVE CHAIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31

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ENGINE
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CRANKCASE SEPARATION AND CAM CHAIN REMOVAL. . . . . . . . . . . . . . . . . . . . . 3.33
CRANKSHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . 3.34
CRANKCASE / BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CRANKCASE OIL STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
BEARING / SEAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
CHAIN GUIDE/TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CRANKSHAFT, BALANCE SHAFT AND STARTER DRIVE GEAR INSTALLATION . . 3.37
OIL PUMP AND CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
CYLINDER HEAD AND CAMSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
ROCKER ARM / SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
ROCKER ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
INTAKE VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
STARTER DRIVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
STATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
STATOR HOUSING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
SPARK PLUG FOULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51

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ENGINE
TOOLS TORQUE SPECIFICATIONS
Special Tools Engine Torque Specifications

PART NUMBER TOOL DESCRIPTION TORQUE SPECIFICATIONS

2870390 Piston Support Block Thread ES35C
PA-45153 Flywheel Puller Fastener
Size ft-lbs (Nm)
Transmission Output Shaft Camshaft Chain Guide
PA-49959 6mm 5-7 (7-9 Nm)
Collar Tool Pivot Bolt
Balance Shaft Slotted Nut Camshaft Chain
PA-47344
Socket
Crankshaft Slotted Nut
Tensioner
6mm 5-7 (7-9 Nm)
3
PA-49935 Chain Tensioner Cap 6mm 5-7 (7-9 Nm)
Socket
Flywheel Puller Adaptor Carburetor Intake 6mm 7-8 (9-11 Nm)
PA-49936
(Use with PA-45153)
Cylinder/Head Nuts 10mm 18 (25 Nm)
SPX Corp: 1-800-328-6657 or [Link]
Cylinder Base Screws 6mm 5-7 (7-9 Nm)

Crankcase (inner) 6mm 14-15 (19-21 Nm)

Crankshaft Slotted Nut 14mm 43 (58 Nm)

Balancer Shaft Nut 14mm 43 (58 Nm)

Exhaust Nuts 6mm 7-8 (9-11 Nm)

Flywheel Nut 14mm 43 (58 Nm)

Cooling Fan 6mm 4-5 (5-7 Nm)

Oil Drain Bolt 14mm 18 (25 Nm)

Oil Pump 
6mm 4-5 (5-7 Nm)
Screws
Oil Pump Sprocket Nut 6mm 7-8 (9-11 Nm)

Oil pump baffle plate 6mm 4-5 (5-7 Nm)

Stator Assembly 6mm 7-8 (9-11 Nm)

Stator Housing 6mm 7-8 (9-11 Nm)

Valve Cover 6mm 7-8 (9-11 Nm)

Valve Adjuster Lock Nut 5mm 4-5 (5-7 Nm)

Starter Motor 6mm 5-7 (7-9 Nm)

Spark Plug 12mm 11 (15 Nm)

Pulse Coil Screws 5mm 4-5 (5-7 Nm)

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ENGINE
Torque Patterns
Tighten cylinder head, cylinder base, and crankcase
fasteners in 3 steps following the sequence outlined. Refer
to the table for torque specifications.

3 2
5
6 mm
6
1 4

Cylinder Base / Head and

Rocker Assembly

1 2

RH Crankcase - (Inside Stator Cover)

1 5
8
6

3
2

9
4 7

RH Crankcase - Stator Cover

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ENGINE
ENGINE INFORMATION
Engine Exploded Views

Crankcase Cylinder / Cylinder Head

Crankshaft and Piston Valve Train

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ENGINE
Engine Lubrication Accessible Components
Oil Type:** The following components can be serviced or removed
Performance Synthetic (PS-4) Extreme Duty Oil with the engine installed in the frame:

Capacity: Approximately 37 oz. (1.1 ltr.) • Flywheel

• Alternator/Stator
Drain Plug (Engine Oil): 18 ft-lbs (23 Nm) • Starter Motor/Starter Drive
• Oil pump / Chain
Screen Fitting: 11 ft-lbs (15 Nm)
• Rocker Arms
Oil Pressure Specification: Not Applicable  • Carburetor
 • Transmission Components
** For break-in period after engine top end service, use • Valves
Performance Synthetic (PS-4) Extreme Duty oil to ensure • Cylinder Head
complete piston ring seating to cylinder wall. Change to • Cylinder
above recommendation after 10 hours. • Piston/Rings
• Camshaft
Piston Identification The following components require engine removal for
The piston may or may not have an identification mark for service:
piston placement. If the piston has an identification mark,
• Cam Chain and Sprockets
follow the directions for piston placement below. If the
• Crankshaft
piston does not have an identification mark, the direction
• Crankshaft Main Bearings
for placement of the piston does not matter.
• Crankcase/Bearings
Note the directional and identification marks when viewing • Balancer/Bearings
the pistons from the top. The letters “IN” must always be NOTE: Cam chain service requires crankshaft
toward the intake side of the engine. The other numbers removal, as the chain is located on the pto side of
are used for identification as to diameter, length and the engine.
design. Four stroke engine rings are rectangular profile.
Any numbers or letters on the rings (except oil control NOTE: Crankshaft components are not serviceable.
rings) must be positioned upward. See text for oil control Replace crankshaft as an assembly.
ring upper rail installation.

Oversize Standard Piston

Engine Model No.
Available (mm) Identification
”IN” marking on
ES35C N/A top of piston
toward intake

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ENGINE
Engine Service Data

Cylinder Head / Valvetrain ES35C

Rocker arm ID .3936 - .4007" (10.00 - 10.18 mm)
Rocker Arm/Shaft
Rocker shaft OD .3925 - .3931" (9.972 - 9.987 mm)
Std 1.1730" (29.795 mm)
In
Limit 1.1574" (29.40 mm)
Camshaft Cam lobe height
Std 1.1637" (29.56 mm)
Ex
Limit 1.1480" (29.16 mm)
Cylinder Head Surface warpage limit .002” (.05 mm) 3
In Std .003" (.07 mm)
Valve Clearance
Ex Std .003" (.07 mm)
Std .039" (1.0 mm)
In
Limit .063" (1.6 mm)
Valve Seat Angle Contacting width
Std .039" (1.0 mm)
Ex
Limit .063" (1.6 mm)
In .1958 - .1960" (4.975 - 4.980 mm)
Valve Stem diameter Ex .1950 - .1956" (4.955 - 4.970 mm)
Limit .1921" (4.9 mm)
In .1968 - .1973" (5.0 - 5.012 mm)
Valve Guide Inner Diameter Ex .1968 - .1973" (5.0 - 5.012 mm)
Limit .1980" (5.03 mm)
Inner 1.275" (32.4 mm)
Free Length
Valve Spring Outer 1.385" (35.2 mm)
Squareness 0.075” (1.9 mm)
Cam Chain Install new as a part of any crankshaft
removal

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; 
PTO: Power Take Off

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ENGINE
Engine Service Data

Cylinder / Piston / Connecting Rod ES35C

Surface warpage limit (mating with cylinder
.002” (0.05 mm)
head)
Cylinder bore Std 2.4015 - 2.4019" (61 - 61.01 mm)
Taper limit .002” (0.05 mm)
Cylinder Out of round limit .002” (0.05 mm)
Std .00039 - .0015" (0.01 - 0.04 mm)
Piston to cylinder clearance
Limit .0039" (0.1 mm)

Boring Limit Not Applicable

Std 2.4003 - 2.4011" (60.97 - 60.99 mm)

Outer diameter 1st O.S. Not Applicable
Piston
2nd O.S. Not Applicable
Pin Bore - Inner Diameter .5906 - .5908" (15.002 - 15.008 mm)
Pin outer diameter clearance in piston .00015 - .00047” (.004 - .012 mm)
Piston Pin Piston Pin must be a push (by hand) fit at 68 F
Degree of fit
(20 C)
Std .0059 - .013" (.15 - .35 mm)
Top ring
Limit .0196" (0.5 mm)

Second Std .0059 - .013" (.15 - .35 mm)

Piston Ring Piston Ring Installed gap
ring Limit .0196" (0.5mm)
Std .0079 - .0314" (0.2 - 0.8 mm)
Oil ring
Limit .059" (1.5 mm)
Std .00078 - .0023" (0.02. - 06 mm)
Top ring
Standard clearance -  Limit .0035" (0.09 mm)
Piston Ring
piston ring to ring groove Std .00078 - .0023" (0.02 - 0.06 mm)
Second
ring Limit .0035" (0.09 mm)
Connecting rod small end ID .5903 - .5916” (15.01 - 15.028 mm)

Connecting Rod Connecting rod big end axial clearance Std .0039 - .011" (0.1 - 0.3 mm)

Connecting rod big end radial

Std Not Applicable
clearance
Crankshaft end runout 0.0015" (0.04 mm)
Crankshaft
Crankshaft end runout - limit 0.0039" (0.1 mm)

Oil pump chain Install new as a part of any oil pump replacement

Cam Shaft Chain Install new as a part of any crankshaft

replacement
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off.

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ENGINE
Oil Flow Diagram

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ENGINE
ENGINE SYSTEMS SERVICE
Breather / Oil Separator
The breather / oil separator is located on the upper rear cab support. This system provides ventilation for the valve cover
and engine crankcase to the air box. A one-way valve (A) allows pulses from the crankcase to travel in one direction
only, thereby vacuuming the crankcase. NOTE: Over-filling of crankcase will result in oil in the air box. Always keep oil
volume at recommended level.

7-8 ft-lbs (9-11 Nm)

To One-Way Valve

To Air Box

7-8 ft-lbs (9-11 Nm)

To Valve Cover

To Crank Case

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ENGINE
Emissions Secondary Air System
The secondary air system is located on the upper rear cab support and engine. This system introduces air into the
exhaust system for more complete burning of the exhaust emissions. The air control valve (A) is operated by intake
manifold pulses from the intake manifold, which releases the air to the one-way valve (B) to combine with the pull of the
exhaust gas stream from the cylinder head. Check the air control valve (A), one-way valve (B), filter housing (C) and
related components according to the maintenance schedule in Chapter 2 for proper operation and emissions compliance.

7-8 ft-lbs (9-11 Nm)

3
C
A Air In

16 ft-lbs (22 Nm)

To Intake (impulse)

Air To Cylinder Head Exhaust Passage

7-8 ft-lbs (9-11 Nm)

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ENGINE
Cooling Shroud Removal/Installation and attaching bolt into the engine case. Hand tighten
sufficiently, using care not to over-tighten.
The cooling shroud directs air generated by the fan around
the cylinder and casing for cooling. 9. Install the fan shroud (A) and attaching screws to
housing (C). Install the fan shroud bolts to the stator
REMOVAL: housing. Hand tighten sufficiently, using care not to
over-tighten.
1. Remove the carburetor and intake.
10. Install the exhaust pipe onto the cylinder. Torque to
2. Remove the exhaust pipe. specification.
3. Remove the screws that attach the fan shroud (A) to
the housing (C). =T
4. Remove the bolts that attach the fan shroud to the
stator housing. Pipe Flange Fasteners:
7-8 ft. lb. (9-11 Nm)
5. Remove the screws that attach the upper and lower
housings together (C). 11. Install the carburetor and intake. Torque fasteners to
specification.
6. Remove the bolt that attaches the housing to the
engine case on the PTO side.
7. Separate the upper and lower housings at the snap-
=T
hooks and lift housings away from the engine.
Fasteners:
INSTALLATION: 7-8 ft. lb. (9-11 Nm)

8. Install the upper and lower housings (C), making sure

the snap-hooks are secure. Install the housing screws
A
Cooling Shroud Exploded View
MAG View PTO View
A. Fan Shroud

C B

B. Air Horn Assembly

C. Housing

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ENGINE
Engine Removal Engine Installation Notes
1. Clean work area. After the engine is installed in the frame, review this
checklist and perform all steps that apply:
2. Thoroughly clean the engine and chassis.
3. Disconnect battery. General Items

4. Drain engine oil. • Install previously removed components using new

gaskets, seals, and fasteners where applicable.
5. Disconnect spark plug high tension lead.
• Perform checks on fluid levels, controls, and all
6. Disconnect all electrical wires from the engine. important areas on the vehicle as outlined in the
daily pre-ride inspection checklist (refer to Chapter
7. Remove the following parts as required:
2). 3
• Rear Cab Assembly (Refer to Chapter 5)
CVT System
8. Remove exhaust pipe.
• Clean clutch sheaves thoroughly and inspect inlet
9. Remove the carburetor. Insert a clean shop towel into
and outlet ducts for proper routing and sealing.
the carburetor flange to prevent dirt from entering the
• Inspect clutch rollers, shoes and springs before
intake.
reassembly.
10. At the starter motor, note the chassis ground cable
location and remove it. Transmission

11. Mark the positive (+) cable mounting angle and • Inspect transmission operation and adjust linkage
remove cable. if necessary.
12. Remove the transmission shift cables from the Exhaust
transmission and secure out of the way.
• Replace exhaust gaskets. Seal connections if
13. Raise the rear of the unit until the wheels are off the
desired with high temp sealant.
ground. Secure with jackstands under the frame.
• After running the engine, verify all bolted exhaust
14. Remove the drive chain. connections are tight and in good condition.
15. Remove the top rear shock bolts and allow the swing Engine Mount Torque
arm to drop. (OPTIONAL - Refer to Chapter 5 to
remove the axle and swing arm as an assembly) • Front Mount
• Rear Mounts
16. Remove all engine mount bolts and / or engine mount
plates. Engine Break In Period
17. Using the aid of an assistant, lift and remove engine
4 Cycle Engine Break-In Period is defined as the first 10
out the rear of the vehicle.
hours of engine operation or 2 full tanks of fuel.

• Use only Performance Synthetic (PS-4) Extreme

Duty Oil, or API certified “SH” oil equivalent.
• Use fuel with a minimum octane of 87 (R+M)/2
method.
• Change break-in oil at 10 hours or 100 miles,
whichever comes first.

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ENGINE
TOP-END DISASSEMBLY
Engine Removal/Installation
Refer to page 3.12 for engine removal / installation notes.

Finding Top Dead Center (TDC)

1. Remove the cooling shroud.
2. Remove the inspection cap from the stator housing.
3. Remove the valve cover and emissions pipe
assembly.

To position the crankshaft at Top Dead Center (TDC) on

the compression stroke:

4. Rotate the engine slowly in the direction of rotation

Cam Chain Tensioner Inspection
while watching the intake valve open and start to
close. 1. Remove the two cam chain tensioner flange bolts.
NOTE: The plunger is under spring tension.
5. Continue to rotate slowly while watching the camshaft
Maintain inward pressure on the tensioner body
sprocket marks and timing mark in the inspection
while removing.
hole.
Single TDC Mark Aligned

TDC Mark

Rotation

6. The engine is at Top Dead Center when the single

(TDC) mark on flywheel is visible within the inspection 2. Allow the cam chain tensioner plunger to extend
hole and the cam sprocket hole is facing upward. outward to the end of its travel. Inspect tensioner and
NOTE: The sprocket marks should align with the plunger (A) for wear or damage.
gasket surface, the cam lobes must be pointed
downward and the rockers must have valve
clearance at this point.

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ENGINE
3. Using a small flat blade screwdriver, turn the tensioner 5. Remove each rocker arm shaft using a hex bolt.
clockwise to retract the plunger. The plunger should NOTE: Place the hex bolt head in a vise and lightly
move smoothly in and out of the tensioner body. tap the rocker housing with a non-marring
hammer to pull the rocker arm shafts.
4. Tap lightly on tensioner body with a soft face hammer
to loosen and remove tensioner if required.
5. Replace tensioner assembly if any part is worn or
damaged.

Rocker Assembly 
Disassembly and Inspection
NOTE: Orientation of the components is important
3
for reassembly. Mark components as needed before
disassembly.

1. Remove the valve cover and secondary air injection

pipe as an assembly.
2. Loosen each of the four cylinder head nuts evenly 1/ 6. Measure O.D. of rocker shafts for out-of-round.
4 turn each time in a cross pattern until loose. Inspect for wear or damage. Replace if excessive
wear is evident. NOTE: Orientation of the rocker
shafts is important for reassembly. Place only the
exhaust rocker shaft into the exhaust side of the
cam support.

Exhaust
C

3. Remove the nuts and tap the rocker assembly with a

plastic hammer to loosen, then remove. Mark or tag
rocker arms to keep them in order for assembly.
7. Measure I.D. of each rocker arm for out-of-round and
4. Inspect each rocker arm cam follower surface. If there visually inspect the I.D. surface. Replace arm if
is any damage or uneven wear, replace the rocker excessive wear is evident.
arm. NOTE: Always inspect camshaft lobes if
rocker arms are worn or damaged.

Inspect

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ENGINE
8. Inspect the lash adjusters for wear, pitting, or damage Camshaft Inspection
to threads of the adjuster or locknut. Replace all worn
or damaged parts. NOTE: The end of the lash 1. Inspect cam sprocket teeth for wear or damage.
adjuster is hardened and cannot be ground or re- Replace if necessary.
surfaced.

Camshaft Removal
NOTE: Cam chain tensioner must be removed
before performing this procedure.

1. Verify the valve cover and cam chain tensioner have

been removed.
Inspect for Areas of
2. Remove the 4 cylinder head bolts evenly by loosening Tooth Wear or Damage
each one 1/4 turn at a time until loose. Tap the rocker
assembly with a non-marring hammer to loosen and 2. Inspect the compression release mechanism. This is
remove the assembly. a one-way rotating shoulder that lifts the exhaust valve
slightly during start-up. If the one-way mechanism is
not functioning, replace the cam. Verify the stop
bracket and spring is functioning correctly. Replace if
excessive wear of components is found.
Compression Release
One-Way Operation

3. Remove the cam chain from the sprocket by tilting the

cam assembly and simultaneously lifting the chain.

3. Visually inspect each cam lobe and bearing for wear,

chafing or damage.

Bearings

4. If not removing the cylinder for other service, secure

the cam chain with a wire to prevent it from falling into
the crankcase. Lobe Height

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ENGINE
Cylinder Head Removal
NOTE: Cam chain and tensioner must be removed. If
no crankshaft service is being performed, secure
Compression Release-One-way stop cam chain with mechanics wire to avoid chain falling
into the crankcase.

1. Verify the valve cover and tensioner are removed.

2. Remove the two 6mm cylinder/head base screws.
3. Loosen each of the four cylinder head nuts evenly 1/
4 turn each time in a cross pattern until loose.
3
= In. / mm.

Cam Lobe Height:

Intake
Std: 1.1730” (29.795 mm)
Limit: 1.1574” (29.40 mm)
Exhaust
Std: 1.1637” (29.56 mm)
Limit: 1.1480” (29.16 mm)
4. Remove the nuts and tap the rocker assembly with a
4. Thoroughly clean the cam shaft. plastic hammer until loose. Remove.

5. Measure height of each cam lobe using a micrometer. 5. After removing the camshaft and securing the cam
Replace cam if worn below minimum height. chain, tap the cylinder head lightly with a plastic
hammer until loose. CAUTION: Tap only in
Replace camshaft if damaged or if any part is worn reinforced areas or on thick parts of cylinder head
excessively. casting to avoid damaging casting.
6. Remove cylinder head (A) and head gasket (B).

A
B

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ENGINE
Cylinder Head Inspection Cylinder Head Disassembly
1. Thoroughly clean cylinder head surface to remove all
traces of gasket material and carbon. WARNING

CAUTION Wear eye protection or a face shield during

cylinder head disassembly and reassembly.
Use care not to damage sealing surface.
If there is damage found on the cylinder head NOTE: Keep all parts in order with respect to their
combustion chamber, it is recommended the location in the cylinder head.
component be replaced. NOTE: Valves have inner and outer springs.

Cylinder Head Warp Inspection 1. Using a valve spring compressor, compress the valve
springs and remove the split keeper. NOTE: To
1. Lay a straight edge across the surface of the head at prevent loss of tension, do not compress the valve
several different points and measure warpage by spring more than necessary.
inserting a feeler gauge between the straight edge
and the cylinder head surface. If warpage exceeds
the service limit, replace the cylinder head.

2. Remove spring retainer and spring.

= In. / mm.

Cylinder Head Warp Limit: .002” (.05 mm)

Combustion Chamber Inspection

Clean all accumulated carbon deposits from combustion
chamber and valve seat area with a soft wire brush.
Inspect the combustion chamber for cracks and/or
damage from foreign debris.
NOTE: The valve springs should be positioned with
the tightly wound coils against the cylinder head on
progressively wound springs (A).

3. Push valve out, keeping it in order for reassembly in

the same guide.

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ENGINE
4. Measure free length of the inner and outer springs Valve Inspection
with a Vernier caliper, Ill.1. Check spring for
squareness as shown in Ill.2. Replace spring if 1. Remove all carbon from valve with a soft wire wheel.
measurements are out of specification. 2. Check valve face for runout, pitting, and burned spots.
To check for bent valve stems, mount valve in a drill
or use “V” blocks and use a dial indicator.

Valve Spring
Free Length

III.1

3. Check end of valve stem for flaring, pitting, wear or

damage (A).

Coil Fatigue / Squareness

III.2

5. Remove valve seals. NOTE: Replace seals whenever 4. Inspect split keeper groove for wear or flaring of the
the cylinder head is disassembled. Hardened, keeper seat area (B). NOTE: The valves cannot be re-
cracked or worn valve seals will cause excessive oil faced or end ground. Valves must be replaced if worn,
consumption and carbon buildup. bent, or damaged.
5. Measure diameter of valve stem with a micrometer in
three places and in two different directions (six
measurements total). Replace if excessive wear is
evident.
Measure valve stem in
several places

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ENGINE
6. Measure valve guide inside diameter at the top middle Follow the manufacturers instructions provided with the
and end of the guide using a small hole gauge and a valve cutting kit (commercially available). Abrasive stone
micrometer. Measure in two directions, front to back seat reconditioning equipment can also be used. Keep
and side to side. valves in order with their respective seat.

NOTE: Valve seat width and point of contact on the

valve face is very important for proper sealing. The
valve must contact the valve seat over the entire
circumference of the seat, and the seat must be the
proper width all the way around. If the seat is
uneven, compression leakage will result. If the seat
is too wide, seat pressure is reduced, causing
carbon accumulation and possible compression
loss. If the seat is too narrow, heat transfer from
valve to seat is reduced and the valve may overheat
and warp, resulting in burned valves.

1. Install pilot into valve guide.

7. Subtract valve stem measurement to obtain stem to
guide clearance. NOTE: Be sure to measure each
guide and valve combination individually.
8. Replace valve and/or guide if clearance is excessive.

NOTE: If valve guides are replaced, valve seats must

be reconditioned. Refer to Valve Seat
Reconditioning for procedure.

Valve Seat Reconditioning

Valve Seat Inspection

Inspect valve seat in cylinder head for pitting, burnt spots,

roughness, and uneven surface. If any of the above 2. Apply cutting oil to valve seat and cutter.
conditions exist, the valve seat must be reconditioned. If 3. Place 46 cutter on the pilot and make a light cut.
the valve seat is cracked the cylinder head must be
replaced.

Too Uneven Good Too

Wide Narrow

Cylinder Head Reconditioning

NOTE: Servicing the valve guides and valve seats

requires special tools and a thorough knowledge of 4. Inspect the cut area of the seat.
reconditioning techniques.
• If the contact area is less than 75% of the
circumference of the seat, rotate the pilot 180 and
CAUTION make another light cut.
• If the cutter now contacts the uncut portion of the
Wear eye protection when seat, check the pilot. Look for burrs, nicks, or
performing cylinder head service. runout. If the pilot is bent it must be replaced.

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ENGINE
• If the contact area of the cutter is in the same • If the seat is too wide or uneven, use both top and
place, the valve guide is distorted from improper bottom cutters to narrow the seat.
installation and must be replaced. Be sure the • If the seat is too narrow, widen using the 45 cutter
cylinder head is at the proper temperature and and re-check contact point on the valve face and
replace the guide. seat width after each cut.
• If the contact area of the initial cut is greater than
75%, continue to cut the seat until all pits are Top 30o
Seat 45o or 46o
removed and a new seat surface is evident. Bottom 60o or 75o
NOTE: Remove only the amount of material
necessary to repair the seat surface.
5. To check the contact area of the seat on the valve face,
apply a thin coating of Prussian Blue™ paste to the 3
valve seat. If using an interference angle (46)apply
black marker to the entire valve face (A).

(A)

6. Insert valve into guide and tap valve lightly into place
a few times.
7. Remove valve and check where the Prussian Blue™
or black marker indicates seat contact on the valve
face. The valve seat should contact the middle of the
valve face or slightly above, and must be the proper
width (A).
(B)

(A)

Proper Seat Contact On Valve Face

• If the indicated seat contact is at the top edge of

the valve face and contacts the margin area(B) it is
too high on the valve face. Use the 30 cutter to
lower the valve seat.
• If too low use the 60or 75 cutter to raise the
seat. When contact area is centered on the valve
face, measure seat width.

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ENGINE
NOTE: When using an interference angle, the seat 12. Clean rocker assembly, cylinder head, valves, and
contact point on the valve will be very narrow, and is camshaft oil supply passages thoroughly.
a normal condition. Look for an even and
continuous contact point on the black marker, all the
way around the valve face.

Seat
Width
Intake Exhaust

13. Spray electrical contact cleaner into oil passages and

dry using compressed air.
8. Clean all filings from the area with hot soapy water,
rinse, and dry with compressed air. Cylinder Head Assembly
9. Lubricate the valve guides with clean engine oil, and
apply oil or water based lapping compound to the face
CAUTION
of the valve. Lapping is not required with an
interference angle.
Wear eye protection during assembly.
10. Insert the valve into its respective guide and lap using
a lapping tool or a section of fuel line connected to the NOTE: Assemble the valves one at a time to
valve stem. maintain proper order.

1. Install new valve seals on valve guides.

11. Rotate the valve rapidly back and forth until the cut
sounds smooth. Lift the valve slightly off of the seat,
rotate 1/4 turn, and repeat the lapping process. Do this 2. Apply engine oil to valve guides and seats.
four to five times until the valve is fully seated, and 3. Coat valve stem with molybdenum disulfide grease.
repeat process for the other valve.
4. Install valve carefully with a rotating motion to avoid
damaging valve seal.

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ENGINE
5. Dip valve springs and retainer in clean engine oil and Cylinder Removal
install springs with closely spaced coils toward the
cylinder head. Follow engine disassembly procedures to remove the
valve cover, rocker assembly, camshaft and cylinder
head.

1. Remove cam chain guide at front of cylinder.

2. Tap cylinder lightly with a soft-faced hammer in
Closely spaced
reinforced areas only until loose. NOTE: Orientation
coils toward
of the dowels (arrows) is important for oil flow.
cylinder head
Note their position for reassembly.
3

6. Place retainer on springs and install valve spring

compressor. Compress spring only enough to allow
split keeper installation and prevent loss of spring
tension. Install split keepers with the gap even on both
sides.

3. Rock cylinder back and forth while lifting it from the

crankcase, piston and connecting rod. Support piston
with Piston Support Block (PN 2870390).

Cam Chain Follower / Tensioner Guide

Removal
1. Remove bolt securing the tensioner guide to
crankcase (A). NOTE: CVT disassembly is
required to gain access to the tension guide bolt.
Refer to Chapter 7.
7. Repeat procedure for remaining valve.
8. When all valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the keepers.

Valve Sealing Test A

1. Clean and dry the combustion chamber area.
2. Pour a small amount of cleaning solvent into each port
and check for leakage around each valve. The valve
seats should hold fluid with no leaking.

2. Remove chain guides and inspect for cracks, wear or

damage. Replace assemblies as required.

