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If you continue browsing the site, you agree to the use of cookies on this website. See our User Agreement and Privacy Policy.If you continue browsing the site, you agree to the use of cookies on this website. See our Privacy Policy and User Agreement for details.You can change your ad preferences anytime. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. All pages are is great to have2003 POLARIS SPORTSMAN 700 TWIN Service Repair Workshop Manual. Above 1800Above (6000) 150 145Altitude. Shift. Weight. Drive Clutch. Spring. Driven Clutch. Spring. Driven. HelixAltitude Weight Spring Spring Helix. Meters 0-1800. MetersDisplacement 597 cc. Bore 3.012I (76.5 mm). Stroke 2.559I (65 mm). Cooling Liquid. Lubrication Type Pressurized Wet Sump. Operating RPM 200 6000 RPM. Idle RPM 100 (lights off) 1100 RPM. Compression Pressure 150--170psi 15.......Main Jet 155. Pilot Jet 45. Jet Needle J8--4FA01--3. Needle Jet P-4. Pilot Screw 1.5 Turns Out. Pilot Air Jet 160. Valve Seat 1.5. Float Height 14.7mm (.58I) 1mm.........Belt 3211091. Belt Width (Projected) 1.188I (30.18mm). Side Angle (Overall) 28 2. Outside Circumference 40.875.188I. Center Distance 10.12I (254.5mm). Clutch Offset 0.5I (12.7mm). Driven Helix Compound (EBS).............Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L). Grill (2) 27 Watts Quartz Brake (Hand) Dot 3. Tail 8.26 watts Brake (Foot) Dot 3. Brake 26.9 watts. Body Style Gen IV 4 Wheel Independent Shaft Drive. Front Suspension MacPherson Strut Gear Reduction-Low 7.49:1. Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.11:1. Turning Radius 76I (181.61 cm) Gear Reduction-High 2.89:1. Ground Clearance 11I (27.94 cm) Final Drive Ratio 3.10:1.
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Front Vertical Travel 6.7I (17.02 cm) Brake (Hand) Single Lever, Hyd. Disc. Rear Suspension Progressive Rate Independent Brake (Auxiliary Foot) Hydraulic. Rear Travel 9.5I (24.13 cm) Transmission Park Lock. Rear Shock 2I Twin Tube. Shock Adjustment Cam..Tire Size - Rear 25 x 11 - 12. Total Width 46I (116.84 cm). Total Length 85I (215.90 cm). Total Height 47I (119.38 cm). Wheel Base 50.75I (128.90 cm). Weight - Dry 740 lbs. (335.60 kg).......Rear Rack (Std) 200 lbs. (91 kg). Tongue Weight 150 lbs. (68 kg). Hitch Towing Capacity.1500 lbs. (681)Above 1800Above (6000) 147.5 142.5Altitude. Shift. Weight. Drive Clutch. Spring. Driven Clutch. Spring. Driven. HelixAltitude Weight Spring Spring Helix. Meters 0-1800. MetersDisplacement 683 cc. Bore 3.149I (80 mm). Stroke 2.677I (68 mm). Cooling Liquid. Lubrication Type Pressurized Wet Sump. Operating RPM 200 6000 RPM. Idle RPM 100 (lights off) 1100 RPM. Compression Pressure 150--170psi 15.......Main Jet 155. Pilot Jet 47.5. Jet Needle J8--4FA01--3. Needle Jet P-6M (829). Pilot Screw 1.5 Turns Out. Pilot Air Jet 160. Valve Seat 1.5. Float Height 14.7mm (.58I) 1mm.........Belt 3211091. Belt Width (Projected) 1.188I (30.18mm). Side Angle (Overall) 28 2. Outside Circumference 40.875.188I. Center Distance 10.12I (254.5mm). Clutch Offset 0.5I (12.7mm). Driven Helix Compound (EBS).............Flywheel I.D. 4060152 Fuel Tank 4.75 gals. (17.9 L). Grill (2) 27 Watts Quartz Brake (Hand) Dot 3. Tail 8.26 watts Brake (Foot) Dot 3. Brake 26.9 watts. Body Style Gen IV 4 Wheel Independent Shaft Drive. Front Suspension MacPherson Strut Gear Reduction-Low 7.49:1. Tow Capacity 1225 lbs. (555.6 kg) Gear Reduction-Rev 5.1:1. Turning Radius 76I (181.61 cm) Gear Reduction-High 2.89:1. Ground Clearance 11I (27.94 cm) Final Drive Ratio 3.10:1. Front Vertical Travel 6.7I (17.02 cm) Brake (Hand) Single Lever, Hyd. Disc. Rear Suspension Progressive Rate Independent Brake (Auxiliary Foot) Hydraulic. Rear Travel 9.5I (24.13 cm) Transmission Park Lock.
