GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION1

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2VIN AND ENGINE SERIAL NUMBER LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3MODEL: 2009 PHOENIX 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5PAINT CODES:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6MISCELLANEOUS SPECIFICATIONS AND CHARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

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VEHICLE IDENTIFICATION

Model Identification

The machine model number must be used with any correspondence regarding warranty or service.

Engine Designation Number

ES20PFE - Single, Air Cooled, SOHC 4 Stroke, Electric Start

VIN Identification

VIN and Engine Serial Number Location

The vehicle identification number (1) and engine serial number (2)are important for vehicle identification. The vehicle identificationnumber (VIN) is stamped on the LH lower front of the frame.

Machine Model Number Identification

Year Designation

Basic Chassis Designation Engine Designation

Emissions & Model Option

A 0 9 P B 2 0 A B

4 X A P B 2 0 A * 9 P 0 0 0 0 0 0

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

World Mfg. ID

Engine

Vehicle Descriptor Vehicle Identifier Check Digit

ModelYear

Body Style Plant No

Individual Serial Number

* This could be either a number or a letter

Powertrain Emissions

1

2

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GENERAL SPECIFICATIONS

MODEL.................2009 PHOENIX 200

MODEL NUMBER.......A09PB20AB,AD,EBENGINE MODEL............................ES20PFE

Category Dimension

Length 65 in. / 165.1 cm

Width 42 in. / 106.7 cm

Height 42 in. / 106.7 cm

Wheel Base 45 in. / 114.3 cm

Ground Clearance 5.7 in. / 14.5 cm

Dry Weight 395 lbs. / 179.2 kg

Gross Vehicle Weight 720 lbs. / 326 kg

Front Rack Capacity n/a

Rear Rack Capacity 70 lbs. / 31.7 kg

Towing Capacity 300 lbs. / 136 kg

Hitch Tongue Weight 30 lbs. / 13.6 kg

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MODEL: 2009 PHOENIX 200 MODEL NUMBER: A09PB20AB,AD,EBENGINE MODEL: ES20PFE

JETTING CHART

CLUTCH CHART

Engine

Platform Aeon 4 stroke, Single Cylinder

Engine Model Number ES20PFE

Engine Displacement 196cc

Number of Cylinders 1

Bore & Stroke (mm) 65 x 59 mm

Compression Ratio 9.2:1

Compression Pressure 160-190 psi

Engine Idle Speed 1500 ± 100 Rpm

Cooling System/Capacity Oil/ Air

Overheat Warning n/a

Lubrication Wet Sump

Oil Requirements Polaris 2W-50 / 1.26qt (1.2L)

Exhaust System USFS Approved

Carburetor

Carburetor model Keihin VM 22mm

Main Jet 98

Pilot Jet 40

Jet Needle 2MKNN - 4 clip

Needle Jet n/a

Pilot/Air Screw 2.25 Turns Out(Initial setting, varies by ATV)

Float Height Parallel To Float Bowl

Fuel Delivery Gravity Feed System

Fuel Capacity / Requirement

2.5 gal. (9.5 L)87 Octane (minimum)

89 Oxygenated

Electrical

Alternator Output 210 w @ 5000 RPM

Voltage Regulator 3-Phase

Lights: High Beam 35 watts

Low Beam 35 watts

Brake 21 watts

Tail 5 watts

Ignition System CDI Ignition

Ignition Timing 32 ± 2 BTDC @ 3000 RPM

Spark plug / Gap NGK CR6HSA.024 - .028 in./ .6-.7 mm

Battery / Model / Amp Hr Maintenance-Free - 12 Amp Hr

Circuit Breakers Harness 15 amp

Starting Electric / Kick Start Backup

Indicator Panel Neutral / Reverse

Drivetrain

Transmission Type Inline F/N/R

Transmission Capacity 18.6 oz. (550 ml)

Rear Gearcase Capacity 4 oz. (120 ml)

Drive Type Shaft

Clutch Type CVT Non EBS

Belt 0452496

Steering / Suspension

Front Suspension / Shock Dual A-arm / Coil over Shocks

Front Travel 7 in. / 17.8 cm

Rear SuspensionStyle / Shock

Mono Shock Swingarm / Coil over shock

Rear Travel 6.5 in. / 16.5 cm

Ground Clearance 5.7 in. / 14.5 cm

Shock Preload AdjustmentFront / Rear

Front - CamRear - Cam

Turning Radius 64 in. / 106.7 cm unloaded

Toe Out 0 - 1/16 in / .0 - .159 mm

Wheels / Brakes

Tire/Rim Size - Front 21 x 7 - 10 / 4-156

Tire/Rim Size - Rear 20 x 10 - 9 / 4-110

Air Press. F/R TiresFront - 4 psi (28 kPa)Rear - 4 psi (28 kPa)

Brake - FrontRH Control

Dual Hydraulic Disc

Brake - RearLH Control / Foot BrakeSingle Drum Mechanical

Brake Fluid Polaris DOT 3 Brake Fluid

Altitude

Ambient Temperature

Below 40 FBelow 5 C

Above +40 F Above +5 C

Meters(Feet)

0-1800(0-6000)

102 98

above 1800 (above 6000)

96 92

Altitude Shift Weight

Meters(Feet)

0-1800(0-6000)

6 @ 14.7 grams

1800-3700(6000 - 12000)

6 @ 11 grams(PN 0453091)

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VEHICLE INFORMATION

Publication Numbers

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

NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased fromwww.purepolaris.com.

Paint Codes:

Replacement Keys

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

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

2009 Phoenix 200 A09PB20AB,AD 9921841 9921842

2009Phoenix 200 Quadricycle

A09PB20EB 9922082 9922083

PAINTED PART COLOR DESCRIPTION POLARIS NUMBER

Frame Vapor Silver P-385

Frame Matte Black P-458

Key Blank

0453013

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SPECIAL TOOLS

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other toolsmaybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polarisproduct. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 oron-line at http://polaris.spx.com/.

MISCELLANEOUS SPECIFICATIONS AND CHARTS

Standard Torque Specifications

The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engineareas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.

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Conversion Table

°C to °F: 9/5(°C + 32) = °F

°F to °C: 5/9(°F - 32) = °C

Unit of Measure Multiplied by Converts to

ft. lbs. x 12 = in. lbs.

in. lbs. x .0833 = ft. lbs.

ft. lbs. x 1.356 = Nm

in. lbs. x .0115 = kg-m

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

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GENERAL INFORMATION

SAE Tap Drill Sizes

Metric Tap Drill Sizes

Decimal Equivalents

Thread Size / Drill Size Thread Size / Drill Size

#0-80 3/64 1/2-13 27/64

#1-64 53 1/2-20 29/64

#1-72 53 9/16-12 31/64

#2-56 51 9/16-18 33/64

#2-64 50 5/8-11 17/32

#3-48 5/64 5/8-18 37/64

#3-56 45 3/4-10 21/32

#4-40 43 3/4-16 11/16

#4-48 42 7/8-9 49/64

#5-40 38 7/8-14 13/16

#5-44 37 1-8 7/8

#6-32 36 1-12 59/64

#6-40 33 1 1/8-7 63/64

#8-32 29 1 1/8-12 1 3/64

#8-36 29 1 1/4-7 1 7/64

#10-24 24 1 1/4-12 1 11/64

#10-32 21 1 1/2-6 1 11/32

#12-24 17 1 1/2-12 1 27/64

#12-28 4.6mm 1 3/4-5 1 9/16

1/4-20 7 1 3/4-12 1 43/64

1/4-28 3 2-4 1/2 1 25/32

5/16-18 F 2-12 1 59/64

5/16-24 I 2 1/4-4 1/2 2 1/32

3/8-16 O 2 1/2-4 2 1/4

3/8-24 Q 2 3/4-4 2 1/2

7/16-14 U 3-4 2 3/4

7/16-20 25/64

Tap Size Drill Size Decimal Equivalent

Nearest 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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Glossary Of Terms

ABDC: After bottom dead center.ACV: Alternating current voltage.Alternator: Electrical generator producing voltage alternating current.ATDC: After top dead center.BBDC: Before bottom dead center.BDC: Bottom dead center.BTDC: Before top dead center.CC: Cubic centimeters.Center Distance: Distance between center of crankshaft and center of driven clutch shaft.Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches.CI: Cubic inches.Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and gripthe drive belt.Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocksor resting in crankcase. Measure at various points especially at PTO.CVT: Centrifugal Variable Transmission (Drive Clutch System)DCV: Direct current voltage.Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore.Electrical Open: Open circuit. An electrical circuit which isn't complete.Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching thechassis).End Seals: Rubber seals at each end of the crankshaft.Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.ft.: Foot/feet.Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.g: Gram. Unit of weight in the metric system.gal.: Gallon.ID: Inside diameter.in.: Inch/inches.Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.kg/cm2: Kilograms per square centimeter.kg-m: Kilogram meters.Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.l or ltr: Liter.lbs/in2: Pounds per square inch.Left or Right Side: Always referred to based on normal operating position of the driver.m: Meter/meters.Mag: Magneto.Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy isconverted to electrical energy in the stator.mi.: Mile/miles.mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".Nm: Newton meters.OD: Outside diameter.Ohm: The unit of electrical resistance opposing current flow.oz.: Ounce/ounces.Piston Clearance: Total distance between piston and cylinder wall.psi.: Pounds per square inch.PTO: Power take off.qt.: Quart/quarts.Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.Reservoir Tank: The fill tank in the liquid cooling system.Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.RPM: Revolutions per minute.Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.TDC: Top dead center. Piston's most outward travel from crankshaft.Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.Watt: Unit of electrical power. Watts = amperes x volts.WOT: Wide open throttle.

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MAINTENANCE

CHAPTER 2

MAINTENANCE

2

GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 2.3PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3POLARIS LUBRICANT SYMBOL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3LUBRICATION LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4FRAME, NUTS, BOLTS, AND FASTENER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 2.4PHOENIX HANDLEBAR AND COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . 2.5

PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6PERIODIC MAINTENANCE OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.750 HOUR MAINTENANCE INTERVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

POLARIS LUBRICANTS AND SERVICE PRODUCTS. . . . . . . . . . . . . . . . . . . . . . . . . . 2.10POLARIS LUBRICANTS, MAINTENANCE, AND SERVICE PRODUCTS. . . . . . . . . . . 2.10

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11THROTTLE OPERATION / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11ELECTRONIC THROTTLE CONTROL (ETC) / THROTTLE CABLE ADJUSTMENT . . 2.11CHOKE (ENRICHER) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12FUEL / AIR MIXTURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14MAIN AIR FILTER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14AIR FILTER / PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14AIR BOX SEDIMENT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

ENGINE/TRANSMISSION/REAR GEARCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16ENGINE OIL AND FILTER CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16COMPRESSION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18ENGINE FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18KICKSTART LEVER AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18EXHAUST CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18CVT DRAIN PLUG / DRYING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19SHIFT CABLE INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22SPARK PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23ENGINE / FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

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STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24TOE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25FRONT / REAR SUSPENSION SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . 2.25FRONT SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25REAR SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26BRAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26FRONT BRAKE PAD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26HOSE / FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26REAR BRAKE ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27REAR BRAKE LEVER TRAVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28WHEEL REMOVAL - FRONT / REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28WHEEL INSTALLATION - FRONT / REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

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MAINTENANCE

2

GENERAL VEHICLE INSPECTION AND MAINTENANCE

Pre-Ride / Daily Inspection

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

• Tires - check condition and pressures

• Fuel and oil - fill both to their proper level; Do not overfill

• All brakes - check operation(includes auxiliary brake)

• Throttle - check for free operation

• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

• Engine stop switch - check for proper function

• Wheels - check for loose wheel nuts

• Air cleaner element - check for dirt or water; clean or replace

• Steering - check for free operation, noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

• Engine coolant(if applicable) - check for proper level at the recovery bottle

Polaris Lubricant Symbol Identification

NOTE: The symbols are used to properly identify the correct lube or grease to use in the maintenancesection.

Polaris DOTBrake Fluid

Polaris SyntheticGearcase Lube

Polaris Synthetic2W-50 Oil

Polaris All Season Grease Polaris ATVAngle Drive Fluid

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Lubrication Locations

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

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

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

3 Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special

Frame, Nuts, Bolts, and Fastener Inspection

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.

III. # Item Lube Rec. Method Frequency*

1Engine Oil Polaris 2W-50

SyntheticAdd oil to proper level.

Change after 1st month (25 hours), 50 hours thereafter; Change more often (25 hours) in severe duty conditions, or short trip cold weather operation.

2 Transmission Polaris AGL Lubricant Add oil to proper level. Change annually 2

3 Brake Fluid Polaris DOT Brake FluidFill master cylinder reservoir to indicated level inside reservoir.

As required. Change fluid every 2 years.

4 Rear GearcasePolaris ATV Angle Drive Fluid

Drain and refill with pre-measured amount of lubricant.

As required*

5 A-Arm BushingsPolaris All Season Grease 3

Locate grease fittings and apply grease with grease gun.

Semi-annually 1

2. Transmission Oil

4. Rear Gearcase Oil

5. Top and Bottom Front A-Arms

3. Brake Fluid

1. Engine Oil

Reservoir Level

Level Indicator

Level Indicator

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2

Phoenix Handlebar and Component Locations

Throttle

Front Brake

Choke

Rear Brake

Start Button

Indicator Lights

Brake Fluid Reservoir

Ignition/ Key

Light Control& Run Switch

Reverse Override

Rear Axle & Drivetrain

Rear RackBattery

Air Filter

HeadlightFuel Valve

Kick Start Shaft CVT Cover

Engine Oil Filter

Foot Brake

Muffler

Transmission OilLevel Indicator

Engine OilLevel Indicator Gear

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PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubricationof important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genu-ine 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 qualifieddealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately10 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 orcrankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue useand 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 anauthorized Polaris dealer.

= SEVERE USE ITEM --If vehicle is subjected to severe use, decrease interval by 50% (Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpmuse, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is requiredunder these conditions. Fluid changes, cable, chain and chassis lubrication are required more frequently. Forengine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A risingoil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil imme-diately and monitor level. If oil level begins to rise, discontinue use and determine cause.)

E= Emission Control System Service (California).

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

WARNING

Improperly performing the procedures marked with a couldresult in component failure and lead to serious injury or death.Have an authorized Polaris dealer perform these services.

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2

Pre-Ride - 25 Hour Maintenance Interval

Periodic Maintenance Chart

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.

Item

Maintenance Interval(whichever comes first)

RemarksHours Calendar Miles

(KM)Steering - Pre-Ride - Check for free operation.

Front Suspension - Pre-Ride -Make adjustments as needed. See Pre-Ride Checklist on Page 2.9Rear Suspension - Pre-Ride -

Tires - Pre-Ride -Engine Stop Switch - Check Operation

Brake Fluid Level - Pre-Ride -Make adjustments as needed. See Pre-Ride Checklist on Page 2.9

Brake Lever Travel - Pre-Ride - Make adjustments as needed. See Pre-Ride Checklist on Page 2.9Brake Systems - Pre-Ride -

Throttle - Pre-Ride - Check OperationWheels / Fasteners - Pre-Ride - Make adjustments as needed. See Pre-Ride

Checklist on Page 2.9Frame Fasteners - Pre-Ride -

EEngine Oil Level - Pre-Ride -

Make adjustments as needed. See Pre-Ride Checklist on Page 2.9

E Idle Speed - - - Adjust as needed

Toe Adjustment - Pre-Ride -Inspect periodically; adjust when parts are replaced

Auxiliary Brake - Pre-Ride - Inspect daily; adjust as needed

Headlight Aim - Pre-Ride - Adjust as needed

EAir Filter, Pre-Filter - Daily - Inspect; clean often

EAir Box Sediment Tube - Daily - Drain deposits when visible

Headlamp / Tail Lamp - Daily -Check operation; apply dielectric grease if replacing

EAir Filter,Main Element

- Weekly - Inspect; replace as needed

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

Battery 20 H Monthly 200 (320) Check terminals; clean; test

EEngine Oil Change (Break-In)

20 H 1M 100 (160) Perform a break-in oil change at one month

Rear Gearcase Oil (if equipped)

25 H Monthly 250 (400) Inspect level; change yearly

Transmission Oil 25 H Monthly 250 (400) Inspect level; change yearly

EEngine Breather Filter (if equipped)

25 H Monthly 250 (400) Inspect; replace if necessary

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MAINTENANCE

50 Hour Maintenance Interval

Periodic Maintenance Chart

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.

Item

Maintenance Interval (whichever comes first)

RemarksHours Calendar Miles

(KM)

General Lubrication 50 H 3 M 500 (800)Lubricate all grease fittings, pivots, cables, etc.

Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust

Steering 50 H 6 M 500 (800) Inspect daily, Lubricate

Front suspension 50 H 6 M 500 (800) Inspect, Lubricate, Tighten Fasteners

Rear suspension 50 H 6 M 500 (800) Inspect, Lubricate, Tighten FastenersCarburetor float bowl 50 H 6 M 500 (800) Drain bowl periodically and prior to storage

EThrottle Cable/ETC Switch

50 H 6 M 500 (800) Inspect; adjust; lubricate; replace if necessary

EChoke cable 50 H 6 M 500 (800) Inspect; adjust; lubricate; replace if necessary

ECarburetor air intake ducts/flange

50 H 6 M 500 (800) Inspect ducts for proper sealing/air leaks

E

Engine oil change*Severe Duty

**Normal Duty

25 H

50 H

6 M

12 M

500(800)

1000 (1600)

Perform a break-in oil change at 25 hours / one month, change more frequently during cold weather

E

Oil filter change *Severe Duty

**Normal Duty

25 H

50 H

6 M

12 M

500(800)

1000 (1600)

Replace at oil change

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2

100 - 300 Hour Maintenance Interval

Periodic Maintenance Chart

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.

Item

Maintenance Interval (whichever comes first)

RemarksHours Calendar Miles

(Km)Engine breather hose 100 H 6 M 1000 (1600) Inspect

EValve clearance 100 H 12 M 1000 (1600) Inspect; adjust as required

Drive belt 100 H 12 M 1000 (1600) Inspect; adjust; replace as needed

EFuel system 100 H 12M

1000(1600)

Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor, replace lines every two years

EFuel Filter 100 H 12M

1000(1600)

Replace yearly

Engine mounts 100 H 12M1000

(1600)Inspect

Exhaust muffler / pipe 100 H 12M1000

(1600)Inspect

ESpark plug 100 H 12M

1000(1600)

Inspect; replace as needed

EIgnition Timing 100 H 12M

1000(1600)

Inspect

Wiring 100 H 12M1000

(1600)

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

Clutches (drive and driven) 100 H 12M1000

(1600)Inspect;clean; replace worn parts

Front wheel bearings 100 H 12M1000

(1600)Inspect; replace as needed

Brake fluid 200 H 24M2000

(3200)Change every two years

Spark arrestor 300 H 36M3000

(4800)Clean out

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POLARIS LUBRICANTS AND SERVICE PRODUCTS

Polaris Lubricants, Maintenance, and Service Products

NOTE: Each item can be purchased separately at alocal Polaris dealer.

NOTE: The number count indicated by each partnumber in the table above indicates the minimumnumber of units that are shipped with each order.

Part No. Description

Engine Lubricants

2870791 Fogging Oil (12 oz. Aerosol)

2876244Engine Oil (Quart) Performance Synthetic 4-

Stroke 2W-50 (12 Count)

2876245Engine Oil (Gallon) Performance Synthetic 4-

Stroke 2W-50 (4 Count)

Gearcase / Transmission Lubricants

2873602Premium Synthetic AGL Gearcase Lube

(12 oz. bottle) (12 Count)

2873603Premium Synthetic AGL Gearcase Lube

(1 Gal.) (4 Count)

2871653Premium ATV Angle Drive Fluid

(8 oz.) (12 Count)

2872276Premium ATV Angle Drive Fluid

(2.5 Gal) (2 Count)

2870465 Oil Pump for 1 Gallon Jug

Grease / Specialized Lubricants

2871322Premium All Season Grease (3 oz. cartridge) (24 Count)

2871423Premium All Season Grease (14 oz. cartridge) (10 Count)

2871460 Starter Drive Grease (12 Count)

2871312 Grease Gun Kit

2871329 Dielectric Grease (Nyogel™)

Part No. Description

Additives / Sealants / Thread Locking Agents / Misc.

2874275 Loctite™ Primer N, Aerosol

2871956Loctite™ Thread Sealant 565

(50 ml.) (6 count)

2871950Loctite™ Threadlock 242

(6 ml.) (12 count)

2871951Loctite™ Threadlock 262

(50 ml.) (10 count)

2871953Loctite™ Threadlock 271

(6 ml.) (12 count)

28715573-Bond 1215 Sealant

(5 oz.)

2871326Premium Carbon Clean

(12 oz.) (12 count)

2870652 Fuel Stabilizer (16 oz.) (12 count)

2871957Black RTV Silicone Sealer

(3 oz. tube ) (12 count)

2871958Black RTV Silicone Sealer

(11 oz. cartridge) (12 count)

2870990 DOT 3 Brake Fluid (12 count)

2871557 Crankcase Sealant, 3 Bond 1215 (5 oz.)

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2

FUEL SYSTEM AND AIR INTAKE

Fuel System

• Always stop the engine and refuel outdoors or in a wellventilated area.

• Do not smoke or allow open flames or sparks in or nearthe area where refueling is performed or where gasolineis stored.

• Do not overfill the tank. Do not fill the tank neck.

• If you get gasoline in your eyes or if you swallowgasoline, seek medical attention immediately.

• If you spill gasoline on your skin or clothing,immediately wash it off with soap and water andchange clothing.

• Never start the engine or let it run in an enclosed area.Engine exhaust fumes are poisonous and can result lossof consciousness or death in a short time.

• Never drain the float bowl when the engine is hot.Severe burns may result.

Throttle Operation / Inspection

Check for smooth throttle opening and closing in all handlebarpositions. Throttle lever operation should be smooth and levermust return freely without binding.

1. Place the gear selector in neutral.

2. Set parking brake.

3. Start the engine and let it idle.

4. Turn handlebars from full right to full left. If idle speedincreases at any point in the turning range, inspect throttlecable routing and condition. If cable is routed properly andin good condition, repeat adjustment procedure.

5. Replace the throttle cable if worn, kinked, or damaged.

Electronic Throttle Control (ETC) / Throttle Cable Adjustment

1. Slide the boot off throttle cable adjuster and jam nut.2. Place shift selector in neutral and set the parking brake.

3. Start engine and set the idle to specified RPM.

4. Loosen jam nut on the in-line cable adjuster as shown in theillustration below.

5. With handlebars centered and wheels pointing forward,turn adjuster sleeve until freeplay is achieved at the thumblever. After making any adjustment, “flip” the lever slightlyto confirm adjustment.

6. Tighten locknut securely and slide boot over cable adjusteruntil they touch at the middle point of the adjuster.

7. With engine running, turn the handlebars from full left tofull right with transmission in neutral. Engine RPM shouldnot change and the engine should not die. If either of theseoccur, return to the first step.

WARNING

Gasoline is extremely flammable and explosive under certain conditions.

= In. / mm.

Throttle Freeplay: 1/16-3/16” (1.6-4.76 mm)

1

23

4

5

6

ETC CoverRemoval Sequence

Direction of travel

BootLocknut

AdjusterSleeve

Boot

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Choke (Enricher) Adjustment

8.

Verify free play and smooth operation of choke cable.Adjustments to the freeplay can be made by loosening the chokecable adjustment in or out to gain the desired freeplay.

If smooth choke operation is not obtainable, inspect choke cablefor kinks or sharp bends in routing.

Fuel / Air Mixture Adjustment

1. Set idle speed to specification. Always check throttle cablefreeplay after adjusting idle speed and adjust if necessary.

2. To adjust the mixture screw setting, you will need to usethe “D” shaped Carburetor Adjustment Screwdriver PA-47361. Slowly turn the mixture screw clockwise untilengine idle RPM begins to decrease. Stop turning at thispoint.

3. Slowly turn mixture screw counterclockwise until idlespeed returns to maximum RPM. Continue turningcounterclockwise until idle RPM begins to drop. Stopturning at this point.

4. Center the mixture screw between the points in Step 2 and3.

5. Readjust idle speed if not within specification.

= In. / mm.

Choke Cable Freeplay: 1/16-3/16” (1.6-4.76 mm)

Fuel / Air Adjustment Screw

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Idle Speed Adjustment

1. Start engine and warm it up thoroughly.

NOTE: Adjust idle speed by turning the slide adjustmentscrew in (clockwise) to increase or out (counterclockwise) todecrease RPM. (Refer to illustration).

NOTE: Adjusting the idle speed affects throttlecable freeplay and electronic throttle control (ETC)adjustment. Always check throttle cable freeplayafter adjusting idle speed and adjust if necessary.

Fuel Lines

1. Check fuel lines for signs of wear, deterioration, damage,or leakage. Replace if necessary.

2. Be sure fuel lines are routed properly and secured withcable ties.

3. Replace all fuel lines every two years.

Vent Lines

1. Check fuel tank, crankcase, carburetor, battery andtransmission vent lines for signs of wear, deterioration,damage or leakage. Replace every two years.

2. Verify vent lines are routed properly and secured with cableties.

Fuel Filter

The fuel filter should be replaced in accordance with thePeriodic Maintenance Chart. The fuel filter is located betweenthe fuel tank and carburetor.

1. Shut off fuel supply at fuel valve.

2. Remove line clamps at both ends of the filter.

3. Remove fuel lines from filter.

4. Install new filter and clamps onto fuel lines with arrowpointed in direction of fuel flow.

5. Install clamps on fuel line.

6. Turn fuel valve ON.

7. Start engine and inspect for leaks.

Idle Speed: 1500 +/- 100 rpm

CAUTION

Make sure lines are not kinked or pinched

Slide Adjustment Screw

CAUTION

Make sure lines are not kinked or pinched

To Carburetor

Fuel Filter

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MAINTENANCE

Carburetor Draining

The carburetor float bowl should be drained periodically toremove moisture or sediment from the bowl, or before extendedperiods of storage.

NOTE: The bowl drain screw is located on thebottom left side of the float bowl.

1. Turn fuel valve to the off position.

2. Place a clean container beneath the bowl drain spigot orbowl drain hose.

3. Turn drain screw out two turns and allow fuel in the floatbowl 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. Start machine and check for leaks.

Main Air Filter Cleaning

It is advisable to replace the filter when it is dirty. However, inan emergency it is permissible to clean the main filter if youobserve the following practices.

• Never immerse the filter in water since dirt can betransferred to the clean air side of the filter.