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ENGINE
Piston Removal Cylinder Inspection
1. Remove circlip from either side of piston. 1. Remove all gasket material from the cylinder sealing
surfaces.
2. Inspect the top of the cylinder for warpage using a
straight edge and feeler gauge.

2. Push piston pin out of piston. If necessary, heat the

crown of the piston slightly with a propane torch.
CAUTION: Do not apply heat to the piston rings. The
rings may lose radial tension.
3. Remove the compression rings, starting with the top
ring.
= In. / mm.

Cylinder Warp:
.002” (.05 mm) MAX

3. Inspect cylinder for wear, scratches, or damage.

4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in
two different directions, front to back and side to side,
on three different levels (1/2” down from top, in the
middle, and 
1/2” up from the bottom).
1/2” Down From Top of Cylinder

X Y
* Using a piston ring pliers: Carefully expand ring and lift
it off the piston. CAUTION: Do not expand the ring more
than the amount necessary to remove it from the piston, or
the ring may break. Y
X
* By hand: Placing both thumbs as shown, spread the ring
open and push up on the opposite side. Use care to not
scratch the ring lands.
Y
X
4. Repeat procedure for second ring.
5. The oil control ring is a three piece design consisting
of a top and bottom steel rail and a center expander 1/2” Up From Bottom
section. Remove the top rail first followed by the
bottom rail and expander.

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ENGINE
5. Record measurements. If cylinder is tapered or out of contact cleaner if necessary to clean these areas. Rinse
round beyond specification, the cylinder must be thoroughly, dry with compressed air, and oil the bore
honed, bored or replaced. immediately with Polaris 4 Cycle Lubricant to prevent the
formation of surface rust.

= In. / mm. If cylinder wear or damage is excessive, it will be

necessary to replace the cylinder. Hone only enough to
deglaze the outer layer of the cylinder bore.
Cylinder Taper:
Limit: .002” (.05 mm) Max.
Cylinder Out of Round:
Limit: .002” (.05 mm) Max.
3
Cylinder Hone Selection / Honing Procedure

CAUTION

A hone which will straighten as well as remove

material from the cylinder is very important.
Using a common spring loaded glaze breaker for
honing is not advised. Polaris recommends
EXAMPLE OF CROSS HATCH PATTERN
using a rigid hone or arbor honing machine.

Cylinders may be wet or dry honed depending upon the Piston Inspection
hone manufacturer’s recommendations. Wet honing
removes more material faster and leaves a more distinct 1. Measure piston outside diameter at a point 7 mm up
pattern in the bore. from the bottom of the piston at a right angle to the
direction of the piston pin.
Honing to Deglaze
A finished cylinder should have a cross-hatch pattern to
ensure piston ring seating and to aid in the retention of the
fuel/oil mixture during initial break in. Hone cylinder 7mm
according to hone manufacturer’s instructions, or these
guidelines:

• Use a motor speed of approximately 300-500 Piston

RPM, run the hone in and out of the cylinder Piston Pin
rapidly until cutting tension decreases. Remember
to keep the hone drive shaft centered (or cylinder
centered on arbor) and to bring the stones
approximately 1/2” (1.3 cm) above and below the 2. Subtract this measurement from the maximum
bore at the end of each stroke. cylinder measurement obtained earlier.
• Release the hone at regular intervals and inspect
the bore to determine if it has been sufficiently
deglazed, and to check for correct cross-hatch. = In. / mm.
NOTE: Do not allow cylinder to heat up during
honing. Piston to Cylinder Clearance
• After honing has been completed, inspect cylinder Std: .00039- .0015” (0.01- 0.04 mm)
for thinning or peeling. Limit: .0039” (.1 mm)
IMPORTANT: Clean the Cylinder After Honing
It is very important that the cylinder be thoroughly cleaned
after honing to remove all grit material. Wash the cylinder
in a solvent, then in hot, soapy water. Use electrical

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ENGINE
3. Measure piston pin bore. Replace piston if out-of- groove clearance exceeds service limits.
round
Piston

Ring

Feeler Gauge

Piston Pin Bore

4. Measure piston pin O.D. Replace piston pin if out-of-

round. Piston Ring Installed Gap
1. Place each piston ring inside cylinder using piston to
push ring squarely into place as shown.

Piston ring end gap installed

Feeler Gauge
Piston Pin Measurement Locations
Cylinder
25-50 mm
5. Measure connecting rod small end ID. Replace
crankshaft if out-of-round.

Piston Ring

= In. / mm.

Piston Ring Installed Gap:

Top Ring
Std: .0059- .013” (.15-.35 mm)
Limit: .0196” (0.5 mm)
6. Measure piston ring to groove clearance by placing Second Ring
the ring in the ring land and measuring with a Std: .0059- .013” (.15-.35 mm)
thickness gauge. Replace piston and rings if ring-to- Limit: .196” (0.5 mm)
Oil Ring
Std: .0079-.0314” (0.2- 0.8 mm)
Limit: .059” (1.5 mm)

2. Measure the gap with a feeler gauge at both the top

and bottom of the cylinder.

NOTE: Measure at two points in the cylinder A

difference in end gap indicates cylinder taper. The
cylinder should be measured for excessive taper
and out of round.

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ENGINE
3. If the installed gap measurement exceeds the limit, BOTTOM-END DISASSEMBLY
replace the rings. If using new rings and the
measurement is too small, file the ring ends to achieve Starter Drive Gear Removal and Inspection
the proper gap.
1. Remove the fan from the hub.
NOTE: Always check piston ring installed gap after
re-boring a cylinder or when installing new rings. A
re-bored cylinder should always be scrubbed
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with an oil rag
immediately to remove residue and prevent rust.
3

2. Remove the fan hub by removing the flywheel nut,

washer and pulling the hub from the crankshaft.

Washer

Flywheel Nut

3. Remove stator housing bolts and remove housing.

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ENGINE
4. Remove the start drive gear and shaft by pulling the Flywheel Removal / Inspection
shaft and tilting the gear slightly.

CAUTION

Avoid damage to the flywheel or crankshaft end.

Do not strike components or special tools with
hammers or heavy objects.

1. Before removing the flywheel, remove the shaft collar

(A) from the crankshaft. NOTE: Shaft collar
installation is important for proper loading of the
flywheel upon reassembly.

5. Measure the OD of the starter drive shaft on both ends

for out-of-round.
6. Measure the ID of the bushing in the stator housing A
(A) and in the crankcase (B) in two directions 90 apart
to determine if out-of-round. Calculate the clearance.
Replace components if clearance is excessive.

2. Install Flywheel Adapter PA-49936 and Puller PA-

45153 and remove the flywheel.
A B
NOTE: PA-45153 has left-hand threads which
correspond with the left-hand threads on PA-49936.
Use caution to avoid thread damage to flywheel or
tools.

7. Inspect gear teeth on starter drive. Replace starter

drive if gear teeth are cracked, worn, or broken.
8. Inspect the stator housing bearing. Replace if worn,
rough or damaged. P A -49
936

PA-45153

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ENGINE
3. Inspect the flywheel for loose components, cracks or NOTE: Slotted nut is left-hand thread.
other damage. Replace flywheel if any damage is
found.

Removal
Flywheel Special Tools
Flywheel Adapter PA-49936
Flywheel Puller PA-45153

Crankshaft One Way Gear / Drive Sprocket 

Removal and Inspection PA-49935
3
1. Remove the baffle plate.

C Install

PA-49959
Remove

2. Using the Slotted Nut Socket PA-49935, remove the

crankshaft slotted nut (C) and washer (B) from the Slotted Nut Socket Tool
starter drive one-way gear assembly (A).
PA-49935

3. Remove the starter drive one-way gear assembly (A)

from the crankshaft.

4. Remove drive sprocket (D) and woodruff key from the

crankshaft.

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ENGINE
5. Inspect sprocket teeth of both gears for wear or Balance Shaft Sprocket 
damage. Removal and Inspection
1. The cooling shroud, stator housing and flywheel and
starter drive one-way gear must be removed prior to
accessing the balance shaft gear and oil pump gear
2. Using Slotted Nut Socket PA-47344, remove the
balance shaft slotted nut and washer.

NOTE: Slotted nut is right-hand thread.

Inspect for Areas of

Tooth Wear or Damage
E
6. Inspect woodruff key for wear. Replace if damaged.
7. Replace any worn or damaged parts. D
C
Starter Drive One-way Clutch 
Removal and Inspection
1. The cooling shroud, stator housing and flywheel must
be removed prior to accessing the one-way starter PA-47344
drive.
2. Pull the starter drive assembly from the crankshaft.
Inspect the bearing surfaces and drive teeth for signs C
of wear or gouging. Replace the one-way clutch as an
assembly if it is not working properly. Assembly should
turn in one direction only. B

A Remove
One-way Assembly

Drive Gear
PA-47344
Install
Bearing

Slotted Nut Socket

PA - 47344

NOTE: One-way clutch components are not

serviceable. Replace the component as an
assembly.

3. Do not add specialized lubricants or greases to the

bearing or one-way components, as this may cause
undesirable operation.

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ENGINE
3. Remove the oil pump galley cover, oil pump gear and Oil Pump Removal / Drive Chain Inspection
chain to facilitate removal of the balance shaft
sprocket. NOTE: Oil pump is a replace-only assembly.

1. Remove the oil pump galley cover, pump gear nut,

and balancer shaft nut prior to chain and sprocket
removal.
2. Inspect the sprockets and chain for wear or damage.
Inspect chain for wear or damage. Replace chain
anytime the oil pump is replaced or if excessively
worn.
Note: Install new chain as 3
part of oil pump repair.

4. Remove the oil pump gear nut.

3. Remove the oil pump retaining screws and pull the

pump from the engine case.

5. Remove drive sprocket (A), chain (B), pump sprocket

B 4. Thoroughly clean all oil passages with clean solvent.

6. Inspect sprockets and gear teeth for wear or damage.

7. Inspect woodruff key for wear.
8. Replace any worn or damaged parts.

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ENGINE
5. Install a new pump with the oil galley pointed down as
shown.

Install with the oil galley pointing down

6. Torque screws to specification.

=T
Oil Pump Screw:
4-5 ft-lbs (5-7 Nm)

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ENGINE
CRANKCASE DISASSEMBLY NOTE: Tapping the pto end of the crankshaft with a
soft-face hammer may also separate the cases. Use
NOTE: Engine must be removed from the frame to care not to damage the crankshaft end or cases.
perform any crankcase or crankshaft removal. Crankcase Separator Tool
PA-46087
NOTE: The starter, starter drive, flywheel, stator, oil
pump and transmission can be serviced with the
engine in the frame.

Crankcase Separation and 

Cam Chain Removal
NOTE: Stator housing, flywheel and gears are 3
previously removed for this procedure. Use care
during the removal process to avoid damage to the
cam chain.

NOTE: Cylinder head and cylinder removal must be

performed prior to this procedure. 3. Watch the gap along the crankcase mating surface
and separate the crankcase evenly.
NOTE: Always replace the pto crankshaft seal after
performing this procedure. 4. Once the crankshaft bearing is free from the case, the
crankshaft and cam chain can be removed by hand for
1. Remove two case bolts (circled) from the magneto replacement.
side crankcase.

2. Separate crankcase using a press or by pressing on Crankshaft Removal

the pto end of the crankshaft using special tool (PA- 1. Support the MAG side crankcase on blocks. Press
46087). the crankshaft out using a press or special tool (PA-
46087). Use care not to damage the crankshaft oil
passage on the mag end crankshaft end.

NOTE: Tapping the pto end of the crankshaft with a

soft-face hammer may also separate the cases. Use
care not to damage the crankshaft end or cases.

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ENGINE
Crankshaft / Cam Chain / Sprocket 5. Remove cam chain. Inspect chain for wear or
Inspection damage. Replace if worn excessively or as part of
any crankshaft repair.
1. Inspect the crankshaft main bearings and cam chain
sprocket for wear or damage.
Note: Install new chain as
a part of crankshaft repair.

Crankcase / Bearing Inspection

NOTE: Due to extremely close tolerances and
NOTE: Removal and installation of new seals is
minimal wear, the bearings must be inspected
recommended anytime the crankcase is
visually, and by feel. Look for signs of discoloration,
disassembled.
scoring or galling. Turn the outer race of each
bearing. The bearings should turn smoothly and 1. Inspect the bearings in the crankcase.
quietly. The inner race of each bearing should fit
tightly in the crankshaft. The outer race should be NOTE: Due to extremely close tolerances and
firm with minimal side to side movement and no minimal side wear, the bearing must be inspected
detectable up and down movement. visually and by feel. Look for signs of discoloration,
scoring or galling. Turn the inner race of bearing.
2. Replace the crankshaft if the components fail visual The bearing should turn smoothly and quietly. The
inspection. outer race should fit tightly in the crankcase. The
3. The connecting rod utilizes a roller bearing. Clearance inner race should be firm with minimal side to side
is minimal and cannot be measured. Visually inspect movement and no detectable up and down
bearing journal for scoring, damage or excessive movement.
wear. Replace crankshaft if it fails visual inspection.
2. To remove crankcase bearings, use a blind hole
bearing puller.

NOTE: Bearings are damaged during the removal

procedure and should not be re-used.

3. Remove all traces of gasket material from the

crankcase mating surfaces. Inspect the surfaces
closely for nicks, burrs or damage.

Crankcase Oil Strainer Inspection

1. Remove drain plug.
2. Remove oil strainer and visually inspect for any
damage or obstructions in screen.
4. Check oil passages to make sure they are clear.
3. Replace oil strainer if it fails visual inspection.

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ENGINE
ENGINE REASSEMBLY NOTE: Tapping the end of the crankshaft with a soft-
face hammer may also install the crankshaft. Use
Bearing / Seal Installation care not to damage the crankshaft end.

NOTE: To ease crankcase bearing installation, warm

the crankcase until hot to the touch. Placing the
bearings in a freezer prior to installation will assist
the assembly process.

1. Install the bearings so the numbers are visible.

2. Drive or press the new bearings into the crankcase,
using the proper driver. 3
CAUTION

Press bearings only on outer race of bearing to

prevent bearing damage.

3. Install new seals with the lip facing in.

2. Install the balance shaft into the mag side of the
crankcase.
CAUTION

Press seals only on outer diameter Mag-side

to prevent damage. Crankcase

Crankcase Reassembly
Crankshaft and Cam Chain Installation

Lubricate all bearings with clean engine oil before

assembly.

1. Support the mag side crankcase cover on blocks high

enough to allow the crankshaft to drop. Install the
crankshaft using a hydraulic tool. Press on the pto
3. Install a new gasket onto the pto case half. Applying
end of the crankshaft. Use care not to damage the
a thin amount of crankcase sealer to the gasket will
crankshaft end.
help hold it in place.
4. Mate the mag side case, balancer and crankshaft to
the PTO side. During installation of the crankshaft,
loop the cam chain down into the chain room and over
the pto end.
5. Press the mag and pto assembles together using a
press. Verify the balance shaft is seated and both
shafts turn freely once installed.

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ENGINE
NOTE: Tapping the mag end of the crankshaft with a Chain Guide/Tensioner Installation
soft-face hammer may also install the crankshaft in
the PTO side. Use care not to damage the crankshaft 1. Install the chain guide and tighten the mounting bolt
end. to specified torque.

=T
6. Loop the cam chain through the chain room and
secure with mechanic’s wire. Chain Guide Bolt:
5-6.5 ft-lbs (7-9 Nm)
7. Install the two mag side flange bolts and torque to
specification.

=T
Crankcase Bolt Torque:
14 - 15 ft-lbs (19-21 Nm)

Crankcase Sealant
PN 2871557

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ENGINE
Crankshaft, Balance Shaft and Starter Drive 5. Install the Starter Drive one-way gear assembly,
Gear Installation washer and slotted nut.

1. Install woodruff keys on the balancer shaft and

crankshaft.
2. Install and align the marks of the balance shaft gear
and the crankshaft gear as shown.

3
6. Using Slotted Nut Socket PA-49935, tighten the crank
Alignment marks shaft nut to the specified torque. NOTE: Slotted nut is
left hand threaded.

3. Install the oil pump drive sprocket, washer and slotted

nut onto the balance shaft.

Install

=T
Crankshaft Slotted Nut Torque:
43 ft-lbs (59 Nm)
4. Using Slotted Nut Socket PA-47344, tighten the nut to Special Tool:
the specified torque. PA-49935
B

Install A

=T
Balance Shaft Slotted Nut:
43 ft-lbs(59 Nm)
Special Tool:
PA-47344

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ENGINE
7. Install the baffle plate and torque to specification. 3. Install the chain (A) over the sprocket on the balance
shaft gear (B).

A B
C

4. Loop the chain around the oil pump drive sprocket (C)
and install the sprocket onto the oil pump shaft.
=T
NOTE: The oil pump sprocket and shaft have a “D”
configuration for alignment.
Baffle Plate Screw:
5-7 ft-lbs (7-9 Nm) 5. Install the pump gear washer and nut. Torque to
specification.
Oil Pump and Chain Installation
NOTE: Oil pump is not a serviceable assembly. Do
not disassemble pump. Replace entire component.

1. Inspect the oil pump sealing surface on the

crankcase. Apply a liberal amount of engine oil to the
surfaces and pump.
NOTE: Do not use gasket sealer on the pump
mating surfaces.

2. Install oil pump as shown. Install and torque screws

to specification.

=T
Oil Pump Gear Nut:
5-7 ft-lbs (7-9 Nm)

6. Install the oil baffle plate (Item D -See illustration) and

torque screws to specification.

=T
Install with the oil galley pointing down
Oil Pump Baffle Plate Screw:
5-7 ft-lbs (7-9 Nm)

=T
Oil Pump Cover Screw:
4-5 ft-lbs (5-7 Nm)

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ENGINE
Piston Ring Installation Piston Installation
NOTE: Apply clean engine oil to all ring surfaces
and ring lands. Always check piston ring installed CAUTION
gap before rings are installed on piston. If the piston
has been in service, clean any accumulated carbon Do not re-use circlips. Circlips become
from the ring grooves and oil control ring holes. deformed during the removal process. Do not
compress the new clip more than necessary to
1. Oil Control Ring: Place the oil control ring expander
prevent loss of radial tension. Severe engine
in oil ring groove with the end gap facing forward. The
damage may result if circlips are re-used or
expander has no up or down marking and can be
deformed during installation.
installed either way. The ends should butt squarely
together and must not overlap. 1. Install a new circlip on one side of the piston with the
3
2. Install the oil ring top rail with the end gap at least 30 end gap facing up or down.
from the end of the expander. 2. Apply clean engine oil all components before
3. Install the bottom rail with the gap at least 30 from the assembly. Generously lubricate the connecting rod
end of the expander on the side opposite the top rail (both ends) and crankshaft main bearing area.
gap. 3. Install the wrist pin and piston onto the connecting rod.
Top IMPORTANT: Install the piston on the connecting
Ring Profile rod with the ’IN” casting mark facing the intake
side of engine. The piston pin should be a push fit
into the piston.
Install chamfer up

Second
Ring Profile

4. Second Ring: Install the second ring with the mark

facing up (if applicable). Position the end gap toward
the rear (intake) side of the piston.
5. Top Ring: Install the top ring with the chamfered edge
facing up (if applicable).
6. Check to make sure the rings rotate freely in the 4. Install the other circlip with the gap facing up or down.
groove when compressed by hand. Verify that the (See note with Step 3 above). Push the piston pin in
ring gaps are 120 degrees apart from each other both directions to make sure the clips are properly
before installation. seated in the groove.

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ENGINE
5. Place the dowel pins in the PTO side of the crankcase 4. Push the rings into the cylinder taper using a non-
and install a new cylinder base gasket. metallic, blunt-edge tool while pushing the cylinder
down. This will help push the piston past the ring taper
into the cylinder.
5. Remove the support block once the piston rings are
inside the cylinder. Seat the cylinder firmly on the base
gasket.
6. Install the cam chain guide and dowel pins into the
cylinder. Verify the bottom end of the guide is seated
properly in the crankcase.

6. Lubricate the piston and rings with assembly lube and

install a ring compressor on the piston assembly.
Verify that the ring gaps are 120 degrees apart
from each other before installation.

Cylinder Installation
NOTE: Clean the gasket surfaces on the crankcase
and cylinder. Remove all traces of old gasket
material and apply a new base gasket

1. Verify the cylinder base dowel pin(s) and a new base

gasket are installed. Position the Piston Support
Block (PN 2870390) (A) beneath the piston skirt to
support the piston during cylinder installation.

NOTE: Route cam chain through the cylinder chain

room and secure it, holding it up while rotating the
engine to avoid damage to the chain, drive sprocket
teeth or tensioner blade.

2. Apply clean engine oil liberally to the bore and tapered

area of the cylinder. Place the cylinder on to the studs.
3. Loop the cam chain through the cylinder chain room
and secure with mechanic’s wire. Seat the cylinder
fully on the piston and support block.

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ENGINE
Cylinder Head and Camshaft Installation Camshaft Timing
NOTE: Verify the gasket surfaces on the cylinder
head and cylinder are clean. Remove all traces of old CAUTION
gasket material.

1. Install the dowel pin(s) and a new cylinder head Serious engine damage will result if the
gasket over the cylinder studs. camshaft is not properly timed to the crankshaft.

IMPORTANT CAMSHAFT TIMING NOTE: In order to

time the camshaft to the crankshaft, the piston must be
precisely located at Top Dead Center (TDC). This can be
accomplished using one of two methods. 3
1. Install the cam chain over the crankshaft.

When the stator housing is removed, use Method 1. This

method uses the camshaft gear marks and the crankshaft
keyway to establish TDC (see Method 1 illustration). It is
important to note that this method can only be used when
the stator housing is removed and the crankshaft keyway
is in view. The camshaft sprocket alignment marks are
parallel to the gasket surface, and camshaft lobes are
pointing down. Cam chain plate links are not used to time
2. Pull the cam chain through the cylinder head chain the camshaft.
room and secure with mechanic’s wire.
When the stator housing is installed, use Method 2. This
3. Place the cylinder head onto the cylinder.
method establishes Top Dead Center (TDC) by aligning
4. Install the two 6 mm base bolts, but do not tighten at the single mark on the flywheel in the timing inspection
this time. hole (see Method 2 illustration). The camshaft sprocket
alignment marks are parallel to the gasket surface, and
5. Install the cam according to the “Cam Shaft Timing”
camshaft lobes are pointing down. Cam chain plate links
procedure. Verify the cam chain is in place around the
are not used to time the camshaft.
crankshaft gear.
Camshaft Installation - Timing Method 1
NOTE: Verify camshaft timing is accurate before
Reference Illustration Page 3.43
installing the rocker and tensioner assemblies.
Stator housing is removed. NOTE: Use this method only
when the stator is removed and cam shaft drive sprocket
is in view.

1. Rotate the crankshaft until the keyway on the

crankshaft is pointed ’UP” (keyway facing upward)
and the piston is at TDC.
2. Align the cam chain onto the teeth of the crankshaft
sprocket. Use a wire to pull the chain up through the
cylinder and cylinder head and to hold it in place.
Secure and maintain tension so that the chain does
not fall off the crankshaft sprocket.
3. Apply engine assembly lubricant to the camshaft main
journals and cam lobes. Lubricate automatic
compression release mechanism with clean engine
oil.
4. Orientate the camshaft for installation with the lobes
facing downward.

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ENGINE
5. Disconnect the wire securing the cam chain and loop
the cam chain over the camshaft sprocket while
verifying the cam is inserted with the alignment marks
parallel to the gasket surface.

TDC
Cam Alignment

6. Verify all cam timing marks to verify proper cam timing,

and install the rocker arm assembly (see Method 1
illustration). Torque the cylinder stud nuts to
specification.
NOTE: Do not rotate engine until rocker assembly
and tensioner are installed.
7. Install the tensioner. Torque fasteners to specification.
8. After tensioner installation, rotate engine at least two
revolutions and re-check marks/timing.

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ENGINE

Method 1 - Camshaft Timing with Stator Housing Removed

Sprocket marks aligned with gasket surface at TDC on

compression stroke (cam lobes facing downward)

Crankshaft Keyway ‘UP’

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ENGINE
Camshaft Installation - Timing Method 2  3. Apply engine assembly lubricant to the camshaft main
Reference Illustration Page 3.44 journals and cam lobes. Lubricate automatic
compression release mechanism with clean engine
Stator housing is installed. NOTE: Use this method only oil.
when the stator is installed and cam shaft drive sprocket
is in view. 4. Orientate the camshaft for installation with the lobes
facing downward.
1. Rotate the crankshaft until the single (TDC) timing 5. Disconnect the wire securing the cam chain and loop
mark (Top Dead Center) on the flywheel is view in the the cam chain over the sprocket while verifying the
center of the timing inspection window. Be sure to use cam is inserted with the alignment marks parallel to
the single TDC mark when installing the cam. Do not the gasket surface.
use any advance marks (if evident).
6. Check all cam timing marks to verify proper cam
2. Align the cam chain onto the teeth of the cam chain timing, and install the rocker arm assembly. Torque
drive sprocket. Use a wire to pull the chain up through the cylinder stud nuts to specification.
the cylinder and cylinder head and to hold it in place.
Secure the chain. Secure and maintain tension so that NOTE: Do not rotate engine until tensioner and
the chain does not fall off the crankshaft sprocket. rocker assembly is installed.

7. Install the tensioner. Torque fasteners to specification.

8. After tensioner installation, rotate engine at least two
revolutions and re-check marks/timing.

Method 2 - Camshaft Timing Using Flywheel TDC Mark

Sprocket marks aligned

with gasket surface at
TDC on compression stroke
(cam lobes facing downward)

Single TDC Mark Aligned

TDC Mark

Rotation
Cam Timing
(View through timing inspection hole)
Position crankshaft at TDC

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ENGINE
Rocker Arm / Shaft Assembly 3. Install cylinder head nuts and torque to specification.
Torque in 3 step cross pattern
1. Apply engine assembly lube to all components and
3
assemble the arms, shafts and decompression
components into the rocker assembly. 1 2
4
IMPORTANT: Install rocker shafts in their correct
positions. The exhaust side shaft is shorter and is
held in place by the cylinder stud. The intake side
shaft has a ‘half-moon’ section that aligns with the
cylinder stud to hold it in place.

3
5

.
Exhaust

=T
Intake
Cylinder Head Nut:
18 ft-lbs (25 Nm)
2. Apply engine lube to the shafts and cam follower
surfaces. 4. Torque the cylinder base screws to specification.
5. Adjust valves according to the “VALVE CLEARANCE
Rocker Assembly Installation ADJUSTMENT” procedures.
1. Apply engine lube to all components and assembly 6. Install valve cover and secondary air assembly with
arms, shafts and decompression components of the new gaskets. Torque bolts to specification.
rocker assembly.

2. Verify the cam is still in the TDC position before

installing the rocker assembly onto the cylinder studs.
=T
Valve Cover/ Secondary Air Pipe Bolt:
7-8 ft-lbs (9-11 Nm)

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ENGINE
Cam Chain Tensioner Installation Intake Valve Clearance Adjustment
1. Using a small flat blade screwdriver, turn the 1. Remove the valve cover and secondary air pipe
tensioner clockwise to retract the plunger (B) all the assembly.
way into the tensioner body.
2. Verify cam lobes are pointed down.
3. Insert the correct thickness feeler gauge between end
of intake valve stem and adjuster screw.
4. When clearance is correct, hold adjuster screw and
tighten locknut securely.
B
5. Re-check the valve clearance.
6. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.

A = In. / mm.