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Rear Shock 2I Twin Tube. Shock Adjustment Cam..Tire Size - Rear 25 x 11 - 12. Total Width 46I (116.84 cm). Total Length 85I (215.9 cm). Total Height 47I (119.38 cm). Wheel Base 50.75I (128.90 cm). Weight - Dry 740 lbs. (335.60 kg).......Rear Rack (Std) 180 lbs. Tongue Weight 150 lbs. Hitch Towing Capacity.1500 lbs.Please Click Here. Then Get More. Information.Now customize the name of a clipboard to store your clips. In doing so, no representation of affiliation, association or the like is intended, unless otherwise stated. Moreover, we are in fact owners of intellectual property, property that is a valuable asset to our business. 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. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm. When servicing your 2004 Sportsman it is important to identify which model you are working on. Throughout this service manual the different procedures (titles) are identified as “EARLY 2004”. Owner’s Parts Parts Manual Manual PN Micro Fiche 2004 Early Sportsman 600 A04CH59 9918540 9918610 9918611 2004 Early Sportsman 700 A04CH68 9918540 9918612 9918613 2004 Late Sportsman 600 A04CH59 9918724 9918731 9918732. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.
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Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.Description Part No. Aerosol) 2870585 Loctitet Primer N, Aerosol, 25 g 2871098 Premium 2 Cycle Engine Oil (Quart) (12. G The correct front gearcase lubricant to use is 2. Clean and reinstall drain plug using a new sealing Polaris Premium Demand Hub Fluid. washer. The Late 2004 front gearcase has a NOTE: 3. G Check vent hose to be sure it is routed properly and unobstructed. G The correct rear gearcase lubricant to use is Polaris ATV Angle Drive Fluid. REAR GEARCASE SPECIFICATIONS Specified Lubricant:. Torque to specification. 4. Remove fill plug. 5. Add Polaris AGL Gearcase Lubricant to proper View From Front level as described above. 6. Check for leaks. NOTE: Shift rod is preset at time of manufacture. 2. Set parking brake. 3. Start the engine and let it idle. Shift Linkage Rod 4. The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened.Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Adjuster Boot Lock-. Check fuel tank, oil tank, carburetor, battery and 4. Inspect the drained fuel for water or sediment.Follow manufacturer’s instructions to perform a cylinder leakage test. (Never use high WARNING pressure leakage testers, as crankshaft seals may dislodge and leak). Battery electrolyte is poisonous. Refer to specifications for proper spark plug type and gap. 1. Disconnect holder strap and remove cover. Adjust gap if necessary by bending the side 2. Disconnect battery negative (-) (black) cable first, electrode carefully. Straight water or antifreeze may cause the system to freeze, corrode, or overheat.
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It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty conditions, replacement is required more often. CAUTION: Make sure lines are not kinked or pinched.See notes secure handlebars in this position. NOTE: The below. This will tell G Do not perform clean out immediately after the engine has been run, as the ex- you which tie rod needs adjusting. Check brake system hoses and fittings for cracks, Use Polaris DOT 3 Brake Fluid (PN deterioration, abrasion, and leaks. Tighten any loose 2870990).Adjustas necessary. Shock Spanner Wrench Floor (PN 2870872) Board Surface AUXILIARY BRAKE ADJUSTMENT (HYDRAULIC) FRONT SUSPENSION Use the following procedure to inspect the hydraulic Compress and release front suspension. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. NOTE: The switch on the handlebar does not have to be in the OUT position. FREESPOOL Thumb Warmer The hand warmer switch is located on the left side of the headlight pod. Apply White GEAR TIMING AT TDC Lithium Grease. Apply Polaris 0W--40 oil to seal. Loctitet Pipe Sealant (PN 2871956) Bolts Water Pump Cover Bolt Gasket (Tighten Top Bolt First) Tighten Sequence (NO Grease or Oil!) 8 ft. lbs. Pushrods Bushing Do not expansion plug install more than 1.5 mm inward. Expansion 1.5 mm Plug Cylinder Side View Piston Assembly Circlip UP for Install Gasket Hydraulic Lifter Apply Polaris 0W--40 oil. Apply Moly Lube Grease. Disconnect the coolant hoses. Properly dispose of any antifreeze from the engine or hoses. 1. Clean work area. 13. Refer to PVT System Chapter 6 to remove outer clutch cover, drive belt, drive clutch, driven clutch, 2. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.