• If compressed air is used never exceed a pressure of 40PSI. Always use a dispersion type nozzle to preventfilter damage and clean from the inside to the outside.

• Replace the air filter every 50 hours, and possibly moreoften in very dirty conditions.

Air Filter / Pre-Filter Service

It is recommended that the air filter and pre filter be replacedannually. When riding in extremely dusty conditions,replacement is required more often.

The pre filter should be cleaned before each ride using thefollowing procedure:

1. Lift up on the rear of the seat.

2. Pull the seat back and free of the tabs. NOTE: Whenreinstalling seat, make sure the slots in the seat engage thetabs in the fuel tank.

3. Remove clips from air box cover (A) and remove cover.Inspect the gasket (E). It should adhere tightly to the coverand seal all the way around.

Drain Screw

Drain Tube attached here

Fuel Valve

OFF RES

ON

A

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4. Loosen clamp and remove air filter assembly (B & C).

Cleaning:

5. Slip the pre-filter element (C) off of main element. Cleanthe pre filter with hot soapy water.

6. Rinse and dry thoroughly.

7. Inspect element for tears or damage.

8. Inspect main filter and replace if necessary. If the filter hasbeen soaked with fuel or oil it must be replaced.

Installation:

9. Reinstall pre-filter element over main filter. Be sure theelement covers entire surface of main filter without folds,creases, or gaps.

10. Reinstall filter on main filter mount. Place filter clamp overthe assembly and tighten.

NOTE: Apply a small amount of general purposegrease to the sealing edges of the filter beforereinstalling.

NOTE: The air filter should rest on the filter support.Proper placement of the air filter is important toprevent rattles and air leaks. See Illustration above.

11. Install air box cover and secure with clips.

Air Box Sediment Tube

Periodically check the air box drain tube located toward the rearof the machine. Drain whenever deposits are visible in the cleartube.

NOTE: The sediment tube will require more frequentservice if the vehicle is operated in wet conditions orat high throttle openings for extended periods.

1. Remove drain plug from end of sediment tube.

2. Drain Tube.

3. Reinstall drain plug.

III.1

A

B

C

E

Rear

Air Box

FilterSupport

Main Filter

Proper Filter Placement

Sediment Tube

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MAINTENANCE

ENGINE/TRANSMISSION/REAR GEARCASE

Engine Oil Level

To check the oil level:

1. Set machine on a level surface.

2. Start and run engine for 20-30 seconds. This will return oilto its true level in the engine sump.

3. Stop engine and check oil level sight glass.

4. Check to see that the oil level is in the ’normal’ range. Thelevel should be, at minimum, halfway between to the topof the viewing area. Add oil as needed to reach the indicatedlevel shown. Do not overfill.

NOTE: Do not fill the over the normal oil operatingrange. Filling over the normal operating range couldcause a mist of oil to enter the air box.

NOTE: Rising oil level between checks in coolweather driving, can indicate moisture collecting inthe oil reservoir. If the oil level is over the full mark,change the oil.

Engine Oil and Filter Change

1. Place vehicle on a level surface.

2. Clean area around drain plug at bottom of oil pan.

3. Run engine two to three minutes until warm. Stop engine.

4. Place a drain pan beneath oil pan and remove drain plugfrom under the crankcase. CAUTION: Oil may be hot. Donot allow hot oil to come into contact with skin as seriousburns may result.

5. Allow oil to drain completely.

6. Inspect the O-ring on drain plug, replace if needed.NOTE: The sealing surfaces of the drain plug andcrankcase should be clean and free of burrs, nicks orscratches.

7. Reinstall drain plug and torque to specification.

8. The oil filter is located on the right side of the machine.Place drain pan beneath oil filter. Using an oil filter wrench,turn filter counterclockwise to remove.

9. Using a clean dry cloth, clean filter sealing surface oncrankcase.

10. Lubricate O-ring on new filter with a film of engine oil.Check to make sure the O-ring is in good condition.

=

Recommended Engine Oil:Polaris Premium Synthetic OW-50 (PN 2874865)

NORMAL

Crankcase Drain

Engine Oil Drain Plug - Bottom View

Oil Filter

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11. Install new oil filter and turn by hand until filter gasketcontacts the sealing surface, then turn and additional 1/2turn.

NOTE: The sealing surfaces on the drain plug andcrankcase should be clean and free of burrs, nicksor scratches.

12. Remove oil cap and fill with Polaris Premium 0W-50Synthetic Oil (PN 2874865).

13. Place gear selector in neutral and set parking brake.

14. Start the engine and let it idle for one to two minutes. Stopthe engine and inspect for leaks.

15. Re-check the oil level and add oil as necessary to bring thelevel to the upper level.

16. Dispose of used filter and oil properly.

Compression Test

NOTE: This 4-Stroke engine is equipped with anautomatic decompressor. Compression readingswill vary in proportion to cranking speed during thetest. Average compression (measured) is about 160-190 psi during a compression test.

Smooth idle generally indicates good compression. Low enginecompression is rarely a factor in running condition problemsabove idle speed. Abnormally high compression can be causedby a decompressor malfunction, or worn or damaged exhaust

cam lobes. Inspect camshaft and automatic decompressionmechanism if compression is abnormally high.

A cylinder leakage test is the best indication of engine conditionon models with automatic decompression. Follow testermanufacturer’s instructions to perform a cylinder leakage test.(Never use high pressure leakage testers as crankshaft seals maydislodge and leak).

Valve Clearance Adjustment

INTAKE VALVE CLEARANCE:

1. Verify cam lobes are pointed down.

2. Insert a .003” (.07mm) feeler gauge between end of intakevalve stem and adjuster screw.

3. When clearance is correct, hold adjuster screw and tightenlocknut securely.

4. Re-check the valve clearance.

5. Repeat adjustment procedure if necessary until clearance iscorrect with locknut secured.

= T

Crankcase Drain Plug Torque: 14 ft. lbs. (19 Nm)

Oil Filter Torque: Install by hand until filter gasket contacts

sealing surface, then turn an additional 1/2 turn.

NORMAL

Cylinder Compression Standard: 160-190 PSI

Cylinder Leakage Service Limit: 10%

(Inspect for cause if leakage exceeds 10%)

= In. / mm.

INTAKE / EXHAUST VALVE CLEARANCE.003” (.07 mm)

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EXHAUST VALVE CLEARANCE

1. Verify cam lobes are pointed down.

2. Insert an .003” (.07mm) feeler gauge between end ofexhaust valve stem and adjuster screw.

3. Loosen locknut and turn adjuster screw until there is a slightdrag on feeler gauge.

4. When clearance is correct, hold adjuster screw and tightenlocknut securely.

5. Re-check the valve clearance.

6. Repeat adjustment procedure if necessary until clearance iscorrect with locknut secured.

Engine Mounts

Inspect rubber engine mounts for cracks or damage.

Engine Fastener Torque

Check engine fasteners and ensure they are tight.

Kickstart Lever and Operation

If the battery becomes too weak to start the engine, use the kick-start lever to start the engine until the battery is serviced.

The kickstart lever is located under the left rear fender. It isbolted to the frame.

Kickstart Installation

NOTE: If not installed, make sure the rubber cap isinstalled on the kick-start shaft to protect the rider.

1. Remove the rubber plug covering the kick shaft.

2. Remove the kickstart lever from the frame and attach it tothe kick shaft located on front portion of the CVT cover.

3. Position the vehicle on a level surface.

4. Lock the parking brake. Place the transmission in neutral.

5. Verify the stop switch and main key switch are on.

6. Fold out the kick-start lever on the left side of the ATV.

7. Place your foot on the kick-start. Thrust your heeldownward to crank the engine.

NOTE: If the engine is cold, use the choke to assistin starting.

8. After the engine has started, fold the kick-start lever backinto place.

Exhaust Cleaning

The exhaust pipe must be periodically purged of accumulatedcarbon as follows:

1. Remove the three screws (A) and remove the arrestor fromthe end of the muffler.

WARNING

Do not perform clean out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result

from contact with exhaust components.To reduce fire hazard, make sure that there are

no combustible materials in the area when purging the spark arrestor.

Wear eye protection.Do not stand behind or in front of the vehicle

while purging the carbon from the spark arrestor.

Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas. Do not go under the machine while it is inclined. Set the hand brake and block the

wheels to prevent roll back. Failure to heed these warnings could result in serious

personal injury or death.

A

Arrestor

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2. Use a non-synthetic brush to clean the arrestor screen. Asynthetic brush may melt if components are warm. Ifnecessary, blow debris from the screen with compressedair.

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

4. Remove and inspect the gasket. Replace if worn ordamaged.

5. Reinstall the gasket and arrestor.

6. Use a wire brush to clean the arrestor screen. (NOTE: Asynthetic brush may melt if components are warm.) Ifnecessary, blow debris from the screen with compressedair.

7. Reinstall the clean out plug and arrestor.

8. Torque screws to 50 in. lbs. (5.6 Nm).

CVT Drain Plug / Drying

NOTE: If operating the ATV through water, be sureto check the CVT and other components for wateringestion. The ATV should be checked immediately.

1. To release any water that maybe trapped in the CVT cover,remove the CVT drain plug and O-ring located on thebottom of the CVT cover. Reinstall the drain plug andtighten sufficiently after draining.

2. To further expel water from the cover and to dry out theCVT system, shift the transmission to neutral and revengine slightly to expel the moisture and air-dry the belt andclutches. Allow engine RPM to settle to idle speed, shifttransmission to lowest available range and test for beltslippage. Operate ATV in lowest available range for a shortperiod of time until CVT system is dry.

Transmission Lubrication

The transmission lubricant level should be checked and changedin accordance with the maintenance schedule.

• Be sure vehicle is level before proceeding.

• Check vent hose to be sure it is routed properly andunobstructed.

To change / check transmission fluid:

1. Place a drain pan beneath oil pan and remove drain plugfrom the crankcase. Allow oil to drain completely.

2. Reinstall the drain plug. Tighten to specification.

=

Specified Lubricant:Polaris AGL Gearcase Lubricant:

(PN 2873603) Gallon (PN 2873602) 12 oz.Capacity:

Add as required to ‘normal’ operating range

= T

Drain Plug Torque: 18 ft. lbs. (24 Nm)

Transmission DrainRear

Front

Transmission Drain Plug - Bottom View

TransmissionDrain

Hex Plug - Shift Detent

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3. Add the proper amount of lubricant to bring level intooperating range as shown.

4. Verify fluid level is correct and no leaks are present.

Shift Cable Inspection and Adjustment

NOTE: Shift cable adjustment can be done at thetransmission or the shifter. Middle cable adjustmentis usually not required.

1. Inspect shift cable ends, cable jackets and pivot bushings.Replace if worn, damaged or if cables can no longer beadjusted. Lubrication of all pivot points with a light aerosollubricant or grease is recommended.

2. With the tranmission in neutral, loosen both cable lock nutsand adjust cable tension evenly on both cables as needed.Adjust cables only enough to remove cable slack or “loosefeeling” in the shift handle. Cables that are too tight willbind and create difficult shifting.

3. After adjusting the cable tension, verify the shift handle iscentered in the middle of it’s travel range when in neutral.Check shift function and tighten all lock nuts sufficientlyonce desired tension has been achieved.

Rear Gearcase Lubrication

The rear gearcase lubricant level should be checked andchanged in accordance with the maintenance schedule.

• Be sure vehicle is level before proceeding.

• Check vent hose to be sure it is routed properly andunobstructed.

Lubricant Level Check

1. Position the ATV on a level surface.

NORMAL

=

Specified Lubricant: Polaris ATV Angle Drive Fluid:

(PN 2872276) 2.5 gallon (PN 2871653) 8 oz.

Capacity: 3.38 oz. (100 ml)

= T

Drain/ Check Plug Torque:18 ft. lbs. (24 Nm)

Fill Plug Torque:

25 Ft. lbs. (34 Nm)

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2. Collapse the suspension with an adjustable (buckle type)trailer tie down strap (A). Fasten the strap around the axleand rear bumper tube.

3. Tighten the strap (A) until the rear bumper reaches 25”(63.5 cm) from the level ground (see Pic. 1).

4. To check the gearcase fluid level, use a light colored andnon-absorbent measuring instrument (i.e. white zip tie)approximately 6” (15.24 cm) long or longer.

5. Measure 5.5” (13.97 cm) on the measuring instrument andmark this spot on the measuring instrument (see Pic. 2).

6. Remove the top fill plug (B) from the top of the gearcase.

7. Vertically lower the measuring instrument into the fill plughole until the mark on the measuring instrument reaches thetop of the fill plug hole.

8. Pull the measuring instrument from the hole and read thelevel, following guidelines A, B, and C:

A: If fluid is present on the bottom tip of the measuringinstrument, the fluid level is to specification.

B: If there is no fluid present on the measuring instrument, add1 oz. (29.57 ml) of the recommended fluid and re-check the

level. Keep adding fluid until there is fluid present on the bottomtip of the measuring instrument.

C: If fluid level is more than 0.25” (6.35 mm) beyond the tipof the measuring instrument, a portion of the fluid will need tobe drained and the level re-checked, following the ‘A’ and ‘B’procedures of step 8.

9. Reinstall the fill plug (B). Torque to specification.

10. Check for leaks.

Lubricant Level Check / Change

NOTE: This is a drain and fill procedure. To completelydrain the rear gearcase, it must be allowed to drain over a15 minute period to ensure all fluid is drained from thegearcase.

1. Position the ATV on a level surface.

2. Place a suitable container under the rear gearcase.

3. Remove the drain plug (C) and drain lubricant intocontainer.

4. Let the rear gearcase drain over 15 minutes to ensure thatmost of the fluid has drained. Discard of the used oilproperly.

5. Clean and reinstall the drain plug (C) with a new sealingwasher. Torque to specification.

6. Remove the fill plug (B) and add the pre-measured amountof Polaris Angle Drive Fluid.

7. Reinstall the fill plug (B). Torque to specification.

8. Check for leaks.

25 ft. lbs. (34 Nm)

B

C

A

18 ft. lbs. (24 Nm)

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ELECTRICAL AND IGNITION SYSTEM

Battery Maintenance

NOTE: All Phoenix batteries are Low Maintenancedesign and construction. All Low Maintenancebatteries are fully charged and tested at the factorybefore installation. Expected shelf life is 6-8 monthsdepending on storage conditions. As a general rulebefore placing the battery into service, check thebattery condition and charge accordingly.

Low Maintenance batteries are permanently sealed at the time ofmanufacture. The use of lead-calcium and AGM technologyinstead of lead-antimony allows the battery acid to be fullyabsorbed. For this reason, a Low Maintenance battery case isdark and the cell caps are not removable, since there is no needto check electrolyte level.

NEVER attempt to add electrolyte or water to a LowMaintenance battery. Doing so will damage the case and shortenthe life of the battery.

The battery is located under the seat.

To remove the battery:

1. Disconnect holder strap.

2. Disconnect battery negative (-) (black) cable first, followedby the positive (+) (red) cable.

3. Remove the battery.

4. Clean battery cables and terminals with a stiff wire brush.Corrosion can be removed using a solution of one cup waterand one tablespoon baking soda. Rinse well with cleanwater and dry thoroughly.

5. Reinstall battery, attaching positive (+) (red) cable first andthen the negative (-) (black) cable.

6. Coat terminals and bolt threads with Dielectric Grease (PN2871329).

7. Reinstall battery cover and holder strap.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from

contact with skin, eyes or clothing. Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or

vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space.

Always shield eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

CAUTION

To reduce the chance of sparks: Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the

battery, install the negative cable last.

Battery

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Spark Plug

1. Remove spark plug high tension lead. Clean plug area sono dirt and debris can fall into engine when plug isremoved.

2. Remove spark plug.

3. Inspect electrodes for wear and carbon buildup. Look for asharp outer edge with no rounding or erosion of theelectrodes.

4. Clean with electrical contact cleaner or a glass bead sparkplug cleaner only. CAUTION: A wire brush or coatedabrasive should not be used.

5. Measure gap with a wire gauge. Refer to specifications forproper spark plug type and gap. Adjust gap if necessary bybending the side electrode carefully.

6. If necessary, replace spark plug with proper type.CAUTION: Severe engine damage may occur if theincorrect spark plug is used.

7. Apply a small amount of anti-seize compound to the sparkplug threads.

8. Install spark plug and torque to specification.

Ignition Timing

Timing is CDI controlled and has no adjustment procedure.

Engine / Frame Ground

Inspect engine-to-frame ground cable connection. Be sure it isclean and tight.

STEERING AND SUSPENSION

Steering

The steering components should be checked periodically forloose fasteners, worn tie rod ends, and damage. Also check tomake sure all cotter pins are in place. If cotter pins are removed,they must not be re-used. Always use new cotter pins.

Replace any worn or damaged steering components. Steeringshould move freely through entire range of travel withoutbinding. Check routing of all cables, hoses, and wiring to be surethe steering mechanism is not restricted or limited.

NOTE: Whenever steering components are replaced,check front end alignment. Use only genuine Polaris parts.

Recommended Spark Plug:

NGK CR6HSA

Spark Plug Torque: 9-11 Ft. Lbs. (12 - 14 Nm)

Inspect electrode for wear and buildup

Spark Plug Gap

Ignition Timing:

32° + 2° BTDC@3000RPM

WARNING

Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris Dealer.

Only a qualified technician should replace worn or damaged steering parts. Use only genuine

Polaris replacement parts.

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One of two methods can be used to measure toe alignment: Thestring method and the chalk method. If adjustment is required,refer to following pages for procedure.

Tie Rod End / Steering Inspection

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

• Repeat inspection for inner tie rod end (on steeringpost).

• Replace any worn steering components. Steering shouldmove freely through entire range of travel withoutbinding.

• Elevate front end of machine so front wheels are off theground. Check for any looseness in front hub / wheelassembly by grasping the tire firmly at top and bottomfirst, and then at front and rear. Try to move the wheeland hub by pushing inward and pulling outward.

• If abnormal movement is detected, inspect the hub andwheel assembly to determine the cause.

Camber and Caster

The camber and caster are non-adjustable.

Toe Alignment

1. Place machine on a smooth level surface.

2. Set handlebars in a straight ahead position and securehandlebars in this position. NOTE: The steering arm can beused as an indicator of whether the handlebars are straight.The arm should always point straight back from the steeringpost.

3. Place a chalk mark on the center line of the front tiresapproximately 10” (25.4 cm) from the floor or as close tothe hub/axle center line as possible. NOTE: It is importantthat the height of both marks be equally positioned in orderto get an accurate measurement.

4. Measure the distance between the marks and record themeasurement. Call this measurement “A”.

5. Rotate the tires 180° by moving vehicle forward orbackward. Position chalk marks facing rearward, even withthe hub/axle centerline.

6. Again measure the distance between the marks and record.Call this measurement “B”. Subtract measurement “B”from measurement “A”. The difference betweenmeasurements “A” and “B” is the vehicle toe-outalignment. This means that measurement (A) is wider than

Check for Loose Wheel or Hub

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the measurement at the rear (B).

Toe Alignment Adjustment

If toe alignment is incorrect, measure the distance betweenvehicle center and each wheel. This will tell you which tie rodneeds adjusting. NOTE: Be sure handlebars are straight aheadbefore determining which tie rod(s) need adjustment.

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both end of the tie rod.

• Shorten or lengthen the tie rod until alignment is asrequired to achieve the proper toe setting - (1/8” to 1/4”).

• Important: When tightening the tie rod end jam nuts,the rod ends must be held parallel to prevent rod enddamage and premature wear. Damage may not be

immediately apparent if done incorrectly. Seeillustration.

Front / Rear Suspension Spring Preload Adjustment

Operator weight and vehicle loading affect suspension springpreload requirements. Using Spanner Wrench (PN 2870872)adjust as necessary to avoid bottoming of the shocks.

Front Suspension Inspection

Compress and release front suspension. Damping should besmooth throughout the range of travel.

Check all front suspension components for wear or damage.

Inspect front shocks for leakage.

Rear Suspension Inspection

Compress and release rear suspension. Damping should besmooth throughout the range of travel.

• Check all rear suspension components for wear ordamage.

= In. / mm.

Wheel Toe-out Alignment: 1/8” to 1/4” (.3 to.6 cm)

CAUTION

During tie rod adjustment, it is very important that the following precautions be taken when tightening tie rod end jam nuts. If the rod end is positioned

incorrectly it will not pivot and may break

Measurement “B” Chalk Line

Measurement “A”

Shock Spanner Wrench

(PN 2870872)

HoldRod End

CorrectlyTightenedJam Nut

Incorrectly

TightenedJam Nut

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• Inspect shock for leakage.

BRAKE SYSTEM

Brake System Inspection

The following checks are recommended to keep the brakesystem in good operating condition. Service life of brake systemcomponents depends on operating conditions. Inspect brakes inaccordance with the maintenance schedule and before each ride.

• Keep fluid level in the master cylinder reservoir to theindicated level inside reservoir.

• Use Polaris DOT 3 Brake Fluid (PN 2870990)

• Check brake system for fluid leaks, excessive travel orspongy feel.

• Check friction pads for wear, damage or looseness.

• Check surface condition of the disc.

• Inspect thickness of brake pad friction material.

Front Brake Pad Inspection

Front brake pads should be changed when friction material isworn to the service limit. Refer to Chapter 6 for service.

Rear brake shoes should be changed when friction material isworn to the service limit. Refer to Chapter 6 for service.

Hose / Fitting Inspection

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

Shock Spanner Wrench

(PN 2870872)

= In. / mm.

Brake Pad Service Limit: FRONT - .180” (4.6 mm)

REAR - .080” (2 mm)

Front Brake Pads

Brake Pad MeasureThickness

Rear Brake Shoes

MeasureThickness

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Rear Brake Adjustments

Rear Hand Brake Lever

1. Check the brake cable, lever, and foot brake for looseconnections, free play, and damage.

2. Measure the rear park brake lever freeplay. Freeplay shouldbe 0.40-0.80 in. (10-20 mm).

If excessive free play exists, adjust the lower adjusting nut asneeded.

NOTE: To lubricate the cable pivot points, use acommercially available cable lubricant.

Rear Foot Brake

1. Check foot brake effectiveness by applying approximately50 lb. (23 kg) downward force on the pedal. Themeasurement taken at the top of the pedal should compareto the specification.

2. If less than the specification, two things must be examined:

• Free play of the brake pedal should be 1/8 - 1/4 inch(3.2 - 6.35 mm).

• If free play is excessive: adjust the upper adjuster nut,inspect pedal, linkage springs, and cable for wear ordamage and replace any parts as needed.

Rear Brake Adjustment

1. Position the vehicle on a level surface.

2. Block the front wheels.

3. Place the transmission in neutral.

4. Using suitable stands, elevate the rear of the vehicle so therear wheels are slightly off the ground.

5. Slowly tighten the hand brake wing nut (A) while rotatingthe rear wheels with your hand. When you begin to feelresistance (drag) in the wheel rotation, loosen the wing nutone full turn.

6. Slowly tighten the foot brake wing nut (B) until the footbrake lever arm begins to move. Loosen the wing nut 1/2turn so it doesn’t influence the hand brake adjustment.

7. Test the hand brake and the foot brake for proper operation.

= In. / mm.

Rear Brake Lever Travel Limit: Footbrake- 1.0” (25.4 mm) w/50 ft. lb (23kg) force

LH Brake Lever Free Play

.40” - .80”(10-20 mm)

Rear Brake

50 lbs

Floorboard

Foot Brake-Upper

Front Brake Lever-Lower

A

B

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Rear Brake Lever Travel

1. Service the rear brakes when brake lever travel reaches thespecified travel limit. Always service the brakes whenthere is no longer sufficient stopping ability at the specifiedlever travel setting.

Controls

Check controls for proper operation, positioning andadjustment.

• Brake control and switch must be positioned to allowbrake lever to travel throughout entire range withoutcontacting switch body.

WHEELS AND TIRES

Wheels

Inspect all wheels for runout or damage. Check wheel nuts andensure they are tight. Do not over tighten the wheel nuts.

Wheel, Hub, and Spindle Torque Table

Wheel Removal - Front / Rear

1. Stop the engine, place the transmission in gear and lock theparking brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a suitable standunder the footrest frame.

4. Remove the wheel nuts and remove the wheel.

= In. / mm.

LH Rear Brake Lever Travel Limit: 2.5” (65 mm)

Brake Lever Travel

2 1/2”(65 mm)

Item Specification

Front Wheel Nuts 30 Ft. Lbs. (41 Nm)

Rear Wheel Nuts 30 Ft. Lbs. (41 Nm)

Front Spindle Nut 40 Ft. Lbs. (54 Nm)

Rear Hub Retaining Nut 80 Ft. Lbs. (108 Nm)

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Wheel Installation - Front / Rear

1. With the transmission in gear and the parking brakelocked, place the wheel in the correct position on the wheelhub. Be sure the valve stem is toward the outside androtation arrows on the tire point toward forward rotation.

2. Attach the wheel nuts and finger tighten them.

3. Lower the vehicle to the ground.

4. Securely tighten the wheel nuts to the proper torque listedin the table.

Tire Pressure

Tire Inspection

TIRE TREAD DEPTH

Always replace tires when tread depth is at the service limit .

CAUTION

If wheels are improperly installed it could affect vehicle handling and tire wear. Be sure to properly torque and install all wheel nuts.

Front Wheel

Front Spindle Nut40 ft. lbs. (54 Nm)

CotterKey

Washers

Front Wheel Nuts(4)30 ft. lbs. (41 Nm)

Rear Wheel

Rear Wheel Nuts (4) 30 ft. lbs. (41 Nm)

CotterKey

Rear Hub Nut80 ft. lbs. (108 Nm)

Tire Pressure Inspection (PSI - Cold)

Front Rear

4 3

WARNING

Operating an ATV with worn tires will increase the possibility of the vehicle skidding and

possible loss of control.

Worn tires can cause an accident.

Always replace tires when the tread depth measures 1/8” (.3 cm) or less.

CAUTION

Maintain proper tire pressure. Refer to the tire pressure warning decal applied to the vehicle.

Improper tire inflation may affect ATV maneuverability.

When replacing a tire always use original equipment size and type.

The use of non-standard size or type tires may affect ATV handling.

= In. / mm.