2. Keeping the plunger retracted, install the tensioner Valve Clearance:

assembly with a new gasket and tighten the bolts to .003” (.07 mm)
specification.
Exhaust Valve Clearance Adjustment
1. Remove the valve cover and secondary air pipe
assembly.
2. Verify cam lobes are pointed down.
3. Insert the correct thickness feeler gauge between end
of exhaust valve stem and adjuster screw.
4. Loosen locknut and turn adjuster screw until there is
a slight drag on feeler gauge.
5. When clearance is correct, hold adjuster screw and
tighten locknut securely.
6. Re-check the valve clearance.
=T 7. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.
Tensioner Bolt and Cap:
5-7 ft-lbs (7-9 Nm)
= In. / mm.
3. Release the tensioner and install the tensioner cap.
Torque cap to specification.
Valve Clearance:
4. Slowly rotate engine two to three revolutions and re- .003” (.07 mm)
check cam timing once chain is tight.

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ENGINE
Starter Drive Assembly Stator Installation
1. Apply Starter Drive Grease (PN 2871460) to the drive NOTE: The stator, flywheel, and starter drive
bushings in the cases. components can be serviced with the engine in the
frame.
2. Slide the starter drive gear into position on the one-
way gear and install the shaft. 1. Install the stator and pulse coil. Route the wires
appropriately to avoid contact with any moving parts.
Torque bolts to specification.

Starter Drive Grease:

(PN 2871460) =T
Stator Bolt:
3. Install stator housing and torque bolts to specification. 7-8 ft-lbs (9-11 Nm)

Flywheel Installation Pulse Coil Bolt:

4-5 ft-lbs (5-7 Nm)
Install flywheel key, flywheel and the flywheel spacer.
Proceed to “Stator Housing Installation” if the stator 2. Apply a small amount of Crankcase Sealant (PN
assembly is already installed. 2871557) to the stator wire grommet and install into
the housing cavity.

IMPORTANT: Flywheel spacer installation is critical

for proper clamp-load when applying torque to the
flywheel nut. Verify spacer is installed before
assembly of the stator housing to the crankcase.

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ENGINE
Stator Housing Installation 3. Install the fan hub, washer, and flywheel nut. Torque
the flywheel nut to specification.
NOTE: The stator, flywheel, starter drive, and stator
can be serviced with the engine in the frame.

1. Apply a small amount of Crankcase Sealant (PN

2871557) to the mounting surface and install a new
gasket. Install the dowel pins if removed.

=T
Flywheel Nut:
43 ft-lbs (58 Nm)
2. Install the housing. Torque bolts in sequence to 4. Install the fan and fan bolts. Tighten bolts evenly to
specification. specification.

=T
Fan Bolt:
4-5 ft-lbs (5-7 Nm)

5. Install the cooling shroud and tighten the fasteners

sufficiently. Use care not to over-tighten.

3
10 7
8

5
4
(#1, #2 RH case bolts)

11
6 9
RH Crankcase - Stator Cover

=T
Stator Housing Bolt:
7-8 ft-lbs (9-11 Nm)

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ENGINE
Exhaust System exhaust gasket and clean the spark arrestor anytime
engine rebuilding is performed. Torque all fasteners to
The exhaust silencer should be cleaned of accumulated specification.
carbon and all fasteners checked in accordance with the
periodic maintenance table in Chapter 2. Replace the

3
Silencer Gasket

Spark Arrestor

7-8 ft-lbs (9-11 Nm)

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ENGINE
TROUBLESHOOTING General Troubleshooting
Engine Turns Over But Fails to Start
Spark Plug Fouling
• Spark plug cap loose or faulty • No fuel
• Choke cable adjustment or plunger/cable sticking • Dirt in fuel line or filter
• Foreign material on choke plunger seat or plunger • Fuel will not pass through fuel valve
• Incorrect spark plug heat range or gap • Fuel pump inoperative/restricted
• Carburetor inlet needle and seat worn • Tank vent plugged
• Jet needle and/or needle jet worn or improperly • Carb starter circuit
adjusted • Engine flooded
• Excessive carburetor vibration (loose or missing • Low compression (high cylinder leakage)
needle jet locating pins) • No spark (Spark plug fouled)
• Loose jets in carburetor or calibration incorrect for Engine Does Not Turn Over
altitude/temperature
• Incorrect float level setting • Dead battery
• CVT system calibrated incorrectly or components • Starter motor does not turn
worn or mis-adjusted • Engine seized, rusted, or mechanical failure
• Fuel quality poor (old) or octane too high • Start components damaged
• Low compression
• Restricted exhaust Engine Runs But Will Not Idle
• Weak ignition (loose coil ground, faulty coil, stator,
or TRS switch) • Restricted carburetor pilot system
• TRS switch mis-adjusted • Carburetor misadjusted
• Restricted air filter (main or pre-cleaner) or • Choke not adjusted properly
breather system • Low compression
• Improperly assembled air intake system • Crankcase breather restricted
• Restricted engine breather system • Air filter restriction
• Oil contaminated with fuel
Engine Idles But Will Not Rev Up
• Restricted crankcase vent
• Spark plug fouled/weak spark
• Broken throttle cable
• Obstruction in air intake
• Air box removed (reinstall all intake components)
• Incorrect or restricted carburetor jetting
• TRS switch limiting speed
• Reverse speed limiter limiting speed
• Carburetor vacuum slide sticking/diaphragm
damaged
• Incorrect ignition timing
• Restricted exhaust system
• Cam lobe worn

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ENGINE
Engine Has Low Power Backfiring

• Spark plug fouled • TRS or speed limiter system malfunction

• Cylinder, piston, ring, or valve wear or damage • Fouled spark plug or incorrect plug or plug gap
(check compression) • Carburetion faulty - lean condition
• CVT not operating properly • Intake / Exhaust system air leaks
• Restricted exhaust muffler • Ignition system faulty:
• Dirty carburetor • Spark plug cap cracked/broken
• Cam lobe worn • Ignition coil faulty
• Ignition or kill switch circuit faulty
Piston Failure - Scoring • Ignition timing incorrect
• Lack of lubrication
•
•
Sheared flywheel key
Poor connections in ignition system
3
• Dirt entering engine through cracks in air filter or
• System wiring wet
ducts
• Cam lobe worn or Valve sticking
• Engine oil dirty or contaminated
• Lean condition
Excessive Smoke and Carbon Buildup

• Excessive piston-to-cylinder clearance

• Worn rings, piston, or cylinder
• Worn valves, guides or seals
• Restricted crankcase vent
• Air filter dirty or contaminated

Low Compression

• Decompressor stuck
• Cylinder head gasket leak
• No valve clearance or incorrectly adjusted
• Cylinder or piston worn
• Piston rings worn, leaking, broken, or sticking
• Bent valve or stuck valve
• Valve spring broken or weak
• Valve not seating properly (bent or carbon
accumulated on valve area)
• Rocker arm sticking

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ENGINE

NOTES

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FUEL SYSTEM
CHAPTER 4
FUEL SYSTEM
CARBURETION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETOR FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
CARBURETOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
CARBURETOR FLOAT BOWL DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
CARBURETOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
CARBURETOR DISASSEMBLY - KEIHIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
CARBURETOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
FLOAT HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
CARBURETOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
NEEDLE AND SEAT LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
ASSEMBLY VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
FUEL VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FUEL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
ASSEMBLY VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
SECONDARY AIR INJECTION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
CRANKCASE VENTILATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
FUEL STARVATION / LEAN MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
RICH MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
POOR IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15

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FUEL SYSTEM
CARBURETION Carburetor Function

Special Tools Carburetor Component Function

Main Main Main
System
PART NUMBER TOOL DESCRIPTION Components Function Effect
Maintains
Mity Vac Float Inlet Pipe, specified fuel
2870975 All systems;
Pressure Test Tool System Needle and level in float
all throttle
(Level Seat, Float and chamber
Carburetor Float ranges
2872314 Control) Float Pin (carburetor float
Adjustment Tool
bowl).
Supplies
SPX Corp: 1-800-328-6657 or [Link] Passages in All systems;
atmospheric
Venting carburetor and all throttle
pressure to float
vent lines. ranges.
WARNING chamber.
All throttle
Gasoline is extremely flammable and explosive under Supplies ranges.
certain conditions. Starter Choke Lever, additional fuel Greatest
(Choke Cable, and air mixture effect at low
Always stop the engine and refuel outdoors or in a well Plate) Choke Butterfly necessary for throttle
ventilated area. cold starting. settings and
idle.
Do not overfill the tank. The tank is at full capacity when Mainly idle
Primarily
the fuel reaches the bottom of the filler neck. Leave Pilot Jet / to
Pilot supplies fuel at
room for expansion of fuel. Passage-ways, 1/4 throttle.
(Idle idle and low
Pilot Outlet and Minimal
System) throttle
Never start the engine or let it run in an enclosed area. Throttle Valve. effect after
positions.
Gasoline powered engine exhaust fumes are 1/2 throttle.
poisonous and can cause loss of consciousness and Meters the
death in a short time. amount of air
Pilot Air introduced into
Air Screw All ranges.
Never drain the float bowl when the engine is hot. Screw the pilot and
Severe burns may result. main fuel
circuits.
Do not smoke or allow open flames or sparks in or near Main Jet, Main
the area where refueling is performed or where Supplies fuel at
Air Passage,
gasoline is stored. Main mid–range and 1/4 to full
Needle Jet, Jet
System high throttle throttle.
Needle, Throttle
If you get gasoline in your eyes or if you should swallow settings.
Valve.
gasoline, seek medical attention immediately.
Torque Specifications
If you spill gasoline on your skin or clothing,
immediately wash with soap and water and change
clothing. TORQUE
DESCRIPTION
Ft. Lbs. (Nm)

Intake Manifold Nuts 7-8 (9-11 Nm)

Fuel Pump
7-8 (9-11 Nm)
Mount Bolt

Fuel Tank Strap Bolts 17 (23 Nm)

Crankcase Vent System Mount Bolts 7-8 (9-11 Nm)

Secondary Air System Mount Bolts 7-8 (9-11 Nm)

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FUEL SYSTEM
Carburetor Assembly

CAP AND GASKET

SPRING
JET NEEDLE RETAINER
E-CLIP
AIRBOX
JET NEEDLE

PILOT AIR SCREW SLIDE (THROTTLE VALVE)

COVER
NEEDLE JET
THROTTLE STOP SCREW FLOAT BOWL VENT NIPPLE
FUEL INLET 4
O-RINGS
CHOKE LEVER / SPRING

CHOKE CABLE SUPPORT

ENGINE
NEEDLE VALVE

MAIN JET
PILOT JET

FLOAT / VALVE ASSEMBLY

FLOAT BOWL

BOWL DRAIN

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FUEL SYSTEM
CARBURETOR SERVICE Carburetor Removal
1. Turn the fuel valve “OFF” and drain the fuel from the
Carburetor Float Bowl Draining
carb through the drain screw.
The carburetor float bowl should be drained periodically to 2. Loosen or remove screw (A) retaining the choke cable
remove moisture or sediment from the bowl, or before from the choke cable bracket and disconnect the
extended periods of storage. cable end from the choke arm.
3. Remove the carburetor mounting bolts (B) from the
intake manifold.
4. Loosen the intake boot clamp (C) between the
carburetor and air cleaner.
Carburetor Bowl
Drain Screw 5. Unscrew the throttle slide cap (D). Remove the throttle
slide and components from the carburetor.
6. Remove the fuel line and vent lines (E). Remove
carburetor from vehicle.

C
B
NOTE: Drain screw is located on the side of the E
float bowl. A

Fuel Cap
Fuel Valve

1. Place a clean container beneath the bowl drain hose.

2. Turn the fuel valve to “OFF”.
3. Loosen drain screw and allow fuel in the float bowl and
fuel line to drain completely.
4. Inspect the drained fuel for water or sediment.
5. Tighten drain screw.
6. Turn fuel valve to “ON”.
7. Inspect carburetor for fuel leaks
8. Start machine and re-check for leaks.

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FUEL SYSTEM
Carburetor Disassembly - Keihin 4. Remove the main jet (F), emulsion tube (G), and
needle jet (H) from the carburetor body.
Use the following procedure to disassemble the Keihin
carburetor.

1. Remove the float bowl screws (A) and float bowl.

F G H
A

A 4
NOTE: Typically, the needle jet (H) can be left in the
carburetor body and only requires removal if
damaged.
2. Remove the float pin (B), float (C), and inlet needle
(D). 5. Note the position of both the pilot mixture screw (J)
and idle speed adjustment screw (K) and remove both
B from the carb body.

C K

J
3. Remove the pilot jet (E).
E

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FUEL SYSTEM
Carburetor Cleaning Carburetor Inspection
1. Remove the carburetor slide assembly. Disassemble
WARNING the components and inspect for wear. Inspect slide
needle and look for discoloration, shiny spots, or an
Protect eyes from contact with cleaner. Take area that looks different than the rest of the needle.
appropriate safety measures during these The middle to upper portion of the needle contacts
procedures. Safety glasses and chemical the needle jet and is the most likely wear point. If slide
resistant gloves are required. Should you get needle shows signs of wear replace both the needle
cleaner in your eyes or if you swallow cleaner, and needle jet to prevent a rich condition.
seek medical attention immediately.
Retainer
Carburetor cleaners can be extremely caustic. Inspect this area
Extended periods of soaking can loosen the
E-Clip
adhesive sealer on the passage drill-way plugs.
Do not soak rubber or plastic components or O-
rings in caustic cleaning solutions. Irreparable
damage may occur. Do not use agitator-type
carburetor cleaning equipment.
Rubber parts must be cleaned with mild
detergent and hot water only.

Slide Jet Needle

1. Thoroughly clean the carburetor body, jets, and all

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

5. Use low pressure air to dry carburetor body and all

components.

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FUEL SYSTEM
3. Inspect the idle speed adjust screw tip for flat spots Float Height Adjustment
and the pilot mixture screw tip for damage. If any
damage is present on either screw, it must be 1. Place the carburetor at a level position to remove
replaced. weight from float arm. In this position, the float tongue
will rest slightly outward.

Keihin Pilot Air Screw 2. With the carburetor at rest and level, slightly tilt the
carburetor back. The float should fall into the correct
position, with the float tongue resting lightly on the
inlet needle valve pin without compressing the spring.
The bottom of the float should be parallel with the float
bowl mating surface.

Inspect

4. Inspect the float bowl vent tube for cracks near the 4
bottom of the tube.

NOTE: A continuous fuel leak from the carburetor

drain hose can be a result of a cracked bowl vent
tube.

Float Height:
Parallel to Gasket Surface ± 1mm

IMPORTANT: When measuring the height, verify the

Inspect inlet needle valve spring is not compressed.
NOTE: If the float is past parallel with the mating
surface, the carburetor has likely been tilted back
too far and the float tongue is compressing the
needle valve pin.

Float
Tongue

3. If adjustment is required, carefully bend the float

tongue up or down to achieve the proper float height.

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FUEL SYSTEM
Carburetor Assembly
1. Replace parts in proper order. Refer to the parts
exploded view or “Disassembly” steps for further
detail.
2. Install the pilot air mixture screw and spring. Turn the
screw in until it lightly contacts the seat. Back out the
specified number of turns.
3. Tighten all screws by hand sufficiently, using care not
to over tighten.
NOTE: The final pilot (idle) mixture must be adjusted
with the engine running. Refer to Chapter 2 for
procedure.

Pilot Air Screw Base Setting

(Set at Factory)

Initial Setting:
2.25 Turns Out

Special Tool:
PA-47361

Needle and Seat Leak Test

1. Install the float bowl.
2. Invert the carburetor and install a Mity-Vac™
(PN 2870975) to the fuel inlet fitting.
3. 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 or gasket.
Image for
Reference Only

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FUEL SYSTEM
FUEL TANK

Assembly View

FUEL TANK STRAPS

VENTED FUEL CAP

PICKUP

FUEL TANK w/PICKUP

ROCK GUARD

NOTE: The fuel tank and pickup are supplied as an assembly. The pickup cannot be replaced separately and
should not be removed from the tank.

=T
Fuel Tank Strap Fastener Torque
17 ft-lbs (23 Nm)

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FUEL SYSTEM
Fuel Tank Removal 4. Rear Strap Fasteners

See Chapter 5 for seat and panel removal required to

access the fuel tank. The following components will have
to be removed:

• Seats
• Console panel
• Seat shield panel
1. Completely drain fuel from fuel tank. Be sure the fuel
valve is set to “RES” to get the majority of the fuel
drained from the tank.
2. Remove the main (M) and reserve (R) fuel pickup
hoses from the pickup assembly. Mark the hoses to
aid assembly.

5. To reinstall the tank, reverse the removal procedure.

Be sure to torque the tank mounting strap bolts.

=T
Fuel Tank Mounting Strap Bolt Torque
17 ft-lbs (23 Nm)

6. Finish the installation process by installing the seat

shield panel, console panel, and seats. See Chapter
5.

3. Remove the two tank straps by removing the four

fasteners securing them to the frame.

Front Strap Fasteners

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FUEL SYSTEM
Fuel Valve Service Fuel Pump Assembly
1. Turn the fuel valve “OFF”. The fuel pump assembly is secured to the frame behind
the seat shield panel on the RH side of the vehicle.
2. Reference Chapter 5 and loosen the fasteners that Replace the pump as an assembly, as it is not serviceable.
secure the RH rocker panel to the frame.
IMPULSE HOSE
3. Remove line clamps and fuel lines from the fuel valve. (TO INTAKE MANIFOLD BASE)
4. Remove the fastener retaining the dial on the valve FUEL SUPPLY
assembly. Remove the two screws that secure the (TO CARB)
valve assembly to the rocker panel.
5. Note the location of the main and reserve fuel hose
inlet nipples, as well as the carburetor feed nipple.

4
RESERVE
MAIN

FUEL SUPPLY
(FROM SHUTOFF VALVE)

=T
OUTLET HOSE
Fuel Pump Mounting Bolt Torque
7-8 ft-lbs (9-11 Nm)
6. Reverse procedures to reinstall fuel valve.
The pump diaphragm is driven by the pressure pulse
Fuel Filter generated from the intake manifold tube.
The fuel filter is located in-line on the carburetor fuel feed
hose. The filter should be inspected and replaced as
outlined in the periodic maintenance table in Chapter 2.

When installing a new filter, verify the arrow points in the

direction of the carburetor.

Fuel Pump Pulse Line

FILTER

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FUEL SYSTEM
AIR FILTER
Assembly View

COVER

COVER GASKET

INLET COVER

AIR FILTER

MESH SCREEN MID INTAKE TUBE

INLET MOUNT

AIR BOX

AIR FILTER SPACER

INTAKE TUBE OIL SEPARATOR

HOSE NIPPLE

SEDIMENT TRAP

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FUEL SYSTEM
Secondary Air Injection System

AIR INJECTION FILTER / SCREEN

DUAL INTAKE VALVE

4
IMPULSE HOSE - TO INTAKE MANIFOLD NIPPLE

HOSE - TO CYLINDER HEAD

The secondary air injection system adds additional air to

the exhaust system while the engine is running.

The air injection filter housing houses a filter element and

screen and should be cleaned as part of periodic SCREEN
maintenance as outlined in Chapter 2.

FILTER

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FUEL SYSTEM
Crankcase Ventilation System

HOSE - INTAKE VALVE TO OIL SEPARATOR

OIL SEPARATOR

DUAL INTAKE VALVE

HOSE - VALVE COVER

HOSE-TO AIR FILTER BOX TO OIL SEPARATOR

HOSE - INTAKE VALVE TO CRANKCASE

NOTE: The crankcase ventilation system is

sensitive to excessive engine oil volume. Never
over-fill the oil level in the engine. Doing so may
cause oil to accumulate inside the airbox.

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FUEL SYSTEM
TROUBLESHOOTING Poor Idle
Idle Too High
Fuel Starvation / Lean Mixture
Symptoms: Hard start or no start, bog, backfire, popping • Idle adjusted improperly / idle mixture screw
through intake / exhaust, hesitation, detonation, low damaged
power, spark plug erosion, engine runs hot, surging, high • Throttle cable sticking, improperly adjusted, routed
idle, idle speed erratic. incorrectly
• Choke cable sticking, improperly adjusted, routed
• No fuel in tank incorrectly
• Restricted tank vent, or routed improperly • Plugged or restricted pilot jet
• Fuel lines or fuel valve restricted
• Fuel filter plugged Idle Too Low
• Carburetor vent line(s) restricted
• Choke cable bending or incorrectly adjusted
• Plugged or restricted inlet needle and seat screen
• Idle speed set incorrectly
or inlet passage
•
•
Clogged jets or passages
Float stuck, holding inlet needle closed or inlet
•
•
Idle mixture screw misadjusted or damaged
Belt dragging 4
• Ignition timing incorrect
needle stuck
• Worn jet needle / needle jet
• Float level too low
• Plugged or restricted pilot jet
• Intake air leak (throttle shaft, intake ducts, airbox
or air cleaner cover)
Erratic Idle
• Jet needle position incorrect
• Incorrect pilot screw adjustment • Choke cable bending or incorrectly adjusted
• Throttle cable incorrectly adjusted
Rich Mixture • Air leaks, dirty carburetor passages (pilot circuit)
• Pilot mixture screw damaged or adjusted
Symptoms: Fouls spark plugs, black, sooty exhaust
incorrectly
smoke, rough idle, poor fuel economy, engine runs rough/
• Tight valves
misses, poor performance, bog, engine loads up, backfire.
• Ignition timing incorrect
• Air intake restricted (inspect intake duct) • Belt dragging
• Air filter dirty / plugged • Dirty air cleaner
• Choke plate sticking, incorrectly adjusted choke • Engine worn
• Choke cable binding or improperly routed • Spark plug fouled
• Incorrect pilot air / fuel screw adjustment • Idle speed set incorrectly
• Faulty inlet needle and seat • Worn jet needle / needle jet
• Faulty inlet needle seat O-Ring • Plugged or restricted pilot jet
• Float level too high
• Poor fuel quality (old fuel)
• Loose jets
• Worn jet needle / needle jet or other carburetor
parts
• Dirty carburetor (air bleed passages or jets)
• Weak or damaged choke plate return spring
• Fouled spark plug

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FUEL SYSTEM

NOTES

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BODY / SUSPENSION / STEERING
CHAPTER 5
BODY / SUSPENSION / STEERING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2
BODY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
SEAT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3
SEAT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3
FRONT BUMPER REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4
FRONT CAB REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4
ROCKER PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6
REAR BUMPER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6
REAR CAB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6
SERVICE PANEL (SEAT SHIELD) REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7
CONSOLE COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7
KEY SWITCH / INDICATOR LIGHT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .5.9
DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.9
BODY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
CAB FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
CAB FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
MAIN FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5
FRONT A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
FRONT HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
HUB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
HUB SEAL AND BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
SHOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
SHOCK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
SHOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
SHOCK REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
SHOCK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
REAR SWING ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19
SWING ARM REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
SWING ARM INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
AXLE HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
AXLE HOUSING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
AXLE HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
AXLE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
AXLE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
STEERING WHEEL / STEERING SHAFT / STEERING GEARBOX VIEW . . . . . . . . . .5.26
STEERING SHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
STEERING SHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
STEERING GEARBOX REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
STEERING GEARBOX INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.29
TIE ROD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30
TIE ROD END / TIE ROD / STEERING KNUCKLE ASSEMBLY EXPLODED VIEW . . .5.30
TIE ROD REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.31
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32

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BODY / SUSPENSION / STEERING
GENERAL INFORMATION Fastener Torque
Special Tools Front Sprocket Bolts 87 in-lbs (9.8 Nm)
Chain Tensioner Bolt 84 in-lbs (10 Nm)
Description Part Number
Chain Guard Bolts 84 in-in-lbslbs (10 Nm)
Shock Spring Compressor Tool 2870623
Shock Spanner Wrench N/A - Part of tool kit.

SPX Corp: 1-800-328-6657 or [Link]

Torque Specifications

Fastener Torque
Body Fasteners
Body Component Fasteners 16 in-lbs (1.8 Nm)
Seat Retaining Nuts 10 ft-lbs (13.5 Nm)
Seat Support Bolts 36 ft-lbs (49 Nm)
Cab Frame Fasteners 20 ft-lbs (27 Nm)
Steering Fasteners
Steering Pivot Tube Bolts 16-17 ft-lbs (22-23 Nm)
Steering Wheel Adjustment
10 ft-lbs (13.5 Nm)
Bolt
Steering Shaft Pinch Bolts 29-37 ft-lbs (39-50 Nm)
Tie Rod Plate Pinch Bolt 17 ft-lbs (23 Nm)
Steering Gearbox Mounting
21 ft-lbs (28 Nm)
Bolts
Steering Wheel Fasteners 11 ft-lbs (15 Nm)
Tie Rod End Castle Nuts 25 ft-lbs (34 Nm)
Tie Rod End Jam Nuts 12–14 ft-lbs (17–19 Nm)
Suspension Fasteners
A–Arm to Frame Fasteners 30 ft-lbs (41 Nm)
A–Arm to Spindle Castle Nuts 30 ft-lbs (41 Nm)
Front Shock Mounting Bolts 36 ft-lbs (49 Nm)
Rear Shock Mounting Bolts 43 ft-lbs (58 Nm)
Swing Arm Mounting Bolts 72 ft-lbs (98 Nm)
Final Drive Fasteners
Front Hub Castle Nut 40 ft-lbs (55 Nm)
Rear Hub Castle Nut 40 ft-lbs (55 Nm)
Front / Rear Wheel Nuts 27 ft-lbs (37 Nm)
Rear Axle Housing Bolts 72 ft-lbs (98 Nm)
Rear Axle Clamp Bolts 36 ft-lbs (49 Nm)

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BODY / SUSPENSION / STEERING
BODY REMOVAL 3. To remove the passenger seat, remove the two nuts
located at the front of the seat mounting rails. Lift the
Seat Removal front of the seat up and slide it forward to remove it
from the vehicle.
1. Lift up the seat latch lever located under the right front
edge of the driver’s seat.

Seat Latch Lever

Seat Installation
2. While holding the lever upward, slide the seat
1. Lift up the seat latch lever located under the right front
5
completely forward to remove it from the seat
edge of the driver’s seat.
mounting rails.
2. While holding the lever upward, line up the seat
guides with the seat mounting rails and slide the seat
rearward to install it. Adjust the seat to the appropriate
distance and be sure the seat is latched
3. To install the passenger seat, place the seat mounts
into the mounting loops on the frame support and
install the front retaining nuts.

Mounting
Loops

4. Torque the front retaining nuts to specification.

=T
Passenger Seat Retaining Nuts:
10 ft-lbs (13.5 Nm)

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BODY / SUSPENSION / STEERING
Front Bumper Removal / Installation Front Cab Removal / Installation
1. Remove the (2) push rivets from each side of the front 1. Remove the (6) push rivets retaining the rear portion
bumper. of the front cab to the frame.

2. Remove the (2) push rivets from each side, retaining

the front cab to the front bumper.

2. Remove the (4) screws retaining the front bumper to

the frame.
3. Disconnect the daytime running lights as shown and
remove the bumper from the vehicle.

3. Remove the (3) fasteners from each side, retaining

the front cab to the rocker panels.

4. Reverse this procedure to reinstall the front bumper.

Tighten all fasteners securely.

=T
Body Component Fasteners:
16 in-lbs (1.8 Nm)

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BODY / SUSPENSION / STEERING
4. Using a 6 mm Allen socket, remove the (4) bolts 8. Disconnect the indicator lights and key switch harness
retaining the front cab frame to the rear cab frame. connections under the dash as shown.