CYLINDER HEAD REMOVAL 2. Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. CAUTION: Use care not to damage sealing surface. 1. Place the hydraulic lifters (C), pushrods (D), and Std: 1.827I (46.40 mm) rocker arms (E) in a safe, clean area. Installed Height: 1.47” (37.34 mm) 6. Remove valve guide seals. IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled. VALVE SEAT RECONDITIONING Cylinder Head Reconditioning NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area. NOTE: The cylinder head valve guides cannot be replaced. WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly. WARNING Wear eye protection or a face shield when working with compressed air during cylinder head disassembly and reassembly. 9. Refer to Page 3.23 for cleaning tips. 2. Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage. Before reassembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts. 1. Install the head gasket (A) on the cylinder (B). 5. Torque thermostat housing 8. Install breather reed (G) into rocker cover (H).The ring may lose b) Remove the expander. CAUTION: Do not expand the Compression Rings ring more than the amount necessary to remove it. The cam gear assembly contains three loaded recommended that all of the gears be replaced. A springs. To open the cam gear assembly: gear kit is available in the parts book. Place the cam gear on a flat surface with the timing mark side facing up. Cam Gear Spring Installation Tool Kit: NOTE: Install the Cam Gear Alignment Tool (PU- -45497) (PU- -45497- -2) into one assembly hole counter clockwise from the timing mark. Tapered Pins: (PU- -45497- -1) Cam Gear Tooth Align Tool:.
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If the crankshaft gear does not need to be replaced, it does not need to be removed. If the crankshaft gear is damaged, remove the 26. Inspect the the valve (dowel) for signs of WARNING Wear appropriate safety gear possible obstructions. Use compressed air to during this procedure. Remove PTO end engine mount. Remove bearing’s outer race. Do not use the shaft to press crankcase bolts. Lobe height 3. Measure height of each cam lobe using a micrometer. Compare to specifications.Apply LocTitet balance shaft bearing surfaces of the MAG case 242 (PN 2871949)to the threads and pipe sealant halve. Install cam and balance shafts.Partially install the piston pins into the pistons. Cylinder Installation 11. The clip could fall into the engine during installation. Line Up Marks 18. Apply moly lube, lubriplate, or oil to the rotors on the oil pump shaft. NOTE: The application of oil or lubriplate aids in priming the oil pump during initial engine start up. The new bolts contain patch lock, so Loctitet is not needed on the new bolts.Install the washer and bolt.Use of lubricants (oil, soapy water, etc.) will not allow the seal to PU- -45543 wear- -in and seal properly. Do not touch seal surface or allow seal surface to come in contact with contaminates during installation. Carefully install the tapered end of the 33. With the tools installed, through the paper side of the crankshaft seal. This will ensure proper sealing when installing bolts. Install the Oil System Priming Adapter (PU- -45778) into the oil plug hole. Push 3--5 oz. (approx.) of Polaris 0W--40 into the adapter until resistance is felt. Remove the adapter. Apply pipe dope or Teflon tape to the plug threads. Polaris Premium Antifreeze Fill the reservoir only after you have completely filled the cool- 2871534 Quart ing system at the radiator filler neck. Gas Cap Early 2004 Models are NOT equipped with a sender Seal and have the reserve feature on fuel valve.