Minimum Tire Tread Depth: 1/8” (3 mm)

TreadDepth 1/8” (3 mm)Par

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CHAPTER 3

ENGINE

3

ENGINE

TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5ENGINE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7OIL FLOW DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8PISTON IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9ENGINE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10OIL FLOW TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10ENGINE BREATHER / OIL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

TOP-END DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11ROCKER ARM SHAFT DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . 3.12CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20CAM CHAIN FOLLOWER / TENSIONER BLADES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21CYLINDER HONE SELECTION / HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 3.22HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23

BOTTOM-END DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24STARTER DRIVE GEAR REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 3.24FLYWHEEL REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24STARTER DRIVE ONE-WAY CLUTCH REMOVAL AND INSPECTION . . . . . . . . . . . . 3.25CRANKSHAFT DRIVE SPROCKET REMOVAL AND INSPECTION. . . . . . . . . . . . . . . 3.25BALANCE SHAFT SPROCKET REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . 3.26OIL PUMP REMOVAL / DRIVE CHAIN INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

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ENGINE

CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27CRANKCASE SEPARATION AND CAM CHAIN REMOVAL. . . . . . . . . . . . . . . . . . . . . 3.27CRANKSHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . 3.28CRANKCASE / BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29CRANKCASE OIL STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29

ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29BEARING / SEAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29BALANCE SHAFT AND CRANKSHAFT GEAR INSTALLATION . . . . . . . . . . . . . . . . . 3.30OIL PUMP AND CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32TENSIONER BLADE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33CYLINDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33CYLINDER HEAD AND CAMSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 3.34CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34CAMSHAFT TIMING - METHOD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36CAMSHAFT TIMING - METHOD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37ROCKER ARM / SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38CAM CHAIN TENSIONER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38INTAKE VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39STARTER DRIVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39STATOR HOUSING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39OIL FILTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40SPARK PLUG FOULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40

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ENGINE

3

TOOLS

Special Tools

TORQUE SPECIFICATIONS

Engine Torque Specifications

PART NUMBER TOOL DESCRIPTION

2200634Valve Seat

Reconditioning Kit

2870390 Piston Support Block

PA-47308 Flywheel Puller

PA-47309Transmission Output

Shaft Collar Tool

PA-47344Balance Shaft Slotted

Nut Socket

2871293-BCrankshaft Slotted Nut

Socket

TORQUE SPECIFICATIONS

FastenerThread

SizeES20PFE

Ft. Lbs. (Nm)

Camshaft Chain Tensioner Lever

6mm 5-6.5 (7-9 Nm)

Camshaft Chain Tensioner

6mm 5-6.5 (7-9 Nm)

Camshaft Chain Tensioner Cap

6mm 5-6.5 (7-9 Nm)

Carburetor Adaptor

8mm 12-14 (16-20 Nm)

Cylinder/Head Nuts 10mm 13-16 (18-22 Nm)

Cylinder/Head Bolts 6mm 5-7 (7-9 Nm)

Crankcase 8mm 14-15 (19-21 Nm)

Crank Sprocket Slotted Nut

25mm 72 (98 Nm)

Balancer Sprocket Slotted Nut

14mm 43 (59 Nm)

Flywheel Nut 14mm 58-72 (78-98 Nm)

Oil Drain Bolt (Crankcase)

14mm 14-17 (19-23 Nm)

Oil Pump Screws

6mm 4-5 (5-7 Nm)

Oil Pump Drive Gear Nut

6mm 5-7 (7-9 Nm)

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

Pulse Coil Assembly

5mm 5-6.5 (7-9 Nm)

Stator Housing 6mm 5-6.5 (7-9 Nm)

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

Rocker Adjuster Screw Lock Nut

5mm 4-5 (5-7 Nm)

Rocker shaft plate nut 6mm 4-5 (5-7 Nm)

Stator Screws 5mm 5-6.5 (7-9 Nm)

Starter Motor 6mm 5-6.5 (7-9 Nm)

Spark Plug 12mm 9-11 (12-15 Nm)

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ENGINE

Torque Patterns

Tighten cylinder head, cylinder base, and crankcase fasteners in 3 steps following the sequence outlined.

2

4

5

6

1

6 mm

Cylinder Base / Head and Rocker Arm Assembly

1

2

3

4

5

6

7

8

9

10

11

RH Crankcase - Stator Cover

1

2

RH Crankcase - Inner Cover

3

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ENGINE

3

GENERAL ENGINE SERVICE

Engine Exploded View

Crankshaft

Cylinder /

and Piston

Cylinder HeadCrankcase

Valve Train

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ENGINE

Engine Service Data

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

Cylinder Head / Valvetrain ES20PFE

Rocker Arm/ShaftRocker arm ID .3936 - .4007" (10.00 - 10.18 mm)

Rocker shaft OD .3925 - .3931" (9.972 - 9.987 mm)

Camshaft Cam lobe height

InStd 1.1730" (29.795 mm)

Limit 1.1574" (29.40 mm)

ExStd 1.1637" (29.56 mm)

Limit 1.1480" (29.16 mm)

Cylinder Head Surface warpage limit .0020” (.05 mm)

Valve ClearanceIn Std .003" (.07 mm)

Ex Std .003" (.07 mm)

Valve Seat Angle Contacting width

InStd .039" (1.0 mm)

Limit .063" (1.6 mm)

ExStd .039" (1.0 mm)

Limit .063" (1.6 mm)

Valve Stem diameter

In .1958 - .1960" (4.975 - 4.980 mm)

Ex .1950 - .1956" (4.955 - 4.970 mm)

Limit .1921" (4.9 mm)

Valve Guide Inner Diameter

In .1968 - .1973" (5.0 - 5.012 mm)

Ex .1968 - .1973" (5.0 - 5.012 mm)

Limit .1980" (5.03 mm)

Valve SpringFree Length

Inner 1.271" (32.3 mm)

Outer 1.377" (35.0 mm)

Squareness 0.075” (1.9 mm)

Cam Chain Install new as a part of any crankshaft removal

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ENGINE

3

ENGINE SERVICE DATA

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

Cylinder / Piston / Connecting Rod ES20PFE

Cylinder

Surface warpage limit (mating with cylinder head) .002” (0.05 mm)

Cylinder bore Std 2.5590 - 2.5594" (65 - 65.01 mm)

Taper limit .002” (0.05 mm)

Out of round limit .002” (0.05 mm)

Piston to cylinder clearanceStd .00078 - .002" (0.02 - 0.05 mm)

Limit .0039" (0.1 mm)

Boring Limit 1st O.S. + .0098” (.25 mm)2nd O.S. + .0197” (.50 mm)

PistonOuter diameter

Std 2.5574 - 2.5582" (64.96 - 64.98 mm)

1st O.S. .0098" (.25 mm) Oversize

2nd O.S. .0197" (.50 mm) Oversize

Pin Bore - Inner Diameter .6298 - .6299" (15.997 - 16.0 mm)

Piston Pin

Pin outer diameter clearance in piston .00015 - .00047” (.004 - .012 mm)

Degree of fit Piston Pin must be a push (by hand) fit at 68° F (20° C)

Piston Ring Piston Ring Installed gap

Top ringStd .0039 - .0098" (.1 - .25 mm)

Limit .0196" (0.5 mm)

Second ring

Std .0138 - .0197" (0.3 - 0.45 mm)

Limit .0196" (0.5mm)

Oil ringStd .0079 - .0275" (0.2 - 0.7 mm)

Limit .059" (1.5 mm)

Piston Ring Standard clearance - piston ring to ring groove

Top ringStd .00078 - .0023" (0.02. - 06 mm)

Limit .0035" (0.09 mm)

Second ring

Std .00078 - .0023" (0.02 - 0.06 mm)

Limit .0035" (0.09 mm)

Connecting Rod

Connecting rod small end ID .6303 - .6310” (16.01 - 16.028 mm)

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

Connecting rod big end radial clearance Std n/a

CrankshaftCrankshaft end runout 0.0015" (0.04 mm)

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

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ENGINE

Oil Flow Diagram

CamSprocket/Chain

Intake Rocker Arm/ Rocker Shaft/

Chain Room

Oil Passage In Cylinder

Through Right Cylinder Head Bolt Passage

Piston

Connecting Rod

Cylinder SleeveCrankcase Oil Passage

CrankcaseOil Pressure

Fitting Location

CrankcaseOil Passage

Oil Filter

CrankcaseOil Passage

Engine Sump

Oil Pickup Screen

Oil Pump

Balance Shaft

Main BearingMain Bearing

Crankshaft

PTO MAG

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ENGINE

3

Piston Identification

The piston may have or may not have an identification mark forpiston placement. If the piston has an identification mark, followthe directions for piston placement below. If the piston does nothave an identification mark, the direction for placement of thepiston does not matter.

Note the directional and identification marks when viewing thepistons from the top. The letters “IN” must always be toward theintake side of the engine. The other numbers are used foridentification as to diameter, length and design. Four strokeengine rings are rectangular profile. The numbers or letters onall rings (except oil control rings) must be positioned upward.See text for oil control ring upper rail installation. Use theinformation below to identify pistons and rings.

Accessible Components

The following components can be serviced or removed with theengine installed in the frame:

• Flywheel

• Alternator/Stator

• Starter Motor/Starter Drive

• Oil pump

• Rocker Arms

• Carburetor

• Transmission

The following components require engine removal for service:

• Cam Chain and Sprockets

• Cylinder Head

• Cylinder

• Piston/RIngs

• Camshaft

• Crankshaft

• Crankshaft Main Bearings

• Crankcase

• Transmission

• Valves

NOTE: Cam chain service requires crankshaftremoval, as the chain is located on the pto side ofthe engine.

NOTE: Crankshaft components are not serviceable.Replace crankshaft as an assembly.

ENGINE SERVICE

Engine Removal

1. Clean work area.

2. Thoroughly clean the ATV engine and chassis.

3. Disconnect battery cables.

4. Drain engine oil.

5. Disconnect spark plug high tension lead.

6. Disconnect all electrical wires from the engine.

7. Remove the following parts as required.

• Seat• Left and Right Side Covers (Refer to Chapter 5)• Fuel Tank Cover / Front Cab (Refer to Chapter 5)• Fuel Tank (Refer to Chapter 4)

8. Remove exhaust pipe.

9. Remove airbox.

10. Remove carburetor. Insert a clean shop towel into thecarburetor flange to prevent dirt from entering the intakeport.

11. Starter motor. Note ground cable location. Mark positive(+) cable mounting angle and remove cable.

12. Remove transmission link rod(s) from gear selector andsecure out of the way.

13. Remove engine to chassis ground cable.

14. Refer to Chapter 7 to remove the swing arm and drive shaftassemblies.

15. Remove all engine mount nuts and / or engine mount plates.

16. Remove engine through left side of frame.

Engine Installation Notes

After the engine is installed in the frame, review this checklistand perform all steps that apply:

Engine Model No.

Oversize Available (mm)

Standard Piston Identification

ES20PFE.25mm.50mm

”IN” marking on top of piston

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3.9

ENGINE

General Items

• Install previously removed components using newgaskets, seals, and fasteners where applicable.

• Perform checks on fluid levels, controls, and allimportant areas on the vehicle as outlined in the dailypre-ride inspection checklist (refer to Chapter 2).

CVT System

• Clean clutch sheaves thoroughly and inspect inlet andoutlet ducts for proper routing and sealing.

• Inspect clutch rollers, shoes and springs beforereassembly

Transmission

• Inspect transmission operation and adjust linkage ifnecessary.

Exhaust

• Replace exhaust gaskets. Seal connections if desiredwith high temp sealant.

• After running the engine, verify all bolted exhaustconnections are tight and in good condition.

Engine Mount Torque

• Front Mount

• Rear Mounts

Engine Break In Period

4 Cycle Engine Break-In Period is defined as the first 10 hoursof engine operation or 2 full tanks of fuel.

• Use only Polaris Premium 4 All Season Synthetic Oil,or API certified “SH” oil.

• Use fuel with a minimum octane of 87 (R+M)/2method.

• Change break-in oil and filter at 20 hours or 100 miles,whichever comes first.

Engine Lubrication

Oil Type:Polaris Premium 0W-50 Synthetic(PN 2874865)

Capacity:Approximately 1.26 U.S. Quarts (1.2 l)

Drain Plug / Screen Fitting:14 ft. lbs. (19 Nm)

Oil Pressure Specification: Continuous oil flow at Idle RPM.

Oil Flow Test

NOTE: Due to the engine assembly having amajority of roller bearings, oil pressure readings hotor cold will be very low. Low oil pressure is not anindication of a oil delivery problem.

1. Remove center plug from the stator housing on thecrankcase. See Page 3.8.

2. Insert a M6 X 8-1.00 oil pressure gauge adaptor into thecrankcase and attach a low pressure gauge (0-10psi / 0-70kpa).

3. Start engine and allow it to reach operating temperaturewhile monitoring gauge indicator. Any pressure above zerois an indication of good oil flow.

Engine Breather / Oil Separator

The breather / oil separator is located behind the gas tank on theleft side. The breather provides ventilation for the valve coverand crankcase through the air box.

WARNING

Oil temperature can cause serious injury and damage. Wear the proper safety gear when

performing these procedures.

A. Inlet - Air Box C. Vent - Valve CoverB. Outlet - Stator Housing

A

BC

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ENGINE

3

TOP-END DISASSEMBLY

Engine Disassembly

Refer to pages 3.9 - 3.10 for engine removal / installation notes.

Cam Chain Tensioner Removal

1. Remove oil fill cap from the stator housing and valvecover.

To position crankshaft at Top Dead Center (TDC) oncompression stroke:

2. Rotate engine slowly in the direction of rotation watchingintake valves open and start to close.

3. Continue to rotate engine slowly while watching camshaftsprocket marks and the mark in the timing inspection hole.

4. Align single (TDC) mark on flywheel with in the inspectionhole, and the cam sprocket pin (facing upward) aligned withthe camshaft to crankshaft center line. NOTE: The sprocketmarks align with gasket surface, the cam lobes should bepointing down and the valves should have clearance at thispoint.

5. Remove the two cam chain tensioner flange bolts.CAUTION: The plunger is under spring tension. Maintaininward pressure while removing.

6. Tap lightly on tensioner body with a soft face hammer toloosen and remove tensioner if required.

Cam Chain Tensioner Inspection

1. Allow cam chain tensioner plunger to extend outward tothe end of its travel. Inspect tensioner (A) and plunger (B)for wear or damage.

2. Using a small flat blade screwdriver, turn the tensionerclockwise to retract the plunger. The plunger should movesmoothly in and out of the tensioner body.

3. Replace entire tensioner assembly if any part is worn ordamaged.

Single TDC Mark Aligned

TDC Mark

Rotation

B

A

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3.11

ENGINE

Rocker Arm Shaft Disassembly and Inspection

NOTE: Orientation of the components is importantfor reassembly. Mark all components beforedisassembly.

1. Loosen each of the four cylinder head bolts evenly 1/4 turneach time in a cross pattern until loose.

2. Remove bolts (C) and tap the cam support tower with aplastic hammer until loose, then remove.

3. Remove the rocker shaft locking plate.

4. Mark or tag rocker arms and shafts to keep them in orderfor assembly.

5. Inspect each rocker arm cam follower surface. If there isany damage or uneven wear, replace the rocker arm.NOTE: Always inspect camshaft lobe if rocker arms are

worn or damaged.

6. Remove each rocker arm shaft using the 10 mm hex boltthat secures the lock plate. NOTE: Placing the hex bolt ina vise and lightly tapping the rocker assembly with a non-marring hammer may be required to pull stuck rocker armshafts.

7. Measure O.D. of rocker shafts for out-of -round. Inspectthem for wear or damage. Replace if excessive wear isevident. NOTE: Orientation of the rocker shafts isimportant for reassembly. Place only the exhaust rockershaft into the exhaust side of the cam support.

C

Inspect

Exhaust Intake

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8. Measure I.D. of each rocker arm for out-of-round andvisually inspect the I.D. surface. Replace arm if excessivewear is evident.

9. Inspect rocker adjuster screws for wear, pitting, or damageto threads of the adjuster or locknut. Replace all worn ordamaged parts. NOTE: The end of the adjuster is hardenedand cannot be ground or re-faced.

Camshaft Removal

NOTE: Cam chain tensioner must be removedbefore performing this procedure.

1. Remove the 4 cylinder head bolts evenly by looseningeach one 1/4 turn at a time until loose. Tap the rockerassembly with a non-marring hammer to loosen theassembly.

2. Remove the cam chain from the sprocket by tilting the camassembly and simultaneously lifting the chain.

3. If not removing the cylinder for other service, secure thecam chain with a wire to prevent it from falling into thecrankcase.

Camshaft Inspection

1. Inspect cam sprocket teeth for wear or damage. Replace ifnecessary.

2. Inspect the compression release mechanism. This is a one-way rotating shoulder that lifts the exhaust valve slightlyduring start-up. If the one-way mechanism is notfunctioning, replace the cam. Verify the stop bracket andspring is functioning correctly. Replace if excessive wearof components is found.

Exhaust

Inspect for Areas of Tooth Wear or Damage

Compression Release One-Way Operation

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

4. Thoroughly clean the cam shaft.

5. Measure height of each cam lobe using a micrometer.Replace cam if worn below minimum height.

Replace camshaft if damaged or if any part is worn excessively.

Cylinder Head Removal

NOTE: Cam chain and tensioner must be removed. Ifno crankshaft service is being performed, securecam chain with mechanics wire to avoid chain dropinto the crankcase.

1. Loosen each of the four cylinder head bolts evenly 1/4 turneach time in a cross pattern until loose.

2. Remove bolts (C) and tap the cam support tower with aplastic hammer until loose. Remove.

3. After removing the camshaft and securing the cam chain,tap cylinder head lightly with a plastic hammer until loose.CAUTION: Tap only in reinforced areas or on thick partsof cylinder head casting to avoid damaging casting.

4. Remove cylinder head and head gasket.

= In. / mm.

Cam Lobe Height:

IntakeStd: 1.1730” (29.795 mm)Limit: 1.1574” (29.40 mm)

ExhaustStd: 1.1637” (29.56 mm)

Limit: 1.1480” (29.16 mm)

Lobe Height

Bearings

Compression Release-One-way stop

C

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Cylinder Head Inspection

1. Thoroughly clean cylinder head surface to remove alltraces of gasket material and carbon.

Cylinder Head Warp Inspection

1. Lay a straight edge across the surface of the head at severaldifferent points and measure warpage by inserting a feelergauge between the straight edge and the cylinder headsurface. If warpage exceeds the service limit, replace thecylinder head.Milling the

Combustion Chamber Inspection

Clean all accumulated carbon deposits from combustionchamber and valve seat area with a soft wire brush. Inspect thecombustion chamber for cracks and/or damage from foreigndebris.

Cylinder Head Disassembly

NOTE: Keep all parts in order with respect to theirlocation in the cylinder head.

NOTE: Valves have inner and outer springs.

1. Using a valve spring compressor, compress the valvesprings and remove the split keeper. NOTE: To preventloss of tension, do not compress the valve spring more thannecessary.

2. Remove spring retainer and spring.

NOTE: The valve springs should be positioned withthe tightly wound coils against the cylinder head onprogressively wound springs (A).

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

CAUTION

Use care not to damage sealing surface. If there is damage found on the cylinder headcombustion chamber, it is recommended the

component be replaced.

= In. / mm.

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

WARNING

Wear eye protection or a face shield during cylinder head disassembly and reassembly.

A

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4. Measure free length of the inner and outer springs with aVernier caliper, Ill.1. Check spring for squareness asshown in Ill.2. Replace spring if measurements are out ofspecification.

5. Remove valve seals. NOTE: Replace seals whenever thecylinder head is disassembled. Hardened, cracked or wornvalve seals will cause excessive oil consumption andcarbon buildup.

Valve Inspection

1. Remove all carbon from valve with a soft wire wheel.

2. Check valve face for runout, pitting, and burnt spots. Tocheck for bent valve stems, mount valve in a drill or use “V”blocks and use a dial indicator.

3. Check end of valve stem for flaring, pitting, wear or damage(A).

4. Inspect split keeper groove for wear or flaring of the keeperseat area (B). NOTE: The valves cannot be re-faced or endground. Valves must be replaced if worn, bent, or damaged.

5. Measure diameter of valve stem with a micrometer in threeplaces and in two different directions (six measurementstotal). Replace if excessive wear is evident.

Inner Outer

Valve SpringFree Length

III.1

III.2

Coil Fatigue / Squareness

A

B

Measure valve stem in

several places

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6. Measure valve guide inside diameter at the top middle andend of the guide using a small hole gauge and a micrometer.Measure in two directions, front to back and side to side.

7. Subtract valve stem measurement to obtain stem to guideclearance. NOTE: Be sure to measure each guide and valvecombination individually.

8. Replace valve and/or guide if clearance is excessive.

NOTE: If valve guides are replaced, valve seats mustbe reconditioned. Refer to Valve SeatReconditioning 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 conditionsexist, the valve seat must be reconditioned. If the valve seat iscracked the cylinder head must be replaced.

Cylinder Head Reconditioning

NOTE: Servicing the valve guides and valve seatsrequires special tools and a thorough knowledge ofreconditioning techniques.

Follow the manufacturers instructions provided with the valveseat cutters in the Valve Seat Reconditioning Kit (PN 2200634).Abrasive stone seat reconditioning equipment can also be used.Keep valves in order with their respective seat.

NOTE: Valve seat width and point of contact on thevalve face is very important for proper sealing. Thevalve must contact the valve seat over the entirecircumference of the seat, and the seat must be theproper width all the way around. If the seat isuneven, compression leakage will result. If the seatis too wide, seat pressure is reduced, causingcarbon accumulation and possible compressionloss. If the seat is too narrow, heat transfer fromvalve to seat is reduced and the valve may overheatand warp, resulting in burnt valves.

1. Install pilot into valve guide.

2. Apply cutting oil to valve seat and cutter.

TooWide

Uneven Good TooNarrow

CAUTION

Wear eye protection when performing cylinder head service. Valve guide replacement will

require heating of the cylinder head.Wear gloves to prevent burns.

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3. Place 46° cutter on the pilot and make a light cut.

4. Inspect the cut area of the seat.

• If the contact area is less than 75% of the circumferenceof the seat, rotate the pilot 180° and make another lightcut.

• If the cutter now contacts the uncut portion of the seat,check the pilot. Look for burrs, nicks, or runout. If thepilot is bent it must be replaced.

• If the contact area of the cutter is in the same place, thevalve guide is distorted from improper installation andmust be replaced. Be sure the cylinder head is at theproper temperature and replace the guide.

• If the contact area of the initial cut is greater than 75%,continue to cut the seat until all pits are removed and anew seat surface is evident. NOTE: Remove only theamount of material necessary to repair the seat surface.

5. To check the contact area of the seat on the valve face, applya thin coating of Prussian Blue™ paste to the valve seat. Ifusing an interference angle (46°)apply black marker to theentire valve face (A).

6. Insert valve into guide and tap valve lightly into place a fewtimes.

7. Remove valve and check where the Prussian Blue™ orblack marker indicates seat contact on the valve face. Thevalve seat should contact the middle of the valve face orslightly above, and must be the proper width (A).

• If the indicated seat contact is at the top edge of thevalve face and contacts the margin area(B) it is too highon the valve face. Use the 30° cutter to lower the valveseat.

• 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.

• If the seat is too wide or uneven, use both top andbottom cutters to narrow the seat.

• If the seat is too narrow, widen using the 45° cutter andre-check contact point on the valve face and seat widthafter each cut.

(A)

Proper Seat Contact On Valve Face

(A)

(B)

Bottom 60o or 75o

Top 30o

Seat 45o or 46o

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NOTE: When using an interference angle, the seatcontact point on the valve will be very narrow, and isa normal condition. Look for an even andcontinuous contact point on the black marker, all theway around the valve face.

8. Clean all filings from the area with hot soapy water, rinse,and dry with compressed air.

9. Lubricate the valve guides with clean engine oil, and applyoil or water based lapping compound to the face of thevalve. Lapping is not required with an interference angle.

10. Insert the valve into its respective guide and lap using alapping tool or a section of fuel line connected to the valvestem.

11. Rotate the valve rapidly back and forth until the cut soundssmooth. Lift the valve slightly off of the seat, rotate 1/4 turn,and repeat the lapping process. Do this four to five timesuntil the valve is fully seated, and repeat process for theother valve.

12. Clean cylinder head, valves, and camshaft oil supplypassages thoroughly.

13. Spray electrical contact cleaner into oil passages and dryusing compressed air.

Cylinder Head Assembly

NOTE: Assemble the valves one at a time tomaintain proper order.

1. Install new valve seals on valve guides.

2. Apply engine oil to valve guides and seats.

3. Coat valve stem with molybdenum disulfide grease.

4. Install valve carefully with a rotating motion to avoiddamaging valve seal.

SeatWidth

CAUTION

Wear eye protection during assembly.

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5. Dip valve spring and retainer in clean engine oil and installspring with closely spaced coils toward the cylinder head.

6. Place retainer on springs and install valve springcompressor. Compress spring only enough to allow splitkeeper installation and prevent loss of spring tension.Install split keepers with the gap even on both sides.

7. Repeat procedure for remaining valve.

8. When all valves are installed, tap lightly with soft facedhammer on the end of the valves to seat the Split keepers.

Valve Sealing Test

1. Clean and dry the combustion chamber area.

2. Pour a small amount of cleaning solvent into each port andcheck for leakage around each valve. The valve seatsshould hold fluid with no seepage.

Cylinder Removal

Follow engine disassembly procedures to remove valve cover,camshaft and rocker arms, and cylinder head.

1. Remove cam chain guide at front of cylinder.

2. Remove the two 6 mm cylinder base bolts.

3. Tap cylinder lightly with a plastic hammer in reinforcedareas only until loose.

4. Rock cylinder forward and backward and lift it from thecrankcase, supporting piston and connecting rod. Supportpiston with Piston Support Block (PN 2870390).

Cam Chain Follower / Tensioner Blades

1. Remove bolt securing tensioner blade to crankcase (A).

2. Remove blades and inspect for cracks, wear, or damage.

Closely spaced coils towardcylinder head

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Piston Removal

1. Remove circlip. Note that opening for circlip access is onthe exhaust side.

2. Remove piston circlip and push piston pin out of piston. Ifnecessary, heat the crown of the piston slightly with apropane torch. CAUTION: Do not apply heat to the pistonrings. The ring may lose radial tension.

3. Remove the compression rings, starting with the top ring.

* Using a piston ring pliers: Carefully expand ring and lift it offthe piston. CAUTION: Do not expand the ring more than theamount necessary to remove it from the piston, or the ring maybreak.

* By hand: Placing both thumbs as shown, spread the ring openand push up on the opposite side. Use care to not scratch the ringlands.

4. Repeat procedure for second ring.

5. The oil control ring is a three piece design consisting of atop and bottom steel rail and a center expander section.Remove the top rail first followed by the bottom rail andexpander.