Key Switch

Disconnect

9. Remove the front cab from the vehicle.

10. Reverse this procedure to reinstall the front cab.
Tighten all fasteners securely.
5
=T
Body Component Fasteners:
5. Remove the (2) fasteners retaining the front cab frame
16 in-lbs (1.8 Nm)
to the main frame. Note the orientation of the (4)
spacers during removal. 11. Torque the cab frame bolts and fasteners to
6. Carefully remove the front cab frame from the vehicle. specification.

7. Remove the (2) screws retaining the choke bracket.

=T
Cab Frame Fasteners:
20 ft-lbs (27 Nm)

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BODY / SUSPENSION / STEERING
Rocker Panel Removal Rear Cab Removal
1. Remove the (3) bolts from each side, retaining the 1. Remove the driver and passenger seats from the
lower portion of the rocker panels. vehicle (see “Seat Removal”).
2. Remove the (3) push rivets from each side, retaining 2. Remove the (4) fasteners retaining the front of the rear
the upper portion of the rocker panels. cab to the frame.
3. Remove the (3) fasteners from each side, retaining 3. Remove the (2) fasteners retaining the top portion of
the rocker panels to the front cab. the rear cab to the frame.
4. Remove the (4) fasteners from each side, retaining 4. Remove the (2) push rivets from each side, retaining
the rocker panels to the rear side panels. the rear side panels to the rear cab.
5. Remove the (4) fasteners from each side, retaining
the rear side panels to the rocker panels.

5. If removing the RH rocker panel, remove the screw 6. Remove the (8) remaining fasteners retaining the rear
retaining the fuel valve knob and the (2) screws cab and rear bumper to the frame.
retaining the fuel valve to the rocker panel.

Rear Bumper Removal / Installation

1. Remove the push rivet from each side of the rear
bumper.

7. Remove the rear cab from the vehicle as an assembly.

8. Reverse this procedure to reinstall the rear cab.
Tighten all fasteners securely.

2. Remove the (6) screws retaining the rear bumper to =T

the frame.
Body Component Fasteners:
3. Reverse this procedure to reinstall the rear bumper. 16 in-lbs (1.8 Nm)
Tighten all fasteners securely.

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BODY / SUSPENSION / STEERING
Service Panel (Seat Shield) Removal Console Cover Removal
1. Remove the seats (see “Seat Removal”). 1. Remove the seats (see “Seat Removal”).
2. Remove the (7) bolts and (2) push rivets retaining the 2. Remove the service panel (see “Service Panel
service panel. Removal”).
3. Remove the (2) bolts retaining the seat support to the
frame.

Seat Support

Service Panel

3. Disengage the service panel from the sides of the rear

cab and remove the panel from the vehicle.
5
4. Disconnect the battery leads and unhook the fuse
holder from the console cover.

Unhook

Disconnect

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BODY / SUSPENSION / STEERING
5. Remove the (4) bolts and (3) push rivets retaining the 8. Lift the console cover out from the vehicle as an
console cover. assembly

Console Cover

6. Remove the (2) nuts retaining the front portion of the IMPORTANT: Route the battery cables through the
drivers seat adjustment rail. console cover prior to removal to prevent from
damaging the cables or fuse holder.

Remove

7. Remove the shift knob cap. Remove the fastener and

shift knob from the shift lever.

Shift Knob

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BODY / SUSPENSION / STEERING
Key Switch / Indicator Light Replacement Decal Replacement
1. Disconnect the key switch harness or indicator light
connectors located under the dash as shown. WARNING
Key Switch
The following procedure involves the use of an
open flame. Perform this procedure in a well
ventilated area, away from gasoline or other
flammable materials. Be sure the area to be
flame treated is clean and free of gasoline
or flammable residue.

Indicator
Lights
WARNING
Disconnect Do not flame treat components that are installed
on the vehicle. Remove the component from the
vehicle before flame treating.
2. If removing the key switch, loosen and remove the
retaining nut. Remove the key switch from underneath The plastic body components are made of plastic
the dash. polyethylene material, and must be “flame treated” prior to
installing a decal to ensure good adhesion. The flame
5
treating procedure can also be used to reduce or eliminate
the whitish stress marks that are sometimes left after a
plastic component is bent, flexed, or damaged.

Loosen
Nut

3. If removing an indicator light, loosen and remove the

retaining nut(s) located under the dash. Remove the
indicator light(s) from the dash.

To flame treat the decal area:

1. Pass the flame of a propane torch back and forth

Indicator Lights quickly over the area where the decal is to be applied
until the surface appears slightly glossy. This should
occur after just a few seconds of flame treating. Do
not hold the torch too close to the surface (2-3 inches
from the flame tip is recommended). Keep the torch
moving to prevent damage.
2. Apply the decal on one edge first. Slowly lay down
NOTE: The indicator lights are a complete
remainder of the decal while rubbing lightly over the
assembly, bulb replacement is not possible.
decal surface to eliminate any air bubbles during the
application.

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BODY / SUSPENSION / STEERING
Body Exploded View

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BODY / SUSPENSION / STEERING
CAB FRAME
Exploded View

Cab Frame Assembly

1. Install the rear cab frame to the mounting brackets at each side of the vehicle. Loosely install the four bolts and
washers.
2. Position the front cab frame onto the front cab mounting posts. Align the two frames at the top joints and install the
Allen bolts using a 6 mm Allen wrench.
3. Install the front cab frame mounting hardware with the bolt and cam to the outside of the frame and the nut and
washer to the inside.
4. Install the side bars (LH or RH frame) to the mounting brackets at the rear frame and hip bars. Install the side nets
according to the procedure listed in the Owner’s Manual.
5. Attach the basket frame to the rear frame if removed.
6. Torque all cab frame fasteners to specification.

=T
Cab Frame Fasteners:
20 ft-lbs (27 Nm)

7. Refer to the Owner’s Manual for the “Cab Nets and Storage Bag” installation procedure.

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BODY / SUSPENSION / STEERING
MAIN FRAME
Exploded View

36 ft-lbs
(49 Nm)

17 ft-lbs
(23 Nm)

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BODY / SUSPENSION / STEERING
FRONT A-ARMS
Exploded View

30 ft-lbs
(41 Nm)

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BODY / SUSPENSION / STEERING
A-arm Replacement 4. Remove the lower shock mounting bolt.

1. Elevate the front end of the vehicle far enough off the
ground to remove the wheel.

CAUTION

Severe injury could occur if machine tips or falls.

2. Loosen and remove the (4) wheel nuts.

5. Remove the cotter pin, castle nut and washer from the
bolt attaching the A-arm to the spindle.

3. Remove the (2) screws from the brake line retainer

attached to the front A-arm.

6. Carefully remove the spindle assembly from the A-

arm.
7. Remove the front and rear A-arm mounting fasteners
(refer to the “Exploded View”) and remove the A-arm
from the vehicle.
Brake Line 8. To reinstall, reverse steps 1-7. Torque fasteners to
Retainer specification.

=T
A-arm to Spindle Castle Nut: 30 ft-lbs (41 Nm)
Front Shock Mounting Bolt: 36 ft-lbs (49 Nm)
Wheel Nuts: 27 ft-lbs (37 Nm)

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BODY / SUSPENSION / STEERING
FRONT HUB 4. Remove the (2) bolts retaining the brake caliper and
remove the caliper from the disc. CAUTION: Do not
Hub Removal hang the caliper by the brake line. Use a strap or
mechanics wire to hang caliper to prevent
1. Elevate the front end of the vehicle far enough off the damage to the brake line.
ground to remove the wheel.

CAUTION

Severe injury could occur if machine tips or falls.

2. Loosen and remove the (4) wheel nuts and remove

the black rubber dust boot.

5. Remove the hub assembly from the spindle.

Remove

3. Remove the cotter pin, castle nut and washers.

Nut

Cotter Pin Washers

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BODY / SUSPENSION / STEERING
Hub Seal and Bearing Replacement 5. Install new seals on each end of the hub. Press the
seals into the hub until the top of the seal is just past
1. Remove the (6) bolts retaining the brake disc to the the chamfer.
hub.
Chamfer

6. Reinstall the brake disc with new mounting bolts.

2. Remove the outer spacer from the hub. Torque the bolts to specification.

=T
Front Brake Disc Bolts:
7 ft-lbs (10 Nm)

7. Reinstall outer spacer into the outer hub seal.

Hub Installation
1. Grease the spindle and reinstall the front hub
assembly.

3. Remove the seals from each end of the hub and press
the bearings and spacer tube out. Grease

4. Using an arbor press, install new bearings along with 2. Install the brake caliper and torque the mounting bolts
the spacer tube back into the hub. to specification.

=T
Brake Caliper Bolts:
18 ft-lbs (24 Nm)

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BODY / SUSPENSION / STEERING
3. Install the washers and torque the castle nut to SHOCKS
specification. Install a new cotter pin into the castle
nut. Shock Exploded View

40 ft-lbs
(55 Nm)

Replace Washers

=T
Front Hub Nut:
5
40 ft-lbs (55 Nm)

4. Install the wheel, wheel nuts and rubber dust boot.

Torque the wheel nuts to specification.

=T
Wheel Nuts:
27 ft-lbs (37 Nm)

Shock Removal
1. Elevate the front or rear end of the vehicle off the
ground to remove shock spring tension.

CAUTION

Severe injury could occur if machine tips or falls.

2. Remove the shock mounting bolts and remove the

shock from the vehicle.
3. Replace the shock, compression spring or adjustment
collar as required (see “Shock Replacement”).

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BODY / SUSPENSION / STEERING
Shock Replacement
1. Using a spring compressor, compress the shock
spring far enough to remove the spring retainer.

Shock Spring
Compressor Tool
2870623

2. Remove the spring and adjustment collar from the

existing shock and install the components onto the
new shock.
3. Compress the shock spring and install the spring
retainer.

Shock Installation
1. Install the shock assembly and torque the mounting
bolts to specification.

=T
Front Shock Mounting Bolt:
36 ft-lbs (49 Nm)

=T
Rear Shock Mounting Bolt:
43 ft-lbs (58 Nm)

2. If the adjustment collar was moved or replaced, adjust

the spring preload evenly between both front or rear
shocks (refer to Chapter 2 “Maintenance”).

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BODY / SUSPENSION / STEERING
REAR SWING ARM
Exploded View

72 ft-lbs
(98 Nm)
7 ft-lbs
(10 Nm) 72 ft-lbs Replace if Removed
(98 Nm) 22 ft-lbs
(30 Nm)

84 in-lbs 7 ft-lbs
(10 Nm) 16 ft-lbs 72 ft-lbs
(22 Nm) (10 Nm)
(98 Nm)

36 ft-lbs
5
(49 Nm)
16 ft-lbs
(22 Nm)
16 ft-lbs
(22 Nm) 84 in-lbs
(10 Nm)
72 ft-lbs
(98 Nm)

36 ft-lbs
(49 Nm)

72 ft-lbs
(98 Nm)
16 ft-lbs
(22 Nm)
72 ft-lbs
(98 Nm)

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BODY / SUSPENSION / STEERING
Swing Arm Removal 5. Loosen the outer jam nut and back off the inner
adjustment nut on each chain adjuster to remove
1. Remove the plastic tie strap retaining the brake lines tension.
to the swing arm.

Loosen

Loosen
Remove

6. Using mechanics wire or a long Panduit strap, tie the

2. Slightly elevate the rear end of the vehicle off the chain tensioner back out of the way.
ground.

CAUTION

Severe injury could occur if machine tips or falls. Chain

Tensioner
3. Remove the (2) bolts retaining the rear brake caliper
and remove the caliper from the disc. CAUTION: Do
not hang the caliper by the brake line. Use a strap or
mechanics wire to hang caliper to prevent damage to
the brake line.

7. Remove the upper shock mounting bolts.

Remove Remove

4. Loosen all (4) axle housing bolts.

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BODY / SUSPENSION / STEERING
8. Remove the (2) swing arm through-bolts. 3. Install a new tie strap to retain the brake lines.

Tie Strap

NOTE: Lower the vehicle slightly to ease removal. 4. Line up the upper shock eyelets with the frame
mounting holes and install the mounting bolts. Torque
9. Remove the drive chain from the front drive sprocket the rear shock mounting bolts to specification.

10. Roll the swing arm assembly out from the vehicle.
=T 5
Rear Shock Mounting Bolts:
43 ft-lbs (58 Nm)

5. Install the rear brake caliper and torque the mounting

bolts to specification.

=T
Brake Caliper Bolts:
18 ft-lbs (24 Nm)

6. Remove the wire or strap retaining the chain tensioner

, allowing it to return to its normal position.
11. Refer to the “Axle Housing Removal” procedure, if
7. Lower the rear end of the vehicle and perform the
replacing the swing arm.
chain adjustment procedure (see Chapter 2
“Maintenance”).
Swing Arm Installation 8. Be sure the rear axle housing fasteners are torqued
to specification.
1. Roll the swing arm assembly back into place and
install the drive chain over the front sprocket.
=T
2. Line up the swing arm with the frame and install the
through-bolts. Torque the swing arm bolts to
Rear Axle Housing Bolts:
specification.
72 ft-lbs (98 Nm)

=T
Swing Arm Mounting Bolts:
72 ft-lbs (98 Nm)

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BODY / SUSPENSION / STEERING
REAR AXLE housing to the swing arm.

Axle Housing Removal

1. Elevate the rear end of the vehicle far enough off the
ground to remove the wheel(s).
Remove
CAUTION

Severe injury could occur if machine tips or falls.

2. Loosen and remove the (4) wheel nuts

Loosen

7. Remove the LH axle housing from the axle (see “Axle

Housing Service” if replacing the bearing or seal).

3. Remove the dust boot to access the rear hub retaining

nut.
4. Remove the cotter pin, castle nut and dome washer.
Axle Housing

Nut 8. Remove the (2) bolts retaining the rear brake caliper
and remove the caliper from the disc. CAUTION: Do
not hang the caliper by the brake line. Use a strap or
mechanics wire to hang caliper to prevent damage to
the brake line.

Washer
Cotter Pin

Remove
5. Loosen the outer jam nut and back off the inner
adjustment nut on each chain adjuster to remove
tension.
6. Remove the (2) fasteners retaining the LH axle

9. Remove the (2) axle retaining nuts and the (2)

fasteners retaining the RH axle housing to the swing

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BODY / SUSPENSION / STEERING
arm (see “Axle Housing Service” if replacing the Axle Housing Installation
bearing or seal).
1. Install each axle housing and fasteners. Do not
torque the fasteners at this time
Remove
NOTE: Remember to install the chain adjusters onto
the lower axle housing fasteners and install the
spacer behind the LH axle housing.

Axle Housing Service

1. Remove the seal from the housing.
2. Remove the circlip using a snap ring pliers.
Axle Housing 5
3. Press the bearing out of the axle housing. 2. Install the axle retaining nuts onto the RH side of the
axle. Torque the inner retaining nut to specification,
then torque the outer jam nut to specification.
Seal
Circlip
7 ft-lbs
(10 Nm)

Bearing
72 ft-lbs
Axle Housing (98 Nm)
(LH Shown)

4. Press a new bearing into the axle housing and install =T

a new circlip.
RH Axle Housing Retaining Nuts:
5. Press the new seal into the axle housing until it is flush Inner Nut: 7 ft-lbs (10 Nm)
with the housing. Outer Nut: 72 ft-lbs (98 Nm)

3. Install the rear brake caliper and torque the mounting

bolts to specification.

=T
Brake Caliper Bolts:
18 ft-lbs (24 Nm)

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BODY / SUSPENSION / STEERING
4. Install the rear hub, dome washer, and nut on each NOTE: There is no need to remove the large axle
side. nuts retaining the RH axle housing if removing the
rear axle assembly from the swing arm.
NOTE: Be sure the dome on the washer is facing
out, away from the rear hub. 2. Remove the axle clamp bolts from each side and
remove the clamp brackets to allow for axle removal.
40 ft-lbs
(55 Nm) Clamp
Bracket

Washer
Replace Remove
RH Side
Shown
5. Torque the rear hub retaining nut to specification and
install a new cotter pin on each side. 3. Remove the rear fastener and front lower fastener
retaining the chain guard.
=T 4. Pull the chain tensioner back to allow enough slack in
the chain to remove it from the front drive sprocket.
Rear Hub Castle Nut:
5. Rotate the RH axle housing to allow the axle assembly
40 ft-lbs (55 Nm)
to be removed.
6. Install the rear wheels, wheel nuts and dust boots. 6. Carefully remove the axle assembly from the swing
Torque the wheel nuts to specification. arm.

=T
Wheel Nuts:
27 ft-lbs (37 Nm)

7. Lower the rear end of the vehicle and perform the

chain adjustment procedure (see Chapter 2
“Maintenance”).
8. Be sure the rear axle housing fasteners are torqued
to specification.

=T
Rear Axle Housing Bolts:
72 ft-lbs (98 Nm) Axle Installation
1. Reverse the “Axle Removal” procedure.
Axle Removal
1. Remove the axle housing fasteners (see “Axle
Housing Removal”).

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BODY / SUSPENSION / STEERING
2. Torque the axle clamp bolts to specification.

=T
Axle Clamp Bolts:
36 ft-lbs (49 Nm)

3. Install the rear axle housing fasteners (see “Axle

Housing Installation”).

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BODY / SUSPENSION / STEERING
STEERING
Steering Wheel / Steering Shaft / Steering Gearbox Assembly Exploded View
11 ft-lbs
(15 Nm)

10 ft-lbs
(13.5 Nm)

16-17 ft-lbs
(22-23 Nm)
16-17 ft-lbs
(22-23 Nm)

29-37 ft-lbs
(39-50 Nm)

17 ft-lbs
(23 Nm)
21 ft-lbs
(28 Nm)

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BODY / SUSPENSION / STEERING
Steering Shaft Removal 4. Slide the pivot tube assembly off the steering shaft
and remove the shaft out of the vehicle from under the
1. Remove the upper pinch bolt located under the dash.
steering pivot tube assembly.

Steering Shaft Installation

1. Reinstall the steering shaft.
2. Install the shaft to the steering gearbox assembly and
install the pinch bolt. Torque the pinch bolt to
specification.

=T
Steering Shaft Pinch Bolt:
29-37 ft-lbs (39-50 Nm)

3. Ensure the wheels are pointing straight ahead. Install

2. Remove the lower pinch bolt located at the steering the pivot tube stub shaft into the upper portion of the
gearbox assembly. steering shaft with the steering wheel properly
aligned. 5
4. Install the pivot tube bolts and steering wheel
adjustment bolt. Torque the bolts to specification.

=T
Steering Pivot Tube Bolts:
16-17 ft-lbs (22-23 Nm)

=T
Steering Wheel Adjustment Bolt:
10 ft-lbs (13.5 Nm)
3. Remove the adjustment bolt and pivot bolts retaining 5. Install the upper pinch bolt and torque to specification.
the steering pivot tube assembly to the frame.

=T
Steering Shaft Pinch Bolt:
29-37 ft-lbs (39-50 Nm)

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BODY / SUSPENSION / STEERING
Steering Gearbox Removal 5. Loosen the brake line retainer and remove the brake
line from the gearbox assembly.
1. Remove the steering shaft (see “Steering Shaft
Removal”).
2. Remove the front bumper to ease gearbox removal
(see “Front Bumper Removal / Installation”).
3. Remove the pinch bolt from the tie rod plate.

6. Remove the (3) bolts retaining the steering gearbox

to the frame and remove the gearbox from the vehicle.

4. Carefully pry up on the tie rod plate and remove it from

the steering gearbox.

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BODY / SUSPENSION / STEERING
Steering Gearbox Installation
1. Install the steering gearbox and torque the (3)
mounting bolts to specification.

=T
Steering Gearbox Mounting Bolts:
21 ft-lbs (28 Nm)

2. Install the brake line under the retainer and securely

tighten the retaining bolt.
3. Align the boss splines on the gearbox stub shaft and
the tie rod plate.

Boss
Spline

4. Install the tie rod plate. Torque pinch bolt to

specification.

=T
Tie Rod Plate Pinch Bolt:
17 ft-lbs (23 Nm)

5. Install the front bumper if previously removed (see

“Front Bumper Removal / Installation”).
6. Install the steering shaft (see “Steering Shaft
Installation”).

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BODY / SUSPENSION / STEERING
TIE ROD
Tie Rod End / Tie Rod / Steering Knuckle
Assembly Exploded View

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BODY / SUSPENSION / STEERING
Tie Rod Removal / Installation 6. After performing the steering toe adjustment, torque
the jam nuts to specification.
Steering tie rods can be replaced by removing the rod-end
castle nut at the tie rod plate and spindle.

1. Elevate the front end of the vehicle.

CAUTION

Severe injury could occur if machine tips or falls.

2. Remove the cotter pin from each rod end castle nut.
3. Loosen and remove the (2) tie rod end castle nuts and
remove the tie rod from the vehicle. Jam Nut
4. If replacing the tie rod ends, loosen the jam nut(s) and
replace the end(s).
5. Install the tie rod and torque the castle nuts to =T
specification. Install a new cotter pin in each castle
nut. Tie Rod End Jam Nuts:
12-14 ft-lbs (17-19 Nm)
5

Cotter Pin

=T
Tie Rod End Castle Nuts:
25 ft-lbs (34 Nm)

NOTE: Refer to Chapter 2 “Maintenance” for the

steering toe alignment procedure.

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BODY / SUSPENSION / STEERING
WHEELS
Front Wheel Exploded View

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BODY / SUSPENSION / STEERING
Rear Wheel Exploded View

Wheel Removal
1. Position the vehicle on a level surface.
2. Set the parking brake and stop the engine.
3. Loosen the wheel nuts slightly. If wheel hub removal
is required, remove the cotter pin and loosen the
castle nut slightly.
4. Elevate the front or rear end of the vehicle off the
ground placing a suitable stand or floor jack under the
frame.

CAUTION

Severe injury could occur if machine tips or falls.

5. Remove the wheel nuts and remove the wheel.

6. If removing the hub, take off the castle nut and
washers(s).

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BODY / SUSPENSION / STEERING
Wheel Installation
1. Verify the parking brake is still engaged.
2. Install the wheel hub, washer(s), and castle nut, if
previously removed.
3. 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.
4. Attach the wheel nuts and finger tighten them.
5. Carefully lower the vehicle to the ground.
6. Torque the wheel nuts and/or hub nut to the proper
torque specification.

=T
Wheel Nuts:
27 ft-lbs (37 Nm)

=T
Front Hub Castle Nut:
40 ft-lbs (55 Nm)

=T
Rear Hub Castle Nut:
40 ft-lbs (55 Nm)

7. If hub nut was removed, install a new cotter pin after

the hub nut has been tightened.

CAUTION

If wheels are improperly installed it could affect

vehicle handling and tire wear. On vehicles with
tapered rear wheel nuts, make sure tapered end
of nut goes into taper on wheel.

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BRAKES
CHAPTER 6
BRAKES
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
BRAKE SYSTEM SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
HYDRAULIC BRAKE SYSTEM - OVERVIEW OF OPERATION . . . . . . . . . . . . . . . . . . . 6.4
BRAKE SYSTEM - MECHANICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
BRAKE SYSTEM - MECHANICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
BRAKE SYSTEM - HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
BRAKE PEDAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
PEDAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
BRAKE PEDAL INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
PARKING BRAKE CABLE FREEPLAY ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 6.10
PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
PARKING BRAKE CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
FRONT PAD REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
FRONT BRAKE PAD ASSEMBLY / CALIPER INSTALLATION. . . . . . . . . . . . . . . . . . . 6.14
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
FRONT CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
FRONT CALIPER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
REAR BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
REAR BRAKE PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
REAR BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
REAR BRAKE PAD ASSEMBLY / CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . 6.20
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
REAR BRAKE DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
REAR CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
6
REAR CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
REAR BRAKE CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24
MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
BRAKES SQUEAL / POOR BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
PEDAL VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
BRAKES LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
PARKING BRAKE DRAGS OR INEFFECTIVE BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . 6.27

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BRAKES
GENERAL SPECIFICATIONS
FRONT BRAKE SYSTEM
Item Standard Service Limit
Front Brake Pad Thickness .300 ± .007" (7.62 ± .178 mm) .180" (4.6 mm)
Front Brake Disc Thickness .160" (4.05 mm) .138" (3.50 mm)
Front Brake Disc Runout - .010" (.254mm)

REAR BRAKE SYSTEM

Item Standard Service Limit
Rear Brake Pad Thickness .300 ± .007" (7.62 ± .178 mm) .180" (4.6 mm)
Rear Brake Disc Thickness .160" (4.05 mm) .138" (3.50 mm)
Rear Brake Disc Runout - .010" (.254 mm)

TORQUE SPECIFICATIONS SPECIAL TOOLS

Item Torque Torque Part Number Tool Description
ft-lbs Nm
2870975 Mity Vac™ Pressure Test Tool
Brake Disc to Hub (Front) 7.0 9.5
SPX Corp: 1-800-328-6657 or [Link]
Brake Disc to Hub (Rear) 21.0 28.5

Brake Line Banjo Bolts 14.5 19.6

(Caliper and master cylinder)

Brake Pad Guide Pins (All) 10.0 13.5

Brake Pedal Mounting Bracket 15.0 20.0

to Frame

Caliper Mounting Bolts  18.0 24.5

(Front and Rear)

Master Cylinder to Frame 17.0 23.0

Master Cylinder Reservoir 15 in-lb 1.7

Hose Clamps

Master Cylinder Reservoir 60 in-lb 6.8

Hose Adaptor Clamp

Parking Brake Adjuster Jam 12.0 16.0

Nut

Wheel Nuts, Front 27.0 37.0

Wheel Nuts, Rear 27.0 37.0

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BRAKES
BRAKE SYSTEM SERVICE NOTES
Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely
encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to
ensure proper system function and maximum pad service life.
• Use only genuine Pure Polaris parts.
• Do not over-fill the master cylinder fluid reservoir.
• Make sure the brake pedal returns freely and completely.
• Check and adjust master cylinder reservoir fluid level after pad service.
• Clean the master cylinder reservoir cap and the area above and around the reservoir before you remove the
cap. Cover the reservoir immediately after filling to prevent contamination. Make sure atmospheric vent on
reservoir is unobstructed.
• Elevate front wheels or rear axle after any brake system service and test for brake drag. Investigate cause if
brake drag is evident.
• Make sure floating caliper move freely on guide pins.
• Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely; check for
leakage.
• Perform a brake burnishing procedure after installing new pads to maximize service life.
• DO NOT clean brake system components with petroleum based products. Use only approved brake cleaning
products.

BRAKE NOISE TROUBLESHOOTING

Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration).
If cleaning does not reduce the occurrence of brake noise, Permatex™ Disc Brake Quiet (PN 2872113) can be applied
to the back of the pads. Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce
the chance of squeaks caused by dirt or dust.