The lines Carburetor Component Function must be free of kinks, restrictions and be properly System Main Main Main routed. Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward, raising the slide against spring pressure. As the fuel fills the float chamber, the float (1) rises and forces the inlet needle against the seat, shutting off the orifice in the seat. The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened.Inspect the diaphragm (A) for holes, deterioration, or damage. Make sure the diaphragm is pliable but not Worn, Deposits Good Condition swollen. The diaphragm should fit properly in the carburetor body. Replace diaphragm assembly if diaphragm is damaged. O-ring as an assembly. Lubricate the O-Ring with oil or light grease before installation. The pump is valves are removed. Refer to “COVER PANEL REMOVAL” in Chapter 5 for details. 3. Remove the gas tank cover vent hose. Be sure to properly route the vent hose upon reassembly. Remove Bolts FRONT GRILL REMOVAL 2. Remove the bolt that secures the panel located in 1. Tighten ball joint nut to 25 ft. lbs. (35 Nm). If cotter pin holes are not aligned, tighten nut slightly to align. Install 1. Elevate and safely support vehicle with weight a new cotter pin with open ends toward rear of removed from front wheel(s). Strut Spring Compressor Tools (PN 2871573) and (PN 2871574) 2. Hold strut rod and remove top nut. 7. During the development of a Polaris ATV, the PVT system is matched first to the Piston Pin Puller 2870386 engine power curve; then to average riding conditions EBS Clutch 2872292 and the vehicle’s intended usage. This also from the drive belt increases, resulting in the belt will prevent water and other contaminants from rotating up toward the outer diameter of the drive. Driven Clutch Puller (PN 2870913) Refer to the appropriate parts manual for proper fasteners and fastener placement. 1. Remove seat. 2.
Remove or loosen rear cab fasteners as 8. Remove driven clutch offset spacers from the necessary to gain access to PVT outer cover. Align the alignment mark on the cover with the mark on the engine seal. Seal this edge to cover on engine side Offset Spacer 8. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM. 2. These shift weights have many different factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance, clutch balance, engagement and shifting characteristics. All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer (MSD) technician who has received the proper training and understands the procedures outlined in this manual. Nut Socket (PN 2870338). Install clutch in 3. Inspect cover bushing (A). The outer cover holding fixture. It is recommended to switch all buttons to the rubber 2. Inspect the Teflont coating on the moveable version during service (if needed).Torque cover bolts evenly to specification 2. Install moveable sheave onto fixed sheave. 3. Install spider spacers. Use same quantity and thickness as were removed. 4. Place another straight edge on top of belt. Measure the distance where the side straight edges intersect the top, as shown in the illustration.If problems are noted in either direction, continue with disassembly. Shim Kit (PN 2200126) CLUTCH OFFSET Important: Inspect clutch alignment and center distance before adjusting offset. Offset is correct when rear of tool contacts rear of inner sheave with driven clutch pushed completely inward on shaft and bolt torqued. BUSHING INSPECTION 1. Inspect the Teflont coating on the moveable sheave bushing. Inspect BOTH sheaves for signs of wear, grooving or cracking.
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Clean surfaces with a 3Mt pad if needed Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflont is visible on the bushing. Move Freely 2. When rotated clockwise, the outer sheave should lock to the shaft and inner sheave without NOTE: Rotating the moveable sheave so that the slipping.Do not lubricate the roller or roller pin. Heat Area Roller Lightly Apply Loctitet 680 To Tapered Portion Of Screw Dry Locking Agent Applied To New Screws 7. Inspect moveable sheave bushing for wear. Inspect BOTH sheaves for signs of wear, grooving or cracking. EBS Driven - Bushing Removal Nut (C) Removal Tool (3) 1. Install puller adapter (Item 10) onto puller. Adapter Reducer (9) Main Adapter. Engine braking (EBS) continues until the drive clutch 9. Retaining Screw Rollers must rotate freely on pins without excessive clearance. Some lateral movement is allowable.REASSEMBLY 2. Be sure to use the alignment marks for reassembly. 1. Simply reverse the steps of the disassembly process. Replace any parts needed. See “EBS LATE 2004 EBS DRIVEN CLUTCH EXPLODED VIEW 1. EBS Driven - Bushing Removal Nut (C) Removal Tool (3) 1. Install puller adapter (Item 10) onto puller. Adapter Reducer (9) Main Adapter. EBS Driven - Stationary Sheave (Inner) Bushing Removal 1. Install puller adapter onto puller. 2. Install adapter reducer. Bushing Tool (2) 3. Belt burnt, thin -Abuse (continued throttle application when -Caution operator to operate machine within guidelines.Front Drive Axle Removal. CAUTION: Do not hang the caliper by the brake PART NUMBER TOOL line. Use wire to hang the caliper to prevent DESCRIPTION possible damage to the brake line. 2872608 Roller Pin Removal Tool. With short, sharp jerks, remove drive shaft from front gearcase. 70 ft. lbs. (95 Nm) DRIVESHAFT AND CV JOINT HANDLING TIPS Care should be exercised during driveshaft removal or when servicing CV joints. Driveshaft components are precision parts. Refer to Front Drive Axle Removal Page 7.