Cylinder Inspection

1. Remove all gasket material from the cylinder sealingsurfaces.

2. Inspect the top of the cylinder for warpage using a straightedge and feeler gauge.

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

4. Inspect cylinder for taper and out of round with atelescoping gauge or a dial bore gauge. Measure in twodifferent directions, front to back and side to side, on threedifferent levels (1/2” down from top, in the middle, and 1/2” up from bottom).

= In. / mm.

Cylinder Warp:.002” (.05 mm) MAX

1/2” Down From Top of Cylinder

1/2” Up From Bottom

X

X

X

Y

Y

Y

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5. Record measurements. If cylinder is tapered or out of roundbeyond specification, the cylinder must be honed, bored orreplaced.

Cylinder Hone Selection / Honing Procedure

Cylinders may be wet or dry honed depending upon the honemanufacturer’s recommendations. Wet honing removes morematerial faster and leaves a more distinct pattern in the bore.

Honing to Deglaze

A finished cylinder should have a cross-hatch pattern to ensurepiston ring seating and to aid in the retention of the fuel/oilmixture during initial break in. Hone cylinder according to honemanufacturer’s instructions, or these guidelines:

• Use a motor speed of approximately 300-500 RPM, runthe hone in and out of the cylinder rapidly until cuttingtension decreases. Remember to keep the hone driveshaft centered (or cylinder centered on arbor) and tobring the stones approximately 1/2” (1.3 cm) above andbelow the bore at the end of each stroke.

• Release the hone at regular intervals and inspect thebore to determine if it has been sufficiently deglazed,and to check for correct cross-hatch. NOTE: Do notallow cylinder to heat up during honing.

• After honing has been completed, inspect cylinder forthinning or peeling.

IMPORTANT: Clean the Cylinder After Honing

It is very important that the cylinder be thoroughly cleaned afterhoning to remove all grit material. Wash the cylinder in asolvent, then in hot, soapy water. Use electrical contact cleanerif necessary to clean these areas. Rinse thoroughly, dry withcompressed air, and oil the bore immediately with Polaris 4Cycle Lubricant to prevent the formation of surface rust.

If cylinder wear or damage is excessive, it will be necessary toreplace the cylinder. Hone only enough to deglaze the outerlayer of the cylinder bore.

Piston Inspection

1. Measure piston outside diameter at a point 7 mm up fromthe bottom of the piston at a right angle to the direction ofthe piston pin.

2. Subtract this measurement from the maximum cylindermeasurement obtained earlier.

= In. / mm.

Cylinder Taper:Limit: .002” (.05 mm) Max.

Cylinder Out of Round:Limit: .002” (.05 mm) Max.

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 using a rigid hone or arbor honing machine.

= In. / mm.

Piston to Cylinder ClearanceStd: .00078- .002” (0.02- 0.05 mm)

Limit: .0039” (.1 mm)

EXAMPLE OF CROSS HATCH PATTERN

PistonPiston Pin

7mm

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3. Measure piston pin bore. Replace piston if out-of-round

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

5. Measure connecting rod small end ID. Replace crankshaftif out-of-round.

6. Measure piston ring to groove clearance by placing the ringin the ring land and measuring with a thickness gauge.Replace piston and rings if ring-to-groove clearanceexceeds service limits.

Piston Ring Installed Gap

1. Place each piston ring inside cylinder using piston to pushring squarely into place as shown.

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

NOTE: Measure at two points in the cylinder Adifference in end gap indicates cylinder taper. Thecylinder should be measured for excessive taperand out of round.

3. If the installed gap measurement exceeds the limit, replacethe rings. If using new rings and the measurement is toosmall, file the ring ends to achieve the proper gap.

NOTE: Always check piston ring installed gap afterre-boring a cylinder or when installing new rings. Are-bored cylinder should always be scrubbedthoroughly with hot soapy water, rinsed, and driedcompletely. Wipe cylinder bore with an oil ragimmediately to remove residue and prevent rust.

Piston Pin Bore

Piston Pin Measurement Locations

Feeler Gauge

Ring

Piston

= In. / mm.

Piston Ring Installed Gap:

Top RingStd: .0039- .0098” (.1- .25 mm)

Limit: .0196” (0.5 mm)Second Ring

Std: .0138- .0197” (0.3- 0.45 mm)Limit: .196” (0.5 mm)

Oil RingStd: .0079- .0275” (0.2- 0.7 mm)

Limit: .059” (1.5 mm)

Piston Ring

Cylinder

Feeler Gauge

25-50 mm

Piston ring end gap installed

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BOTTOM-END DISASSEMBLY

Starter Drive Gear Removal and Inspection

1. Remove stator housing bolts and remove housing.

2. Remove the start drive gear and shaft by pulling the shaftand tilting the gear slightly. Flywheel removal generally isnot required.

3. Measure the OD of the starter drive shaft on both ends forout-of-round.

4. Measure the ID of the bushing in the stator housing (A) andin the crankcase (B) in two directions 90° apart todetermine if out-of-round. Calculate the clearance. Replacecomponents if clearance is excessive.

5. Inspect gear teeth on starter drive. Replace starter drive ifgear teeth are cracked, worn, or broken.

Flywheel Removal / Inspection

1. Remove the oil passage plunge joint (C), flywheel nut andwasher.

2. Install Flywheel Puller (PN PA-47308) and removeflywheel. CAUTION: Do not hammer or strike the toolwhile attached to the crankshaft end, which may becomedamaged.

AB

CAUTION

The crankshaft end contains an oil passage plunge joint (A) as shown below. The plunger must be able to move in and out freely. Avoid

damage to the crankshaft end or plunge joint and spring, which can cause loss of oil pressure,

resulting in severe engine damage.

C

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Starter Drive One-way Clutch Removal and Inspection

1. Remove the hex bolts that attach the one-way drive clutchto the flywheel.

2. Inspect the bearing surfaces and drive teeth for signs ofwear or gouging. Replace the one-way clutch as anassembly if it is not working properly.

NOTE: One-way clutch components are notserviceable. Replace the component as anassembly.

3. To reattach the one way assembly, apply Loctite™ 272 tothe retaining screw threads. Torque to specification.

Crankshaft Drive Sprocket Removal and Inspection

1. Using the Slotted Nut Socket, remove the crankshaftslotted nut (A). NOTE: Slotted nut is left hand thread.

2. Remove cam chain drive sprocket (B) and Woodruff keyfrom crankshaft.

3. Inspect sprocket teeth for wear or damage.

4. Inspect Woodruff key for wear.

5. Replace any worn or damaged parts.

= T

One - Way Clutch Screw Torque:5-6.5 ft. lbs. (7 - 9 Nm)

Slotted Nut Socket

(PN 2871293-B)

A

B

Remove

Inspect for Areas ofTooth Wear or Damage

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Balance Shaft Sprocket Removal and Inspection

1. Using the Slotted Nut Socket (PA-47344), remove thebalance shaft slotted nut (C).

NOTE: Slotted nut is a right-hand thread

2. Remove cam chain drive sprocket (D), drive sprocket (E)and woodruff key from balance shaft.

3. Remove the oil pump galley cover, oil pump gear and chainto facilitate removal of the balance shaft sprocket.

4. Inspect sprocket teeth for wear or damage.

5. Inspect woodruff key for wear.

6. Replace any worn or damaged parts.

Oil Pump Removal / Drive Chain Inspection

NOTE: Oil pump is not a serviceable assembly.

1. Remove the screws on the oil pump galley cover.

2. Remove the oil pump drive gear.

3. Remove the oil pump retaining screws.

Slotted Nut Socket

(PA - 47344)

E

D C

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4. Inspect the sprockets and chain for wear or damage. Inspectchain for worn or missing rollers or damage. Replace chainanytime the oil pump is replaced or if excessively worn.

CRANKCASE DISASSEMBLYNOTE: Engine must be removed from the frame toperform any crankcase or crankshaft removal.

NOTE: The starter, starter drive, flywheel, stator, oilpump and transmission can be serviced with theengine in the frame.

Crankcase Separation and Cam Chain Removal

NOTE: Stator housing, flywheel and gears arepreviously removed for this procedure. Use careduring the removal process to avoid damage to thecam chain.

NOTE: Valvetrain and cylinder removal must beperformed prior to this procedure.

NOTE: Always replace the pto crankshaft seal afterperforming this procedure.

1. Remove two flange bolts (circled) from the magneto sidecrankcase .

2. Separate crankcase using a hydraulic tool or by pressing onthe pto end of the crankshaft using special tool (PA-46087).

NOTE: Tapping the pto end of the crankshaft with asoft-face hammer may also separate the cases. Usecare not to damage the crankshaft end.

3. Watch the gap along the crankcase mating surface andseparate the crankcase evenly.

4. Once the crankshaft bearing is free from the case, thecrankshaft and cam chain can be removed by hand forservice.

Note: Install new chain as part of oil pump repair.

Install with the arrow pointing up

Crankcase Separator Tool PA-46087

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Crankshaft Removal

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

NOTE: Tapping the pto end of the crankshaft with asoft-face hammer may also separate the cases. Usecare not to damage the crankshaft end.

Crankshaft / Cam Chain / Sprocket Inspection

1. Inspect the crankshaft main bearings and cam chainsprocket for wear or damage.

NOTE: Due to extremely close tolerances andminimal wear, the bearings must be inspectedvisually, and by feel. Look for signs of discoloration,scoring or galling. Turn the outer race of eachbearing. The bearings should turn smoothly andquietly. The inner race of each bearing should fittightly in the crankshaft. The outer race should befirm with minimal side to side movement and nodetectable up and down movement.

2. Replace the crankshaft if the components fail visualinspection.

3. The connecting rod utilizes a roller bearing. Clearance isminimal and cannot be measured. Visually inspect bearingjournal for scoring, damage or excessive wear. Replace

crankshaft if it fails visual inspection.

4. Check oil passage to make sure it is clear and free of nicks,burrs and that the plunger moves in and out freely.

5. Remove cam chain. Inspect chain for worn or missingrollers or damage. Replace if worn excessively or as partof any crankshaft repair.

Oil PassagePlunge Joint

Note: Install new chain as a part of crankshaft repair.

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Crankcase / Bearing Inspection

NOTE: Removal and installation of new seals isrecommended anytime the crankcase isdisassembled.

1. Inspect the bearings in the crankcase.

NOTE: Due to extremely close tolerances andminimal side wear, the bearing must be inspectedvisually and by feel. Look for signs of discoloration,scoring or galling. Turn the inner race of bearing.The bearing should turn smoothly and quietly. Theouter race should fit tightly in the crankcase. Theinner race should be firm with minimal side to sidemovement and no detectable up and downmovement.

2. To remove crankcase bearings, use a blind hole bearingpuller.

NOTE: Bearings are stressed during the removalprocedure and should not be re-used.

3. Remove all traces of gasket sealer from the crankcasemating 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 rips, tearsor obstructions in screen.

3. Replace oil strainer if it fails visual inspection.

ENGINE REASSEMBLY

Bearing / Seal Installation

NOTE: To ease crankcase bearing installation, warmthe crankcase until hot to the touch. Placing thebearing in a freezer prior to installation will assistthe assembly process.

1. Install the bearing so the numbers are visible.

2. Drive or press the new bearing into the crankcase, using theproper driver.

3. Install new seals with the lip facing in.

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. Install thecrankshaft using a hydraulic tool. Press on the pto end ofthe crankshaft. Use care not to damage the crankshaft end.

NOTE: Tapping the end of the crankshaft with a soft-face hammer may also install the crankshaft. Usecare not to damage the crankshaft end.

CAUTION

Press only on outer race of bearing to prevent bearing damage.

CAUTION

Press only on outer diameter to prevent damage.

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

3. Install a new gasket onto the pto case half. Applying a thinamount of crankcase sealer to the gasket will help hold itin place. Loop the cam chain over the pto end of thecrankshaft. Press the inner cover and crankshaft assemblyonto the pto crankcase using a hydraulic tool.

NOTE: Tapping the mag end of the crankshaft with asoft-face hammer may also install the crankshaft.Use care not to damage the crankshaft end.

4. Loop the cam chain through the chain room and secure withmechanic’s wire.

5. Install the two mag side flange bolts and torque tospecification.

Balance Shaft and Crankshaft Gear Installation

6. Install the crankshaft gear, woodruff key and slotted nut.Using the Slotted Nut Socket (PN 2871293-B), tighten thenut to the specified torque. NOTE: Slotted nut is left handthreaded.

= T

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

Crankcase Sealant

PN 2871557

= T

Crankshaft Slotted Nut Torque:72 ft. lbs. (98 Nm)

A

B

Tighten

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7. Install the balance shaft gear and align the mark with thecrankshaft gear mark as shown.

8. Install the woodruff key, oil pump drive sprocket, washerand slotted nut. Using the Slotted Nut Socket (PN PA-47344), tighten the nut to the specified torque.

9.

Oil Pump and Chain Installation

NOTE: Oil pump is not a serviceable assembly. Donot 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 andpump.

2. Install oil pump as shown. Torque screws to specifiedtorque.

NOTE: Do not use gasket sealer on the pumpmating surfaces.

3. Install the chain (A) over the sprocket on the balance shaftgear (B).

4. Loop the chain around the oil pump drive gear (C) andinstall the gear onto the pump shaft. NOTE: The oil pumpgear and shaft have a “D” configuration for alignment.

= T

Balance Shaft Slotted Nut Torque:43 ft. lbs. (59 Nm)

Alignment marks

A

B

Tighten

= T

Oil Pump Cover Screw Torque:4-5 ft. lbs. (5-7 Nm)

Install with arrow pointed up

D

A

C

B

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5. Install the washer and nut. Torque to specification.

6. Install the oil baffle plate ( Item D -See illustration) andtorque bolts to specification.

Piston Ring Installation

NOTE: Apply clean engine oil to all ring surfacesand ring lands. Always check piston ring installedgap before rings are installed on piston. If the pistonhas been in service, clean any accumulated carbonfrom the ring grooves and oil control ring holes.

1. Place the oil control ring expander in oil ring groove withthe end gap facing forward. The expander has no up ordown marking and can be installed either way. The endsshould butt squarely together and must not overlap.

2. Install the oil ring top rail with the end gap at least 30° fromthe end of the expander.

3. Install the bottom rail with the gap at least 30° from the endof the expander on the side opposite the top rail gap.

4. Install the second ring with the mark facing up. Position theend gap toward the rear (intake) side of the piston.

5. Install the top ring with the chamfered edge facing up.

6. Check to make sure the rings rotate freely in the groovewhen compressed by hand.

Piston Installation

1. Install a new circlip on one side of the piston with the endgap facing up or down.

2. Apply clean engine oil to the piston rings, ring lands, pistonpin bore, piston pin, and piston skirt. Lubricate theconnecting rod (both ends) and crankshaft main bearingarea.

3. IMPORTANT: Install the piston on the connecting rodwith the ’IN” casting mark facing the intake side of engine.The piston pin should be a push fit into the piston.

4. Install the other circlip with the gap facing up or down. (SeeCaution with Step 3 above). Push the piston pin in bothdirections to make sure the clips are properly seated in thegroove.

5. Place the dowel pins in the crankcase and install a newcylinder base gasket.

= T

Oil Pump Gear Nut Torque:5-7 ft. lbs. (7-9 Nm)

TopRing Profile

Second Ring Profile

Install chamfer up

CAUTION

Do not re-use circlips. Circlips become deformed during the removal process. Do not compress the new clip more than necessary to prevent loss of radial tension. Severe engine damage may result if circlips are re-used or

deformed during installation.

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6. Lubricate the piston and rings with assembly lube andinstall a ring compressor on the piston assembly. Verify thatthe ring gaps are 120 degrees apart from each other beforeinstallation.

Tensioner Blade Installation

1. Install the tensioner blade and tighten the mounting bolt tospecified torque.

Cylinder Installation

NOTE: Clean the gasket surfaces on the crankcaseand cylinder. Remove all traces of old gasketmaterial and apply a new base gasket

1. Install the dowel pin(s). Install an new base gasket onto themating surface and position the Piston Support Block (PN2870390) (A) beneath the piston skirt to support the pistonduring cylinder installation.

NOTE: Route cam chain through the cylinder chainroom and secure it, holding it up while rotating theengine to avoid damage to the chain, drive sprocketteeth or tensioner blade.

2. Apply clean engine oil liberally to the bore and tapered areaof the cylinder. Place the cylinder on to the studs.

3. Loop the cam chain through the cylinder chain room andsecure with mechanic’s wire. Allow cylinder to fully seaton the piston and support block.

4. Push the rings into the taper using a non-metallic, blunt-edge tool while holding the cylinder down. This will helppush the piston past the ring taper into the cylinder.

5. Remove the support block. Seat the cylinder firmly on thebase gasket.

6. Install the cam chain guide and dowel pins into the cylinder.Verify the bottom end is seated properly in the crankcase.

= T

Tensioner Blade Mounting Bolt Torque:5-6.5 ft. lbs. (7-9 Nm)

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Cylinder Head and Camshaft Installation

NOTE: Clean the gasket surfaces on the cylinderhead and cylinder. Remove all traces of old gasketmaterial.

1. Install the dowel pin(s) and a new cylinder head gasket.

2. Pull the cam chain through the cylinder head chain roomand secure with mechanic’s wire.

3. Place the cylinder head on the cylinder.

4. Install the two 6 mm bolts, but do not tighten.

5. Install the cam according to the “Cam Shaft Timing”procedure. Verify the cam chain is in place around thecrankshaft gear.

NOTE: Verify camshaft timing procedure beforeinstalling the rocker shaft assembly.

Camshaft Timing

IMPORTANT CAMSHAFT TIMING NOTE: In order totime the camshaft to the crankshaft, the piston must be preciselylocated at Top Dead Center (TDC). This can be accomplishedusing one of two methods.

1. Install the cam chain over the crankshaft.

When the stator housing is removed, use Method 1. This methoduses the camshaft gear marks and the crankshaft keyway toestablish TDC. It is important to note that this method can onlybe used when the stator housing is removed and the crankshaftkeyway is in view. The camshaft sprocket alignment marks areparallel to the gasket surface, and camshaft lobes are pointingdown. The cam chain plate links are not used to time thecamshaft.

When the stator housing is installed, use Method 2. This methodestablishes accurate Top Dead Center (TDC) by aligning thesingle mark on the flywheel with the notch in the timinginspection hole (see Method 2). The camshaft sprocketalignment marks are parallel to the gasket surface, and camshaftlobes are pointing down. The cam chain plate links are not usedto time the camshaft.

CAUTION

Serious engine damage will result if the camshaft is not properly timed to the crankshaft.

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Camshaft Installation - Timing Method 1Reference Illustration Page 3.36

Stator housing is removed. NOTE: Use this method only whenthe stator is removed and cam shaft drive sprocket is in view.

1. Rotate the crankshaft until the keyway on the crankshaft ispointed ’UP” (keyway facing upward).

2. Align the cam chain onto the teeth of the crankshaftsprocket. Use a wire to pull the chain up through thecylinder and cylinder head and to hold it in place. Securethe chain.

3. Apply Polaris Low Temp Grease (PN 2870577), or engineassembly lubricant to the camshaft main journals and camlobes. Lubricate automatic compression releasemechanism with clean engine oil.

4. Orientate the camshaft with the lobes facing downward.

5. Disconnect the wire securing the cam chain and loop thecam chain over the sprocket while verifying the cam isinserted with the alignment marks parallel to the gasketsurface.

6. Check all cam timing marks to verify proper cam timing,and install the rocker arm assembly. Torque the cylinderstud nuts to specification.

NOTE: Do not rotate engine until tensioner androcker assembly is installed.

7. Install the tensioner and rocker assembly.

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

Camshaft Installation - Timing Method 2 ReferenceIllustration Page 3.37

Stator housing is installed. NOTE: Use this method only whenthe stator is installed and cam shaft drive sprocket is in view.

1. Rotate the crankshaft until the single (TDC) timing mark(Top Dead Center) on the flywheel is view in the center ofthe timing inspection window. Be sure to use the singleTDC mark when installing the cam. Do not use anyadvance marks (if evident).

2. Align the cam chain onto the teeth of the cam chain drivesprocket. Use a wire to pull the chain up through thecylinder and cylinder head and to hold it in place. Securethe chain.

3. Apply Polaris Low Temp Grease (PN 2870577), ormolybdenum disulfide grease to the camshaft main journalsand cam lobes. Lubricate automatic compression releasemechanism with clean engine oil.

4. Orientate the camshaft with the lobes facing downward.

5. Disconnect the wire securing the cam chain and loop thecam chain over the sprocket while verifying the cam isinserted with the alignment marks parallel to the gasketsurface.

6. Check all cam timing marks to verify proper cam timing,and install the rocker arm assembly. Torque the cylinderstud nuts to specification.

NOTE: Do not rotate engine until tensioner androcker assembly is installed.

7. Install the tensioner and rocker assembly.

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

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Camshaft Timing - Method 1

Crankshaft Keyway ‘UP’

Method 1 - Camshaft Timing with Stator Housing Removed

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

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Camshaft Timing - Method 2

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 Installation

1. Assemble arms, shafts and decompression componentsinto cam support.

2. Install and tighten rocker shaft locking plate. Tighten tospecification.

3. Apply engine assembly lube to the cam lobes and camfollower surfaces.

4. Verify the cam lobes are pointing downward beforeinstalling rocker assembly.

5. Apply clean engine oil liberally to the valve springs, camchain, rocker arms, and camshaft.

6. Install cylinder head nuts and torque to specification.

7. Adjust valves according to the “VALVE CLEARANCEADJUSTMENT PROCEDURES”.

8. Install rocker cover and torque bolts to specification.

Cam Chain Tensioner Installation

1. Using a small flat blade screwdriver, turn the tensionerclockwise to retract the plunger (B) all the way into thetensioner body.

2. With the plunger retracted, install the tensioner assemblywith a new gasket and tighten the bolts to specification.

3. Install the tensioner cap. Torque cap to specification.

4. Slowly rotate engine two to three revolutions and re-checkcam timing once chain is tight.

Intake Valve Clearance Adjustment

1. Verify cam lobes are pointed down.

2. Insert a .003”(.07mm) feeler gauge between end of intakevalve stem and adjuster screw.

3. When clearance is correct, hold adjuster screw and tightenlocknut securely.

4. Re-check the valve clearance.

5. Repeat adjustment procedure if necessary until clearance iscorrect with locknut secured.

Intake

Exhaust

Torque in 3 step cross pattern

Torque13-16 ft. lbs.(18-22 Nm)

5

6 Torque5 - 6.5 ft. lbs. (7-9 Nm)

1 2

3

4

= T

Tensioner Bolt and Cap Torque:5-6.5 ft. lbs. (7-9 Nm)

= In. / mm.

Valve Clearance:.003” (.07 mm)

B

A

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Exhaust Valve Clearance Adjustment

1. Verify cam lobes are pointed down.

2. Insert a .003"(.07mm) feeler gauge between end of exhaustvalve stem and adjuster screw.

3. Loosen locknut and turn adjuster screw until there is a slightdrag on feeler gauge.

4. When clearance is correct, hold adjuster screw and tightenlocknut securely.

5. Re-check the valve clearance.

6. Repeat adjustment procedure if necessary until clearance iscorrect with locknut secured.

Flywheel Installation

1. Install flywheel key, flywheel washer, and nut. Torqueflywheel nut to specification.

Starter Drive Assembly

1. Be sure the washer is positioned on the back of the drivegear.

2. Apply Starter Drive Grease (PN 2871460) to the drivebushings in the cases and all moving surfaces of the starterdrive gears and install.

3. Install stator housing and torque bolts to specification.

Stator Housing Installation

NOTE: The stator, flywheel, starter drive, and statorcan be serviced with the engine in the frame.

1. Apply a light amount of Crankcase Sealant (PN 2871557)to the mounting surface and install a new gasket. Install thedowel pins.

2. Seal stator wire grommet with Crankcase Sealant (PN2871557).

= In. / mm.

Valve Clearance:.003” (.07 mm)

= T

Flywheel Nut Torque:58-72 ft. lbs. (78-98 Nm)

Starter Drive Grease:

(PN 2871460)

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3. Install the housing. Torque bolts in sequence tospecification.