Brake Noise Troubleshooting

Possible Cause Remedy
Dirt, dust, or imbedded material on pads or disc Spray disc and pads with CRC Brakleen™ or an equivalent
non-flammable aerosol brake cleaner. Remove pads and/
or disc hub to clean imbedded material from disc or pads.
Pad(s) dragging on disc (noise or premature pad wear) Adjust (where applicable). Investigate / correct the
Parking brake misadjusted condition
Master cylinder reservoir overfilled Adjust. See Maintenance chapter. 
Master cylinder compensating port restricted Set to proper level
Master cylinder piston not returning completely Clean compensating port
Caliper piston(s) not returning Inspect. Repair as necessary
Operator error (riding the brake) Clean piston(s) seal 6
Educate operator
Loose wheel hub, wheel bearings, brake disc Check wheel, hub, and disc for abnormal movement.
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
Noise is from other source (axle, hub, disc or wheel) If noise does not change when brake is applied check
other sources. Inspect and repair as necessary
Wrong pad for conditions Use only Pure Polaris replacement pads. Optional softer
or harder pads may be available

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BRAKES
HYDRAULIC BRAKE SYSTEM - OVERVIEW OF OPERATION
The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, master
cylinder fluid reservoir, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive
line.
When the brake pedal is applied, the master cylinder piston is forced inward. As piston moves inward, pressure is created
in the separate and sealed front and rear brake chambers inside the master cylinder. Pressure travels through the front
and rear brake lines and then to the pistons inside the brake calipers. The caliper pistons are forced outward against
the moveable brake pad. When the pad contacts the brake disc, the floating caliper bracket moves to force the stationary
brake pad against the disc, and the resulting friction reduces brake disc and vehicle speed.
As brake pads wear normally from friction, the caliper pistons move outward to compensate. Fluid from the master
cylinder reservoir fills the additional volume created in the caliper body as the pistons move outward (self adjusting
feature).
Fluid level in the reservoir is a critical maintenance item. If fluid level gets too low, air could enter the system and cause
poor brake performance or even brake system failure. If the fluid level is too high, pressure could build in the brake system
causing the brake pads to drag due to fluid expansion.
Brake fluid and brake system parts expand and contract due to the heating and cooling during normal operation. A very
small hole called the compensating port, located inside the master cylinder, is opened and closed by the master cylinder
piston. When the brake pedal is released, the piston returns to its rest position and the compensating port is open. This
allows expanding or contracting fluid to move back and forth between master cylinder and fluid reservoir, preventing a
buildup of pressure in the system.
It is very important that the master cylinder reservoir have adequate space to allow for fluid expansion. Never overfill the
reservoir. Do not fill it beyond the MAX LEVEL line!
When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle
is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle
of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture. This property is desirable in order to reduce
the chance of corrosion (due to moisture) in the brake system. But an open container of fluid will absorb moisture from
the environment. When brake fluid contains moisture the boiling point is reduced, which can lead to early brake fade and
the possibility of serious injury. Brake fluid must be changed with fresh fluid from a sealed container at recommended
intervals or if contaminated.

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BRAKES
BRAKE SYSTEM - MECHANICAL COMPONENTS
Brake System - Mechanical Components

12 ft-lb
(16 Nm)

Brake Light Switch Spring

Pedal Return Spring Parking Brake Cable Parking Brake Switch

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BRAKES
BRAKE SYSTEM - HYDRAULIC
COMPONENTS

1 Banjo Bolts (All):

14.5 ft-lbs (19.6 Nm).
2 Bleed Screws (All):
47 in-lbs (5.3 Nm)
3 Caliper Mounting Bolts (All):
18.0 ft-lbs (24.5 Nm).
4 Brake Pad Guide Pins:
12.0 ft-lbs (16.2 Nm).

2
60 in-lbs. 4
(6.8 Nm)
3
15 in-lbs.
(1.7 Nm)
17.0 ft-lbs.
(23.0 Nm)
1

1 LH Front Caliper
Adaptor Clamps
60 in-lbs. (6.8 Nm)
2 2

Master Cylinder
4

3 1

RH Front Caliper
1 (All Banjo Bolts)

52 in-lbs.
(5.8 Nm) 3

60 in-lbs.
(6.8 Nm)

Rear Caliper

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BRAKES
BRAKE BLEEDING / FLUID CHANGE 3. Add clean brake fluid from a sealed container to the
indicated MAX level of the reservoir. Set reservoir
NOTE: If system is dry (such as if a brake line was cover loosely in place to keep debris out, but do not
replaced) or if a large amount of air is in the system, secure it.
start by bleeding the master cylinder (both front and
rear bleed screws) then bleed the calipers.
Polaris DOT 4 Brake Fluid
(P/N 2872189)
CAUTION
Master Cylinder Bleeding (If Required)
Always wear safety glasses.
4. Remove protective cap from bleed screw and install
a box end wrench on front or rear screw. Attach one
CAUTION end of a clean, clear hose on bleed screw and place
the other end in a clean container. Be sure hose fits
Brake fluid will damage finished surfaces. Do not tightly.
allow brake fluid to come in contact with finished
surfaces. This procedure should be used to
change fluid or bleed brakes during
regular maintenance.

1. Clean master cylinder reservoir cover and

surrounding area under front left cab thoroughly to
prevent debris from entering the reservoir, then
remove the cover.

“F”
“R”

5. Have an assistant slowly pump the brake pedal until

pressure builds, then hold light pressure on the pedal.

6. While assistant is holding light pressure, open bleed

screw until brake pedal travels to the end of its stroke
and no more fluid moves into the clear hose attached
to the bleed screw. Close the bleed screw, then have
assistant release brake pedal.

2. If changing brake fluid, remove as much old fluid from NOTE: Do not release brake pedal before bleed
6
the reservoir as possible with a Mity Vac™ pump or screw is tight, or air may be drawn into the system.
similar tool. Do not actuate the brake pedal when
reservoir is low. 7. Repeat Steps 5 and 6 until only clean fluid appears in
the hose and all air has been purged. Add fluid to
reservoir if necessary to keep fluid at the MAX level.
Mity Vac™ (PN 2870975)
CAUTION

Maintain at least 1/2"(1.27 cm) of brake fluid in

the reservoir at all times to prevent air from
entering the master cylinder.

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BRAKES
8. Tighten bleed screw securely and remove hose. 12. Add brake fluid to MAX level inside reservoir.
Torque bleed screw to 47 in-lbs (5.3 Nm). Install
protective cap.
Master Cylinder Fluid Level
9. Repeat Steps 4 - 8 for remaining master cylinder bleed
screw, then proceed to caliper bleeding procedure. Between the MIN and MAX line
shown on the reservoir.
Caliper Bleeding

10. The bleeding process is the same for the calipers as 13. Install master cylinder reservoir cover securely.
for the master cylinder. Use the bleed screw on each
caliper. Perform Steps 4-8 for each front caliper. 14. Field test the vehicle at low speed before putting into
service. Check for proper braking action and inspect
pedal travel.

15. Perform brake pedal inspection. See “Brake Pedal

Inspection / Adjustment” on page 6.9.

16. Check brake system for fluid leaks.

CAUTION

Maintain at least 1/2"(1.27 cm) of brake fluid in

the reservoir at all times to prevent air from
entering the master cylinder.

11. Perform Steps 4-8 for the rear caliper.

Open

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BRAKES
BRAKE PEDAL Brake Pedal Inspection / Adjustment
1. Push and release brake pedal. Verify master cylinder
Brake Pedal Removal
actuator rod and pedal mechanism returns fully and
1. Refer to Fig. 2 for pedal removal. pedal contacts pedal stop (on left side of pedal pivot
bracket) when released.
2. Disconnect both springs (A).
2. If pedal does not return freely, remove pedal and
lubricate. parts. See “Brake Pedal Removal” on
page 6.9.
C
F Pedal Free Play and Pedal Travel
D
1. Place vehicle on a flat, level surface.

2. Shift transmission into Neutral.

3. Carefully lift rear tires off the ground with a stable

G platform jack, or set vehicle on stable jack stands.

A B E 4. While rotating the rear wheels by hand, measure

brake pedal movement before any braking occurs
(Free Play), and record.

5. Measure the total brake pedal movement before

3. Remove cotter pin (B) and clevis pin (C). brake is firmly applied (Pedal Travel).

4. Remove E-clip (D) and washer (E) from pedal mount. 6. The pedal should move at least 1/4 inch before any
braking occurs, and no more than 1 - 1 1/2 inch before
5. Remove pedal assembly with bushings (F) and sleeve brakes are firmly applied. See Fig.1. 
(G). Visually inspect pedal, bushings, and sleeve for
wear and replace as required.
Pedal Travel
1 - 1 1/2 in. (25-37mm)
Pedal Installation
1. Apply Polaris Premium All Season grease to pivot
post and install pedal with bushings and sleeve.

2. Install washer and a new retaining E-clip.

3. Align pedal with master cylinder clevis and install pin.

4. Install washer and a new cotter pin.

6
5. Connect brake light switch spring and pedal return Fig. 1 1/4 in. (6mm) Minimum
spring.

6. Push and release brake pedal to be sure linkage rod 7. If pedal travel is excessive, or if brake pedal feels
and pedal mechanism returns fully when pedal is spongy and not firm, inspect brake fluid level in the
released. reservoir, inspect system for leaks, inspect caliper
mounting bolts, disc mounting bolts to be sure they are
7. Inspect brake pedal travel. See “Brake Pedal tight, and bleed the brake system. See “BRAKE
Inspection / Adjustment” on page 6.9. BLEEDING / FLUID CHANGE” on page 6.7.

Brake Pedal Travel:

1/2-3/4” (12-18mm)

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BRAKES
PARKING BRAKE wheels rotate freely with the parking brake off (parking
brake lever is in the DOWN position), and that the
Parking Brake Cable Freeplay Adjustment vehicle will not move when the parking brake is
applied (lever in the UP position).
Use the in-line adjuster to adjust the parking brake cable
freeplay. 9. Verify the park brake lever stays in the UP position
when brake is fully applied.
NOTE: Inspect the brake pads before adjusting
parking brake adjuster.

1. Verify the parking brake lever is down.

2. Inspect the freeplay between the cable end and

caliper bracket by pulling back on the cable.

3. Freeplay should be 1/16"-1/8" (1.5-3mm).

A
4. To adjust the cable freeplay, loosen the in-line adjuster
jam nut. Turn the adjuster nut outwards to decrease
cable freeplay. Turn the adjuster inwards to increase
cable freeplay. B

5. After setting the correct amount of freeplay, tighten the

in-line adjuster jam nut against adjuster.

Inspect Freeplay Here

Inline Adjuster Nut

Jam Nut Hold Adjuster Bolt While

Tightening Jam Nut

Parking Brake Adjustment

1. Place vehicle on a flat, level surface.

2. Shift transmission into Neutral.

3. Carefully lift rear tires off the ground with a stable

platform jack, or set vehicle on stable jack stands.

4. Loosen jam nut (A) on parking brake adjustment bolt.

5. While rotating the rear wheels by hand, tighten the

adjustment bolt (B) until significant brake drag is
detected.

6. Back the adjustment bolt out 1/4 turn.

7. Hold adjustment bolt in place and tighten jam nut

securely against lever arm.

8. Check parking brake lever movement. Verify the rear

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BRAKES
Parking Brake Cable Replacement 5. Secure the vehicle in position and place jack stands
under the front and rear areas of the frame.
1. Release parking brake. Turn the cable adjuster
located near the rear caliper inwards until fully 6. Note location of tie straps for assembly. Cut all tie
seated. straps.

2. Pull cable casing forward and slide cable out of holder, 7. Cable routes on passenger side of shift cables as
then remove cable from lever arm. shown.

3. Cut tie strap and release cable from guide.

8. Hold cable adjuster nut (10mm wrench). Loosen the

jam nut (12mm wrench), and turn adjuster nut fully
WARNING inward to gain maximum cable slack.
6
Use care when supporting vehicle so that it
does not tip or fall. Severe injury or death may occur
if the vehicle tips or falls.

NOTE: If you do not have the proper equipment to

safely lift and securely support the vehicle, refer to
Chapter 5 for information on removing the seats,
rear access panel, and battery tray panel to reach
the parking brake cable and brake lever from the top.

4. Have an assistant help tip the vehicle toward the

passenger side, or secure vehicle to a lift that allows
access to the underside.

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BRAKES
NOTE: Step 9 is only necessary if more slack is Cable Installation
required for removal in Step 10 and Step 11.
1. On a new cable or if adjuster was loosened upon
removal, turn cable adjuster that is located on the
underside of the vehicle out until approximately 3/4
(20mm) of thread is exposed. Screw jam nut against
the adjuster nut. Hold adjuster and tighten jam nut
securely.

2. Turn the cable adjuster located near the rear brake

caliper inwards until it is fully seated.

3. Route cable to passenger side of shift cables and

through holder on park brake lever bracket.

4. Pull inner cable and attach it to parking brake lever

arm.

5. Refer to routing photos in the cable removal process

to route the cable along the frame rails and out the
right side, near swingarm pivot.
9. At caliper end of parking brake cable, have an
assistant push inner cable into the outer cable casing 6. Secure cable to frame with new tie straps.
as far as possible to maximize slack at the lever end.
7. Carefully remove supports and lower the vehicle.

8. Route cable through guide at front of swingarm and

1. Hold back to rear caliper.

9. Secure cable to swingarm with rear brake line.

10. Connect caliper end of the cable.

11. Adjust parking brake and inspect cable freeplay.

2. Push

10. Remove cable from lever arm.

11. Pull cable out of holder on frame.

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BRAKES
FRONT BRAKE PADS NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
Front Pad Removal reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
1. Elevate and support front of vehicle.
6. Remove brake pad guide pin loosened in Step 3.

CAUTION 7. Push mounting bracket (B) inward (toward piston side

of caliper).
Use care when supporting vehicle so that it
does not tip or fall. 8. Slide stationary pad out (away from bracket) and off
Severe injury may occur if machine tips or falls. the threaded post, then rotate pad until it can be
removed from remaining guide pin (C).
2. Remove front wheel.

3. Loosen one of two brake pad guide pins (A) on caliper B

one full turn.

9. Remove inner pad.

10. Inspect caliper piston seals for leakage. Replace

4. Remove caliper mounting bolts slide caliper off disc. caliper assembly if leaking.

NOTE: When removing caliper, use care not to

damage brake line. Support caliper to avoid kinking Pad Inspection
or bending brake line. 1. Measure thickness of each pad. Replace pads as a
set if either is worn beyond the service limit.
5. Slowly push caliper piston into caliper bore, using a
C-clamp or locking pliers with pads installed.
6

Measure
Thickness

Front Brake Pad Thickness

.300” ± .007” (7.6 mm ± .178 mm)
Service Limit: .180” (4.6 mm)

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BRAKES
Front Brake Pad Assembly / Caliper 4. Install caliper onto front hub. Torque both mounting
Installation bolts.
30 ft-lbs
1. Lubricate mounting bracket pins with a light film of (40 Nm)
disc brake caliper lube. Install rubber dust boots
making sure the dust boots are fully seated on caliper
bracket and on caliper body.

=T
Caliper Mount Bolt Torque:
18 ft-lbs (24.5 Nm)
2. Push mounting bracket as far as possible toward the
piston side of the caliper. Install pads with friction 5. Torque brake pad guide pin(s) that were loosened or
material facing each other. removed.

WARNING 10 ft-lbs. (13.5 Nm)

If brake pads are contaminated with grease, oil,

or liquid soaked do not use the pads.
Use only new, clean pads.

3. Screw guide pin (A) through both pads and on to

threaded bracket post. Install pin until it stops against
bracket (B). Pads must slide freely on the pin. The
guide pin will be fully tightened after caliper is
installed. Be sure boots (C) are seated on caliper and
on bracket.
6. Slowly pump brake pedal until pressure builds.
Maintain at least 1/2 inch (12.7 mm) of brake fluid in
B reservoir to prevent air from entering the brake
system.

7. Rotate wheel hub and verify the hub turns freely

without brake drag.

8. Verify fluid level in reservoir is up to MAX line inside

A reservoir and install reservoir cap.
C

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BRAKES
9. Install wheel and torque wheel nuts. 3. Mount a dial indicator and measure disc runout.
Slowly rotate the disc and read total runout on the dial
indicator. Replace the disc if runout exceeds service
=T limit.

Front Wheel Nut:

27 ft-lbs (37 Nm) Brake Disc Runout
Service Limit .010” (.254 mm)
10. Perform the Brake Burnishing Procedure to maximize
pad service life and minimize noise. See “Brake
Burnishing Procedure” on page 6.21.

FRONT BRAKE DISC

Disc Inspection
1. Visually inspect disc for scoring, scratches, or
gouges. If any deep scratches are evident, replace
the disc.

2. Use a 0-1” (0-25mm) micrometer to measure disc

thickness at multiple locations around pad contact
surface. Replace disc if worn beyond service limit at
any measurement point.

X
X

X X
X X

X
X

Brake Disc Thickness

Service Limit: .170" (4.32 mm) 6
Brake Disc Thickness Variance

Service Limit .002” (.051 mm)

difference between measurements

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BRAKES
Disc Replacement FRONT CALIPER
1. Remove front wheel and brake caliper. See “Front
Front Caliper Removal
Pad Removal” on page 6.13.
NOTE: The caliper is not serviceable. Each caliper
2. Remove hub assembly. Refer to Chapter 5. can be replaced as an assembly.
3. Remove (6) bolts and disc from hub. 1. Elevate and safely support front of vehicle.

2. Remove (4) wheel nuts and front wheel.

7 ft-lbs (9.5 Nm)

CAUTION

Use care when supporting vehicle so that it does not

tip or fall. Severe injury may occur.

3. Clean caliper, brake line, and banjo bolt before

removal, and note how front brake lines are routed
and secured.

4. Clean the wheel hub mating surface and install new

disc on wheel hub.

5. Install new bolts and torque to 7 ft-lbs (9.5 Nm).

=T
Wheel Hub Bolt Torque:
7 ft-lbs (9.5 Nm) Line Guides

CAUTION

Always use new brake disc mounting bolts. The

bolts have a pre-applied locking agent which is
destroyed upon removal.

6. Install wheel hub assembly. Refer to Chapter 5.

7. Install front brake caliper (See “Front Brake Pad

Assembly / Caliper Installation” on page 6.14.) and
pump brake pedal to regain pressure and set pads
Driver Side Shown
against disc.

8. Field test unit for proper braking action before putting

into service. Inspect for fluid leaks and firm brakes.
Make sure the brake is not dragging when pedal is
released. If the brake drags, re-check assembly and
installation.

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BRAKES
4. Remove caliper mounting bolts and slide caliper off 3. Orient brake line to proper angle and torque to
disc. specification.

18 ft-lb. (24.5 Nm)

14.5 ft-lb. (19.6 Nm)

5. Place a container below caliper to catch brake fluid =T

and remove brake line from caliper. Immediately
cover and seal end of brake line to prevent Caliper Mount Bolt: 18 ft-lbs (24.5 Nm)
contamination. Brake Line Banjo Bolt: 14.5 ft-lbs (19.6 Nm)

6. Remove two caliper mounting bolts and caliper 4. Bleed the brake system. See “BRAKE BLEEDING /
assembly from front hub. FLUID CHANGE” on page 6.7.

5. Install wheel and torque wheel nuts to specification.

Caliper Installation
1. Separate brake pads and slide over brake disc. Align
caliper mounting holes and install bolts. Torque
=T
mounting bolts to specification.
Front Wheel Nut:
2. Place new sealing washers on each side of brake line 27 ft-lbs (37 Nm)
banjo fitting and install banjo bolt.
NOTE: If new brake pads are installed, brake
burnishing is recommended. See “Brake Burnishing
Procedure” on page 6.21.

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BRAKES
REAR BRAKE PAD 5. Push caliper piston into the caliper bore slowly using
a C-clamp or locking pliers with pads installed.
Rear Brake Pad Removal
NOTE: It may be necessary to back the parking
1. Elevate and support rear of vehicle. brake adjuster screw out a few turns.

CAUTION

Use care when supporting vehicle so that it

does not tip or fall.
Severe injury may occur if machine tips or falls.

2. Remove rear wheel.

3. Loosen the upper brake pad guide pin about 1 turn

before removing caliper.

NOTE: Brake fluid will be forced through

compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.

6. Remove the brake pad guide pin (B) loosened in Step

4. Remove caliper mounting bolts (A) and lift caliper off

disc.

NOTE: When removing caliper, be careful not to

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

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BRAKES
7. Slide outer pad toward outside of caliper body until it Rear Brake Pad Inspection
clears the threaded stud. Rotate pad and remove.
1. Measure the thickness of the pad material. Replace
pads if worn beyond the service limit.

Measure
Thickness

8. Slide inner pad toward outside of caliper body until it Rear Brake Pad Thickness
clears the threaded stud. Rotate pad and remove. .300" ± .007" (7.6 mm ± .178 mm)
Service Limit .180" (4.6 mm)

9. Inspect caliper piston seals for signs of brake fluid

leakage. Replace caliper if leaking.

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BRAKES
Rear Brake Pad Assembly / Caliper 4. Install caliper and torque mounting bolts to
Installation specification.

1. Lubricate mounting bracket pins with a light film of

disc brake caliper lube. Install rubber dust boots
making sure the dust boots are fully seated on caliper
bracket and on caliper body.

=T
Rear Caliper Mount Bolt:
18 ft-lbs (24.5 Nm)
2. Push mounting bracket as far as possible toward the
piston side of the caliper. Install pads with friction 5. Torque brake pad guide pin(s) that were loosened or
material facing each other. removed.

WARNING
10 ft-lbs. (13.5 Nm)

If brake pads are contaminated with grease,

oil, or liquid soaked do not use the pads.
Use only new clean pads.

3. Screw guide pin (A) through both pads and on to

=T
B
Brake Pad Guide Pin:
10 ft-lbs (13.5 Nm)

6. Slowly pump the brake pedal until pressure builds.

Maintain at least 1/2 inch (12.7 mm) of brake fluid in
A the reservoir to prevent air from entering the brake
C
system.

7. Adjust parking brake. See “Parking Brake Cable

Freeplay Adjustment” on page 6.10.

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BRAKES
8. Verify fluid level in reservoir is at the MAX line inside 2. Use a 0-1” micrometer and measure the disc
the reservoir and install reservoir cap. thickness at eight different points around the pad
contact surface. Replace disc if worn beyond service
limit.
Master Cylinder Fluid
X
Up to MAX line inside reservoir X

9. Install wheel and torque wheel nuts. X X

X X
=T Side
X View
Rear Wheel Nut: X
27 ft-lbs (37 Nm) Measure
Thickness

Brake Burnishing Procedure Brake Disc Thickness

To extend service life and reduce noise a burnishing Service Limit: .170” (4.32 mm)
procedure should be performed after installation of new
brake pads .
Start machine and slowly increase speed to 25 mph. Brake Disc Thickness Variance
Gradually apply brakes to stop machine. Allow pads and
disc to cool sufficiently during the procedure. Do not allow Service Limit .002” (.051 mm)
pads or disc to become hot, or warping may result. Repeat difference between measurements
this procedure 10 times.

REAR BRAKE DISC 3. Mount a dial indicator and measure disc runout.
Slowly rotate the disc and read total runout on the dial
Disc Inspection indicator. Replace the disc if runout exceeds
specifications.
1. Visually inspect disc for scoring, scratches, or
gouges. If any deep scratches are evident, replace
the disc . Brake Disc Runout
Service Limit .010” (.254 mm)

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BRAKES
Rear Brake Disc Replacement
1. Remove rear brake caliper. See “Rear Brake Pad
Removal” on page 6.18.

2. Refer to Rear Axle Removal (Chapter 5) to replace the

rear brake disc.

=T
Rear Brake Disc:
21 ft-lbs (28.5 Nm)

CAUTION

Always use new brake disc mounting bolts. The

bolts have a pre-applied locking agent which is
destroyed upon removal.

3. Install rear brake caliper. See “Rear Brake Pad

Assembly / Caliper Installation” on page 6.20.

4. Field test unit for proper braking action before putting

into service. Inspect for fluid leaks and firm brakes.
Make sure the brake is not dragging when pedal is
released. If the brake drags, re-check assembly and
installation.

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BRAKES
REAR CALIPER SERVICE 5. Front routing and clamp shown below.

Rear Caliper Removal

NOTE: The caliper is not serviceable. The caliper
must be replaced as an assembly.

1. Elevate and safely support rear of vehicle.

2. Remove right wheel.

CAUTION

Use care when supporting vehicle so that it does not

tip or fall. Severe injury may occur.

3. Clean caliper, brake line, and banjo bolt before

removal, and note how rear brake line fitting is
oriented on caliper. If brake line is being replaced,
note how brake line is routed and secured.

6. Remove two bolts and separate parking brake lever

arm assembly from caliper or see NOTE below.

Brake line with park

brake cable.

4. Tie straps - secure brake line with throttle cable in

areas (A). Secure with parking brake cable to frame
in area (B). 6

A B

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BRAKES
NOTE: The parking brake cable can be Rear Brake Caliper Installation
disconnected by loosening jam nut (C) and backing
out adjuster bolt (D) a few turns. 1. Install caliper and torque mounting bolts to
specification.

18 ft-lb. (24.5 Nm)

D
14.5 ft-lb. (19.6 Nm)

7. Remove two caliper mounting bolts and caliper

assembly.

8. Place a container below caliper to catch brake fluid =T

and remove brake line from caliper. Immediately
cover and seal end of brake line to prevent Rear Caliper Mount Bolt:
contamination. 18 ft-lbs (24.5 Nm)

=T
Brake Line Banjo Bolt:
14.5 ft-lbs (19.6 Nm)

2. Bleed rear brake system. See “BRAKE BLEEDING /

FLUID CHANGE” on page 6.7.

3. Attach parking brake cable to lever arm with one

washer (A) on each ends of spring. If lever arm plate
was removed, install plate and torque bolts (B) to 12
ft-lbs. (16 Nm).

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BRAKES
4. Adjust parking brake. See “Parking Brake Cable MASTER CYLINDER
Freeplay Adjustment” on page 6.10.
Removal
5. Verify fluid level in reservoir is up to the MAX line NOTE: The master cylinder is not serviceable but
inside reservoir and install reservoir cap. can be replaced as an assembly.

1. Clean master cylinder reservoir cover and

Master Cylinder Fluid surrounding area under front left cab thoroughly to
prevent debris from entering the reservoir. Remove
Up to MAX line inside reservoir
the cover.

6. Install wheel and torque wheel nuts.

=T
Rear Wheel Nut:
27 ft-lbs (37 Nm)

7. Field test unit for proper braking action before putting

into service. Inspect for fluid leaks and firm brakes.
Make sure the brake is not dragging when pedal is
released. If the brake drags, re-check assembly and
installation.
2. Draw as much fluid as possible from the reservoir to
minimize spillage.

CAUTION

Brake fluid will damage finished surfaces.

Do not allow brake fluid to come in contact
with finished surfaces.

3. Place a container under the master cylinder to catch

brake fluid. Loosen hose clamps (A) and remove
hoses from hose adaptors. Drain remaining fluid from
reservoir and hoses. Immediately cover and seal ends
of supply hoses to prevent contamination.

4. Remove front and rear brake line banjo bolts (B). 6

Immediately cover and seal ends of brake lines to
prevent contamination.

NOTE: Note brake line locations on master cylinder.

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BRAKES
NOTE: Dispose of fluid properly. Do not re-use. Installation
A 15 in-lb. (1.7 Nm) 1. Reverse Steps 1-5 for master cylinder installation.
Refer to the torque specifications in the removal
steps. Install new sealing washers on brake lines.

2. After installing the master cylinder, perform the

following:

• Fill the reservoir with Polaris Dot 4 Brake Fluid (PN

2872189) from a new, sealed container.
• Bleed the master cylinder and both front and rear
brake lines and calipers. See “BRAKE BLEEDING
/ FLUID CHANGE” on page 6.7.
B 14.5 ft-lb. (19.6 Nm) • Inspect pedal free play and pedal travel. See
“Brake Pedal Inspection / Adjustment” on
page 6.9.
5. Remove clip (C) and disconnect brake actuator rod
• Test brake system for proper function before
clevis from brake pedal.
returning the vehicle to service.
6. Remove the two mounting fasteners (D) that secure
the master cylinder to the frame.