3 for procedure. 2. Remove cotter pin and castle nut from A-arm ball joint. Pull shaft to remove from CV joint 7. U-JOINT DISASSEMBLY CAUTION: Wear eye protection at all times. 1. Remove internal or external snap ring from all bearing caps. Continually check for free movement of bearing cross as bearing caps are assembled. 7. When installation is complete, Yokes must pivot freely in all directions without binding. If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions. Use wire to hang the caliper to prevent possible Frame damage to the brake line. 6. Remove the front hub from the drive shaft. 7. Remove cotter pin, lower ball joint nut and A-arm from ball joint. The vehicle is now back to rear wheel drive until the next loss of traction. The gearcase coils should measure between 22.8 ohms and 25.2 ohms. 3. Remove output shaft assembly. 7. Inspect the ring gear (C) for consistent wear patterns. Uneven wear of the armature plate (F) indicates a warped plate, which may cause intermittent operation. 11. Remove the thrust bearing (G) from the output hub (D). Inspect the thrust bearing (G) and the dowel (H). To replace, press new bearing on to shaft. Cover Bolts Torque 14 ft. lbs. (19 Nm) 12. There should one or two distinct wear (Wear from Coil bands (one band inside the other). If only one On Armature Plate) band of wear is present (or if there is wear between the two bands, inspect the coil area as. When the AWD switch is activated it engages the Hilliard, locking both front axles into All Wheel Drive. The surfaces should be free of nicks Front Gearcase Coil Resistance: and scratches. 22.8- -25.2 Ohms Gearcase Coil Resistance NOTE: To test the gearcase coils resistance, use the coil harness. Inspect the pinion gear (O) for chipped, broken, or missing teeth. Replace the input cover O--ring. 17. To replace, press new bearing on to shaft. NOTE: Be sure backlash plate is in place. Backlash Plate 11.
Install the output cover assembly onto the main gearcase. 8. Install the retaining ring (F) into the output cover. NOTE: Be sure armature plate tabs are placed into Be sure the retaining ring is properly seated into the slots on roll cage. There should one or two distinct wear bands (one band inside the other). Remove rear hub cap. 9. Remove hub. 2. Remove cotter pin. 3. Loosen the hub retaining nut. 4. Loosen the wheel nuts. 5. Safely support the rear of the ATV. CAUTION: Secure the machine. Rear Hub Nut Torque: 80 ft. lbs. (109 Nm) 12. Remove bearing carrier. Rear Wheel Nut Torque 30 ft. lbs. (41 Nm) REAR HUB INSTALLATION 1. Insert bearing carrier on drive shaft. 5. REAR DRIVE SHAFT REMOVAL 1. Remove rear hub and bearing carrier. (See Pages 7.26). 2. Tip hub outward and remove shaft from hub. 3. HANDLING TIPS 4. Lift bearing carrier into place and install bolt to upper control arm. Torque bolt to 35 ft. lbs. (48 Care should be exercised during driveshaft removal Nm). Tap CV Housing Off Shaft 4. Place a new snap ring in the groove of the CV joint inner hub, with tabs facing the shaft as shown. Take grease for contamination by rubbing it between two care not to damage threads on the outboard CV fingers. Torque the fill plug to 14 ft. lbs. (19 Nm). See next page. 2. Replace O--rings, seals, worn components. 7. Inspect the ring gear for abnormal wear, broken, or chipped teeth. Spin the bearing to check the ball bearings for smoothness. Install the gearcase cover onto the gearcase housing. Gear Shift Selector Removal.Transmission Removal. Refer to Chapter 2 for fill plug locations. Front TORQUE SPECIFICATIONS COMPONENT FT. LBS. (IN.LBS.) Transmission Case Bolts 27--34. Remove the park lock spring.Remove the detent spring. Spring 5. Mark the detent gear with a white pen. Remove the detent gear from the case. Tighten Bolts In Sequence A through E TRANSMISSION DISASSEMBLY 1. Remove the wave spring and reverse engagement dog. Engagement Dogs 14.