Oil Filter Installation

1. Apply clean engine oil to oil filter gasket.

2. Install filter until gasket lightly touches seat and thentighten an additional 3/4 of a turn.

TROUBLESHOOTING

Spark Plug Fouling

• Spark plug cap loose or faulty

• Choke cable adjustment or plunger/cable sticking

• Foreign material on choke plunger seat or plunger

• Incorrect spark plug heat range or gap

• Carburetor inlet needle and seat worn

• Jet needle and/or needle jet worn or improperlyadjusted

• Excessive carburetor vibration (loose or missing needlejet locating pins)

• Loose jets in carburetor or calibration incorrect foraltitude/temperature

• Incorrect float level setting

• CVT system calibrated incorrectly or components wornor mis-adjusted

• Fuel quality poor (old) or octane too high

• Low compression

• Restricted exhaust

• Weak ignition (loose coil ground, faulty coil, stator, orETC switch)

• ETC switch mis-adjusted

• Restricted air filter (main or pre-cleaner) or breathersystem

• Improperly assembled air intake system

• Restricted engine breather system

• Oil contaminated with fuel

• Restricted crankcase vent

General Troubleshooting

Engine Turns Over But Fails to Start

• No fuel

• Dirt in fuel line or filter

• Fuel will not pass through fuel valve

• Fuel pump inoperative/restricted

• Tank vent plugged

• Carb starter circuit

• Engine flooded

• Low compression (high cylinder leakage)

• No spark (Spark plug fouled)

= T

Stator Housing Bolt Torque:5 - 6.5 ft. lbs. (7-9 Nm)

= T

Oil Filter:Hand-tighten 3/4 turn from lightly seated

1

2

3

4

5

6

7

8

9

10

11

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Engine Does Not Turn Over

• Dead battery

• Starter motor does not turn

• Engine seized, rusted, or mechanical failure

• Kickstart components damaged

Engine Runs But Will Not Idle

• Restricted carburetor pilot system

• Carburetor misadjusted

• Choke not adjusted properly

• Low compression

• Crankcase breather restricted

• Air filter restriction

Engine Idles But Will Not Rev Up

• Spark plug fouled/weak spark

• Broken throttle cable

• Obstruction in air intake

• Air box removed (reinstall all intake components)

• Incorrect or restricted carburetor jetting

• ETC switch limiting speed

• Reverse speed limiter limiting speed

• Carburetor vacuum slide sticking/diaphragm damaged

• Incorrect ignition timing

• Restricted exhaust system

• Cam Lobe worn

Engine Has Low Power

• Spark plug fouled

• Cylinder, piston, ring, or valve wear or damage (checkcompression)

• CVT not operating properly

• Restricted exhaust muffler

• Dirty carburetor

• Cam lobe worn

Piston Failure - Scoring

• Lack of lubrication

• Dirt entering engine through cracks in air filter or ducts

• Engine oil dirty or contaminated

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 accumulatedon valve area)

• Rocker arm sticking

Backfiring

• ETC or speed limiter system malfunction

• Fouled spark plug or incorrect plug or plug gap

• Carburetion faulty - lean condition

• Intake / Exhaust system air leaks

• Ignition system faulty:

• Spark plug cap cracked/broken

• Ignition coil faulty

• Ignition or kill switch circuit faulty

• Ignition timing incorrect

• Sheared flywheel key

• Poor connections in ignition system

• System wiring wet

• Cam lobe worn or Valve sticking

• Lean condition

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NOTES

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FUEL SYSTEM

CHAPTER 4

FUEL SYSTEM

4

CARBURETOR EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2AIR CLEANER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3FUEL TANK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5CARBURETION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

CARBURETION SYSTEM FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5CARBURETION SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5OPTIONAL MAIN JETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6CARBURETOR JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6CARBURETOR OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6FLOAT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6PILOT JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7AIR SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7AIR / FUEL MIXTURE RATIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8NEEDLE JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8THROTTLE OPENING VS. FUEL FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8THROTTLE SLIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8MAIN JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9PILOT SYSTEM (IDLE - 3/8 THROTTLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9SLIDE CUTAWAY (1/8 - 3/8 THROTTLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10JET NEEDLE / NEEDLE JET(3/8 - 3/4 THROTTLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10MAIN SYSTEM (3/4 TO FULL THROTTLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11VENT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11

CARBURETOR SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12CARBURETOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12FLOAT HEIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12NEEDLE AND SEAT LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13CARBURETOR FLOAT BOWL DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14FUEL LEVEL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15FUEL STARVATION / LEAN MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15RICH MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15POOR IDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15Par

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FUEL SYSTEM

CARBURETOR EXPLODED VIEW

Carburetor Assembly

REF. QTY. DESCRIPTION REF. QTY. DESCRIPTION

1 1 Carburetor Assy 14 1 Needle Jet Holder

2 1 Float Valve Asy 15 1 Float Assy

3 1 Float Arm Pin 16 1 Diaphragm Cover

4 1 Float Drain Assy 17 1 Spring, Return

5 1 O-Ring 18 1 Screw Set, Slide Stop

6 1 Screw Set, Air 19 1 O-ring

7 1 Choke Lever Assy 20 1 Jet Needle Set

8 1 Needle Jet 21 1 Tube Set

9 1 Screw/Washer, Cover 22 1 Slow Jet

10 1 Screw/Washer, Float Bowl 23 1 Throttle Slide

11 1 Needle Clip Plate 24 1 Main Jet

12 1 Spring, Compression 25 1 Choke Cable

13 1 Top Set

13

12

11

20

23

8

6

9

1619 18

17

7

1

22

14

24

23

15

10 4

21

5

25

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4

AIR CLEANER EXPLODED VIEW

Air Cleaner Assembly

REF. QTY. DESCRIPTION REF. QTY. DESCRIPTION

1 1 Air Box Cover 9 1 Rivet

2 1 Gasket 10 1 Flat Washer

3 2 Bolt 11 1 Air Box Duct

4 1 Air Box 12 1 Duct

5 1 Clamp 13 1 Clamp

6 1 Drain Hose 14 1 Boot

7 1 Trap Plug 15 1 Clamp

8 1 Air Cleaner Element

1

23

4

5

6

7

8

9 1011

12

13

14

15

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FUEL SYSTEM

FUEL TANK EXPLODED VIEW

Fuel Tank Assembly

REF. QTY. DESCRIPTION REF. QTY. DESCRIPTION

1 1 Hose 9 2 Clip

2 1 Fuel Tank Cap 10 1 Hose

3 1 Cap Gasket 11 6 Clip

4 2 Bolt 12 1 Manual Fuel Asm.

5 1 Fuel Tank 13 1 Bolt

6 1 Plain Washer 14 1 Fuel Filter

7 1 Tapping Screw 15 1 Clamp

8 1 Tank Foil

1 2

3

4 5

6 7

4

8

910

1112

13

1011

14

15

10

11

9

10

11

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FUEL SYSTEM

4

SPECIAL TOOLS

NOTE: It is strongly recommended that PolarisCarbon Clean be added regularly as directed to thefuel systems of all Polaris ATVs. Carbon Cleanstabilizes the fuel, preventing clogging of the smallpassages and orifices common to ATV carburetors,and ensures constant performance, reliability andeasier starting.

CARBURETION SYSTEM

Carburetion System Function

Carburetion Specifications

PART NUMBER TOOL DESCRIPTION

2870975Mity Vac™

Pressure Test Tool

2872314Carburetor Float Adjustment Tool

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 overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the

filler neck. Leave room for expansion of fuel.

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes

are poisonous and can cause loss of consciousness and death in a short time.

Never drain the float bowl when the engine is hot. Severe burns may result.

Do not smoke or allow open flames or sparks in or near the area where refueling is performed or

where gasoline is stored.

If you get gasoline in your eyes or if you should swallow gasoline, seek medical

attention immediately.

If you spill gasoline on your skin or clothing, immediately wash with soap and water and

change clothing.

Carburetor Component Function

SystemMain

ComponentsMain

FunctionMain Affect

FloatSystem(Level

Control)

Inlet Pipe, Needle and Seat, Float, Float Pin

Maintains specified fuel level in float chamber (carburetor float bowl)

All systemsAll throttle ranges

Venting

Passages in Carburetor, Vent linesto frame

Suppliesatmospheric pressure to float chamber

All systemsAll throttle ranges

Choke/Enrichment

Manual cable unit, Plate, Return Spring, Carb Passages

Supplies additional fuel air mixture necessary for cold starting

Greatest effect at low throttle settings and idle

Pilot (Idle System)

Pilot Jet Passageways, Bypass Ports (Under Throttle Slide), Pilot Jet, Pilot Outlets, Throttle Slide

Primarily supplies fuel at idle and low throttle positions

Mainly idle to 1/4 throttleMinimal effect after 1/2 throttle

Main System

Main Jet, Main Air Passage, Needle Jet, Jet Needle, Throttle Slide

Supplies fuel at mid-range and high throttle settings.

1/4 to full throttle

Phoenix 200

Air Screw 1 turn out from lightly seated

Pilot Jet 35

Main Jet 108

E-Clip Position #4

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FUEL SYSTEM

Optional Main Jets

Please refer to the Phoenix Parts Manual for information onoptional jets that may be available.

Carburetor Jetting

IMPORTANT: The following guidelines must befollowed when establishing a main jet setting:

1. Select the lowest anticipated temperature at which themachine will be operated.

2. Determine the lowest approximate altitude at which themachine will be operated.

3. Select the correct main jet according to the engines fuel/performance requirements.

Carburetor Operation

The engine of a vehicle is operated under a wide range ofconditions, from idling with the throttle valve remaining almostclosed, to full load or maximum output with the throttle valvefully opened. In order to meet the requirements for the propermixture ratio under these varying conditions, a low speed fuelsystem, or pilot system, and a main fuel system are provided inthese type of carburetors.

The function of a carburetor is to produce a combustible air/fuelmixture by breaking fuel into tiny particles in the form of vapor,to mix the fuel with air in a proper ratio, and to deliver themixture to the engine. A proper ratio means an ideal air/fuelmixture which can burn without leaving an excess of fuel or air.

Whether the proper mixture ratio is maintained or not is the keyto efficient engine operation.

This carburetor has varying operations depending upon varyingdriving conditions. It is constructed of a float system, pilotsystem, main system, and starter system or initial startingdevice.

Float System

The float system is designed to maintain a constant height ofgasoline during operation. When the fuel flowing from the fuelpump into the float chamber through the needle valve reachesthe constant fuel level, the floats rise. When the buoyancy of thefloat and the fuel pressure of the fuel pump balance, the needlevalve seals the orifice in the needle seat, preventing further fueldelivery, and the level of fuel in the bowl remains relativelyconstant.

The fuel level in the bowl assists in controlling the amount offuel in the fuel mixture. Too high a level allows more fuel thannecessary to leave the nozzle, enriching the mixture. Too low alevel results in a leaner mixture, since not enough fuel leaves thenozzle. Therefore, the predetermined fuel level should not bechanged arbitrarily.

CAUTION

A main jet that is too small will cause a leanoperating condition resulting in seriousengine damage.

CAUTION

A main jet that is too small will cause a leanoperating condition resulting in serious enginedamage.

Select the correct main jet carefully for elevationand temperature according to the charts in theSpecifications section or in the Owner’s Safetyand Maintenance Manual for each particularmodel.

Fuel Supply Slide StopAdjustment

Float

General Carburetor Representation

Float Arm

Needle Valve

Idle MixtureAir Screw

ConstantFuel Level

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Pilot Jet

From idling to low speeds, the fuel supply is metered by the pilotjet. There are several air bleed openings in the sides of the pilotjet which reduce the fuel to mist. The number stamped on the jetis an indication of the amount of fuel in cc’s which passesthrough the jet during a one minute interval under a given set ofconditions.

Air Screw

The air screw controls the fuel mixture from idle to low speeds.The tapered tip of the air screw projects into the air passageleading to the pilot jet air bleeds. By turning the screw in or out,the cross sectional area of the air passage is varied, in turnvarying the pilot jet air supply and changing the mixture ratio.

Air / Fuel Mixture Ratio

A carburetor with a slide type throttle valve is also called avariable venturi type carburetor. In this type of carburetor, theneedle jet and jet needle serve to control proper air/fuel mixtureratio at the medium throttle valve opening (between 1/4 and 3/4 opening).

Having the proper needle jet and jet needle has a major impacton engine performance at partial load. The jet needle tapers offat one end and the clearance between the jet needle and theneedle jet increases as the throttle valve opening gets wider. Theair/fuel mixture ratio is controlled by the height of the “E” clipinserted into one of the five slots provided in the head of the jetneedle. The previous chart shows the variation of fuel flowbased on the height of the “E” clip.

35

Pilot Jet IndicatorNumber

Air Screw

E-Clip Position vs. Fuel Flow

Throttle Valve Opening

234

4

3

2

15 50 75 100%

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FUEL SYSTEM

Jet Needle

The jet needle has five adjustment grooves cut into the upperportion, and is tapered from approximately the middle of theneedle to the lower end. The top is fixed to the center of thethrottle valve by the needle clip, and the tapered end extends intothe needle jet. Fuel flows through the space between the needlejet and jet needle. This space does not vary until the throttlereaches the 1/4 open point. At that time the tapered portion of theneedle begins to move out of the jet, affecting fuel flow as theopening enlarges. If the needle clip is changed from the standardposition to a lower groove, the needle taper starts coming out ofthe jet sooner, resulting in a richer mixture. Moving the cliphigher produces a leaner mixture. If the taper is worn due tovibration, fuel flow may be significantly affected.

Needle Jet

The needle jet works in conjunction with the jet needle toregulate fuel flow rate. An air bleed opening in the side of theneedle jet brings in air measured by the air jet. This air initiatesthe mixing and atomizing process inside the needle jet.

Throttle Opening vs. Fuel Flow

In a full throttle condition the cross sectioned area between thejet needle and the needle jet is larger than the cross sectionedarea of the main jet. The main jet therefore has greater controlover fuel flow.

Throttle Slide

The throttle slide controls the rate of engine air intake by movingup and down inside the main bore. At small throttle openings, airflow control is performed chiefly by the cutaway. By controllingair flow the negative pressure over the needle jet is regulated, inturn varying the fuel flow.

Throttle valves are numbered 1.0, 1.5, 2.0, etc., according to thesize of the cutaway. The higher the number, the leaner thegasoline/air mixture.

Leaner

Richer

Position#

Jet Needle

Needle Jet

Main Jet

ClosedThrottle

One-halfThrottle

FullThrottle

SmallClearance

MediumClearance

LargeClearance

Throttle Valve

Higher cutaway number = leaner mixture

Engine Air Box Side

Cutaway

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FUEL SYSTEM

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Main Jet

When the throttle opening becomes greater and the area betweenthe needle jet and jet needle increases, fuel flow is metered bythe main jet. The number on the jet indicates the amount of fuelCCs which will pass through it in one minute under controlledconditions. Larger numbers give a greater flow, resulting in aricher mixture.

Main jets are screwed directly into the needle jet base.

Pilot System (Idle - 3/8 Throttle)

The pilot system’s main function is to meter fuel at idle and lowspeed driving. Though its main function is to supply fuel at lowspeed, it does feed fuel continuously throughout the entireoperating range.

Fuel for the pilot jet is drawn from the float bowl, mixed with airregulated by the air screw, and delivered to the engine throughthe pilot outlet.

The mixture is regulated to some degree by adjusting the airscrew. When the air screw is closed, the fuel mixture is madericher as the amount of air is reduced. When the air screw isopened, the mixture is made more lean as the amount of air isincreased.

Main Jet

Hex Style Main Jet

Larger Number = Richer Mixture

Main Jet

Pilot Jet

Air Screw

Pilot

By-pass

Throttle Stop(Idle Speed)Screw

Throttle Valve

General Carburetor Representation

Outlet

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FUEL SYSTEM

Slide Cutaway (1/8 - 3/8 Throttle)

Throttle valve cutaway effect is most noticeable at 1/4 throttleopening. The amount of cutaway is pre-determined for a givenengine to maintain a 14:1 air/fuel ratio at part throttle. A steepangle would indicate a fairly lean mixture because there is lessresistance to air flow. A flat angle would provide a much richermixture because there is more resistance to air flow.

The venturi shape can be adjusted for each engine’s breathingcharacteristics by using a different valve cutaway angle. Anumber will be stamped into the bottom of the valve (e.g. 2.5)indicating the size of the cutaway. The higher the number, thesteeper the angle.

Jet Needle / Needle Jet(3/8 - 3/4 Throttle)

The jet needle and needle jet have the most effect between 3/8and 3/4 throttle opening. Some mixture adjustment can beaccomplished by changing the location of the “E” clip on theneedle. Moving the clip down raises the needle in the jet passageand richens the mixture. Moving the clip up lowers the needlein the jet passage and leans the mixture. Letter and number codesare stamped into the needle and the jet indicating sizes andtapers of each.

General Carburetor Representation

Cutaway Angle

Air Jet

Air Box Side

Pilot Jet

Needle Jet

Main Jet

EngineSide

Pilot Outlet

By-pass

Jet Needle

Throttle Valve

General Carburetor Representation

Clip Position(Shown in #3)

Air Jet

AirBoxSide

EngineSide

Pilot Jet

Needle Jet

Main Jet

Pilot Outlet

By-pass

Jet Needle

Throttle Valve

Jet Needle “E” Clip Position

1

3

5

2

4

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FUEL SYSTEM

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Main System (3/4 to Full Throttle)

The main system is designed for delivering fuel between lowspeed and high speed operation. This system is made up of thejet needle, needle jet, and main jet. The main system begins totake effect as soon as there is enough air flow into the carburetorventuri to draw fuel up through the main jet and needle jetassembly. This system works in conjunction with the needle jetsystem.

During low speed driving, there is very little clearance betweenthe jet needle and the needle jet; therefore, very little fuel fromthe main jet can pass between the jet needle and the needle jet.As the throttle valve opening is increased, the tapered jet needleis raised farther out of the needle jet, allowing greater fuel flow.Under full throttle opening, the cross sectioned area of clearancebetween the jet needle and the needle jet becomes greater thanthe cross sectioned area of the main jet. Thus the main jet is nowcontrolling the amount of fuel flow.

Fuel Delivery

The throttle opening chart below demonstrates componentrelationship to fuel flow versus throttle valve opening.

The pilot system’s main function is that of a low speed jet. Itsmost effective range of fuel delivery is from idle toapproximately 3/8 throttle valve opening.

The throttle slide controls the rate of engine air by its movementup and down in the carburetor venturi. At small throttle openingsthe air flow is regulated chiefly by the valve cutaway, withgreatest effectiveness at 1/4 throttle opening. Throttle valves arenumbered 1.0, 1.5, 2.0, etc., according to the size of the cutaway.Decreasing the cutaway number will increase the amount of fueldelivered in its effective range.

The jet needle and needle jet have an effective operating rangefrom approximately 1/8 to 7/8 throttle opening. The amount offuel delivered during this range relies upon the jet needle clipposition, as well as the needle jet size and other specifications.

The main jet affects fuel delivery at 1/4 throttle and consistentlyincreases to full throttle opening.

Vent System

The fuel tank vent supplies atmospheric pressure to the fuel inthe tank. The vent must be free of debris and restrictions toprevent lean mixture and possible engine damage. All vent linesmust be properly routed to prevent damage to the line and toprevent contaminants from entering the tank.

General Carburetor Representation

Air Jet

AirBoxSide

EngineSide

Pilot Jet

Needle Jet

Main Jet

Pilot Outlet

By-pass

Jet Needle

Throttle Valve

THROTTLE OPENING - Theory

Throttle Valve Cut-Away

Jet Needle/Needle Jet

EFFECT

INC

RE

AS

ING

DE

CR

EA

SIN

G

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FUEL SYSTEM

CARBURETOR SERVICE

Carburetor Cleaning

1. Thoroughly clean the carburetor body, jets, and allpassages with carburetor cleaner or electrical contactcleaner.

2. If the carburetor is extremely dirty or contaminated withfuel residue and varnish, soak for short periods only incarburetor cleaner, and rinse in hot water.

3. Replace the jets if they have a buildup of fuel residue orbacterial growth that cannot be removed. Even a smallamount of residue will reduce the flow characteristics of thejet.

4. Verify all passages and jets are unobstructed by sprayingelectrical contact cleaner through the passages.CAUTION: Do not use wire or welding tip cleaners as theorifice size may be altered.

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

Carburetor Inspection

1. Inspect jet needle and needle jet for wear. Look fordiscoloration, shiny spots, or an area that looks differentthan the rest of the needle. The middle to upper portion ofthe needle contacts the needle jet and is the most likelywear point. If jet needle shows signs of wear replace boththe needle and needle jet to prevent a rich condition. TIP:A worn needle jet is difficult to spot. To check, slide aslightly larger new jet needle into the needle jet and hold itto a light source. Light will be visible between the needleand needle jet if it is worn.

2. Inspect the inlet needle tapered surface for any sign of wearor damage. Be sure the spring loaded pin is free moving andreturns freely when pushed. The inlet needle and seatshould be pressure tested after assembly.

Float Height Adjustment

1. Illustration 1: Place the throttle side of the carburetor at alevel position to remove weight from float arm. In this

WARNING

Protect eyes from contact with cleaner. Takeappropriate safety measures during theseprocedures.

Safety glasses and chemical resistant glovesare required. Should you get cleaner in youreyes or if you swallow cleaner, seek medicalattention immediately.

Carburetor cleaners can be extremely caustic.Extended periods of soaking can loosen theadhesive sealer on the passage drill-way plugs.

Do not soak rubber or plastic components suchas the vacuum slide diaphragm, needle seatscreen, or O-rings in caustic cleaning solutions.Irreparable damage may occur.

Do not use agitator-type carburetor cleaningequipment. Rubber parts must be cleaned withmild detergent and hot water only.

Jet Needle

Inspect this area

Needle Jet

Good Condition

Seat

Needle

Wear Areas

Worn

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FUEL SYSTEM

4

position, the float tongue will rest slightly outward.

2. Illustration 2: With the carburetor at rest and level, slightlytilt the carburetor back. The float should fall into the correctposition, with the float tongue resting lightly on the inletneedle valve pin without compressing the spring. Thebottom of the float should be parallel with the float bowlmating surface. Illustration 3

NOTE: If the float is past parallel with the matingsurface, the carburetor has likely been tilted backtoo far and the float tongue is compressing theneedle valve pin.

3. Measure the height from the float bowl mating surface tothe top of step of the float as shown in Illustration 2. Bothsides of float should be parallel to each other. Themeasurement should be made at the mid-point on top of thefloat using Float Adjustment Tool (PN 2872314) or avernier caliper. When measuring the height, verify the inletneedle valve spring is not compressed.

Needle and Seat Leak Test

1. Invert the carburetor and install a Mity-Vac™ (PN2870975) to the fuel inlet fitting. Apply 5 PSI pressure toinlet fitting. The needle and seat should hold pressureindefinitely. If not, inspect needle and seat and seat O-ringor gasket.

Carburetor Assembly

1. Replace parts in proper order. Refer to the parts explodedview for more information.

2. Install the air mixture screw, spring, washer, and O-ring asan assembly. Lubricate the O-Ring with oil or light greasebefore installation. CAUTION: Do not damage the O-ringor screw during installation. Turn the screw in until itlightly contacts the seat. Back out the specified number ofturns. NOTE: The final pilot (idle) mixture must beadjusted with the engine running. Refer to Chapter 2.

= In. / mm.

Float Height:Parallel to Gasket Surface ± 1mm

Float Outward

Carburetor LevelIll.1

Ill.2Float Tongue is restingon spring seat

Parallel with FloatBowl Mating Surface

Air Screw Base Setting(Set at Factory)

Factory Specification: 1 Turn Out

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FUEL SYSTEM

Carburetor Float Bowl Draining

The carburetor float bowl should be drained periodically toremove moisture or sediment from the bowl, or before extendedperiods of storage.

NOTE: Drain plug is located on the side of the floatbowl.

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

2. Loosen drain plug and allow fuel in the float bowl and fuelline to drain completely.

3. Inspect the drained fuel for water or sediment.

4. Tighten drain plug.

5. Turn fuel valve to “ON”.

6. Inspect carburetor for fuel leaks

7. Start machine and re-check for leaks.

Fuel Level Test

A fuel level test can be performed on some models if the drainhose fitting is accessible. Be sure to re-attach the bowl drainhose after performing the test. A fuel level test allows you toobserve the height of the fuel in the float bowl without removingthe carburetor. The fuel level can be observed with the engineeither running or shut off, however, engine must run briefly toallow fuel level to stabilize.

1. Attach a clear line to drain fitting. Be sure line fits tightlyon fitting. Position hose along side of carburetor as shown.

2. Open bowl drain screw by turning counterclockwiseapproximately two turns. Start and run engine for 3 to 5seconds to allow fuel level to stabilize in the line. If levelis out of specification, remove carburetor and inspect inletneedle and seat, float height, passages, etc.

NOTE: If a line was removed to perform thisprocedure, it must be replaced.

Carburetor Bowl Drain Screw

RES

ON

OFF

Bowl MatingSurface

1.5mm.060”

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FUEL SYSTEM

4

TROUBLESHOOTING

Fuel Starvation / Lean Mixture

Symptoms: Hard start or no start, bog, backfire, poppingthrough intake / exhaust, hesitation, detonation, low power,spark plug erosion, engine runs hot, surging, high idle, idlespeed erratic.

• No fuel in tank

• Restricted tank vent, or routed improperly

• Fuel lines or fuel valve restricted

• Fuel filter plugged

• Carburetor vent line(s) restricted

• Plugged or restricted inlet needle and seat screen orinlet passage

• Clogged jets or passages

• Float stuck, holding inlet needle closed or inlet needlestuck

• Float level too low

• Intake air leak (throttle shaft, intake ducts, airbox or aircleaner cover)

• Slide stuck closed or sticky

• Improper spring

• Jet needle position incorrect

• Incorrect pilot screw adjustment

Rich Mixture

Symptoms: Fouls spark plugs, black, sooty exhaust smoke,rough idle, poor fuel economy, engine runs rough/ misses, poorperformance, bog, engine loads up, backfire.

• Air intake restricted (inspect intake duct)

• Air filter dirty/plugged

• Choke plunger sticking, incorrectly adjusted choke

• Choke cable binding or improperly routed

• Incorrect pilot air/fuel screw adjustment

• Faulty inlet needle and seat

• Faulty inlet needle seat O-Ring

• 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 / slide return spring

• Fouled spark plug

Poor Idle

Idle Too High

• Idle adjusted improperly/idle mixture screw damaged

• Sticky slide

• Throttle cable sticking, improperly adjusted, routedincorrectly

• Choke cable sticking, improperly adjusted, routedincorrectly

• Plugged or restricted idle jet

Idle Too Low

• Choke cable bending or incorrectly adjusted

• Idle speed set incorrectly

• Idle mixture screw misadjusted or damaged

• Belt dragging

• Ignition timing incorrect

• Worn jet needle/needle jet

• Plugged or restricted idle jet

Erratic Idle

• Choke cable bending or incorrectly adjusted

• Throttle cable incorrectly adjusted

• Air leaks, dirty carburetor passages (pilot circuit)

• Pilot mixture screw damaged or adjusted incorrectly

• Tight valves

• Ignition timing incorrect

• Belt dragging

• Dirty air cleaner

• Engine worn

• Spark plug fouled

• Idle speed set incorrectly (speed limiter)

• Worn jet needle/needle jet

• Plugged or restricted idle jet

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FUEL SYSTEM

NOTES

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4.16

BODY / STEERING / SUSPENSION

CHAPTER 5

BODY / STEERING / SUSPENSION

5

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

PHOENIX BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3BODY ASSEMBLY EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

PHOENIX BODY DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4SEAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4HEADLIGHT COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4FOOTREST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4FRONT CAB REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5SIDE PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5REAR CAB REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5

STEERING / FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6

STEERING SPINDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7

BALL JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8

STEERING POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

HANDLEBAR BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

A-ARM SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11A-ARM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

SHOCK REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12FRONT AND REAR SHOCK REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12

SWING ARM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12SEE CHAPTER 7 FOR REAR SWING ARM REPLACEMENT / SERVICE. . . . . . . . . . 5.12

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12

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5.1

BODY / STEERING / SUSPENSION

GENERAL INFORMATION

Torque Specifications

Special Tools

PART NUMBER TOOL DESCRIPTION

Front A-Arm Attaching Bolts 30 ft. lbs. (41 Nm)

Front A-Arm Ball Joint Stud Nut 35 ft. lbs. (47 Nm)

Handlebar Adjuster Block 10-12 ft. lbs. (14-17 Nm)

Steering Post Lower Nut 39 ft. lbs. (53 Nm)

Master Cylinder Mount Bolts 45-55 in. lbs. (5.2-6.3 Nm)

Rear Shock Bolt (top & bottom)

33 ft. lbs.(44 Nm)

Front Shock Bolt (top & bottom)

33 ft. lbs.(44 Nm)

Front Spindle Nut 40 ft. lbs.(55 Nm)

Front Wheel Nut 30 ft. lbs.(41 Nm)

Rear Hub Nut 80 ft. lbs.(108 Nm)

Rear Wheel Nut 30 ft. lbs.(41 Nm)

Swing Arm Pivot Bolts See Chapter 7

Tie Rod End Jam Nut 14 ft. lbs. (19 Nm)

Tie Rod End Attaching Nut 30 ft. lbs. (35-41 Nm)

PART NUMBER TOOL DESCRIPTION

2870871Ball Joint Replacement

Tool

2870623Spring Compression

Tool

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5.2

BODY / STEERING / SUSPENSION

5

PHOENIX BODY

Body Assembly Exploded View

242

242

242

242

Apply LoctiteTM 242 tothe bolt threads.