D 17.5 ft-lb. (23.0 Nm)

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BRAKES
TROUBLESHOOTING 


Brakes Squeal / Poor Brake Performance Parking Brake Drags or Ineffective Brake
• Air in system • Improper adjustment
• Water in system (brake fluid contaminated) • Rear brake pads worn
• Caliper or disc misaligned or loose • Rear caliper misaligned, damaged, or improperly
• Caliper dirty or damaged assembled
• Brake line damaged or lining ruptured • Rear caliper bracket loose
• Worn disc or bent disc • Parking brake cable not returning freely
• Worn friction pads • Parking brake cam arm not returning
• Incorrectly adjusted parking brake • Broken, missing, or damaged return spring for
• Worn or damaged master cylinder or components parking brake lever or parking brake cam (on rear
• Brake pads dragging caliper)
• Caliper piston seized • Loose or broken caliper mounting bracket,

Pedal Vibration
• Disc damaged, loose, or worn (runout or thickness
variance exceeds service limit)
• Brake pads worn
• Loose caliper

Caliper Overheats (Brakes Drag)

• Compensating port plugged in front or rear
chamber of master cylinder
• Parking brake applied or misadjusted
• Brake pedal binding or unable to return fully
• Caliper piston(s) not returning properly / binding
• Operator riding brakes

Brakes Lock
• Mechanical parts sticking (brake pedal, parking
brake lever, etc.)
• Caliper pistons sticking
• Master cylinder piston sticking
• Improper assembly of brake system components

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BRAKES

NOTES

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CVT / TRANSMISSION
CHAPTER 7
CVT / TRANSMISSION
SPECIFICATIONS / TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2
CVT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
CVT MAINTENANCE / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3
DRIVEN CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3
CVT SYSTEM DRYING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4
CVT OVERHEATING / WATER INGESTION DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . .7.4
CLUTCH (CVT) COVER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5
CLUTCH (CVT) COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5
DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6
DRIVE BELT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6
DRIVE BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
DRIVE CLUTCH REMOVAL, DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . .7.8
DRIVE CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.9
DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
DRIVEN CLUTCH REMOVAL, DISASSEMBLY, INSPECTION . . . . . . . . . . . . . . . . . . . .7.9
DRIVEN CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.11
DRIVEN CLUTCH INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12
TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
TRANSMISSION DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
INPUT SHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.17
TRANSMISSION MAIN SHAFT ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.18
TRANSMISSION ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
OUTPUT GEAR PINION DEPTH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.21
OUTPUT SHAFT HOUSING DISASSEMBLY / ASSEMBLY . . . . . . . . . . . . . . . . . . . . .7.22
7

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CVT / TRANSMISSION
SPECIFICATIONS / TOOLS
Torque Specifications

TRANSMISSION TORQUE SPECIFICATIONS

Fastener Thread Size ft-lbs (Nm)
CVT Cover Bolts 6mm 6-8 (8-11 Nm)
CVT Drain Plug 6mm 6-8 (8-11 Nm)
Drive Clutch Nut 7/16 - 20 29 (39 Nm)
Driven Clutch Nut 7/16 - 20 40 (55 Nm)
Output Shaft Cover 6mm 6-8 (8-11 Nm)
Output Shaft
8mm 12 (16 Nm)
Housing Screws
Oil Drain Bolt
14mm 18 (18-23 Nm)
(Crankcase)
72 (98 Nm)
Output Shaft Collar
- Shimming
Nut
Required
Shift Detent Bolt 10mm 14 (19 Nm)
Transmission 
6mm 6-8 (8-11 Nm)
Cover Bolts

Special Tools

PART NUMBER TOOL DESCRIPTION

PA-49959 Output Shaft Collar Nut Socket

SPX Corp: 1-800-328-6657 or [Link]

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CVT / TRANSMISSION
CVT SYSTEM Drive Clutch Operation
Drive clutches primarily sense engine RPM. The major
WARNING component, which controls shifting function, are the shift
centrifugal weights (rollers) inside the moveable sheave.
All CVT maintenance or repairs should be performed Whenever engine RPM is increased, centrifugal force is
only by a certified Polaris Master Service Dealer (MSD) created, causing the rollers to push against the cam plate
technician who has received the proper training and and force the moveable sheave toward the drive belt. This
understands the procedures outlined in this manual. motion pinches the drive belt between the spinning
Because of the critical nature and precision balance sheaves and causes rotation, which in turn rotates the
incorporated into the CVT components, it is driven clutch. If belt speed is sufficient, centrifugal friction
absolutely essential that no disassembly or repair be shoes on the driven clutch overcome the return spring
made without factory authorized special tools and pressure and swing outward against the transmission
service procedures. drive hub, and the vehicle (if in gear) begins to move.

The Continuously Variable Transmission (CVT) consists At lower RPM, the drive belt rotates low in the drive clutch
of three major assemblies: 1) The Drive Clutch; 2) The sheaves. As engine RPM increases, centrifugal force
Driven Clutch; and 3) The Drive Belt. The internal causes the drive belt to be forced upward on drive clutch
components of the drive clutch and driven clutch control sheaves, changing the ratio of the drive to driven clutch
engagement (initial vehicle movement), clutch upshift and from low to high.
backshift. During the development of a Polaris RZR, the
CVT system is matched first to the engine power curve; Driven Clutch Operation
then to average riding conditions and the vehicle’s
intended usage. Therefore, modifications or variations of CVT driven clutches primarily sense torque, but also react
components at random are never recommended. Proper to RPM, applying and retracting the friction shoes
clutch setup and careful inspection of existing according to the forces applied to it from the drive belt. At
components must be the primary objective when the same time it reacts to the torque at the transmission
troubleshooting and tuning. input shaft. If the torque resistance at the transmission
input shaft is greater than the load from the drive belt, the
drive belt is kept at the outer diameter of the driven clutch
CVT Maintenance / Inspection
Under normal operation the CVT system will provide years
sheaves (low ratio).
As engine RPM and horsepower increase, the load from
7
of trouble free operation. Periodic inspection and the drive belt increases, resulting in the belt rotating up
maintenance is required to keep the system operating at toward the outer diameter of the drive clutch sheaves and
peak performance. The following list of items should be downward into the sheaves of the driven clutch. This
inspected and maintained to ensure maximum action, which increases the driven clutch speed, is called
performance and service life of CVT components. See upshifting.
“CVT Overheating / Water Ingestion Diagnostics” on
page 7.4 for more information. Should the throttle setting remain the same and the
vehicle is subjected to a heavier load, the torque sensing
1. Drive clutch rollers and sheave bushing. driven clutch will close, forcing the drive belt back up
2. Driven clutch rollers, pins, spring, centrifugal friction toward the outer diameter of the driven clutch. This also
shoes, and transmission drive hub. forces the belt downward into the sheaves of the drive
clutch. This action, which decreases the driven clutch
3. Clutch sheave faces. Clean and inspect for wear. speed, is called backshifting.
4. CVT system sealing. The CVT system is air cooled by In situations where loads vary and throttle settings are
fins on the drive clutch. The fins create a low pressure constant, the drive and driven clutches are continually
area around the drive clutch, drawing fresh air in shifting to maintain optimum engine RPM. At full throttle a
through the intake duct. The opening for this intake perfectly matched CVT system should hold engine RPM at
duct is located at a high point on the vehicle. All the peak of the power curve. This RPM should be
connecting air ducts, as well as the clutch cover, must maintained during clutch upshift and backshift. In this
be sealed to ensure clean air is being used for cooling respect, the CVT system is similar to a power governor.
the CVT system. This also reduces the chance of Rather than vary throttle position, as a conventional
water and other contaminants entering the CVT area. governor does, the CVT system reacts to engine load
requirements by either upshifting or backshifting.

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CVT / TRANSMISSION
CVT System Drying 3. Allow engine RPM to settle to idle speed, shift
transmission to lowest available range and test for belt
NOTE: If operating the RZR in wet conditions, be slippage. Repeat as needed.
sure to check the CVT cover and both air ducts for
proper sealing to reduce the chance of water FRONT CVT Drain Plug
ingestion. Refer to Owner’s Manual for Safe Riding
Tips and operational guidelines for wet conditions.

1. To drain any water that may be trapped inside the

CVT area, remove the CVT drain plug and O-ring Transmission
located on the bottom of the crankcase and let the Drain Plug
water drain out. The CVT drain plug is shown at right.
Shift Detent
2. To further expel water from the CVT area cover and
to dry out the CVT system, shift the transmission to
neutral and rev the engine slightly to expel the Engine Oil
moisture. This will also air-dry the belt and clutches. Drain Plug

CVT Overheating / Water Ingestion Diagnostics

During routine maintenance or whenever CVT system temperatures. Be sure all air ducts and connecting boots
overheating is evident, check the inlet and outlet ducts for are in good condition and tightly sealed (clamps are in
obstructions. Obstructions to air flow through the ducts will place and tight).
significantly increase CVT system operating

CVT Air Duct System

Air Outlet Duct

36 in-lb. (4.0 Nm)

Air Inlet Duct Clamps 25 in-lb. (2.8 Nm)

36 in-lb. (4.0 Nm)

Clamps 25 in-lb. (2.8 Nm)

Boot

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CVT / TRANSMISSION
Clutch (CVT) Cover Removal / Inspection Clutch (CVT) Cover Installation
1. Refer to Chapter 5 to remove the seats, rear access 1. Clean gasket surfaces and install a new gasket with
panel, and battery tray panel to access the CVT cover alignment dowels (E) in place.
cover.
2. Install drive and driven clutch with belt. Refer to clutch
2. Remove duct mounting screws (A). Loosen duct installation this chapter.
clamps (B) and slide both ducts off cover.

36 in-lb. E
(4.0 Nm) A

25 in-lb. E
(2.8 Nm) B

3. Remove (8) cover screws. Tap cover to loosen.

4. Pull cover out until disengaged from dowel pins. Tip 3. Guide cover through cables and tip in same manner
bottom of cover up to clear fuel tank. as for removal in order to clear fuel tank.
5. Carefully guide cover to clear shift cables and tank.

4. Install cover and tighten all screws to specified torque.

6. Inspect bearing (C). It should rotate freely without 5. Connect inlet and exhaust air ducts (F) with clamps.
binding. Replace if rough, if inner race is loose, or if
bearing is loose in the cover. Be sure screws for air
duct plate (D) are tight.

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CVT / TRANSMISSION
6. Install battery tray panel, rear access panel, and 4. Hold inner (moveable) sheave (B) inward when
seats. removing belt from drive clutch to prevent rollers from
falling out of the clutch ramps. Remove belt from
driven clutch.
Drive Belt Inspection
1. Inspect surface of drive belt for uneven wear or
grease deposits. Measure width. Replace belt if worn
or glazed.

F
F

Drive Belt Removal

1. Remove CVT cover. See “Clutch (CVT) Cover CVT Drive Belt Width
Removal / Inspection” on page 7.5 Service Limit: .626” (15.9mm)
2. Pull moveable (outer) sheave of driven out and push
belt as far down as possible to create belt slack.
Drive Belt Installation
1. Do not attempt to install drive belt with drive clutch
stationary sheave installed.
2. Push moveable sheave and spacer sleeve of drive
clutch fully inward and measure the amount of
exposed splines on the shaft. Be sure at least 5/16
(mm) of spline is exposed. If less than 5/16 is
exposed, remove clutch and sleeve and check
assembly of components.

3. Remove drive clutch nut (A). Use a strap wrench to

hold stationary sheave.

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CVT / TRANSMISSION
3. Loop belt around driven clutch. Install belt so numbers 7. Tighten nut to specification.
can be read from front of vehicle looking rearward.

=T
4. Compress moveable sheave of driven clutch and
force belt as far down as possible. Hold belt down in Drive Clutch Nut:
driven sheaves and loop front of belt over drive clutch 29 ft-lbs (39 Nm)
shaft.
5. Hold belt as high as possible on sheaves. Install
stationary sheave over shaft splines. Start nut and
tighten finger tight while moving belt and sheave to
ensure FULL engagement of stationary sheave
splines with shaft splines.

6. Hold stationary sheave with a strap wrench.

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CVT / TRANSMISSION
DRIVE CLUTCH SERVICE 8. Inspect both sheave faces (E) for grooves, wear, or
damage.
Drive Clutch Removal, Disassembly and 9. Inspect splines of stationary sheave (F) for wear.
Inspection Temporarily install stationary sheave on crankshaft to
verify splines fit tightly on splines of crankshaft.
1. Remove drive belt. See “Drive Belt Removal” on
page 7.6. 10. Remove and inspect each roller (G). Replace as a set
if any have flat spots or if worn (they should be
2. Remove stationary sheave from splines of shaft, cylindrical).
holding moveable sheave and spacer inward.
11. If rollers are worn, inspect roller tracks in moveable
3. Hold moveable sheave, spacer sleeve, and cam plate sheave for wear also.
together. Slide off crankshaft as an assembly to
prevent rollers from falling out of cam plate. 12. Replace drive clutch assembly if either sheave guide
posts or roller tracks are worn.

D E

H
G

4. Inspect surface of sleeve (A) and bushing (B) for wear, 29 ft-lbs (39 nm)
Fig. 1
pitting, or damage.
5. Inspect cam plate guides and both sides of guide
posts on moveable sheave for wear. Replace guides
as a set.

A B

Refer to Fig. 1.
6. Inspect cam plate for wear on all roller track surfaces
(D).
7. Clean any belt material from sheaves with isopropyl
alcohol or brake parts cleaner.

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CVT / TRANSMISSION
Drive Clutch Assembly faced hammer to release drive hub from splines.

1. Do not grease clutch components.

2. Install rollers in moveable sheave.
3. Install cam plate guides (H, Fig. 1) in cam plate and
assemble cam plate to moveable sheave, aligning
guides with guide posts.
4. Install sleeve in bushing.
5. Install assembly on crankshaft.
NOTE: When installing moveable sheave / cam plate
assembly onto the crankshaft, hold assembly
together to prevent rollers from dislodging.

4. Visually inspect friction surface of drive hub (A) for

deep scoring or damage. Visually inspect splines (B)
for wear.

A B

7
6. See “Drive Belt Installation” on page 7.6 to install belt
and complete the installation of drive clutch stationary
sheave.

5. Measure inside diameter of drive hub.

DRIVEN CLUTCH SERVICE
Driven Clutch Removal, Disassembly,
Inspection
1. Remove belt. See “Drive Belt Removal” on page 7.6.
2. Use a strap wrench to hold drive hub and remove
driven clutch retaining nut.
3. Pull outward on driven clutch and tap shaft with a soft

Drive Hub I. D.
Service Limit: 4.43” (112.5 mm)

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CVT / TRANSMISSION
6. Secure driven clutch assembly in a soft jaw vise or 9. Separate moveable and fixed sheave. Clean all parts
clamp. Loosen retaining nut (counterclockwise) about and sheave faces with isopropyl alcohol or brake parts
1 turn. Hold downward pressure on friction shoe plate cleaner.
(C), then remove nut. Release pressure on plate and
10. Inspect both sheave faces (F) for grooves, wear, or
remove friction shoe assembly and driven spring.
damage.

CAUTION 11. Replace seals (G) and O-rings (H) upon assembly.

Components are under spring pressure. Wear eye F

and face protection and use care during removal.
H

C Fig. 2

12. Inspect spring free length. Replace if less than service

7. Rotate and pull upward on roller pin cover to remove. limit.

Driven Compression Spring Length

Service Limit: 2.74” (69.7mm)
8. Remove (3) rollers and pins (D). Inspect roller tracks
(E) in moveable sheave.

Refer to Fig. 2.

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CVT / TRANSMISSION
13. Measure thickness of friction shoe material. Replace Driven Clutch Assembly
shoes, as a set, if worn beyond service limit. 1. Press new seals (A) into moveable sheave with seal
lips facing inward. Press seals flush with edge of seal
bore.
2. Fill outer cavity between seals (roller area) with
grease and slide moveable sheave onto post of
stationary sheave (B).
3. Align and insert (3) roller/pin assemblies (C).

Driven Clutch Friction Shoe B

Thickness
Service Limit: .039” (1.0mm)
C
14. To replace friction shoes, remove E-clips that retain
the backing plate. Use a suitable tool to remove and
install the return springs, using care not to stretch 4. Lubricate and install new O-rings in grooves of driven
springs more than required for installation. sheave, then install outer roller pin cover (D) until
flange is firmly seated against sheave.

7
D

5. Clean threads (E) to remove all oil, grease, or old

locking agent then apply a few drops of Loctite 272.

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CVT / TRANSMISSION
6. Have an assistant available for final assembly. Install 6. Install drive clutch stationary sheave. See “Drive Belt
spring. Place centrifugal hub (F) over the spring and Installation” on page 7.6.
compress assembly together with both hands,
aligning flats of hub with flats on threaded shaft. With
assembly compressed and threads exposed, have
assistant thread a new nut onto shaft.

New

7. Secure clutch in a clamping device and torque nut. Driven Clutch Nut Torque
40 ft-lbs (55 Nm)

Driven Assembly Nut Torque

50-54 ft-lbs (68-73 Nm)

Driven Clutch Installation

1. Install belt on driven clutch with numbers readable
from centrifugal hub side of clutch.
2. Compress driven clutch and force belt into the
sheaves as far as possible, and hold belt in position.
3. Loop the belt over drive clutch and install driven clutch
on transmission shaft.
4. Install drive hub and engage splines of drive hub to
splines of transmission input shaft.
5. Install driven clutch nut. Tighten nut to specified
torque.

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CVT / TRANSMISSION
TRANSMISSION SERVICE NOTE: Angle drive removal is not required for
transmission cover removal or access to internal
Transmission Disassembly and Inspection transmission components. Drive pinion gear (D) and
IMPORTANT: To ensure proper shifting, verify shift shaft will stay with cover when removed.
cables are in good condition, routed and adjusted
properly after transmission is assembled and engine
is installed.
1. Remove drain plug (A) and drain oil from case.

A
5. Remove (3) angle drive output housing screws.
Remove housing.

2. Remove shift cable bracket (B) and shift arm screw

(C).

6. Note number of shims for assembly.

3. Mark shift shaft and shift cable arm orientation before

removing the arm.

7. Turn output shaft by hand to check for smooth rotation.

Push on splined end and gear end of shaft. There
4. Remove angle drive inspection / oil fill cover.

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CVT / TRANSMISSION
should be no detectable up and down or side to side 10. Remove retaining ring from drive pinion.
movement. Check splines and gear teeth for wear or
damage.

11. Remove spacer and gear.

8. If damage or wear is evident, or if seal is leaking,

replace output housing assembly or replace parts as
required. See “Output Shaft Housing Disassembly /
Assembly” on page 7.22.

If parts are replaced refer to

output gear depth adjustment
in this chapter.

12. Push shaft out of cover housing.

9. Remove all transmission cover screws. Tap lightly

with a soft faced hammer. Pry points (E) can be used
carefully to help release cover and gasket.

13. Inspect gear teeth and bearing. If components are

replaced, inspect output gear pinion depth and adjust
with shims as required. See “Output Gear Pinion
Depth Adjustment” on page 7.21 for procedure.
E

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CVT / TRANSMISSION
14. Remove detent bolt with ball and spring. 17. Remove shift fork shaft. Pull fork out of shift drum
track.

15. Pull shift shaft from case.

18. Remove shift drum.

16. Push and release the spring loaded gear position

switch plunger (F). Be sure it moves freely inward and 19. Remove shift fork.
extends under spring pressure when released.

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CVT / TRANSMISSION
20. Inspect shift drum track (G), paying close attention to 24. Remove countershaft.
corner areas where track changes direction. Inspect
shift fork guide (H) for wear or damage.
21. Inspect gear position detent track (I) of shift drum.
Replace drum if deeply grooved from detent ball
travel.
22. Inspect pad area of shift fork (J) and replace if bent,
worn, discolored, scored, or damaged.

I H
25. Inspect input pinion gear for tooth damage. Push on
shaft to check for play in bearing. Rotate the shaft to
check for smooth bearing rotation.
J 26. Inspect all bearings in case. They should rotate freely
without binding. Bearing inner race should have no
detectable radial (up and down) movement of inner
race.

23. Pull main shaft from case with thrust washer on inside
end.

27. Inspect mainshaft components. See “Transmission

Main Shaft Assembly View” on page 7.18

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CVT / TRANSMISSION
Input Shaft Removal / Inspection
1. Remove bearing stop screw and washer (A).
2. Tap input shaft from CVT side to remove shaft with
bearing.

87 in-lbs (9.8 Nm)

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CVT / TRANSMISSION
Transmission Main Shaft Assembly View 3. Inspect forward / reverse dog gear. Closely inspect
outer corners of dogs for rounding or damage (K).
1. Refer to Fig. 3 for assembly view. Replace all
4. Inspect edges of slots (L) in forward and reverse gears
retaining rings if removed.
for severe rounding that would reduce contact area of
2. Remove flat washer (A), circlip (B), shaft collar (C), sliding gear dog. Compare leading and trailing edges
washers (D) (one washer on each side of gear E), of slots to determine level of wear. Inspect needle
sliding dog gear (F), snap ring retainer (G), splined bearing (M).
washer (H), gear with needle bearing (I), and thrust
washer (J).

J G
F
C

I B
H

E
D
Fig. 3

L
K
M

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CVT / TRANSMISSION
Transmission Assembly • Install gear position switch plunger (E) with spring
in end of shift shaft. Use light grease to hold parts
1. To assemble transmission, reverse disassembly
in place and carefully install shaft in gear case.
procedure, and read the following assembly notes.
• After installing countershaft (A), install mainshaft
as an assembly. Hold washer (B) in place with a
small amount of grease. E

B • Align center teeth of shift shaft and drum (F).

• Assemble shift fork and drum in the Neutral

position. Rotate shift drum to align Neutral detent
notch (C) with center of detent bolt hole (D). F

D
C

7
2. Torque detent bolt to specification.

=T
Detent Bolt:
• Assemble shift detent ball, spring, and bolt into 14 ft-lbs (19 Nm)
bottom of transmission case, but do not fully
tighten the bolt. Leave just enough tension on 3. Verify (two) cover alignment dowel pins are in place.
detent ball to keep shift drum from rotating out of Install cover with a new gasket. Torque cover screws
Neutral. evenly in a cris-cross pattern to specification.

=T
Transmission Cover Screws:
6-8 ft-lbs (8-11 Nm)

4. Install and torque drain plug.

=T
Oil Drain Plug:
18 ft-lbs (24.5 Nm)

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CVT / TRANSMISSION
5. Assemble output shaft housing to case with existing • Verify transmission shift arm is in NEUTRAL
shims. If components were replaced you must inspect
output gear pinion depth. See “Output Gear Pinion
Depth Adjustment” on page 7.21.

Shift Arm - Neutral Position

• Attach cables to bracket and to shift arm.
• Adjust each cable until slack is removed from each
cable and tighten cable adjusters securely.
=T • Check for proper shift operation

Output Housing:
14 ft-lbs (19 Nm)

6. Install outer cover (oil fill cover).

7. Add 27 fl. oz. (800ml) of oil.

LUBRICANT CAPACITY

AGL - Synthetic ATV

27 fl. oz. (800 ml)
Gearcase Lubricant

8. Verify vent hose is clear. After installing engine in

frame, route and secure hose lightly as shown with
open end (G) pointing down.

9. After installation in the frame, adjust shift cables in the

following manner:
• Place gear selector in NEUTRAL

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CVT / TRANSMISSION
Output Gear Pinion Depth Adjustment To obtain correct pinion depth, a shim pack with a
thickness totaling .032 - .036 inch (.8-.9mm) must be
NOTE: This procedure sets pinion depth only. There installed.
are no provisions for backlash adjustment.

1. Remove O-ring from output shaft housing (re-install .020 Measured Gap .020 Measured Gap
for final assembly). + .012 Minimum Clearance +.016 Maximum Clearance

2. Remove any existing shims from housing. .032 in. .038 in.

3. Install housing in transmission case. The pinion gear

and output gear should bottom against each other,
leaving a gap between housing and transmission Minimum shim Maximum shim
pack thickness (inch) pack thickness (inch)
case that can be measured with a feeler gauge at (A).

4. Hold gears in bottomed position by applying light

pressure to the center of the output shaft. Measure the
gap with a feeler gauge and record. 7
= In. / mm.

Output Pinion Shaft Shim Pack Requirement:

Measured Distance
plus
.012-.016 / 0.3mm-0.4mm

5. The specified pinion depth is .012 - .016 inch (0.3mm-

0.4mm) from the bottomed position. Therefore, you
will need to install a shim pack with a thickness of .012
- .016 inch (0.3mm-0.4mm) plus the gap measured in
Step 4.

Example: Gap between housing and case is .020 inch
(0.50 mm) with no shims installed and gears
bottomed.


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CVT / TRANSMISSION
Output Shaft Housing Disassembly / 8. Apply grease to shaft oil seal then carefully slide shaft
Assembly assembly through seal and into housing until
bottomed in bearing bore.
1. If housing is removed from transmission case, 9. Install bearing (E) over splined end of shaft and push
temporarily re-install with all 3 screws (A). into housing until seated.
2. Remove collar nut (B) using special socket PA-49959. 10. Install collar nut hand tight.
3. Push shaft out of bearings. 11. Temporarily install housing to transmission case with
4. Inspect shaft and housing for wear. all 3 screws (A) and fully tighten collar nut to specified
torque. Remove housing from case.
5. Clean housing and inspect for wear in the bearing
bore areas. 12. Perform pinion depth inspection / adjustment to
determine the thickness of shim pack (F) required.
6. Install new bearing (C) on shaft. See “Output Gear Pinion Depth Adjustment” on
7. Install new seal (D) in housing with spring side of seal page 7.21.
facing pinion gear. 13. Install new O-ring (G) on housing after Step 12 is
completed.

B
72ft-lbs (98Nm)

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ELECTRICAL
CHAPTER 8
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
ELECTRICAL SYSTEM SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SWITCHES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
BRAKE PEDAL / PARKING BRAKE SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
THROTTLE RELEASE SWITCH (TRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TRS OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TRS SWITCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
DAYTIME RUNNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
TAIL LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
INDICATOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
TRANSMISSION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
TRANSMISSION SWITCH - CIRCUIT BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.8
IGNITION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
IGNITION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
RPM IGNITION LIMITER FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
RPM LIMITER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
IGNITION COIL TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
CDI OUTPUT TEST USING PEAK READING ADAPTOR . . . . . . . . . . . . . . . . . . . . . . . 8.11
PULSER COIL OUTPUT / RESISTANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
CHARGING SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
MAIN FUSE / FUSE HOLDER LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
VOLTAGE REGULATOR / RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
STATOR / ALTERNATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
BATTERY MAINTENANCE SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
NEW BATTERY ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
BATTERY CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
BATTERY VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
BATTERY LOAD TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
8
BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
BATTERY STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
STARTER RELAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
STARTER MOTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
STARTER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
STARTER BRUSH INSPECTION / REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
ARMATURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
STARTER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
STARTER SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
STARTER SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21

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ELECTRICAL
GENERAL INFORMATION SWITCHES AND CONTROLS
Special Tools Key Switch
The key switch can be tested with an ohm meter.
PART NUMBER TOOL DESCRIPTION
When the key is turned to the “OFF” position, there should
Fluke™77 Digital
PV-43568 be no continuity between any of the wires.
Multimeter
2870836 Peak Reading Adaptor When the key switch is turned to the “ON” position, there
should be continuity between the red (RD) and brown (BN)
2870630 Timing Light wires. There should also be continuity between the black
8712100 or 8712500 Tachometer (BK) and dark green (DG) wires.