Remove the shift forks from the assembly. Note the correct position of each fork. Use a press to remove the gear from the shaft.Remove low gear (33T) and the needle bearing. location. Inspect engagement dogs of gears and replace if button, and thrust button shim.Note the location of the hubs on the gear. When installing the new snap ring, open the the snap ring just far enough to go over the shaft, to avoid stressing the snap ring. If the snap ring is over--stressed, it could come off the shaft and cause internal damage to the transmission. Install the shift gear (16T) on the shift drum shaft. Install the sector gear in the bushing pocket on the left side. Aligning the timing marks on the gears. 28. Refer to Maintenance Chapter 2 for more information. The two styles of brake lines maintenance and perform well in the conditions ATVs are “pipe fit” style and “banjo” style. Be sure to routinely encounter. CHANGE WARNING: Once a bottle is opened, use what is. Install a box end wrench on caliper bleeder screw. There are different brake master cylinders for the different Polaris ATV models. Refer to your parts 5 in. lbs. (0.56 Nm) manual or guide for the correct parts. The master cylinder is not serviceable and is replaced as a unit. Polaris DOT 3 Brake Fluid (PN 2870990) NOTE: Brake fluid will be forced through 4. Follow bleeding procedure on Pages 9.7-9.8. DISASSEMBLY 4. Install disc on hub. 5. Install new bolts and tighten to specified torque. 1. Remove brake pad adjuster screw. Front Brake Disc Mounting Bolt Torque 18 ft. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit.Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance. Front Wheel Nut Torque 20 ft. Remove the rear tire. 6. Remove the brake pads from the caliper. 2. Remove caliper mounting bolts and lift caliper off Remove of disc.
Torque Mounting Install Pads Bolts Rear Brake Caliper Torque: 18 ft. lbs. (25 Nm) 2. Tighten the slide pin with a hex wrench. 5. Slowly pump the brake lever until pressure has 3. Place a container to catch brake fluid draining from brake lines. Install the slide pins and the slide pin retaining ring. Torque the slide 1. Install new O-rings in the slide bolt bushing holes.Torque the brake lines to the proper thickness at 8 different points around perimeter of torque specification. disc. Replace disc if worn beyond service limit. NOTE: See Page 9.3 to identify which style brake line your ATV has installed. The gap Flywheel should be.022--.028 inch (.56--.71 mm). Timing Marks Measure Trigger Coil Gap Built Before Feb- ruary 20, 2003 Kokusan Flywheel Timing Marks Trigger Coil Gap:.022- -.028 inch (.56- -.71 mm) The Polaris ATV Instrument Cluster is powered by battery voltage (12 VDC) and requires inputs from the engine RPM, transmission gear, and wheel speed sensor for proper operation. Two harnesses plug into the cluster head;. This area is blank if a fault occurs. 8. This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. NOTE: 10- -20 variance from these readings is within normal parameters. 628 Ohms in High Screen 5: Programmable service interval. The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. Turn Service Interval OFF: 1. If the service interval is enabled (functioning) on your ATV and you wish to turn it off, toggle to the service interval mode. This will help the instrument cluster slide into the pod assembly more easily. Some of the advantages of DC ignition are:. Be sure to always use the correct CDI box part number. Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting. Reverse meter leads if battery cable. Check for current draw with the key off.
If the draw is excessive, loads should be 4. Shift transmission into neutral and start the disconnected from the system one by one until the engine. Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage (See Remove the battery and properly ser- earlier test). Different types WARNING of batteries require different service procedures. Proper servicing and upkeep of your battery is very important for maintaining long battery life. Do not overfill the battery. Use Polaris corrosion resistant Nyogelt grease (PN 2871329) on battery bolts. See Battery Installation on Refill using only distilled water. Coat threads of battery bolt with battery tray with a mild solution of a corrosion resistant dielectric grease.Rinse with lots of fresh water after cleaning. This will determine the length of time required to charge the battery to full capacity. This test cannot be performed gravity.Electrolyte Freezing Points A battery may indicate a full charge condition in the OCV Specific Gravity Freezing. Torque the rear bolt first, then torque the front bolt.TROUBLESHOOTING Voltage should not exceed.1 DC volts per connection Starter Motor Does Not Turn Battery discharged.Slide brush end frame off end of starter. BRUSH NOTE: The electrical input post must stay with the field coil housing. Inspect O-ring and replace if damaged. 2. Inspect surface of commutator. Replace if excessively worn or damaged. If hacksaw blade is drawn to armature on any pole, the Seal armature is shorted and must be replaced. The resistance should be 2.8-3.6 ohms. (PN 2871460) Refer to Electric Starter System Testing in this section to further test the solenoid. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. With the tester on the VDC position, place the tes- ter’s black lead on the battery negative and the red Remove battery and properly service.