A

B

C

D

D

E

F

GG

H

A. Seat

B. Headlight Housing

C. Rear Fender

D. Side Panel

E. Tank Cover

F. Front Fender

G. Foot Rest

H. Front Bumper

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5.3

BODY / STEERING / SUSPENSION

PHOENIX BODY DISASSEMBLY

Seat Removal

Refer to the pictures and exploded view on Page 5.3

1. Pull release lever at left rear of seat. Lift and pull seatrearward, disengaging seat from the front cab

Headlight Cover Removal

1. Pull up and out to release the locking tabs.

2. If replacing the headlight, remove the 3 screws retaining theheadlight to the bottom front side of the cover.

Footrest Removal

1. Remove the 4 screws from the bottom of the footrest.

2. Then remove the 8 screws that retain the front and rear cabto the footrest.

3. Repeat the procedure for the opposite side.

Lever

4

4

4

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5.4

BODY / STEERING / SUSPENSION

5

Front Cab Removal

1. Remove the 2 screws at the rear portion of the front cabwhere it attaches to the frame.

2. Then remove the 2 screws at the front portion of the frontcab where it attaches to the frame located under theheadlight cover.

3. If footrest is still attached, remove the 8 screws that securethe footrest to the front cab.

Side Panel Removal

1. Remove the 2 plastic inserts and 1 screw (per each side)

Rear Cab Removal

1. Remove the 2 bolts at the front portion and 2 bolts at therear portion of the cab.

2. If footrest is still attached, remove the 8 screws that securethe footrest to the rear cab.

Under Front Cab

Under Headlight Cover

Inserts

Screw

Under Seat

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5.5

BODY / STEERING / SUSPENSION

STEERING / FRONT SUSPENSION

Exploded View

NUT

WASHER

SNAP RING

COTTER KEY

BALL JOINT

A

B

C

D

E

G

F

J

30 ft-lb (41Nm)

H

L

I*

J

30 ft-lb (41Nm)

35 ft-lb(48Nm)

L

30 ft-lb (41Nm)K

A. HandlebarB. Block ClampsC. Steering BushingsD. Steering PostE. Center LinkF. Tie Rod AssemblyG. Steering Mount BlockH. A-ArmI. Steering KnuckleJ. A-Arm BoltsK. Grease ZerksL. Ball Joints

35 ft-lb (48Nm)

*NOTE: APPLY ANTI-SEIZE COMPOUNDONTO SPINDLE BEFORE HUB INSTALLATION

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5.6

BODY / STEERING / SUSPENSION

5

STEERING SPINDLE

Removal

1. Follow the steps in Chapter 7 “FRONT HUB REMOVAL”to remove the hub, if needed.

2. Remove the upper and lower ball joint cotter keys and castlenuts.

3. Lift up on the upper A-arm and pull the top ball joint fromthe steering spindle. Push down on the lower A-arm tomove the lower ball joint from the steering spindle.

Installation

1. Before installation check the condition of the ball joints.Joints should move freely and have no axial play.

2. Place the upper and lower A-arms into the steering spindle.

3. Install the castle nuts onto the upper and lower A-arms.Torque the nuts to 35 ft.lbs. (47 Nm).

4. Install new cotter pins into the castle nuts and ball joints.

BALL JOINT SERVICE

Removal

1. The A-arm must be removed to perform this procedure,Refer to “A-ARM REPLACEMENT” on page 5.15.

2. Be sure to remove the retaining ring from the top of the balljoint (See Ill. 1).

3. A driver must be used for the removal of the ball joints. Usethe dimensions above to fabricate or locate the correct sizedriver to use in the following process.

III. 1

Retaining Ring

A - arm

Ball Joint

1.75 in(4.45 cm)

1.375 in.(3.49 cm)

3 in.(7.62 cm)

* Outside diameter of driver cannot be any larger

Driver Dimensions

than 1.75 in. Inside diameter cannot be any smallerthan 1.375 in. Driver must be 3 in. or taller.

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5.7

BODY / STEERING / SUSPENSION

4. Use a press and correct size driver to remove the ball jointfrom the A-arm. NOTE: The driver must fit the insidediameter of the A-arm (See Ill. 3 below). This will allowthe ball joint to be properly pressed out of the A-armwithout damaging the A-arm.

Installation

1. Place the A-arm in the correct position for ball jointinstallation. Face the A-arm end flat on top of the driver.Carefully drive the ball joint into place until the ball jointis properly installed.

2. After the new ball joint is installed into the A-arm, installa NEW retaining ring. Upon A-arm installation onto thesteering knuckle, install a NEW cotter key also.

Press

Ball Joint

Driver

CorrectDriver Placement

The driver must fit the inside diameter of the A-arm end.

III. 3

Press

Driver

Ball Joint

Press

Driver

Ball Joint

NEW Cotter KeyNut & Washer

NEWRetaining Ring

A-arm

Ball Joint

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5.8

BODY / STEERING / SUSPENSION

5

STEERING POST

Assembly1. Torque the steering post nut (A) to 39 ft. lbs. (53 Nm). Align the holes and install the cotter pin (B), bending both ends of the

cotter pin around the nut in opposite directions.

2. Install the upper mount and thrust bearings. Torque the upper post nuts to 17 ft. lbs. (23 Nm).

3. Check the steering. The post must move freely and easily from full left to full right without binding. Check all cables andelectrical wires for binding and route as needed.

17 ft. lbs. (23 Nm)

39 ft. lbs.

40 ft. lbs. (54 Nm)

A

B

(53 Nm)

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5.9

BODY / STEERING / SUSPENSION

HANDLEBAR BLOCK

Installation Procedure1. Position the two steering post blocks (D) onto the handlebars as shown.

2. Install the four handlebar bolts and pod bracket (C) loosely into the blocks.

3. Install the front block bolts (A) first and evenly tighten the bolts down. Torque the 2 front bolts to specification.

4. Position the handlebar at the desired angle and evenly torque the 2 rear bolts (B) to specification.

5. Install the handlebar pod (E) and screws (F).

NOTE: There will be a slight gap on the backside of the blocks after the procedure is performed.

= T

Handlebar Bolt Torque:11 - 13 ft. lbs.(15 - 18 Nm)

B

C

D

E

F

Clean the knurling whenrepositioning handlebars

*Install and Torque Front Bolts First - A

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5.10

BODY / STEERING / SUSPENSION

5

A-ARM SERVICE

Exploded View

A-Arm Replacement

1. Elevate and safely support vehicle. Remove the frontwheel(s).

2. Remove the upper and lower ball joint cotter pins (K) fromthe ball joint studs (I & L) at wheel end of A-arm. Removethe ball joint nuts until the nuts are flush with end of the balljoints studs.

3. Push up on the upper A-arm (C) to remove the A-arm fromthe steering knuckle (J). Push down on the lower A-arm (H)to remove the A-arm from the steering knuckle (J).

4. Remove the lower shock bolt (M) from the lower A-armand remove the shock from the A-arm.

5. Loosen two bolts on the A-arm tubes (D) (upper and lowerA-arms) until A-arm can be removed.

6. Examine the A-arm shafts (E). Replace if worn. Discardhardware.

7. Insert A-arm shaft (E) into the new A-arm (C & H).

8. Install new A-arm assembly onto vehicle frame (upper andlower). Torque bolts to specification.

9. Attach upper A-arm (C) and lower A-arm (H) to steering

knuckle (J). Tighten both ball joint nuts to specification. Ifcotter pin holes are not aligned, tighten nut slightly to align.Install a new cotter pin with open ends toward rear ofmachine (upper and lower). Bend both ends in oppositedirections around nut.

10. Locate the grease fittings on each A-arm tube and pump A-arm full of grease.

1 Use new bolts upon reassembly. 2 Use new cotter pins upon reassembly. Install with open end toward rear of machine.

A. Grease ZerkB. ShockC. Upper A-ArmD. BoltE. A-Arm ShaftF. BoltG. BushingH. Lower A-ArmI. Lower Ball JointJ. Steering KnuckleK. Cotter PinsL. Upper Ball JointM. Shock BoltN. Ball Joint Castle Nut

A

GE

D

L

K

35 ft-lb(48Nm)

J

B

M 33 ft-lb(44Nm)I

KH

GE

F

A

D 35 ft-lb(48Nm)

N

30 ft-lb(41Nm)

30 ft-lb(41Nm)

C

2

2

1

WARNINGUpon installation completion, test vehicle at low

speeds before putting into regular service.

= T

A-arm Attaching Bolt Torque:30 ft. lbs. (41 Nm)

Ball Joint Stud Nut Torque:35 ft. lbs. (48 Nm)

Shock Bolt Torque:33 ft. lbs. (44 Nm)

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5.11

BODY / STEERING / SUSPENSION

SHOCK REPLACEMENT

Front and Rear Shock Replacement

1. Elevate and safely support vehicle. Remove the wheel(s)to reduce unsprung weight.

2. Remove the upper shock bolt from the frame mount andallow the shock and lower suspension to drop.

3. Remove the lower shock bolt from the lower mount andremove the shock.

4. Examine the shock mounts for signs of wear or damage.

5. Compress the shock spring using PN 2870623 springcompression tool and remove the retaining components.Remove the spring and old shock from the compressor.Note the order of parts removed for reinstallation purposes.

6. Install the new shock assembly inside the spring and placeinto the spring compressor. Compress the spring andreinstall the retaining components.

7. Install the shock assembly and bolt into the upper mountfirst, then raise and guide the lower mount onto the shock.Insert the lower mount bolt.

8. Install and torque nuts to specification.

SWING ARM REPLACEMENT

See Chapter 7 For Rear Swing Arm Replacement / Service

DECALS

Replacement

The side panels, front and rear fender cabs are plasticpolyethylene material. Therefore, they must be “flame treated”prior to installing a decal to ensure good adhesion. A bonus ofthe flame treating procedure is it can be used to reduce oreliminate the whitish stress marks that are sometimes left aftera fender or cab is bent, flexed, or damaged.

To flame treat the decal area:

1. Pass the flame of a propane torch back and forth quicklyover the area where the decal is to be applied until thesurface appears slightly glossy. This should occur after justa few seconds of flame treating. Do not hold the torch tooclose to the surface (2-3 inches from the flame tip isrecommended). Keep the torch moving to prevent damage.

2. Apply the decal on one edge first. Slowly lay downremainder of the decal while rubbing lightly over the decalsurface to eliminate any air bubbles during the application.

WARNINGShock springs are under tension. Do not attempt removal without using the proper tools. Serious injury could occur. Wear safety gear at all times

during shock removal/installation.

= T

Shock Bolt Torque:33 ft. lbs. (44 Nm)

WARNINGUpon installation completion, test vehicle at low

speeds before putting into regular service.

WARNING

The following procedure involves the use of an openflame. Perform this procedure in a well ventilatedarea, away from gasoline or other flammablematerials. Be sure the area to be flame treated isclean and free of gasoline or flammable residue.

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5.12

BRAKES

CHAPTER 6

BRAKES

6

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2BRAKE SYSTEM INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

BRAKE SYSTEM SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3PHOENIX / SAWTOOTH BRAKE SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . 6.4

FRONT BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5CALIPER / MASTER CYLINDER EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6

MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7FRONT BRAKEFLUID REPLACEMENT AND BLEEDING PROCEDURE . . . . . . . . . . . 6.7MASTER CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9

FRONT BRAKE PAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11

FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13BRAKE DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13BRAKE DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13

FRONT BRAKE CALIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16CALIPER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17

REAR BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18REAR MECHANICAL BRAKE SYSTEM OVERVIEW / TROUBLESHOOTING. . . . . . . 6.18REAR BRAKE SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19

REAR BRAKE FOOT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20FOOT BRAKE PEDAL SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20

REAR BRAKE SHOE / DRUM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22

REAR BRAKE ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23

REAR BRAKE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24

REAR BRAKE FREEPLAY / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24REFER TO CHAPTER 2 TO ADJUST THE REAR BRAKES. . . . . . . . . . . . . . . . . . . . . 6.24

BRAKE SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25

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6.1

BRAKES

SPECIFICATIONS

General Specifications

Torque Specifications

NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures are usedwhen torquing certain bolts and fasteners.

SPECIAL TOOLS

Front Brake Caliper

Item Standard Service Limit

Brake Pad Thickness .298" / 7.6 mm .180" / 4.6 mm

Brake Disc Thickness .150 - .165" / 3.810 - 4.166 mm .140" / 3.556 mm

Brake Disc Thickness Variance Between Measurements - .002" / .051 mm

Brake Disc Runout - .010" / .254 mm

Rear Brake Drum

Item Standard Service Limit

Brake Shoe Thickness - 0.08" / 2 mm

Brake Drum Inner Diameter 5.52" / 140.2 mm 5.55" / 141 mm

Item Torque(ft. lbs. except where noted*)

Torque(Nm)

Front Caliper Mounting Bolts 18.0 25

Rear Brake Plate Stud Bolts/Nuts 15.0 21

Master Cylinder ReservoirCover Bolts - Front 5 in. lbs. 0.56

Brake Line Banjo Bolt 15.0 21

Front Brake Disc 18.0 25

Front Master Cylinder Clamp Bolts 25 in. lbs. 3.0

Caliper Bleed Screws 27 in. lbs. 3.1

PART NUMBER TOOL DESCRIPTION

2870975 Mity Vac™PartS

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6.2

BRAKES

6

BRAKE SYSTEM INFORMATION

Brake System Service Notes

Disc brake systems are light weight, low maintenance, andperform well in the conditions ATVs routinely encounter. Thereare a few things to remember when replacing disc brake pads orperforming brake system service to ensure proper systemfunction and maximum pad service life.

• Optional pads are available to suit conditions in yourarea. Select a pad to fit riding style and environment.

• Do not over-fill the master cylinder fluid reservoirs.

• Make sure the brake levers return freely and completely.

• Check and adjust master cylinder reservoir fluid levelsafter pad service.

• Make sure atmospheric vent on reservoirs areunobstructed.

• Test for brake drag after any brake system service andinvestigate cause if brake drag is evident.

• Make sure caliper moves freely on guide pins.

• Inspect caliper piston seals for foreign material thatcould prevent caliper pistons from returning freely.

• Perform a brake burnishing procedure after installingnew pads to maximize service life.

Brake Noise Troubleshooting

Dirt or dust buildup on the brake pads and disc is the mostcommon cause of brake noise (squeal caused by vibration). Ifcleaning does not reduce the occurrence of brake noise, check thebacking of each pad for worn spots allowing metal to metalcontact. See table below.

CAUTION

Use only DOT brake fluid as an assembly aid for all procedures described in this chapter to

prevent brake system contamination. DO NOT USE LUBRICANTS

OF ANY KIND FOR ASSEMBLY.

BRAKE NOISE TROUBLESHOOTING

POSSIBLE CAUSE REMEDY

Dirt, dust, or imbedded material on pads or discSpray disc and pads with a non-flammable aerosol brake cleaner only! Remove pads and/or disc hub to clean imbedded material from disc or pads.

Pad(s) dragging on disc (noise or premature pad wear)Improper adjustmentInsufficient lever or pedal clearanceMaster cylinder reservoir overfilledMaster cylinder compensating port restrictedMaster cylinder piston not returning completelyCaliper piston(s) not returningOperator error (riding the brake / park brake applied)

Adjust pad stop (front calipers)Check position of controls & switches.Set to proper levelClean compensating portInspect. Repair as necessaryClean piston(s) seal Educate operator

Loose wheel hub or bearings Check wheel and hub for abnormal movement.

Brake disc warped or excessively worn Replace disc

Brake disc misaligned or loose Inspect and repair as necessary

Noise is from other source (chain, 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 Change to a softer or harder pad

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6.3

BRAKES

Phoenix Brake System Operation

FRONT HANDLE BRAKE SYSTEM

The front brake system is hydraulically actuated.When the right front brake lever (master cylinder)is applied, the two front brake calipers are activeand under pressure.

Front Brake

Phoenix Brake Levers

Left Brake Lever

Rear Foot Brake Lever (Right Side View of ATV)

REAR BRAKE SYSTEM

Rear BrakeHandle

Rear Foot Brake

The rear brake system operates using mechanical brakecables. The left front brake handle and the right foot brake operate the rear brake drum assembly.

Right Brake Lever (Master Cylinder)

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6.4

BRAKES

6

FRONT BRAKE SYSTEM

Caliper / Master Cylinder Exploded View

A. Master Cylinder

B. Brake Line

C. Pressure Switch

D. Brake Line Retainer

E. Wheel Hub

F. Line Retainer

G. Banjo Bolt & Washers

H. Caliper

I. Caliper Mount Bolt

C

A

B

B

B

D

GF

EH

G

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6.5

BRAKES

Hydraulic Brake System Operation

The Polaris brake system consists of the following components or assemblies: brake lever; master cylinder; hydraulic hose; brakecalipers (slave cylinder); brake pads; and brake discs, which are secured to the drive line.

When the hand activated brake lever (A) is applied it contacts a piston (B) within the master cylinder. As the master cylinder pistonmoves inward it closes a small opening (compensating port) (C) within the cylinder and starts to build pressure within the brakesystem. As the pressure within the system is increased, the piston (D) located in the brake caliper moves outward and applies pressureto the moveable brake pad. This pad contacts the brake disc and moves the caliper in its floating bracket, pulling the stationary sidepad into the brake disc. The resulting friction reduces brake disc and vehicle speed. As the lever pressure is increased, the brakingaffect is also increased.

The friction applied to the brake pads will cause the pads to wear. As these pads wear, the piston within the caliper moves furtheroutward and becomes self adjusting. Fluid from the reservoir fills the additional area created when the caliper piston moves outward.

Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause the brakes to feelspongy. Too much fluid could cause brakes to drag due to fluid expansion.

Located within the master cylinder is the compensating port (C) which is opened and closed by the master cylinder piston assembly.The port is open when the lever is released and the master cylinder piston is outward. As the temperature within the hydraulic systemchanges, this port compensates for fluid expansion (heated fluid) or contraction (cooled fluid). During system service, be sure thisport is open. Due to the high temperatures created within the system during heavy braking, it is very important that the master cylinderreservoir have adequate space to allow for fluid expansion. Never overfill the reservoir! Fill to 1/4” - 5/16” (.64 - .80 cm) fromtop of the cylinder.

This system also incorporates a diaphragm (E) as part of the cover gasket; and a vent port (F) located between the gasket and thecover. The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts.Make sure the vent is open and allowed to function. If the reservoir is over filled or the diaphragm vent is plugged the expandingfluid may build pressure in the brake system leading to brake failure.

When servicing Polaris ATV brake systems use only Polaris DOT-approved High Temperature Brake Fluid.

WARNING

Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture. This causes the boiling temperature of the brake fluid to drop,

which can lead to brake fade and possible loss of control.

Typical Hydraulic Brake System Compensating port compensatesfor temperature changes by allowing

fluid back to master cylinderC

MovableBrake Pad

D

A B

F

E

Must be clear to allowproper diaphragm

movement

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6

MASTER CYLINDER

Front BrakeFluid Replacement and Bleeding Procedure

NOTE: When bleeding the brakes or replacing thefluid always start with the caliper farthest from themaster cylinder.

NOTE: This procedure should be used to changefluid or bleed brakes during regular maintenance.

1. Clean reservoir cover thoroughly.

2. Remove screws, cover, and diaphragm (C) from reservoir.

3. Inspect vent slots (A) in cover and remove any debris orblockage.

4. If changing fluid, remove old fluid from reservoir with aMity Vac™ (PN 2870975) or similar tool.

NOTE: Do not remove brake lever when reservoirfluid level is low.

5. Add brake fluid to the upper level mark on reservoir.

6. Begin bleeding procedure with the caliper that is farthestfrom the master cylinder. Install a box end wrench on thetop caliper bleeder screw. Attach a clean, clear hose tofitting and place the other end in a clean container. Be surethe hose fits tightly on fitting.

NOTE: Fluid may be forced from compensation port(B) when brake lever is pumped. Place diaphragm(C) in reservoir to prevent spills. Do not install cover.Refer to Illustration on Page 6.6.

7. Slowly pump brake lever until pressure builds and holds.

8. While maintaining lever pressure, open bleeder screw torelease any trapped air. Fluid should run clear. Closebleeder screw and release brake lever. NOTE: Do notrelease lever before bleeder screw is tight or air may bedrawn into caliper.

9. Repeat procedure until clean fluid appears in bleeder hoseand all air has been purged. Add fluid as necessary tomaintain level in reservoir.

CAUTION

Always wear safety glasses while performing these procedures.

CAUTION

Brake fluid will damage finished surfaces. Do not allow brake fluid to come in

contact with finished surfaces.

AB

C

D

CAUTION

Maintain at least 1/2” (1.27 cm) of brake fluid in the reservoir to prevent air from

entering the master cylinder.

MAX FILL LINE

BleederScrews

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10. Tighten bleeder screw securely and remove bleeder hose.Torque bleeder screw to specification.

11. Repeat procedure Steps 5-9 for the remaining caliper(s).

12. Add brake fluid to the proper level.

13. Install diaphragm, cover, and screws. Torque the screws tospecification.

14. Field test machine at low speed before putting into service.Check for proper braking action and lever reserve. Withlever firmly applied, lever reserve should be no less than 1/2” (1.3 cm) from handlebar.

15. Check brake system for fluid leaks and inspect all hoses andlines for wear or abrasion. Replace hose if wear or abrasionis found.

Master Cylinder Removal

1. Clean master cylinder and reservoir assembly. Make sureyou have a clean work area to disassemble brakecomponents.

2. Place a shop towel under brake line connection at mastercylinder. Loosen banjo bolt (A); remove bolt and sealingwashers.

3. Loosen the master cylinder clamp bolts (B) on thehandlebar side of the master cylinder.

4. Remove master cylinder from handlebars.

= T

Bleeder Screw Torque: 27 in.lbs. (3 Nm)

=

Master Cylinder Fuild Level:

MAX level inside reservoir - Sight glass must look dark, if sight glass is

clear, fluid level is too low

= T

Reservoir Cover Torque: 5 in. lbs. (0.56 Nm)

CAUTION

Brake fluid will damage finished surfaces. Do not allow brake fluid to come in

contact with finished surfaces.

B

A

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Master Cylinder Installation

NOTE: Install master cylinder on handlebars. Torquemounting bolts to specification. Torque the top bolt first.

NOTE: To speed up the brake bleeding procedurethe master cylinder can be purged of air beforebrake line is attached. Fill with DOT-approved BrakeFluid and pump lever slowly two to three times withfinger over the outlet end to purge master cylinder ofair.

5. Place new sealing washers on each side of banjo brake line.Install the brake line into the master cylinder. Torque thebrake switch bolt to specification.

Front Brake Lines

Brake Lines

Banjo Bolt

Caliper

Line Retainer

Brake Handle

Master Cylinder Assembly Cover5 in. lbs. (0.56Nm) Sight Glass

Diaphragm

Master CylinderPiston Assy

ClampBolts

25 in. lbs.(3 Nm)

= T

Master Cylinder Clamp Bolt Torque:25 in. lbs. (3 Nm)

= T

Brake Switch Bolt Torque:15 ft. lbs. (21 Nm)

15 ft.-lb(21Nm)

A

Torque to 15 ft. lbs. (21 Nm)

Brake Line

Sealing Washers

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6. Fill reservoir with DOT-approved Polaris Brake Fluid.

7. Perform bleeding procedure. Check all connections forleaks and repair if necessary.

FRONT BRAKE PAD

Removal

1. Elevate and support front of machine.

2. Remove the front wheel. With the caliper installed loosenthe brake caliper slide bolts (A).

3. Remove the caliper bolts (B) and caliper from the mountbracket.

Polaris DOT-Approved Brake Fluid

CAUTION

Use care when supporting vehicle so that it does not tip or fall. Severe injury or damage may

occur if machine tips or falls.

A

B

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4. With pads installed, push caliper piston into caliper boreslowly using a C-clamp or locking pliers

NOTE: Brake fluid will be forced throughcompensating port into master cylinder fluidreservoir when piston is pushed back into caliper.Remove excess fluid from reservoir as required.

5. Remove the c-clips (C) from the end of the caliper slidebolts.

6. Remove the loose caliper slide bolts. The brake pad (D) willslide out of the caliper assembly when the caliper slide boltis removed.

7. Measure the thickness of the pad material. Replace pads ifworn beyond the service limit.

Installation

1. Install pads with friction material facing each other. Installthe slide bolts through the brake pads and tighten the slidebolts hand tight. Be sure pads and disc are free of dirt orgrease.

Caliper Bore

Clamp

C

D

= In. / mm.

Front Brake Pad Thickness:New: .298” / 7.6 mm

Service Limit: .180” / 4.60 mm

WARNING

If the brake pads are contaminated with grease, oil, or liquid soaked do not use the pads, use

only new clean pads.

Brake Pad MeasureThickness

Front Brake Pads

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2. Install caliper on the steering knuckle, and torque mountingbolts. (If previously removed.)

3. Use an Allen wrench or socket to torque the front caliperslide bolts to specification.

4. Slowly pump the brake lever until pressure has been builtup. Maintain at least 1/2” (12.7 mm) of brake fluid in thereservoir to prevent air from entering the brake system.

5. Be sure fluid level in reservoir is between MIN and MAXlines and install reservoir cap.

6. Install wheels and torque wheel nuts.

7. BRAKE BURNISHING: It is recommended that aburnishing procedure be performed after installation ofnew brake pads to extend service life and reduce noise. Startmachine and slowly increase speed to 30 mph. Graduallyapply brakes to stop machine. Repeat this procedure 10times, allowing brakes to cool sufficiently after each run.