When the key is turned to the “START” position, there

Electrical System Service Notes
should be continuity between the red (RD) and brown (BN)
Reference the following notes when diagnosing electrical wires. There should also be continuity between the black
problems. (BK), dark green (DG), and dark green/red (DG/RD) wires.

• The ignition system timing is non-adjustable. The

KEY SWITCH CONTINUITY CHART
specifications in Chapter 1 are intended for
reference only. 
Color
• Refer to wiring diagram for stator and electrical RD BN BK DG DG/RD
Switch 
component resistance specifications.
Position
• When measuring resistance of a component that OFF
has a low resistance value (under 10 Ohms),
remember to subtract meter lead resistance from ON
the reading. Connect the leads together and START
record the resistance. The resistance of the
component is equal to tested value minus the lead
resistance.

• Become familiar with the operation of the meter.

Be sure leads are in the proper jack for the test
being performed (i.e. 10A jack for current
readings). Refer to the owner’s manual included
with the meter for more information.

• Voltage, amperage, and resistance values

included in this manual are obtained with a
Fluke™ 77 Digital Multimeter (PV-43568). This
meter is acceptable for use when diagnosing
electrical problems. Readings obtained with other
meters may differ.

• Pay attention to the prefix on the multimeter

reading (K, M, etc.) and the position of the decimal
point.

• For resistance readings, isolate the component to

be tested. Disconnect it from the wiring harness or
power supply.

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ELECTRICAL
Brake Pedal / Parking Brake Switches 2. Disconnect wire harness from each switch and
connect an ohmmeter across the two switch wires. 
When the brake pedal switch is closed, it illuminates the The reading should be infinite (•).
rear brake lamp and completes the START command
circuit. The brake pedal must be depressed to start the 3. Apply either the brake pedal or parking brake and
engine. check for continuity between switch contacts.
Replace switch if there is no continuity, or if the
The parking brake switch is closed when the parking brake resistance is greater than .5 ohms when the brake is
lever is pulled, which signals the CDI to limit engine RPM. applied with slight pressure.

1. Locate the parking brake and brake pedal switches.

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ELECTRICAL
Throttle Release Switch (TRS) TRS Switch Adjustment
Always check the throttle pedal for smooth operation 1. Slide the boot off the throttle cable adjuster and jam
before riding. Periodically check the throttle free play. It nut.
should be kept between 1/16” and 1/8” (1.5mm – 3.2mm).

If adjustment is required, turn the throttle cable adjuster

until the free play falls within the acceptable limit.
Adjuster
TRS Operation
When the throttle is closed (idle), the throttle pedal arm
depresses a small micro switch that limits engine rpm.
This action opens the circuit.
Boot

Throttle Arm

2. Set parking brake.

3. Start engine and set idle to specified RPM.

NOTE: Be sure the engine is at operating

Micro Switch temperature. See “Idle Speed Adjustment” in
Chapter 2.

4. Loosen the adjustment nut on in–line cable adjuster.

5. Turn cable adjuster out until engine RPM begins to

When the throttle pedal is pushed forward, the throttle arm increase.
moves off the micro switch and allows the engine rpm to
increase with lever movement. This action closes the 6. Turn cable adjuster back in until throttle lever has 1/
circuit. 16”
(.16 cm) of travel before engine RPM increases.
If the throttle cable would become hung up or stuck while
the vehicle is being operated, the spring loaded throttle 7. Tighten lock nut securely and slide boot completely in
arm will return back and depress the micro switch, limiting place to ensure a water–tight seal.
engine rpm.
NOTE: Verify TRS switch plunger is held inward at
The TRS switch and throttle arm are located in a sealed idle position.
throttle pedal assembly. Switch or throttle cable
replacement requires removing the assembly cover.
Always replace the cover gasket with a new one during
assembly.

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ELECTRICAL
DAYTIME RUNNING LIGHTS “DRL” Lamp Replacement
If the daytime running lights do not operate, lamp
“DRL” Test
replacement may be required. Install only the
The daytime running lights are powered by an AC current recommended replacement lamps.
from the Generator / Stator.

If running lights are not working, perform the

following:

1. Disconnect the harness from the faulty light.

2. Using a Volt Ohm Meter, measure the AC voltage

between the (YELLOW) and (BLACK) wires. Voltage
above 5 VAC should be present when unit is running.

If voltage is present:
1. Replace the faulty bulb.

If voltage is not present: 1. Remove cover from back of light housing

1. The black wire should have continuity to ground. If no 2. Press in and rotate the lamp socket counter-clockwise
continuity is present, check for a short or break in the and remove it from the housing.
wiring harness, or a poor connection. 3. Apply Dielectric Grease PN 2871329 to the new bulb
contacts and install.
2. If the black wire has good continuity to ground, check
the wiring harness from the stator to the running lights. 4. Verify the new lamp filament is horizontal, and then
There should be continuity between the (YELLOW) reinstall the socket into the housing and rotate
wire at the light connector and the (YELLOW) wire at clockwise about 1/4 turn. Replace the cover.
the Generator / Stator. 5. Start the engine to make sure the lights come on. If
the lights do not operate, check the charging system
3. If continuity is good, perform stator resistance tests and related wiring for possible malfunction.
using the resistance chart located in the wiring
diagram.

4. Replace Generator / Stator if resistance is not within

specification.

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ELECTRICAL
TAIL LIGHT INDICATOR LAMPS
Tail Light Lamp Replacement Indicator Lamp Replacement
If the tail light lamp does not work, the lamp may need to 1. The indicator lamps are located on the dash.
be replaced.
2. Disconnect the indicator light wire connections from
the harness.

1. Remove the two screws securing the lens cover and

remove the lens cover.
2. Remove the lamp and replace it with a new
(recommended) lamp. Apply Dielectric Grease (PN
2871329) to the lamp terminals.
3. Remove the nut from the backside of the indicator
3. Test the light for proper operation. lamp.
4. Reinstall the lens cover. 4. Remove the lamp.
5. Install new lamp(s) into the dash and secure with
retaining nut.
6. Apply dielectric grease to the wire connections of the
new lamp.
7. Turn ignition key to the “ON” position and shift the
transmission into “Neutral” or “Reverse” to verify light
operation.
8. If the lights do not operate, check battery voltage at
the light harness and check related wiring for possible
malfunction.

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ELECTRICAL
TRANSMISSION SWITCH
Transmission Switch - Circuit Breakout

Testing 3. Then shift the transmission into “reverse” and test for
continuity between the DB wire and ground. In both
1. With the switch installed, use an ohmmeter to test tests you should have continuity to ground.
continuity between the switch leads and engine
ground.

2. First, shift the transmission into “neutral” and test for

continuity between the DG/WH wire and ground. 8

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ELECTRICAL
Removal IGNITION SYSTEM
1. Remove the CVT cover. The indicator switch will be
Overview
visible between the drive and driven clutch. Refer to
CVT Chapter for CVT cover removal and installation. The ignition system consists of a simple magneto-driven
system that includes a stator pulser coil, CDI Box, ignition
2. Remove the (2) screws and pull on switch to release coil and related wiring / connectors.
from crankcase. Timing is non-adjustable on this ignition system.
3. Inspect the shift indicator contacts, shift drum, pin and
spring. Verify the pin is not sticking in the drum or is Ignition System Troubleshooting
damaged. Replace any worn or damaged No Spark, Weak or Intermittent Spark
components.
• No 12 volt power on brown (BN) wire at CDI box or
INSPECT no CDI box ground path from the black/white (BK/
WH) wire

• Spark plug gap incorrect

• Fouled spark plug

• Faulty spark plug cap or poor connection to high

tension lead

• Related wiring loose, disconnected, shorted, or

corroded

• Engine Stop switch or ignition switch faulty

• TRS switch faulty

Installation
• Poor ignition coil ground
1. Install spring and pin into shift drum.
• Faulty stator (measure resistance of all ignition
2. Install switch with new O-ring. Route wires through related windings)
crankcase. Install screws.
• Incorrect wiring (inspect color coding in connectors
3. Torque screws to specification. etc)

• Faulty ignition coil winding (measure resistance of

primary and secondary)

• Sheared flywheel key

Pin
• Flywheel loose or damaged

• Excessive crankshaft runout on magneto. (RH)

end should not exceed .005”

• Faulty CDI module

=T
Indicator Switch Screw:
39-52 in-lbs (4.5-6 Nm)

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ELECTRICAL
Ignition System Testing
Whenever troubleshooting an electrical problem, first check all terminal connections to be sure they are clean and tight.
Use the following flow chart as a guide for troubleshooting. NOTE: The brown (BN) wire on youth models carries
12V key-on power.

Condition: No spark or intermittent spark.

Turn key switch to

ON.
Disconnect 2-wire
connector from
CDI

Measure between
engine ground and
BROWN wire.

Battery voltage on
Battery voltage on RED Replace key
Battery Voltage? NO YES BROWN wire at key NO
circuit at key switch? switch.
switch at ON position?

NO YES
YES

Check wiring
Check 15A fuse
between switch
and battery.
and CDI.
Disconnect 4-wire
plug from CDI.
Check the BLACK
wire for continuity
to ground.

Continuity? NO Check wiring.

YES

Disconnect DG
wire from ignition
coil.
Check for Check wiring and/
8
Continuity? NO
continuity between or key switch.
plug and key
switch in ON
position.
YES

Perform CDI
output test, pulser
coil output test and Replace suspect
Components
ignition coil NO components and
pass tests?
resistance test recheck.
detailed within this
chapter.
YES

If vehicle still has no spark,

repeat troubleshooting steps.
Pay close attention to
condition of wires and
connections.

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ELECTRICAL
RPM Ignition Limiter Functions
NOTE: The CDI box reads the RPM signal from the stator. The CDI box acts as a limiter by retarding the
ignition timing if RPM reaches the specified limit. In reverse gear, the CDI box retards ignition timing and
limits RPM once it receives a ground path from the transmission switch dark blue (DB) wire indicating the
vehicle is in reverse. The CDI box can also receive a ground path from the TRS switch causing the CDI box to
retard timing and limit RPM if the throttle cable becomes slack or stuck.

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ELECTRICAL
RPM Limiter Specifications Pulser Coil Output / Resistance Tests
Disconnect the 4-wire connector at the CDI box. Install the
Ignition
Model Max RPM Peak Reading Adaptor (PV-39991) to your meter and
Timing
connect one meter lead to the dark blue / black wire (DB/
170cc 8000 N/A YEL) and the other to engine ground. Set meter to read DC
Volts. Crank engine and verify pulser coil output.
NOTE: There are no timing advance marks stamped
on the flywheel to read with a timing light. Connect Reading
Voltage
Meter Leads (With Peak Reading
Test
Between: Adapter)
Ignition Coil Test
DB/YEL to
Pulser 5 DC Volts minimum @
Engine
Measure between Coil cranking RPM
Ground
the two wire tabs for
primary reading.
If readings are within specifications, test the resistance
value of the pulser coil. When finished, reconnect the 4-
wire connector to CDI box.

Connect
Ohm Test W Reading
Meter Leads To:
Pulser Coil DB/YEL to Black 151  ± 20%

Test Description Resistance

Ignition Coil Primary Winding 0.2  ± 20%
Ignition Coil Secondary Winding
(With Cap Installed) 8 K  ± 20%
(Without Cap Installed) 3 K  ± 20%
Spark Plug Resistor Cap 5K

CDI Output Test

Using Peak Reading Adaptor
Re-connect all wires to the CDI box. Disconnect the
8
(BLACK/YEL) CDI output wire from ignition coil primary
terminal. Install the Peak Reading Adaptor (PV-39991) to
your meter and connect one meter lead to engine ground
and the other to the (BLACK/YEL) CDI output wire at the
ignition coil. Set meter to read DC Volts. Crank engine and
verify CDI output to the ignition coil. When finished,
reconnect CDI output wire to ignition coil.

Connect Meter
Output Test Reading
Leads To:
BLK/YEL to
CDI Output 180 DC Volts ± 20%
Engine Ground

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ELECTRICAL
CHARGING SYSTEM
Charging System Testing
Whenever charging system problems are suspected, proceed with the following system checks:

Using a volt meter, set it to read D.C. volts, Remove the battery and properly
measure the battery open circuit voltage No service. Reinstall the fully charged
(across the positive and negative posts). battery or a fully charged shop battery.
Is the reading 12.8 volts or more? Verify condition of 15A fuse.

Yes

Meter Setting: DC Volts

With the transmission in neutral, start the
engine and increase RPM to between 3000
and 4000. Read battery voltage with the Yes Check for a system current draw.
a voltmeter. Voltage readings should start
to increase towards 13.0 V D.C.
Was an increase noticed?
No

Meter Setting: AC Volts

Disconnect the wire connector between the Perform the resistance tests detailed
regulator / rectifier and stator. Using a volt in this chapter under the
meter perform a stator output test.
See the test procedure detailed in this chapter Stator / Alternator Tests. If stator
No tests good, inspect the flywheel
under Stator / Alternator Tests.
magnets, stator coils and stator
Does stator AC output meet specification? wire harness for damage. Repair or
Yes replace any damaged components.

Meter Setting: DC Volts

Reconnect the alternator wires. Note: Red
wire must be connected to harness. Battery Check regulator / rectifier connections
voltage must be present on red wire terminal and ground, battery connections,
on harness side of voltage regulator connector. No main fuse and connecting wires.
Is it? Repair or replace faulty wiring or
components.
Yes

If all of the previous tests indicate a

good condition, but the charging voltage does
not rise above battery voltage at the
connector or terminal board, replace the
voltage regulator.

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ELECTRICAL
Main Fuse / Fuse Holder Location Stator / Alternator Tests
A 15 Amp fuse protects the main electrical system. The Two tests can be performed using a multimeter to
fuse is located in the battery compartment. determine the condition of the stator:

15 Amp Fuse Take Measurements on

Stator Side of Harness

NOTE: Use only the recommended fuse capacity, as TEST 1: Measure resistance value of each stator leg.
use of a higher amperage fuse to correct blown-fuse
situations could lead to electrical component 1. Measure the resistance value of the stator legs. Use
damage. the following chart as a reference when testing.

Voltage Regulator / Rectifier Connect

Ohm Test  Reading
Meter Leads To:
The voltage regulator / rectifier is located near the front of BK to Ground 0.1  ± 20%
the engine. Battery Charge
BK to YEL 0.9  ± 20%
Coil
The regulator diodes can be tested with an ohm meter. BK to RED 1.1  ± 20%
Attach the positive ‘+’ lead to the BK pin and the negative
‘-’ lead to the WHT pin. There should be measurable
TEST 2: Measure AC voltage output of each stator leg.
resistance. Reverse the leads and test. There should be
Test at cranking rpm with a voltmeter set to read AC volts.
no continuity. The YEL and RED pins should be tested the
same and achieve the same results. 1. Turn over the engine with the starter motor.

2. First measure from the red wire (RD) to engine

ground. Compare readings to specifications.

3. Next measure from the yellow wire (YE) to engine

ground. Compare readings to specifications. 8
Connect
AC Output Test AC Reading
Meter Leads To:
Battery Charge YEL to Ground 8 Vac
Coil RED to Ground 5 Vac

NOTE: To check the charging system output further,

start the engine and perform the same tests. Voltage
should increase with increased RPM.

Maximum Stator Output

6.5 Amps @ W.O.T.

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ELECTRICAL
BATTERY New Battery Activation

Battery Maintenance Service Notes

WARNING

WARNING Battery electrolyte is poisonous. It contains sul-

furic acid. Serious burns can result from contact
CALIFORNIA PROPOSITION 65 WARNING: with skin, eyes or clothing. Antidote:
Batteries, battery posts, terminals and related
accessories contain lead and lead compounds External: Flush with water.
and other chemicals known to the State of Internal: Drink large quantities of water or milk.
California to cause cancer, birth defects, or Eyes: Flush with water for 15 minutes and get
other reproductive harm. prompt medical attention.

Batteries produce explosive gases. Keep

CAUTION sparks, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always
shield eyes when working near batteries.
Always wear safety glasses, rubber protective KEEP OUT OF REACH OF CHILDREN
gloves and appropriate clothing when
working with batteries. To ensure maximum service life and performance from a
new battery, perform the following steps.
IMPORTANT: DO NOT activate Youth RZR batteries
unless they will be put into service within 30 days of 1. Remove the battery (1), battery acid (2), funnel (3)
activation. and cap (4) from the box.

Youth RZR vehicles use a low maintenance battery. Do not

1 2
remove the battery cap strip to check acid level or add
water once the battery has been activated. Perform the
proper battery tests and charge or replace the battery as
required.

New batteries must be fully charged before use or battery

life will be significantly reduced (10-30% of the battery’s
full potential).

NOTE: DO NOT use a constant high-amperage

battery charger to charge this style of battery. Use a
low-amperage charger capable of charging voltage 4 3
that is 1/10 of the battery amp-hour rating.
2. Remove the protective strip from the top of the battery.
Insert the battery electrolyte funnel into the filler holes.

3. Carefully press the battery electrolyte pack onto the

funnel. The funnel will puncture the pack seals,
releasing electrolyte into the battery. Allow the pack
to drain for 20 minutes, periodically tapping the sides
to release any air-lock or bubbles that may be present.

4. Properly dispose of the battery electrolyte pack. Let

battery set with the vent cap strip off for 30 minutes to
allow full absorption of the electrolyte. After 30
minutes, install the battery seal strip onto the battery.

5. Charge the battery initially for 3 to 5 hours using

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ELECTRICAL
Battery Removal Battery Installation
1. Place the fully charged battery in its holder.
WARNING 2. Attach the hold-down strap(s).
3. Connect and tighten the red positive (+) cable first.
Improperly connecting or disconnecting battery 4. Connect and tighten the black negative (-) cable last.
cables can result in an explosion and cause 5. Torque the battery terminal bolts to 3.5 ft. lbs. (4.7 Nm)
serious injury or death. When removing the
6. Verify that the cables are properly routed.
battery, always disconnect the negative (black)
cable first. NOTE: When installing a new battery, make sure it's
When reinstalling the battery, always connect fully charged prior to its initial use. Using a new
the negative (black) cable last. battery that has not been fully charged can damage
the battery and result in a shorter life. It can also
To remove the battery: hinder vehicle performance. If charging is
necessary, use a .5 amp battery charger.
1. Remove the driver’s seat to access the battery.
Battery Voltage Test
Battery voltage should be checked with a digital multi-
tester. Readings of 12.8 or less require further battery
testing and charging. See Load Test.

NOTE: Batteries should be kept at or near a full

charge as possible. If the battery is stored or used in
a partially charged condition, crystal sulfation will
form on the plates, reducing the efficiency and
Battery Location
service life of the battery.

Battery Load Test

2. Disconnect the hold-down strap securing the battery CAUTION

in position.
Remove the spark plug high tension lead and
3. Disconnect the black negative (-) battery cable first.
connect securely to engine ground before
4. Disconnect the red positive (+) battery cable last. proceeding.
5. Lift the battery out of the compartment. A battery may indicate a full charge condition in the battery
voltage test and the specific gravity test, but still may not
CAUTION have the storage capacity necessary to properly function
in the electrical system. 8
To reduce the chance of sparks:
For this reason, a battery capacity or load test should be
Whenever removing the battery, disconnect the
conducted whenever poor battery performance is
negative (black) cable first. When reinstalling the
suspected. To perform this test:
battery, install the negative cable last.
1. Connect a multi-tester to the battery in the same
manner as was done in the battery voltage test. The
Battery Cleaning reading should be 12.8 volts or greater.
2. Engage the electric starter and view the registered
Keep the battery terminals and connections free of
battery voltage while cranking the engine. Continue
corrosion. If cleaning is necessary, remove the corrosion
the test for 15 seconds. During this cranking period,
with a stiff wire brush. Wash with a solution of one
the observed voltage should not drop below 9.5 volts.
tablespoon baking soda and one cup water. Rinse well
with tap water and dry off with clean shop towels. Coat the 3. If the beginning voltage is 12.8 or higher and the
terminals with dielectric grease or petroleum jelly. cranking voltage drops below 9.5 volts during the test,
replace the battery.

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ELECTRICAL
Battery Conductance Analyzer There is no need to remove the cell cap strip or add water
for the life of the battery.
Conductance describes the ability of a battery to conduct
current. A conductance tester functions by sending a low
frequency AC signal through the battery and a portion of BATTERY CHARGING CHART
the current response is captured, from this output a
conductance measurement is calculated. Conductance State
testing is more accurate than voltage, specific gravity, or of VOLTAGE ACTION CHARGE TIME
Charge
load testing.
FULL None
Authorized Polaris dealers/distributors are required to use 100% 12.8-13.0 None
Required
the conductance analyzer when testing 12V Polaris
batteries. Slight
75% 12.5-12.8 3-6 Hours @ 0.5 A
Charge

50% 12.0-12.5 Charge 5-11 Hours @ 0.5 A

13+ Hours @ 0.5 A

25% 11.5-12.0 Charge
Check Charging

20 Hours @ 0.5 A
Less
0% Charge Battery may be
than 11.5
dead

Because of the characteristics of a sealed battery,

overcharging decreases the volume of electrolyte. The
longer the overcharge time, the greater the drop in
electrolyte, and subsequently starting power. Water
cannot be added to a sealed battery. If a sealed battery is
overcharged, it will have to self-discharge before it can be
used. Overcharging can also warp plates, making future
charging difficult. Watch charging times carefully, or use a
charger with limited charging time/current capabilities.
Polaris MDX-610P Polaris recommends using the Christie Multi Battery
SPX PN: PU-50296 Charger (PV-67030), available from tool provider SPX for
charging batteries. Always stop charging if the battery
becomes warm to the touch. Let it cool sufficiently before
Battery Charging Procedure resuming charging.
Charge the battery using a charger capable of producing
Battery Storage
voltage 1/10th of the battery’s amp/hr rating. Example:
Youth batteries have an amp/hr rating of 12 amps. Do not Whenever the vehicle is not used for a period of three
exceed 1.2 amps charging voltage or damage to the months or more, remove the battery from the vehicle,
battery will result. ensure that it's fully charged, and store it out of the sun in
a cool, dry place. Check battery voltage each month
Fully charged, the battery should read 12.8-13.0 Volts. during storage and recharge as needed to maintain a full
After charging is completed, let the battery stand 1-2 hours charge.
and re-test the voltage. Do not overcharge the battery!

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ELECTRICAL
STARTER SYSTEM Starter Motor Service
The starter motor is a complete service part. If it is
Starter Relay
determined that the starter motor has failed, replace as
The starter relay consists of a simple 2-way circuit. Power needed. See the parts manual for the correct part number.
is present at the (RD) wire from the battery. Once the
switching side of the relay receives power from the brake Although the starter motor is not serviceable, it can be
switch and a ground path when the key is turned to the disassembled, tested and cleaned.
START position, battery power is sent to the starter motor
to crank the engine. O-ring

The relay assembly is attached to a cross member located

above the engine.
O-ring

Starter Disassembly
NOTE: Use only electrical contact cleaner to clean
starter motor parts. Other solvents may leave a
Use the illustration below when troubleshooting a “No residue or damage internal parts and insulation.
Start” condition.
NOTE: Some starter motors may not be serviceable
and replacement of the entire assembly may be
required. Check the parts manual for replacement
part information.

1. Disconnect the negative battery cable and starter

motor harness. Remove the (2) bolts from the starter
and pull it from the engine.

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ELECTRICAL
2. Remove the three screws and washers. Starter Brush Inspection / Replacement
1. Using an Ohm meter, measure the resistance
between the cable terminal and the insulated brush.
The reading should be .3 ohms or less. Measure the
resistance between the cable terminal and brush
housing. Make sure the brush is not touching the
case. The reading should be infinite (no reading).

2. Remove the brush plate and brushes. Measure the

brush length and replace if worn past the service limit.

3. Remove magnet housing while holding the armature

and brush holder section together.

0.20'' (5 mm)

Brush Length Service Limit

0.20'' (5 mm)

3. Inspect the surface of the commutator for wear or

discoloration. See Armature Test.

4. Be sure that the terminal bolt insulation washer is

properly seated in the housing and the tab on the
brush plate engages the notch in the brush plate
housing.

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ELECTRICAL
Armature Test 6. Inspect the permanent magnets in starter housing.
Make sure they are not cracked or separated from
1. Inspect surface of commutator. Replace if housing.
excessively worn or damaged.

2. Using a digital multi-tester, measure the resistance CAUTION

between each of the commutator segments. The
reading should be .3 ohms or less. Use care when handling the starter housing.
Do not drop or strike the housing, as magnet
damage is possible. If the magnets are damaged,
the starter must be replaced.

Starter Reassembly
1. Place armature in field magnet casing.
2. Inspect and replace the O-rings if damaged.
3. Install case sealing O-ring. Make sure O-ring is in
good condition and not twisted on the case. Lubricate
the ends of the armature shaft and oil seal with a light
film of grease, and install housing.
4. Install brush housing onto the armature, pushing back
brushes while installing armature shaft.
3. Measure the resistance between each commutator
segment and the armature shaft. The reading should 5. Reinstall starter motor housing screws and washers.
be infinite. (no continuity) Make sure O-rings are in good condition and seated
in groove. Tighten sufficiently.
6. Reinstall the starter motor to the engine.

Voltage Drop Test

The Voltage Drop Test is used to test for bad connections.
When performing the test, you are testing the amount of
voltage drop through the connection. A poor or corroded
connection will appear as a high voltage reading.

To perform the test, place the meter on DC volts and place

the meter leads across the connection to be tested. Refer
to the chart on next page to perform voltage drop tests on
the starter system. 8
4. Check commutator bars for discoloration. Bars Voltage should not exceed
discolored in pairs indicate shorted coils, requiring .1 DC volts per connection
replacement of the starter motor.
5. Place armature in a growler. Turn growler on and
position a hacksaw blade or feeler gauge lengthwise
1/8² (.3 cm) above armature coil laminates. Rotate
armature 360°. If hacksaw blade is drawn to armature
on any pole, the armature is shorted and must be
replaced.

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ELECTRICAL
Starter System Troubleshooting
Starter Motor Does Not Turn

• Battery discharged - low specific gravity

• Loose or faulty battery cables or corroded connections (see Voltage Drop Tests)

• Related wiring loose, disconnected, or corroded

• Poor ground connections at battery cable, starter motor or starter solenoid (see Voltage Drop Tests)

• Faulty starter button

• Faulty ignition switch (Do other systems function?)

• Faulty starter solenoid or starter motor

• Engine problem - seized or binding (Can engine be rotated easily with recoil starter?).

Starter Motor Turns Over Slowly

• Battery discharged - low specific gravity

• Excessive circuit resistance - poor connections (see Voltage Drop Test below)

• Engine problem - seized or binding (Can engine be rotated easily with recoil starter?)

• Faulty or worn brushes in starter motor

• Automatic compression release inoperative

Starter Motor Turns - Engine Does Not Rotate

• Faulty starter drive

• Faulty starter drive gears or starter motor gear

• Faulty flywheel gear or loose flywheel

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ELECTRICAL
Starter System Testing
Condition: Starter motor fails to turn engine. 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.

Locate the starter relay.

See “Starter Relay”
earlier in this chapter for
location reference

Disconnect the 2-wire connector at

Connect meter Disassemble starter
the starter relay. Set volt meter to
leads to RED lug to motor to test and
read DC voltage and connect meter
YES starter motor and clean internal
leads between the DG/YEL and DG/
engine ground and YES components.
RED wires. Turn the key switch to
retest. If tests fail, or motor
the “START” position, and push in
Is battery voltage still does not work,
the brake pedal.
present? replace assembly.
Is battery voltage present?