= T

Front Caliper Mounting Bolts Torque: 18 ft. lbs. (24 Nm)

= T

Front Caliper Slide Bolts Torque: 33 ft. lbs. (45 Nm)

18 ft.-lb(24Nm

33 ft.-lb(45Nm)

=

Master Cylinder Fuild Level:

MAX level inside reservoir - Sight glass must look dark, if sight glass is

clear, fluid level is too low

= T

Front Wheel Nut Torque:30 ft. lbs. (41 Nm)

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6

FRONT BRAKE DISC

Brake Disc Inspection

1. Visually inspect the brake disc for nicks, scratches, ordamage.

2. Measure the disc thickness at 8 different points around thepad contact surface using a 0-1” micrometer. Replace discif worn beyond service limit.

3. Mount dial indicator as shown to measure disc runout.Slowly rotate the disc and read total runout on the dialindicator. Replace the disc if runout exceeds specifications.

Brake Disc Replacement

1. Apply heat to the hub in the area of the brake disc mountingbolts to soften the bolt locking agent.

2. Remove bolts and disc.

3. Clean mating surface of disc and hub.

4. Install disc on hub.

5. Install new bolts and tighten to specified torque.

= In. / mm.

Brake Disc Thickness:New .150 - .164” (3.810-4.166 mm)

Service Limit .140” / 3.556 mm)

Brake Disc Thickness Variance:Service Limit: .002” (.051 mm)

difference between measurements

= In. / mm.

Brake Disc Runout:Service Limit: .010” (.254 mm)

CAUTION

Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is

destroyed upon removal.

= T

Front Brake Disc Mounting Bolt Torque:18 ft. lbs. (24 Nm)

18 ft. lbs. (25 Nm)

Use new bolts with pre-appliedlocking agent.

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BRAKES

FRONT BRAKE CALIPER

Exploded View

NOTE: BRAKE COMPONENTS ARE NOT SOLD SEPARATELY,REFER TO YOUR PARTS BOOK FOR PARTS BREAK DOWN.

A

B

C

D

E

FG

H

N

I

K

L

M

J

33 ft.-lb(45Nm)

18ft-lbs (24Nm)

27 in-lb. (3Nm)

A. Anvil BodyB. BushingC. Brake PadsD. Caliper BracketE. PistonF. O-ringG. Dust BootH. Caliper BodyI. O-ringJ. SleeveK. Slide BoltL. Caliper BoltM. Bleeder ScrewN. Circlip

Apply Polaris DOT 3 brake fluid to component

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Caliper Removal

1. Remove brake pads. See Page 6.8-6.9.

2. Using a line wrench, loosen and remove brake line (A) tocaliper. Place a container under caliper to catch fluiddraining from brake line. Drain the fluid into the container.

3. Remove the two brake caliper mounting bolts (B) andremove the brake caliper.

Caliper Disassembly

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

2. Remove the caliper slide bolts (B), mounting bracket (C),and brake pads (D).

3. Remove the outside dust boot (E).

4. Remove the piston and dust seal (F).

CAUTION

Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if

machine tips or falls.

A

B

B

A

A

B C D

E

F

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5. Remove the caliper body bolts (G). Pull the caliper bodiesapart (if necessary).

6. Clean the caliper body, piston, and retaining bracket withbrake cleaner or alcohol.

NOTE: Be sure to clean seal grooves in caliperbody.

Caliper Inspection

1. Inspect caliper body bore for nicks, scratches or wear.Measure bore for roundness. Replace if damage is evident.

2. Inspect piston for nicks, scratches, wear or damage.Replace if damaged or worn.

3. Inspect the brake disc and pads as outlined for brake padreplacement in this chapter.

G

Inspect Piston

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Caliper Reassembly

4. Reassemble the two caliper halves if previouslydisassembled. Torque the caliper body bolts tospecification.

5. Lubricate with brake fluid and install new o-ring (A) in thecaliper body. Install the dust boot (B) over the caliper andseat the dust boot into caliper groove. Be sure groove isclean and free of residue or brakes may drag.

6. Coat piston and inside of caliper body with clean brakefluid. Install piston with a twisting motion while pushinginward. Piston should slide in and out of bore smoothly,with light resistance. NOTE: Be sure that the O-ring doesnot bind when installing the piston.

7. Seat the dust boot securely onto the caliper body.

8. Install the caliper mount (C), brake pads (D), caliper slidebolts (E), and c-clips (F).

Caliper Installation

9. Install caliper on hub spindle and torque mounting bolts tospecification.

= T

Caliper Body Bolt Torque:18 ft.lbs (24 Nm)

18 ft.-lb(24Nm)

B

A

= T

Caliper Mount Bolt Torque:18 ft.lbs (24 Nm)

F

D C

E

18 ft.-lb. (24Nm)

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BRAKES

10. Torque the caliper slide bolts to specification. Install thebrake line and torque with a line wrench to specification.

11. Follow brake bleeding procedure outlined in this chapter.

NOTE: BRAKE BURNISHING - It is recommended thata burnishing procedure be performed after installation ofnew brake pads to extend service life and reduce noise.Start machine and slowly increase speed to 30 mph.Gradually apply brakes to stop machine. Repeat thisprocedure 10 times, allowing brakes to cool sufficientlyafter each run.

REAR BRAKE SYSTEM

Rear Mechanical Brake System Overview / Troubleshooting

The Pheonix is equipped with mechanical rear drum brakes. Therear drum brake assembly is located on the rear left side of theATV. The drum brake assembly consists of backing plate (A),brake shoes (B), brake drum (C), and drum cover (D).

NOTE: Refer to Pages 6.8 and 6.9 for moreinformation on the rear brake system.

Troubleshooting - Poor Rear Brake Performance

• Worn rear brake shaft

• Incorrectly installed rear brake arm

• Contamination on brake shoes or drum

• Water or fluid in brake drum

• Worn brake shoes or drum

• Improperly adjusted brake

• Improperly routed brake cable

• Brake cable not adjusted correctly

= T

Caliper Slide Bolt Torque:33 ft.lbs. (45 Nm)

= T

Caliper Banjo Bolt Torque:15 ft.lbs. (21 Nm)

33 ft.-lb.(45Nm)

15 ft.-lb.(21Nm)

A

B

C

D

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REAR BRAKE SYSTEM EXPLODED VIEW

Rear Brake Drum OperationThe left front brake lever and the foot brake both move thebrake actuator (E). The brake actuator then rotates the shaft

and the brakes shoes (G) are pushed outward making with the brake drum (H).

A

B

D

C

E

F

G

H

I

A. Left brake LeverB. Hand Brake CableC. Right Foot brakeD. Foot Brake Cable

Hand Brake

Foot Brake

E. Brake ActuatorF. ShaftG. Brake ShoesH. Brake DrumI. Brake Cover

(F) contact

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BRAKES

REAR BRAKE FOOT PEDAL

Removal

1. Remove the right footwell if needed.

2. Remove the brake switch spring (A) and pedal return spring(B).

3. Remove the cotter pin (C) and washer from the pedal shaft.

4. Remove the brake cable (D) from the brake pedal.

5. Slide the brake pedal off of the lever shaft.

Installation

1. Apply a small amount of grease to the pedal shaft.

2. Attach the brake cable to the brake pedal and install thebrake pedal.

3. Install the washer and a NEW cotter pin (C).

4. Install the brake switch spring (A) and pedal return spring(B).

5. Adjust the rear brake as needed (Refer to Chapter 2 “REARBRAKE FREEPLAY / ADJUSTMENT” to adjust the rearbrakes) . Install the right footwell if previously removed.

Foot Brake Pedal Switch Removal

1. Remove the brake switch spring.

2. Loosen the jam nut (A) and remove the brake switch.

REAR BRAKE SHOE / DRUM

Removal

1. Remove the rear tire and hub assembly (refer to “REARHUB REMOVAL” in Chapter 7).

2. Remove the phillips screws (C) that secure the drum cover(A). Remove the brake drum (B).

A

BD

C

A

A

B

C

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3. Loosen the adjuster nut on the brake arm.

4. Remove the shoe springs (D) using a spring tool.

5. Remove the brake shoes from the drum assembly.

NOTE: To remove the brake shaft (E) refer to “REARbrake Arm Removal” later in this chapter.

INSPECTION

1. Measure the thickness of the pad material. Replace pads ifworn beyond the service limit.

CAUTION

Use caution when removing the springs. Wear safety goggles during this procedure, the spring

may cause serious bodily injury.

B

Foot Brake Upper Adjuster Nut

= In. / mm.

Rear Brake Shoe Service Limit:0.08” / 2 mm

E

Rear Brake Shoes

MeasureThickness

Service Limit - 0.08” (2 mm)

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BRAKES

2. Measure the thickness of the brake drum liner. Replace thedrum if worn beyond the service limit.

Installation

1. Place the bottom brake shoe (A) onto the brake plate (B).Be sure the rounded edge of the pad rests on the anchorpin.

2. Orientate the rear brake shaft (C) to a horizontal position.

3. Install the brake shoe springs (D) into the bottom brakeshoe.

4. Install the top brake shoe (E) and install the springs (D) intothe top brake shoe. Install a new O-ring (F) onto the brakeplate if needed.

5. Install the brake drum (G). Install the screws (H) that securethe rear cover (I). Install a new seal (J) in the rear cover (I)if needed.

6. Install the rear hub and wheel (refer to “REAR HUBINSTALLATION” in Chapter 7).

= In. / mm.

Rear Brake Inner Diameter:New: 5.52” / 140.2 mm

Service Limit: 5.55” / 141 mm

WARNING

If the brake shoes are contaminated with grease, oil, or liquid soaked do not use the

shoes, use only new clean shoes.

Rear Brake Drum

Measure I.DB F

C

E

D

A

C

Anchor Pin

G

H

I

J

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REAR BRAKE ARM

Disassembly

NOTE: The brake pads should be removed whenremoving the brake shaft. Refer to the “REAR BrakeShoe / Drum Removal” to remove the rear brakeshoes.

1 FOLLOW THE STEPS FOR THE “REAR BRAKE SHOE/ DRUM REMOVAL”.

2. Remove the bolt and nut (A) that secures the rear brake arm(B) to the brake shaft (C).

3. Remove the brake arm (B) from the brake shaft (C).

4. Remove the spring (D).

5. To remove the brake shaft (C), press the shaft inward. Pullthe brake shaft out on the drum side.

Installation

1. Install the brake shaft (C) if previously removed. Install anew O-ring (E) onto the shaft.

2. Install the spring (D). Align the tip of the spring into thealignment hole located in the brake plate.

3. Apply a light amount of grease onto the brake shaft. Installthe brake arm (B) with the spring (D) installed.

A

B

C

D B

C

E

C

D

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BRAKES

4. Install and tighten the bolt and nut (A).

REAR BRAKE PLATE

Removal

1. The rear brake shoes and brake arm must be removedbefore the brake plate can be removed. Refer to thefollowing sections: “REAR BRAKE SHOE / DRUM and“REAR BRAKE ARM”

2. Remove the four nuts (C) and studs (D) that secure thebrake plate to the axle tube.

3. Pull the brake plate (E) from the axle tube.

Installation

1. Install the four studs (D) that secure the brake plate to theaxle tube.

2. Install the brake plate (E) onto the axle tube and torque thenuts (C) to specification .

REAR BRAKEFREEPLAY / ADJUSTMENT

Refer to Chapter 2 to adjust the rear brakes.

“REAR BRAKE FREEPLAY / ADJUSTMENT”

A

D B

CD

C

C

ED

Axle Tube

= T

Brake Plate Nut Torque:35 ft. lbs. (48 Nm)

C

C

ED

35 ft. lbs.

(48 Nm)

Axle Tube

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BRAKE SYSTEM TROUBLESHOOTING

Brakes Squeal

• Dirty/contaminated friction pads

• Improper alignment

• Worn disc

• Worn disc splines

• Glazed brake pads

Poor Brake Performance

• Air in system

• Water in system (brake fluid contaminated)

• Caliper/disc misaligned

• Caliper dirty or damaged

• Brake line damaged or lining ruptured

• Worn disc and/or friction pads

• Incorrectly adjusted lever

• Incorrectly adjusted stationary pad

• Worn or damaged master cylinder or components

• Improper clearance between lever and switch

Lever Vibration

• Disc damaged

• Disc worn (runout or thickness variance exceeds service limit)

• Caliper Overheats (Brakes Drag)

• Compensating port plugged

• Pad clearance set incorrectly

• Auxiliary brake pedal incorrectly adjusted

• Brake lever or pedal binding or unable to return fully

• Parking brake left on

• Residue build up under caliper seals

• Operator riding brakes

Brakes Lock

• Alignment of caliper to disc

• Fluid overfill of the reservoir

• Stuck caliper piston

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NOTES

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FINAL DRIVE

CHAPTER 7

FINAL DRIVE

7

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

FRONT HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3HUB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4HUB DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

REAR HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7HUB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

SWING ARM / REAR GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9SWING ARM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9SWING ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9REAR GEARCASE - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11REAR GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12REAR GEARCASE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13REAR GEARCASE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14SWING ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16

REAR AXLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18AXLE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18RUN-OUT INSPECTION (IN AXLE TUBE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19

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SPECIFICATIONS

Torque Specifications

NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures are usedwhen torquing certain bolts and fasteners.

Special Tools

Item Torque(ft. lbs.)

Torque(Nm)

Wheel Nuts 30.0 41

Front Hub Nut 40.0 54

Rear Hub Nut 80.0 108

RH Pivot Bolt 83.0 113

LH Pivot Bolt Pre-load 4.0 5.4

LH Pivot Bolt Locking Nut 83.0 113

Gearcase Cover Bolts (small x 6) 19.0 25

Gearcase Cover Bolts (large x 2) 36.0 49

Axle Tube Bolts 40.0 54

Brake Line Banjo Bolt 15.0 21

Front Brake Disc 18.0 25

Front Caliper Mounting Bolts 18.0 25

Rear Brake Plate Stud Bolts/Nuts 35.0 48

Rear Shock Bolt/Nut 33.0 44

PART NUMBER TOOL DESCRIPTION

PA-47310 Swing Arm Pivot Bolt Removal Tool

PA-47360 Gearcase Input Shaft Collar Tool

PA-47310

PA-47360

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FRONT HUB

Exploded View

Table 7-1: Front Hub

REF. QTY. DESCRIPTION REF. QTY. DESCRIPTION

1 2 Outer Spacer 10 2 Front Tire

2 2 Oil Seal 11 8 Lock Nut

3 2 Bearing 12 2 Flat Washer

4 2 Spacer 13 2 Washer

5 2 Wheel Hub 14 2 Castle Nut

6 2 Bearing 15 2 Cotter Pin

7 2 Oil Seal 16 2 Hub Cap

8 2 Inner Spacer 17 2 Valve, Rim

9 2 Rim

12

3

4

5 6

78

17

9

10

11

12

13

1415

1611

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Hub Removal

1. Loosen wheel nuts before elevating the front end.2. Elevate front end and safely support machine under footrest

/ frame area.

3. Check bearings for side play by grasping wheel firmly (topand bottom, side to side) and checking for movement. Itshould rotate smoothly without binding or rough spots.

4. Remove wheel nuts and wheel.

5. Remove the two brake caliper hex bolts (B) and the brakecaliper. Use mechanic’s wire or other suitable material tosupport the caliper assembly. Do not allow caliper assemblyto hang by the brake line.

6. Remove hub cap (C), cotter pin, front spindle nut, andwasher.

7. Remove the outer spacer (D) from the spindle. Inspect outerspacer for wear, replace if needed. The spacer maybeembedded in the hub.

CAUTION

Serious injury may result if machine tips or falls.Be sure machine is secure before beginning thisservice procedure. Wear eye protection whenremoving bearings and seals.

Wheel Nuts

B

C

D

E

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8. Remove the hub (E) from the spindle. Remove the innerspacer (F), the spacer maybe in the hub or located on spindleduring removal. Inspect the inner spacer for wear, replaceif needed.

Hub Disassembly / Inspection

1. Rotate each bearing inside the hub by hand and check forsmooth rotation. Visually inspect bearing for moisture,dirt, or corrosion. Replace bearing if moisture, dirt,corrosion, or roughness is evident.

2. Place a shop towel on hub to protect surface. Carefully pryseal (G) out of hub.

3. Using a brass drift, tap bearing spacer to one side to exposeinner bearing race. Drive bearing out using a drift throughopposite side of hub and discard.

4. Remove spacer. Drive other bearing out and discard.

5. Clean hub and spacer thoroughly.

6. Inspect components for wear or damage. Measure thetapered spacer for wear, replace as needed.

Hub Assembly

Drive or press one new bearing into hub using a bearing driver.

7. Coat bearing spacer with grease and install into hub. Driveor press the other bearing into hub until seated againstspacer.

F

G

Tap spacer to side

CAUTION

Do not drive on the inner race of the bearing.

Premium All-Season Grease

(PN 2871322) (3 oz. Tube) (PN 2871423) (14 oz. Tube)

Tapered Spacer

.774 + .005

.797 + .005

Spacer (2)

Seals (2)

Tapered Spacer

Hub

Bearings (2)

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8. Install seal into hub (with numbers facing out) until flushwith end of seal bore. Install seals on both sides if needed.

Hub Installation

1. Apply anti-seize compound to spindle area, this will aidfuture removal of the wheel hub.

2. Inspect spindle and bearing surface for wear or damage.Install the inner spacer (A).

3. Install hub (B) on spindle. Install the outer spacer (C)

4. Install the washer (D) and spindle nut (E). Torque thespindle nut to specification.

5. Install a new cotter pin. Tighten nut slightly if necessary toalign cotter pin holes. Install the cotter pin. Bend both endsof cotter pin around end of spindle in different directions.Install hub cap.

6. Install brake caliper. Torque bolts to specification.

7. Install the wheel and hand tighten the four wheel nuts.Rotate wheel and check for smooth operation.

8. Lower the ATV and torque the wheel nuts to specification.

Seal

Apply Anti-SeizeCompound

A

B

C

= T

Spindle Nut Torque: 40 ft. lbs. (55 Nm)

= T

Caliper Mount Bolt Torque: 18 ft. lbs. (24 Nm)

= T

Wheel Nut Torque: 30 ft. lbs. (41 Nm)

D

E

18 ft-lb.(24Nm)

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REAR HUB

Exploded View

Table 7-2: Description for each wheel

REF. QTY. DESCRIPTION REF. QTY. DESCRIPTION

1 8 Nut 6 2 Washer

2 2 Rim 7 2 Cotter Pin

3 2 Wheel Hub 8 2 Castle Nut

4 8 Stud 9 2 Hub Cap

5 2 Rear Tire 10 2 Valve, Rim

1 2

3

45

6

78

9

10

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Hub Removal

1. Remove the hub nut cover. Remove the cotter key from thehub nut.

2. Slightly loosen the hub nut and the four wheel nuts.

3. Elevate the rear of the ATV and safely support machineunder the frame area.

4. Remove the four wheel nuts. Remove the wheel from theaxle.

5. Remove the hub (axle) nut (A), washer (B), and slide thehub (C) off of the axle.

Hub Installation

1. Install the hub onto the axle.

2. Install the washer and hub nut finger tight onto the axle.

3. Install the wheel and four wheel nuts onto the hub. Tightenthe wheel nuts.

4. Lower the ATV to the ground.

5. Torque the four wheel nuts to specification.

6. Torque the hub nut to specification.

7. Install a new cotter pin into the rear hub nut and axle.

Hub Inspection

1. Support machine securely with rear wheels elevated.2. Grasp wheel / hub and check for movement.

3. If movement is detected, inspect hub, hub nut torque andbearing condition and correct as necessary.

CAUTION

Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Wear eye protection when

removing bearings and seals.

A

B

C

= T

Wheel Nut Torque: 30 ft. lbs. (41 Nm)

= T

Rear Hub Nut Torque: 80 ft. lbs. (108 Nm)

Rear Wheel

Cotter Key

Rear Hub Nut

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SWING ARM / REAR GEARCASE

Swing Arm Exploded View

Swing Arm Removal

1. Safely jack up the ATV and place jackstands under theATV frame and rear swingarm.

2. Remove the two rear wheels.

3. Remove the cotter pin, axle nut, and wheel hub (both sides).

4. Remove the brake cable/arm assembly from the rear axle.Refer to Chapter 6, “REAR brake Arm Removal/Install”.

5. Remove the lower shock bolt (A) and rear gearcase ventline.

242

24

2

24

2

A. ClampB. Rubber BootC. Drive Shaft AssemblyD. RH Pivot BoltE. SealF. Bearing

G. LH Pivot BoltH. Jam NutI. Swing Arm AssemblyJ. O-RingK. Rear Gearcase to Swing Arm Bolts

H 83 ft-lb(113Nm)

G 4ft-lb(5.4Nm)

E

F

A

B

A

C

K 40 ft-lb(54Nm) J K 40 ft-lb. (54Nm)

D 83 ft-lbs(113Nm)

E

F

I

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6. Remove the jam nut (C) from the left side of the swingarmpivot using a 1-13/16” socket.

7. Remove the swingarm pivot bolts (D) from both sides ofthe swingarm. Support the front of the swingarm duringremoval.

8. With the swingarm apart from the frame, loosen the rubberboot clamp on the swingarm. Slide the rubber boot (F) fromthe swingarm. Slide the drive shaft from the transmissionoutput shaft (E)

9. Inspect the swing arm bearings (G) and seals (H), replaceif needed.

C

D

PA-47310

F

E

GH

GH

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Rear Gearcase - Exploded View

Table 7-3:

REF

.QTY

.DESCRIPTION

REF

.QTY

.DESCRIPTION

REF

.QTY

.DESCRIPTION

1 1 O-ring 17 1 Rear Brake Shaft 33 6 Bolt

2 2 Retainer 18 1 Spring 34 1 Oil Seal

3 3 Bearing 19 1 Bolt 35 2 Bolt

4 1 Rear Brake Assy. 20 1 Nut 36 1 Gearcase

5 6 Bolt 21 1 Oil Seal 37 1 Gasket Cover

6 6 Flat Washer 22 1 Cap 38 2 Shim Assy

7 4 Stud Bolt 23 1 Tappet Cap O-ring 39 1 Gearcase Plate

8 1 Rubber Cap 24 1 Cap Assy. 40 2 Rubber Spacer

9 1 Brake Plate 25 1 Gearcase 41 1 Bearing, Plain

10 1 O-ring 26 1 Oil seal 42 1 Shaft,Pinion 10T, Bevel

11 1 O-ring 27 2 Bearing 43 1 Bearing, Ball

12 1 Rear Brake Shaft 28 2 Shim 44 1 Ring, Retaining

13 1 Drum Brake 29 2 Shim 45 1 Ring, Retaining

14 1 Rear Cover 30 2 Shim 46 1 Seal, Triple Lip

15 6 Bolt 31 1 Ring Gear 47 1 Spring, Wave

16 1 Seal 32 1 Axle 48 1 Thrust Button

39

12

3

5 67 8 9

10

11 1712

13

14

15

4

16

1819

20

32

22

2324

2627

2829

30 31

2829

3027

65 33

34

35

36

37

5

40

4645

4443

4241

48

11

1

38

47

5

6

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FINAL DRIVE

Rear Gearcase Removal

1. Remove the four nuts (A) that secure the brake drumassembly to the tube assembly. Pull the brake drumassembly from the axle tube.

2. Slide the axle out of the axle tube assembly through the leftside.

3. Loosen the eight bolts that secure the swing arm to the reargearcase.

4. Remove the gearcase from the swing arm assembly.

5. Pull the shaft (D) and spring (E) from the gearcase.

A

D

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Rear Gearcase Disassembly

1. Remove the gearcase side cover (F).

2. Remove the bevel gear from the housing (G).

3. Remove the shims (H) from the bevel gear. Keep and recordthe shim pack for reassembly.

NOTE: A shimming procedure is outlined in theassembly process later in this chapter.

4. Inspect and replace the inner bearing (I) and seal (J) ifneeded.

5. Remove the pinion shaft seal (K) to gain access to thepinion gear holding nut (L). Use the Rear Gearcase InputShaft Collar Tool (PA-47360) to remove the pinion holdingnut.

6. Remove the pinion shaft. Inspect the gear for abnormalwear, broken, or chipped teeth. Spin the bearing to checkthe ball bearings for smoothness.

7. Before reassembly:

• Inspect the gearcase for cracks or abnormal wear

• Replace bushings as needed

• Inspect all bearing for wear and smoothness

• Replace all seals during re-assembly

F

G

H

J

I

KL

PA-47360

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FINAL DRIVE

Rear Gearcase Assembly

1. Replace all seals and O-rings during re-assembly.2. Install the pinion shaft (A) into the gearcase. Install the

pinion holding nut (B) and torque to specification. Use theRear Gearcase Input Shaft Collar Tool (PA-47360).

3. Install a new pinion shaft seal (C).

SHIMMING PROCEDURE

4. Install a 0.4 mm, 0.5 mm, and 0.6 mm shims onto the bevelgear (D). Total thickness of shims is 1.5 mm.

5. Install the shims and bevel gear into the gearcase housing.Turn the drive gear shaft (pinion) to feel for gear backlash.

6. If there is NO backlash:

• Increase the shim thickness by 0.10 mm.

• Only use three shims.

• Example: To increase to 1.60 mm, remove the 0.4shim and add a 0.5 shim. You will now have 0.5 mm,0.5 mm, 0.6 mm = 1.60 mm.

• Check for backlash again

7. If there still is NO backlash, continue adding 0.10 mm tothe shim thickness until backlash is achieved. Rememberto use only three shims in the process.

8. If there is excessive backlash, reduce the shim thickness by0.10 mm each time until reasonable backlash is achieved.

9. With reasonable backlash achieved, shims should now beplaced on the outside of the bevel gear.

= T

Input Shaft Collar Torque: 72 ft.lbs. (98 Nm)

A B

PA-47360

C

.04,.05,.06mm shims

D

Feel for backlash

3 Shims - Start with 1.5 mmadd 0.10 mm until backlashachieved

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10. IMPORTANT: The total shim thickness of both sides ofthe bevel gear should equal 3 mm. To determine the correctthickness of shims for the outside of the bevel gear, subtractthe thickness of the inside shims from 3 mm.

11. Once the outside shim thickness is determined, add theappropriate three shims.

12. Install the gasket and gearcase cover (D).

13. Apply Loctite™ 242 (PN 2871949) to the cover bolts. Placethe two larger cover bolts (I) in the correct cover holesduring assembly. Torque the cover bolts as shown below.

14. Check the backlash again after cover installation. Ifbacklash is excessive repeat the shimming procedure untilreasonable backlash is met.