NO
NO

Replace starter
relay.
Check battery condition,
Recharge and test
RED battery connections
battery, replace 15A
at relay and 15A fuse. NO
fuse, or repair
connections.
Condition Good?

YES

Check the key switch for

proper function. Turn key to
“START”. NO
Replace key switch and/or
Is there continuity between
check wiring circuits.
DG/RED and BLACK?
Is there continuity between
RED and BROWN? 8
YES

Set the meter to read Ohms.

Check the function of the foot
NO
brake switch. Replace foot brake
Is there continuity between the DG/ pedal switch.
YEL and BROWN wires when the
foot brake pedal is pressed?

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ELECTRICAL

NOTES

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A Cam Chain Tensioner, Installation . . . . . . . . . . . . 3.46
A-arm, Exploded View . . . . . . . . . . . . . . . . . . . . . . 5.13
A-arms, Installation . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Camshaft, Inspection . . . . . . . . . . . . . . . . . . . . . . 3.16
Camshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . 3.16 IX
Camshaft, Timing Method 1 . . . . . . . . . . . . . . . . . 3.41
Adjustment, Parking Brake . . . . . . . . . . . . . 2.35, 6.10
Camshaft, Timing Method 2 . . . . . . . . . . . . . . . . . 3.44
Air Cleaner, Assembly View . . . . . . . . . . . . . . . . . 4.12
Carburetion System . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Carburetion, Carburetor Assembly . . . . . . . . . . . . . 4.3
Alternator, Testing . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
Carburetor Service . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Assembly, Drive Clutch . . . . . . . . . . . . . . . . . . . . . . 7.9
Carburetor, Assembly . . . . . . . . . . . . . . . . . . . . . . . 4.8
B Carburetor, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Backlash, Output Shaft, Shimming Procedure, Output Carburetor, Disassembly, Keihin . . . . . . . . . . . . . . 4.5
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21 Carburetor, Draining . . . . . . . . . . . . . . . . . . . . . . . 2.16
Balance Shaft, Sprocket Removal . . . . . . . . . . . . . 3.30 Carburetor, Float Bowl Draining . . . . . . . . . . . . . . . 4.4
Battery Charging . . . . . . . . . . . . . . . . . . . . . 2.29, 8.16 Carburetor, Float Height Adjustment . . . . . . . . . . . 4.7
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 Carburetor, Function . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Battery Maintenance . . . . . . . . . . . . . . . . . . 2.28, 8.14 Carburetor, Idle Speed Adjustment . . . . . . . . . . . . 2.14
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 Carburetor, Inspection . . . . . . . . . . . . . . . . . . . . . . 4.6
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 Carburetor, Needle and Seat Leak Test . . . . . . . . . 4.8
Battery, Installation . . . . . . . . . . . . . . . . . . . . . . . . 8.15 Carburetor, Pilot Air Screw Adjustment . . . . . . . . 2.14
Battery, Load Test . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 Carburetor, Removal . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Battery, New Activation . . . . . . . . . . . . . . . . . . . . . 8.14 CDI Output, Testing . . . . . . . . . . . . . . . . . . . . . . . 8.11
Battery, Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16 Chain Guide Removal . . . . . . . . . . . . . . . . . . . . . . 3.23
Battery, Voltage Test . . . . . . . . . . . . . . . . . . . . . . . 8.15 Chain Guide, Installation . . . . . . . . . . . . . . . . . . . . 3.36
Brake Burnishing . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21 Chain, Adjustment and Lubrication . . . . . . . . . . . . 2.26
Brake Caliper Installation, Front . . . . . . . . . . . . . . 6.17 Charging System, Testing . . . . . . . . . . . . . . . . . . . 8.12
Brake Caliper Removal, Front . . . . . . . . . . . . . . . . 6.16 Choke Cable, Adjustment . . . . . . . . . . . . . . . . . . . 2.13
Brake Caliper Removal, Rear . . . . . . . . . . . . . . . . 6.23 Choke Cable, Replacement . . . . . . . . . . . . . . . . . 2.13
Brake Disc, Front . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 Clutch Cover Installation . . . . . . . . . . . . . . . . . . . . . 7.5
Brake Disc, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21 Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . 3.18
Brake Front Pad Assembly . . . . . . . . . . . . . . . . . . 6.14 Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
Brake Hose and Fitting Inspection . . . . . . . . . . . . . 2.33 Cooling Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Brake Lever Switches . . . . . . . . . . . . . . . . . . . . . . . 8.3 Crankcase, Disassembly . . . . . . . . . . . . . . . . . . . 3.33
Brake Light Lamp Replacement . . . . . . . . . . . . . . . 8.6 Crankshaft, Inspection . . . . . . . . . . . . . . . . . . . . . 3.34
Brake Pad Assembly, Front . . . . . . . . . . . . . . . . . . 6.14 Crankshaft, Removal . . . . . . . . . . . . . . . . . . . . . . 3.33
Brake Pad Inspection . . . . . . . . . . . . . . . . . . . . . . 2.33 Crankshaft, Sprocket Removal . . . . . . . . . . . . . . . 3.29
Brake Pad Thickness, Front . . . . . . . . . . . . . . . . . 6.13 CVT Cover Installation . . . . . . . . . . . . . . . . . . . . . . 7.5
Brake Pad, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18 CVT, Clutch Operation . . . . . . . . . . . . . . . . . . . . . . 7.3
Brake Pads, Front . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 CVT, Disassembly and Inspection . . . . . . 7.5, 7.6, 7.8
Brake Pads, Removal, Front . . . . . . . . . . . . . . . . . 6.13 CVT, Drive Clutch Assembly . . . . . . . . . . . . . . . . . . 7.9
Brake Pedal Assembly View . . . . . . . . . . . . . . . . . . 6.5 CVT, Driven Clutch Disassembly . . . . . . . . . . . . . . 7.9
Brake Pedal, Adjustment . . . . . . . . . . . . . . . . . . . . . 6.9 CVT, Driven Reassembly . . . . . . . . . . . . . . . . . . . 7.11
Brake Pedal, Installation . . . . . . . . . . . . . . . . . . . . . 6.9 CVT, Drying Procedure . . . . . . . . . . . . . . . . . . . . . . 7.4
Brake Pedal, Removal . . . . . . . . . . . . . . . . . . . . . . . 6.9 CVT, Maintenance / Inspection . . . . . . . . . . . . . . . . 7.3
Brake System Inspection . . . . . . . . . . . . . . . . . . . . 2.33 CVT, Operation Overview . . . . . . . . . . . . . . . . . . . . 7.3
Brake System, Bleeding . . . . . . . . . . . . . . . . . . . . . 6.7 CVT, Overheating / Diagnosis . . . . . . . . . . . . . . . . 7.4
Brake System, Exploded View . . . . . . . . . . . . . . . . 6.6 Cylinder Head, Disassembly . . . . . . . . . . . . . . . . . 3.18
Brake System, Mechanical Components . . . . . . . . . 6.5 Cylinder Head, Reassembly . . . . . . . . . . . . . . . . . 3.22
Brake System, Operation . . . . . . . . . . . . . . . . . . . . 6.4 Cylinder Head, Removal . . . . . . . . . . . . . . . . . . . . 3.17
Breather Hose Inspection . . . . . . . . . . . . . . . . . . . 2.21 Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
C Cylinder, Fastener Torque Pattern . . . . . . . . . . . . 3.45
Cable Freeplay Adjustment . . . . . . . . . . . . . 2.34, 6.10 Cylinder, Inspection . . . . . . . . . . . . . . . . . . . . . . . 3.24
Cable Replacement, Parking Brake . . . . . . . . . . . 6.11 Cylinder, Installation . . . . . . . . . . . . . . . . . . . . . . . 3.40
Caliper, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 Cylinder, Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
Caliper, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23 D
Cam Chain Tensioner, Inspection . . . . . . . . . . . . . 3.14 Daytime Running Lamps, Replacement . . . . . . . . . 8.5

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Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 I
Decimal Equivalents . . . . . . . . . . . . . . . . . . . . . . . 1.12
Idle Speed, Adjustment . . . . . . . . . . . . . . . . . . . . . 2.14
Drive Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Ignition Coil, Testing . . . . . . . . . . . . . . . . . . . . . . . 8.11
Driven Clutch Installation . . . . . . . . . . . . . . . . . . . . 7.12
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
E Ignition System Troubleshooting . . . . . . . . . . . . . . 8.8
Electrical Service Notes . . . . . . . . . . . . . . . . . . . . . 8.2 Ignition System, Testing . . . . . . . . . . . . . . . . . . . . . 8.9
Electrical Special tools . . . . . . . . . . . . . . . . . . . . . . 8.2 Indicator Lamp, Replacement . . . . . . . . . . . . . . . . . 8.6
Engine Breather/Separator . . . . . . . . . . . . . . . . . . 3.10 Indicator Light, Replacement . . . . . . . . . . . . . . . . . 5.9
Engine Designation Number . . . . . . . . . . . . . . . . . . 1.2 Inspection, Drive Belt . . . . . . . . . . . . . . . . . . . . . . . 7.6
Engine Secondary Air System . . . . . . . . . . . . . . . . 3.11 K
Engine Serial Number Location . . . . . . . . . . . . . . . . 1.2
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Engine, Accessible Components . . . . . . . . . . . . . . . 3.6
Keys, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Engine, Bottom End Disassembly . . . . . . . . . . . . . 3.27
Engine, Compression Test . . . . . . . . . . . . . . . . . . 2.22 L
Engine, Exploded Views . . . . . . . . . . . . . . . . . . . . . 3.5 Lights, Daytime Running . . . . . . . . . . . . . . . . . . . . . 8.5
Engine, Fastener Torque Patterns . . . . . . . . . . . . . 3.4 M
Engine, Fastener Torque Specifications . . . . . . . . . 3.3 Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Engine, Installation Notes . . . . . . . . . . . . . . . . . . . 3.13 Maintenance Chart, 30 - 100 Hours . . . . . . . . . . . . 2.5
Engine, Lubrication Requirements . . . . . . . . . . . . . 3.6 Maintenance Chart, Pre-Ride - 25 Hours . . . . . . . . 2.4
Engine, Oil and Filter Change . . . . . . . . . . . . . . . . 2.20 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 2.36
Engine, Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 Maintenance, Brake System . . . . . . . . . . . . . . . . . 2.33
Engine, Reassembly . . . . . . . . . . . . . . . . . . . . . . . 3.35 Maintenance, Electrical and Ignition . . . . . . . . . . . 2.28
Engine, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 Maintenance, Engine . . . . . . . . . . . . . . . . . . . . . . 2.20
Engine, Service Data . . . . . . . . . . . . . . . . . . . . . . . . 3.7 Maintenance, Final Drive . . . . . . . . . . . . . . . . . . . 2.25
Engine, Special Tools . . . . . . . . . . . . . . . . . . . 3.3, 7.2 Maintenance, Fuel System . . . . . . . . . . . . . . . . . . 2.12
Engine, Top End Disassembly . . . . . . . . . . . . . . . 3.14 Maintenance, General Vehicle Inspection . . . . . . 2.10
Exhaust Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3.49 Maintenance, References . . . . . . . . . . . . . . . . . . . . 2.9
Exhaust, Spark Arrestor . . . . . . . . . . . . . . . . . . . . 2.23 Maintenance, Service Products and Lubricants . . . 2.8
F Maintenance, Steering . . . . . . . . . . . . . . . . . . . . . 2.30
Fastener Torque Table, Body/Suspension/Steering 5.2 Maintenance, Transmission and Gearcases . . . . 2.24
Flywheel Removal / Inspection . . . . . . . . . . . . . . . 3.28 Master Cylinder, Installation . . . . . . . . . . . . . . . . . 6.26
Flywheel, Installation . . . . . . . . . . . . . . . . . . . . . . . 3.47 Master Cylinder, Removal . . . . . . . . . . . . . . . . . . 6.25
Front Cab, Removal and Installation . . . . . . . . . . . . 5.4 Metric Bolt Torque Specification . . . . . . . . . . . . . . 1.10
Fuel Filter, Inspection . . . . . . . . . . . . . . . . . . . . . . 2.15 O
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 Oil Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Fuel Pump, Maintenance . . . . . . . . . . . . . . . . . . . 2.16 Oil Pump and Chain Removal . . . . . . . . . . . . . . . 3.31
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Fuel System, Crankcase Ventilation System . . . . 4.14
P
Fuel System, Filter . . . . . . . . . . . . . . . . . . . . . . . . 4.11 Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Fuel System, Fuel Pump . . . . . . . . . . . . . . . . . . . . 4.11 Parking Brake Adjustment . . . . . . . . . 2.34, 2.35, 6.10
Fuel System, Secondary Air Injection . . . . . . . . . . 4.13 Parking Brake Cable Replacement . . . . . . . . . . . . 6.11
Fuel Tank, Assembly View . . . . . . . . . . . . . . . . . . . 4.9 Parking Brake, Assembly View . . . . . . . . . . . . . . . . 6.5
Fuel Tank, Removal . . . . . . . . . . . . . . . . . . . . . . . 4.10 Pedal, Brake, Assembly View . . . . . . . . . . . . . . . . . 6.5
Fuel Valve, Location . . . . . . . . . . . . . . . . . . . . . . . 2.16 Periodic Maintenance Chart . . . . . . . . . . . . . . . . . . 2.3
Fuel Valve, Service . . . . . . . . . . . . . . . . . . . . . . . . 4.11 Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Fuse, Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13 Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . 3.39
Piston, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
G Piston, Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
General Specifications, Brakes . . . . . . . . . . . . . . . . 6.2 Piston, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
Ground, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 Pre-Ride / Daily Inspection . . . . . . . . . . . . . . . . . . 2.10
H Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Hand Brake, . . . . . . . . . . . . . . . . . . . . . . . . 2.35, 6.10 Pulser Coil Output, Testing . . . . . . . . . . . . . . . . . . 8.11
Hand Brake, Assembly View . . . . . . . . . . . . . . . . . . 6.5

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R Specification, Tie Rod Nut Torque . . . . . . . . . . . . 5.31
Rear Cab Removal . . . . . . . . . . . . . . . . . . . . . 5.3, 5.6
Regulator / Rectifier . . . . . . . . . . . . . . . . . . . . . . . . 8.13
Specification, Transmission Fastener Torque . . . . 7.19
Specification, Valve Clearance . . . . . . . . . . .2.22, 3.46 IX
Specification, Wheel Toe-Out . . . . . . . . . . . . . . . . 2.31
Relay, Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
Specifications, Camshaft Lobe Height . . . . . . . . . 3.17
Rocker Arm, Disassembly and Inspection . . . . . . . 3.15
Specifications, Engine Fastener Torques . . . . . . . . 3.3
Rocker Assembly Installation . . . . . . . . . . . . . . . . 3.45
Specifications, Engine Service Data . . . . . . . . . . . . 3.7
Rocker Panel, Removal . . . . . . . . . . . . . . . . . . . . . . 5.6
Specifications, Fuel System Torque Values . . . . . . 4.2
RPM Limiter Specifications . . . . . . . . . . . . . 8.10, 8.11
Specifications, General . . . . . . . . . . . . . . . . . . . . . . 1.6
S Specifications, Transmission Fastener Torques . . . 7.2
Secondary Air System . . . . . . . . . . . . . . . . . . . . . . 3.11 Standard Bolt Torque Specification . . . . . . . . . . . 1.10
Service Locations . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Starter Drive Reassembly . . . . . . . . . . . . . . . . . . . 3.47
Shift Cable Inspection and Adjustment . . . . . . . . . 2.10 Starter Drive Removal / Inspection . . . . . . . . . . . . 3.27
Shift Cable Replacement . . . . . . . . . . . . . . . . . . . . 2.11 Starter Motor Service . . . . . . . . . . . . . . . . . . . . . . 8.17
Shock Removal, Front . . . . . . . . . . . . . . . . . 5.17, 5.18 Starter System Testing . . . . . . . . . . . . . . . . . . . . . 8.21
Shock Removal, Rear . . . . . . . . . . . . . . . . . . . . . . 5.18 Starter System Troubleshooting . . . . . . . . . . . . . . 8.20
Shocks, Installation . . . . . . . . . . . . . . . . . . . . . . . . 5.17 Starter, One-Way Clutch Removal / Inspection . . 3.30
Spark Plug Service . . . . . . . . . . . . . . . . . . . . . . . . 2.29 Stator Housing Installation . . . . . . . . . . . . . . . . . . 3.48
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Stator, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
Special Tools, Brakes . . . . . . . . . . . . . . . . . . . . . . . 6.2 Steering Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.31
Special Tools, Electrical . . . . . . . . . . . . . . . . . . . . . 8.2 Steering Post, Assembly . . . . . . . . . . . . . . . .5.26, 5.30
Special Tools, Fuel System . . . . . . . . . . . . . . . . . . . 4.2 Steering Wheel Freeplay . . . . . . . . . . . . . . . . . . . 2.30
Specification Chart, Maintenance . . . . . . . . . . . . . 2.24 Steering, Alignment . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Specification, Balance Shaft Slotted Nut Torque . . 3.37 Steering, Exploded View . . . . . . . . . . . . . . . . . . . . 5.26
Specification, Cam Chain Tensioner Bolt Torque . 3.46 Steering, Toe Adjustment . . . . . . . . . . . . . . . . . . . 2.32
Specification, Cam Chain Tensioner Cap Torque . 3.46 Steering, Wheel Toe Alignment . . . . . . . . . . . . . . 2.31
Specification, Carburetor Air Screw Setting . . . . . . 4.8 Suspension , Special Tools . . . . . . . . . . . . . . . . . . . 5.2
Specification, Compression Spring Length . . . . . . 7.10 Suspension, Spring Preload Adjustment . . . . . . . 2.32
Specification, Crankshaft Slotted Nut Torque . . . . 3.37 Swing Arm, Removal . . . . . . . . . . . . . . . . . . . . . . 5.19
Specification, Cylinder Fastener Torque . . . . . . . . 3.45 Switch, Transmission . . . . . . . . . . . . . . . . . . . . . . . 8.7
Specification, Cylinder Head Warp . . . . . . . . . . . . 3.18
Specification, Cylinder Taper . . . . . . . . . . . . . . . . . 3.24
Specification, Cylinder Warp . . . . . . . . . . . . . . . . . 3.24
Specification, Drive Belt Width . . . . . . . . . . . . . . . . 7.6
Specification, Driven Assembly Nut Torque . . . . . 7.12
Specification, Driven Clutch Nut Torque . . . . . . . . 7.12
Specification, Driven Clutch Wear Limits . . . . . . . . 7.11
Specification, Engine Compression . . . . . . . . . . . . 2.22
Specification, Engine Drain Plug Torque . . . . . . . . 2.21
Specification, Engine Lubrication Requirements . . . 3.6
Specification, Engine Oil Type . . . . . . . . . . . . . . . . 2.20
Specification, Flywheel Nut Torque . . . . . . . . . . . . 3.47
Specification, Idle Speed . . . . . . . . . . . . . . . . . . . . 2.14
Specification, Oil Filter Torque . . . . . . . . . . . . . . . 2.21
Specification, Oil Pump Baffle Plate Screw Torque 3.38
Specification, Oil Pump Gear Nut Torque . . . . . . . 3.38
Specification, Oil Pump Screw Torque . . . . . . . . . 3.38
Specification, Piston Ring Installed Gap . . . . . . . . 3.26
Specification, Shock Mounting Torque . . . . . . . . . 5.18
Specification, Starter Idle Gear Bolt Torque 7.5, 7.6, 7.8
Specification, Stator Housing Fastener Torque . . 3.47,
3.48
Specification, Stator Housing Fastener Torque Pattern
3.47, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
Specification, Tensioner Blade Bolt Torque . . . . . 3.36
Specification, Tie Rod Jam Nut Torque . . . . . . . . . 5.31

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T
Tail Light Lamp Replacement . . . . . . . . . . . . . . . . . 8.6
Tap Drill Sizes, Metric . . . . . . . . . . . . . . . . . . . . . . 1.12
Tap Drill Sizes, SAE . . . . . . . . . . . . . . . . . . . . . . . 1.12
Tensioner Blade, Installation . . . . . . . . . . . . . . . . . 3.36
Throttle Freeplay Adjustment . . . . . . . . . . . . . . . . 2.18
Throttle Pedal Inspection . . . . . . . . . . . . . . . . . . . . 2.17
Throttle Release Swtich (TRS) . . . . . . . . . . . . . . . . 8.4
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Toe Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Top Dead Center, (TDC) . . . . . . . . . . . . . . . . . . . . 3.14
Torque Specifications, Brakes . . . . . . . . . . . . . . . . . 6.2
Torque Specifications, Wheel, Hub, and Spindle . 2.25
Transmission Lubrication . . . . . . . . . . . . . . . . . . . 2.24
Transmission Switch, Inspection . . . . . . . . . . . . . . . 8.7
Transmission Switch, Installation . . . . . . . . . . . . . . 8.8
Transmission Switch, Removal . . . . . . . . . . . . . . . . 8.8
Transmission Switch, Testing . . . . . . . . . . . . . . . . . 8.7
Transmission, Disassembly . . . . . . . . . . . . . . . . . . 7.13
Transmission, Inspection . . . . . . . . . . . . . . . . . . . . 7.13
Transmission, Output Shaft Shimming Procedure 7.21
Transmission, Reassembly . . . . . . . . . . . . . . . . . . 7.19
Troubleshooting, Brake Noise . . . . . . . . . . . . . . . . . 6.3
Troubleshooting, Brake System . . . . . . . . . . . . . . 6.27
Troubleshooting, Carburetion . . . . . . . . . . . . . . . . 4.15
Troubleshooting, Engine . . . . . . . . . . . . . . . . . . . . 3.50
Troubleshooting, Spark Plug Fouling . . . . . . . . . . 3.50
TRS, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TRS, Switch Adjustment . . . . . . . . . . . . . . . . . . . . . 8.4
V
Valve Clearance Adjustment . . . . . . . . . . . . 2.22, 3.46
Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . . . 3.23
Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . 3.20
Valve, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
Valve, Rocker Arm Installation . . . . . . . . . . . . . . . 3.45
Vehicle Information
Model Number 1.2
VIN Number 1.2
Vent Lines, Inspection . . . . . . . . . . . . . . . . . . . . . . 2.15
VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
W
Wheel, Installation . . . . . . . . . . . . . . . . . . . . 2.25, 5.34
Wheel, Removal . . . . . . . . . . . . . . . . . . . . . 2.25, 5.33

IX.4 9923983 - 2012-2013 RZR 170 Service Manual

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2012-2013 RZR 170

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Common questions

When routing a new throttle cable, it's crucial to follow the factory cable routing to prevent pinching, binding, or damage to the cable. Ensure the cable does not hang below the vehicle frame, as improper installation could lead to loss of vehicle control, resulting in severe injury or death . Before removing the old cable, document the location of cable ties and the routing. While installing the new cable, retrace this path precisely, fastening the cable with ties at the previously removed locations. The cable should be routed inside retainers and follow the brake line as a guide .

Using genuine parts is vital for maintaining optimal brake system performance because these parts are specifically designed and tested to meet the precise specifications and operational conditions of the vehicle. Genuine parts ensure reliable function under varied operating environments, contributing to the longevity and safety of the vehicle's brake system. Non-genuine parts may lead to suboptimal performance, more frequent maintenance, or even failure, thus affecting safety and the service life of the brake system .

The pilot air screw regulates the amount of air that is introduced into the pilot and main fuel circuits, impacting the air-fuel mixture delivered to the engine at various throttle settings. Proper adjustment of the pilot air screw ensures optimal combustion, improved engine performance, efficient fuel use, and reduced emissions across all throttle ranges. Misadjustment could lead to either a lean or rich air-fuel mixture, affecting idle stability and throttle response .

To ensure effective operation of the brakes after replacing the brake pads, verify the brake fluid level in the master cylinder reservoir and adjust as necessary to avoid low fluid levels, which can allow air into the system, or high levels, which can cause pressure buildup . After pad installation, torque the brake pad guide pins and caliper mounting bolts to the specified torque values . Perform a brake burnishing procedure by gradually applying the brakes from a speed of 25 mph to maximize pad life and performance . Elevate the vehicle to check for brake drag, indicating issues like misalignments or improper fluid levels . Ensure there are no leaks around brake fittings and that the pads move freely . Finally, make sure that the parking brake and other adjustments are correctly set . Do not use petroleum-based cleaners on brake components; use only approved cleaners .

The CVT system enhances the Polaris RZR's performance by providing seamless power delivery through its drive and driven clutches and the drive belt. It allows for smooth transitions in power application and compensates for varying terrain conditions, contributing to improved fuel efficiency and performance. The CVT system is calibrated to the engine power curve and typical riding conditions, preventing arbitrary modifications that could detract from the vehicle's reliable and efficient performance .

Ensure all cooling shroud fasteners are properly torqued and secure all clamps tightly to avoid air leaks that could impair the cooling system function . Conduct a general inspection to ensure the vehicle's cooling ducts are clear of obstructions and properly sealed to prevent water or dirt ingress . It's also important to check and maintain proper fluid levels and inspect the condition of the cooling system components such as hoses when reinstalling the cooling shroud . Use proper gaskets and seals during reassembly to ensure a tight fit .

Key procedures and precautions for replacing a fuel filter in a vehicle include: 1. Ensure the engine is stopped and refueling is conducted outdoors or in a well-ventilated area, as gasoline is highly flammable and explosive . 2. Turn off the fuel supply at the fuel valve to prevent fuel leakage . 3. Remove line clamps at both ends of the existing fuel filter and detach the fuel lines from the filter . 4. Install the new filter, ensuring the arrow on the filter points in the direction of the carburetor to maintain proper fuel flow . 5. Reattach the clamps onto the fuel lines and turn the fuel valve to ‘ON’ . 6. Start the engine and inspect for any fuel leaks to ensure proper installation . Precautions include not smoking or allowing sparks near the work area and washing off any gasoline spills immediately . Additionally, never perform this maintenance when the engine is hot to avoid burns .

Critical steps in the reassembly and installation of an engine after maintenance work include: ensuring previously removed components are installed with new gaskets, seals, and fasteners where applicable, performing checks on fluid levels and important vehicle areas from a pre-ride inspection checklist, and replacing exhaust gaskets while checking bolted exhaust connections for tightness post-installation . Additionally, it is vital to adhere to torque specifications for engine mounts; typically for front and rear mounts, ensuring correct torque patterns and specifications are crucial to prevent damage and ensure proper engine operation . Furthermore, any camshaft timing and alignment procedures should ensure the proper positioning of the crankshaft at Top Dead Center (TDC) and correct alignment of cam sprocket marks . All these steps ensure proper engine function post-maintenance.

The air control valve system ensures proper emissions compliance in an engine setup by introducing additional air into the exhaust system to facilitate more complete burning of exhaust emissions. The system is operated by intake manifold pulses that open an air control valve, allowing air to flow through a one-way valve. This incoming air combines with the exhaust gas stream from the cylinder head, thereby aiding in the oxidation of any remaining hydrocarbons and carbon monoxide in the exhaust . This process reduces emissions and helps the engine comply with regulatory standards for pollutants . Checking components such as the air control valve, one-way valve, and filter housing is part of routine maintenance for ensuring the system's effectiveness ."}

The 'Brake Burnishing Procedure' is crucial after installing new brake pads to extend their service life and reduce noise. This procedure involves making ten stops from a speed of 25 mph to properly seat the pads against the disc, which ensures optimal contact and friction without causing excessive heat that could lead to disc warping . It allows the surface of the new pads to wear evenly, avoiding issues such as glazing or uneven pad distribution, which can lead to noise or reduced efficiency . Implementing a correct burnishing procedure is an essential maintenance step to maximize the brake system's performance and longevity ."

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