15. Install the shaft (E) and spring into the gearcase.

16. Install the assembled gearcase into the swingarm.

Outside Shims

Inside Shims

Total Shim Thickness 3 mm

Inside Shim Thickness = ?

Outside Shim Thickness = ?

3 Shims

= T

Gearcase Bolt Torque:36 ft.lbs. (49 Nm) x 219 ft.lbs. (25 Nm) x 6

E I

D

19 ft. lbs.(25 Nm)

36 ft. lbs.(49 Nm)

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17. Apply Loctite™ 242 (PN 2871949) to the bolts. Install andtorque the eight bolts that secure the axle tube to thegearcase to specification.

18. Install the axle (F) into the left axle tube through thegearcase. If necessary, rotate the shaft for the axle to feedthrough the gearcase.

19. Install the brake hub assembly. Install the four nuts (G) ontothe studs that secure the brake drum to the axle and tubeassembly. Torque the nuts to specification.

Swing Arm Installation

1. Reinstall bearings (G) and seals (H), if removed. Refer tothe swingarm illustration.

2. Align the rear swing arm assembly and rear drive shaft tothe transmission output shaft. Install the drive shaft onto thetransmission output shaft.

= T

Swing Arm to Gearcase Bolt Torque:40 ft.lbs. (54 Nm) Loctite 242

40 ft-lb. (54Nm)

40 ft-lb. (54Nm)

F

= T

Brake Plate Nut Torque: 35 ft.lbs. (48 Nm)

G

35 ft-lb. (48Nm)

GH

GH

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3. Install the boot and tighten the clamps.

4. Align the swingarm pivot holes to the frame while keepingthe swingarm supported.

5. Apply Loctite™ 242 to right side pivot bolt (I) and to theleft side pivot bolt (J). Install both into the frame andswingarm.

6. Tighten both pivot bolts until engaged inside the swingarmbearings.

7. Using tool PA-47310, torque right side pivot bolt (I) tospecification.

8. Using tool PA-47310, torque left side pivot bolt (J) pre-loadto specification.

9. Apply Loctite™ 242 to the exposed threads of the left sidepivot bolt and lock nut.

10. Install and torque lock nut to specification. Use a 1-13/16”socket to tighten the lock nut.

11. Reinstall the rear shock bolt and torque to specification.Install rear gearcase vent tube.

12. Install the rear brake and cable assembly.

13. Route brake lines and secure with the brake line brackets.= T

RH Pivot Bolt Torque: 83 ft.lbs. (113 Nm)

I

Loctite 242

IPA-47310

= T

RH Pivot Bolt Pre-load Torque: 4 ft.lbs. (5.4 Nm)

= T

LH Pivot Bolt Lock Nut Torque: 83 ft.lbs. (113 Nm)

= T

Rear Shock Bolt Torque: 33 ft.lbs. (44 Nm)

J

Loctite 242

PA-47310

Loctite 242

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REAR AXLE SERVICE

Axle Removal / Installation

1. Remove rear hub caps.2. Remove cotter pins.

3. Slightly loosen - but do not remove - the hub retaining nuts.

4. Slightly loosen - but do not remove - the wheel nuts.

5. Safely jack up the ATV and place jackstands under theATV frame and rear swingarm.

6. Remove wheels.

7. Remove the hub nuts and washers (A). Remove hubs (B)from the axle.

8. Remove the brake arm assembly (C). Refer to Chapter 6“REAR BRAKE ARM”.

9. Remove the four nuts (D) that secure the brake drumassembly to the axle and tube assembly.

10. Slide the axle out of the axle tube assembly through the leftside.

11. Inspect the axle splines for wear, cracks, and abrasions.Replace as needed.

12. Reverse the removal steps for installation.

CAUTION

Serious injury could occur if machine tips or falls.

B

A

C

D

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Run-Out Inspection (In Axle Tube)

1. Park the vehicle on a flat surface and apply the parkingbrake.

2. Place a jack under the rear gearcase and raise until the rearwheels are off the ground.

3. Strap the vehicle securely to the ground so that the machineis held solid and will not wiggle.

4. Remove the rear wheels and hub nuts. (discard the usedcotter pin).

5. Remove the rear brake drums.

6. Verify the swing arm bolts are properly torqued.

7. Wipe the axle clean with a shop rag. Pay special attentionto cleaning the splines at the end of the axle and the smallcylindrical surface next to the splines.

8. Grab the end of the axle with your hand and try to movethe axle up and down and side to side in the eccentrichousing. The axle should not move. If movement isdetected, carrier bearings should be inspected and / orreplaced before continuing.

9. Secure a dial indicator to the work surface and themeasuring point on the small cylindrical surface next to thespline on the end of the axle.

10. With the vehicle in neutral, slowly spin the axle one fullrotation and measure the total run out (total dialmovement). Be very careful not to bump the machine ordial indicator while performing the measurement. (Seephoto and illustration below).

11. Repeat on the other end of the axle. If the measurement isover 0.040” (1.01mm) on either side, the axle needs to bereplaced.

Reassembly:

12. Refer to the “REAR HUB INSTALLATION” earlier in thischapter for reassembly.

13. Unstrap the vehicle and remove the jack.

NOTE: If vibration in the rear end persists, the rimsmay be bent or out of balance due to wear.

Axle

= In. / mm.

Rear Axle Run-out Limit: 0.040” (1.01 mm)

Phoenix / Sawtooth Axle Run-out Inspection with V-Blocks

Run-out must not exceed .040” (1.01 mm) Maximum

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NOTES

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CVT / TRANSMISSION

CHAPTER 8

CVT / TRANSMISSION

8

SPECIFICATIONS / TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

SHIFT CABLES / GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2SHIFT CABLE INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2GEAR SELECTOR, SHIFT ARM AND CABLE REMOVAL / INSTALLATION . . . . . . . . . 8.3

CVT SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4CVT OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4CVT MAINTENANCE / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4DRIVEN CLUTCH OPERATON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4CVT SYSTEM DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4CVT OVERHEATING / DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

CVT SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7DRIVE CLUTCH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11DRIVEN CLUTCH BEARING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11CVT REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12

TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13TRANSMISSION DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 8.13INPUT SHAFT REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16OUTPUT SHAFT REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16OUTPUT SHAFT SHIMMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17TRANSMISSION REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18TRANSMISSION SHIFT DETENT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18

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SPECIFICATIONS / TOOLS

Torque Specifications

Special Tools

SHIFT CABLES / GEAR SELECTOR

Shift Cable Inspection and Adjustment

NOTE: Shift cable adjustment can be done at thetransmission or the shifter. Middle cable adjustmentis usually not required.

1. Inspect shift cable ends, cable jackets and pivot bushings.Replace if worn, damaged or if cables can no longer beadjusted. Lubrication of all pivot points with a light aerosollubricant or grease is recommended.

2. With the tranmission in neutral, loosen both cable lock nutsand adjust cable tension evenly on both cables as needed.Adjust cables only enough to remove cable slack or “loosefeeling” in the shift handle. Cables that are too tight willbind and create difficult shifting.

3. After adjusting the cable tension, verify the shift handle iscentered in the middle of it’s travel range when in neutral.Check shift function and tighten all lock nuts sufficientlyonce desired tension has been achieved.

TRANSMISSION TORQUE SPECIFICATIONS

Fastener Thread SizeES20PFE

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 40 (55 Nm)

Driven Clutch Nut 7/16 - 20 40 (55 Nm)

Output Shaft Flange Screws

6mm 6-8 (8-11 Nm)

Output Shaft Collar

--72 (10 kgm)Shimming Required

Oil Drain Bolt (Crankcase)

14mm 14-17 (19-23 Nm)

Shift Crank Bolt 6mm 6-8 (8-11 Nm)

Shift Detent Lock Nut

10mm 6-8 (8-11 Nm)

Transmission Cover Bolts

6mm 6-8 (8-11 Nm)

Transmission/Engine Mount Nuts

10mm 25 (35 Nm)

Transmission Shaft Collar Tool PA-47309

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Gear Selector, Shift Arm and Cable Removal / Installation

1. Remove the shift knob.2. Disconnect cables from transmission holding bracket and

shift selector bracket.

3. Remove the pivot retainer at the shift selector.

4. Pull shift handle off of pivot bracket and away from frame.

5. Remove the bolt reataining the shift arm at the transmissionand pull the shift arm off.

6. To reinstall, reverse order of disassembly. Apply lubricantto all pivot points before reassembly. Tighten retainerssufficiently.

7. Adjust cable tension as described. Tighten all lock nutssufficiently.

NOTE: Shift cable adjustment can be done at thetransmission or the shifter. Middle cable adjustmentis usually not required.

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CVT SYSTEM OPERATION

CVT Operation Overview

The Polaris Variable Transmission (CVT) consists of threemajor assemblies: 1) The Drive Clutch; 2) The Driven Clutch;and 3) The Drive Belt. The internal components of the driveclutch and driven clutch control engagement (initial vehiclemovement), clutch upshift and backshift. During thedevelopment of a Polaris ATV, the CVT system is matched firstto the engine power curve; then to average riding conditions andthe vehicle’s intended usage. Therefore, modifications orvariations of components at random are never recommended.Proper clutch setup and careful inspection of existingcomponents must be the primary objective whentroubleshooting and tuning.

CVT Maintenance / Inspection

Under normal operation the CVT system will provide years oftrouble free operation. Periodic inspection and maintenance isrequired to keep the system operating at peak performance. Thefollowing list of items should be inspected and maintained toensure maximum performance and service life of CVTcomponents. Refer to the troubleshooting checklist for moreinformation.

1. Drive and Driven Clutch Rollers, Buttons, Bushings, DriveClutch Shift Weights, Pins and Driven Clutch Springs.

2. Clutch Sheave Faces. Clean and inspect for wear.

3. CVT System Sealing. Refer to appropriate illustrations andphotos. The CVT system is air cooled by fins on the driveclutch stationary sheave. The fins create a low pressure areain the crankcase casting, drawing fresh air into the systemthrough an intake duct. The opening for this intake duct islocated at a high point on the vehicle (location varies bymodel). All connecting air ducts, as well as the inner andouter covers, must be properly sealed to ensure clean air isbeing used for cooling the CVT system. This also willprevent water and other contaminants from entering the

CVT area. A sealed CVT is especially critical on unitssubjected to frequent water forging

Drive Clutch Operation

Drive clutches primarily sense engine RPM. The two majorcomponents which control its shifting function are the shiftweights and the coil spring. Whenever engine RPM is increased,centrifugal force is created, causing the shift weights to pushagainst rollers on the moveable sheave, which is held open bycoil spring preload. When this force becomes higher than thepreload in the spring, the outer sheave moves inward andcontacts the drive belt. This motion pinches the drive beltbetween the spinning sheaves and causes it to rotate, which inturn rotates the driven clutch.

At lower RPM, the drive belt rotates low in the drive clutchsheaves. As engine RPM increases, centrifugal force causes thedrive belt to be forced upward on drive clutch sheaves.

Driven Clutch Operaton

CVT driven clutches primarily sense torque, but also react toRPM, applying and retracting the friction shoes according to theforces applied to it from the drive belt, while at the same timereacting to the torque at the transmission input shaft. If thetorque resistance at the transmission input shaft is greater thanthe load from the drive belt, the drive belt is kept at the outerdiameter of the driven clutch sheaves.

As engine RPM and horsepower increase, the load from thedrive belt increases, resulting in the belt rotating up toward theouter diameter of the drive clutch sheaves and downward intothe sheaves of the driven clutch. This action, which increases thedriven clutch speed, is called upshifting.

Should the throttle setting remain the same and the vehicle issubjected to a heavier load, the drive belt rotates back up towardthe outer diameter of the driven clutch and downward into thesheaves of the drive clutch. This action, which decreases thedriven clutch speed, is called backshifting.

In situations where loads vary (such as uphill and downhill) andthrottle settings are constant, the drive and driven clutches arecontinually shifting to maintain optimum engine RPM. At fullthrottle a perfectly matched CVT system should hold engineRPM at the peak of the power curve. This RPM should bemaintained during clutch upshift and backshift. In this respect,the CVT system is similar to a power governor. Rather than varythrottle position, as a conventional governor does, the CVTsystem changes engine load requirements by either upshifting orbackshifting.

CVT System Drying

NOTE: If operating the ATV through water, be sureto check the CVT cover and other ATV components

WARNING

All CVT maintenance or repairs should beperformed only by a certified Polaris MasterService Dealer (MSD) technician who hasreceived the proper training and understandsthe procedures outlined in this manual. Becauseof the critical nature and precision balanceincorporated into the CVT components, it isabsolutely essential that no disassembly orrepair be made without factory authorizedspecial tools and service procedures.

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for water ingestion. The ATV should be checkedimmediately. Refer to the Owner’s Manual.

1. To drain any water that may be trapped inside the CVTcover, remove the CVT drain plug and O-ring located onthe bottom of the CVT cover and let the water drain out.The CVT drain plug is shown below.

2. To further expel water in the CVT cover and to dry out theCVT system, shift the transmission to neutral and revengine slightly to expel the moisture. This will also air-drythe belt and clutches. Allow engine RPM to settle to idlespeed, shift transmission to lowest available range and testfor belt slip. Repeat as needed. Operate ATV in lowestavailable range for a short period of time until CVT system

is dry.

CVT Drain Plug

Outlet Duct

BootClamps

Cover

Clamps

Boot

Inlet Duct

Inlet Cover Duct

PHOENIX CVT AIR DUCT SYSTEM

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CVT Overheating / Diagnosis

During routine maintenance or whenever CVT systemoverheating is evident, it’s important to check the inlet and outletducting for obstructions. Obstructions to air flow through the

ducts will significantly increase CVT system operatingtemperatures. The ATV should be operated in low range (ifequipped) when pulling or plowing heavy loads, or if extendedlow speed operation is anticipated.

DIAGNOSIS OF CLUTCH DRIVE BELT & COVER RELATED ISSUES:

POSSIBLE CAUSES SOLUTIONS / WHAT TO DO

Loading the ATV into a pickup or tall trailer when in high range.

Shift transmission to low range (if equipped) during loading of the ATV to prevent belt burning.

Starting out going up a steep incline.When starting out on an incline, use low range (if equipped), or dismount the ATV after first applying the park brake and perform the “K” turn.

Driving at low RPM or low ground speed (at approximately 3-7 MPH).

Drive at higher speed or use Low Range. (if equipped) The use of Low Range is highly recommended for cooler CVT operating temperatures and longer component life.

Insufficient warm-up of ATVs exposed to low ambient temperatures.

Warm engine at least 5 min., then with transmission in neutral, advance throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.

Slow and easy clutch engagement.Fast, effective use of the throttle for efficient engagement. Continuous operation at the point of engagement (initial vehicle movement) increases CVT temperatures and component wear.

Towing/Pushing at low RPM/low ground speed.

Use Low Range only. (if equipped)

Plowing snow, dirt, etc./utility use. Use Low Range only. (if equipped)

Stuck in mud or snow.Shift the transmission to Low Range (if equipped), carefully use fast, aggressive throttle application to engage clutch. Warning: Excessive throttle may cause loss of control and vehicle overturn.

Climbing over large objects from a stopped position.

Shift the transmission to Low Range (if equipped), carefully use fast, aggressive, throttle application to engage clutch. Warning: Excessive throttle may cause loss of control and vehicle overturn.

Belt slippage from water or snow ingestion into the CVT system.

Shift the transmission to neutral. Using the throttle, vary the engine rpm from idle to 3/4 throttle. Engage transmission in the lowest possible range (if equipped) and test for belt slippage Repeat several times as required. During this procedure, the throttle should not be held at the full position. CVT seals should be inspected for damage if repeated leaking occurs.

Clutch malfunction.Inspection/repair of clutch components should be performed by a certified Polaris MSD technician.

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CVT SYSTEM SERVICE

Drive Clutch Service

1. Remove the side cover and drive belt.

2. Remove the lock nut, washer, and the kick-start pawl fromthe crankshaft.

3. Remove the fixed sheave (A), starter pawl (B) and slidebushing (C). Inspect the fixed sheave and slide bushing forscoring, grooving, or abnormal wear. Replace any worn ordamaged parts.

4. Remove the primary sliding sheave and cam plate assembly(D) as one assembly. Inspect the movable sheave forscoring, grooving, or abnormal wear.

NOTE: Use two hands to hold the cam plate and theprimary sliding sheave together when removing theprimary sliding sheave and the cam plate assembly.This prevents the roller weights from falling out ofthe assembly.

5. Remove the roller weights from the primary sliding sheave.Check the rollers for wear and scoring. Remove and inspectthe slide bushings and cam plate. Replace any componentsthat found to be worn excessively or appear abnormal.

6. To reassemble, reverse the procedures. Do not apply anylubricants to the components. Torque the retaining nut tospecification.C

A

B

Fixed Sheave

= T

CVT Drive Clutch Nut Torque:40 ft. lbs. (55 Nm)

D

C

Sliding Sheave

Slide Bushings

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Driven Clutch Service

NOTE: The PHOENIX utilizes a torque limitingsystem to prevent transmission damage. Use careremoving the clutch assembly, as the torque-limitingcomponents become free and could fall apart. Markor note orientation of parts during disassembly.

1. Remove the driven clutch assembly by releasing the setscrew and removing the nut from the shaft. Pull the entireclutch off as an assembly.

2. Set the driven clutch assembly on a flat surface. Removethe cover, spring washer stack, and ball bearing retainer.Inspect components for excessive wear or damage. Replacecomponents as required.

Spring Washer Orientation

Additional 1mm washer

can be added here to

increase spring preload

Washer Cover Ball Bearing Retainer

Retaining Nut

1 mm Washer1 mm Washer

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3. Remove the ball bearings. Use a snap-ring pliers to removethe retainer on the hold cam. Remove the washer. Inspectthe hold cam for excessive spline wear or damage. Replacethe component if required.

4. Inspect the condition of the clutch drum. Measure the insidediameter of the cover at 90 degree intervals using a caliper.Inspect the condition and diameter of the drum lining. Ifeither the measurements or the lining indicates excessivewear, replace the clutch cover.

5. Inspect the condition of the friction pads. Measure theamount of remaining pad using a depth caliper. Inspect thecondition of the pads. If either the measurements or the padcondition indicates excessive wear, replace the friction

pads.

6. Secure the assembly in a clamping device. To access thedriven spring, mark and remove the outer sheave retainingnut. Remove the friction pad assembly and driven spring.

NOTE: Outer sheave retaining nut replacement isstrongly recommended. Use Loctite™ 272 uponreassembly.

= In. / mm.

Drive Clutch Friction Pad Service Limit:.078” (2 mm)

CAUTION

Spring Pressure can cause components to eject suddenly. Always wear the appropriate safety

gear. Use care during removal.

.078” (2 mm)

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7. Use a vernier caliper to check the free length of thecompression spring. At full extension, the measurementshould be no less than . If less than the specification, replacethe spring.

8. Remove the outer roller pin cover by turning and pullingup on the cover. Replace the 2 o-rings.

9. Remove the rollers and pins using a needle-nose pliers andinspect all components. Replace if any damage or excesswear is found. Replace the o-rings and seals anytime thedriven is apart.

10. To replace the friction shoes, remove the e-clips that retainthe backing plate. Use a suitable tool to remove and installthe springs connecting the shoes, using care not to over-stretch the springs more than is necessary.

11. To reassemble the driven assembly, reverse thedisassembly procedures. Fill the outer sheave cavity withfresh grease and slide onto the inner sheave shaft. Align andinsert the (2) roller/pin assemblies. Install new o-rings andthe outer roller pin cover. Place the washer onto thethreaded shaft and apply Loctite™ 272 to the threads.

= In. / mm.

Driven Compression Spring Free Length Service Limit:

3.50” (89 mm)

O-rings

Outer Sheave Assembly

O-rings

Outer Cover

Seals

Rollers and Pins (2)

Remove E-Clips

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12. Have an assistant available for final assembly. Install thecompression spring. Place the friction pad assembly overthe spring and compress the driven assembly together withboth hands. With the assembly compressed and the threadsexposed, have an assistant thread a new retaining nut ontothe shaft. Secure the assembly in a clamping device andtorque the retaining nut to specification.

NOTE: Sheave retaining nut replacement isstrongly recommended. Use Loctite™ 272 on thethreads during reassembly.

Belt Inspection

13. Inspect the surface of the drive belt for uneven wear orgrease deposits. Using a vernier caliper, measure the widthof the belt. If the width of the belt is less than the servicelimit, or if the belt is worn, glazed or hour-glassed, replaceit.

Driven Clutch Bearing Service

1. Remove the circlip on the inside diameter of the cover. Usea slide puller to remove the bearing. NOTE: Do not re-useas removal damages bearing.

2. Press or drive a new bearing into the cover. Press or driveonly on the outer diameter. Fit should be snug with notightness or sticking.

3. Insert the circlip and proceed with clutch cover reassembly.= T

Sheave Retaining Nut Torque: 50-54 ft lbs (68-73 Nm)

= In. / mm.

CVT Drive Belt Width Service Limit:.708” (18 mm)

Loctite 272CirclipBearing

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CVT Reassembly

1. Install the driven assembly onto the transmission inputshaft. Do not tighten the nut at this time.

2. Install the bushing, the primary sliding sheave, and the camplate assembly.

NOTE: When installing the primary sliding sheaveand the cam plate assembly, hold the cam plate andthe primary sliding sheave together. The weightrollers will fall out if the assembly is not installedproperly.

3. Install the primary fixed sheave, washer, starter pawl andnut. Do not tighten the nut at this time.

4. Install the drive belt by looping the belt over the looseneddrive and driven clutches.

5. Finish installing the lock nut and washer onto thecrankshaft. Torque the drive clutch nut to specification.

6. Install the driven clutch assembly and driven clutch nut.Torque the nut to specification. Apply Loctite™ 272 to theset screw and tighten securely.

7. Install the clutch cover and ducting. Tighten the cover boltsto specification.

= T

CVT Drive Clutch Nut Torque:40 ft. lbs. (55 Nm)

= T

Driven Clutch Nut Torque:60 - 80 ft. lbs. (81 - 108 Nm)

Set Screw: Loctite™ 272

= T

Clutch Cover Bolt Torque:6-8 ft. lbs. (8-11 Nm)

Loctite 272

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TRANSMISSION SERVICE

Transmission Disassembly and Inspection

IMPORTANT: To prevent difficult shifting, verify theinternal detent and external shift arm aresynchronized to the same position upon reassembly.

1. Remove the external shift arm assembly.

2. Drain the oil from the gear case. Remove the retaining bolts,transmission cover, and gasket. NOTE: Some componentsmay remain inserted in the cover upon disassembly.

3. Remove the output shaft by pulling up and out from thecase.

4. Remove the shift shaft and move the shift fork away fromthe shift drum. Remove the shift fork, drum and shaft.Inspect the shift components for signs of excess wear ordamage. Replace components as needed.

5. Remove the shift drum and shift shaft assembly. Inspect thecam guide, and shift gears for signs of damage or wear.

Inspect

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Note orientation of the shift gearing for reassembly. 6. Lift entire gear / dog assembly up and out of the case.

7. Inspect the shift dog / gear assembly and shift fork, lookingfor signs of wear or damage. The dog edges should appearsharp. Replace components if excess wear or damage to thegears or shift dogs is found. Use the illustrations as a guidefor reassembly. Make note of parts orientation forreassembly.

NOTE: Always wear the appropriate protective gearwhen working with spring tensioned retainers.

NOTE: Keep parts in order. Mark or note prior todisassembly.

Inspect

REVERSE

NEUTRAL

FORWARD

Inspect

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8. To disassemble the main shaft assembly, remove the flatwasher (A), circlip (B), shaft collar (C), gear and washers(D), and the shift dog (E) from the end of the shaft.

9. Remove the snap ring (H) using snap ring pliers. Removethe spline washer (E), reverse gear (F), and washer (G) fromthe shaft. NOTE: Replace the snap ring during reassembly.

10. Inspect the gears and bearing for signs of wear or damage.Component replacement is required if excess wear ordamage is found.

11. Remove the counter shaft assembly. Inspect the gears forsigns of wear or damage. Component replacement requiredif any wear or damage to the shaft or gears is found.

12. With the transmission components removed, inspect thebearings for signs of wear or damage. Bearings should rollsmoothly, with no wobble or noise. Replace only thebearings that are damaged or worn, as the removal processdamages the bearing.

B

A

B

C

D

E

H

H

GF E

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Input Shaft Removal / Inspection

1. Input shaft (A) can be removed by tapping the shaft/bearing combination from the input side with a non-marring hammer as shown in the photos.

2. The input shaft and bearing (A) has a circlip that must beremoved before attempting bearing removal from the shaft.Replace the output shaft seal whenever the transmission isdisassembled.

Output Shaft Removal / Inspection

1. To disassemble the output shaft and gear, loosen the (3)output flange screws and tap the assembly from thetransmission with a plastic hammer. Record the shim packthickness upon removal. Replace the o-ring.

NOTE: If a new pinion gear is installed, you mustfully assemble the transmission and perform theoutput shaft shimming procedure.

2. The pinion shaft can be tapped out in order to service thebearing and seal. Use a slide puller to remove the innerneedle bearing and seal.

Install a new seal with the lip facing in. Install the needle bearingby pressing on the outer diameter of the bearing until fullyseated.

A

Circlip

Seal

A

Shim Pack

O-ring

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3. The outer bearing can be serviced by removing the shaftcollar nut using Shaft Collar Tool (PA-47309) and using apuller to remove the bearing.

4. After installing a new outer bearing, install the shaft collarassembly onto the transmission flange and secure thefasteners. Install shaft collar nut (B) and torque tospecification using Shaft Collar Tool (PA-47309).

Output Shaft Shimming

NOTE: This procedure sets pinion depth only. Thereare no provisions for backlash adjustment.

1. Begin with a fully assembled transmission output collarassembly removed from the case with no shims.

2. Install output collar assembly to transmission case with noshims installed. The pinion gear should bottom against theoutput gear, leaving a space between the output collar andtransmission case.

3. Measure the distance between the output collar andtransmission case with a feeler gauge. The specified piniondepth is 0.3mm-0.4mm from the bottomed position.Therefore, you will need to install a shim pack of 0.3mm-0.4mm plus the measured distance of the collar to the case.

Example: Output collar is installed without shims and thepinion gear is bottomed. A distance of 1.0mm is measuredbetween the output collar and the case. To obtain the correctpinion depth, a shim pack totaling 1.3mm-1.4mm must beinstalled.

= T

Transmission Shaft Collar Nut Torque:72 ft.lbs. (98 Nm)

PA-47309

PA-47309

= In. / mm.

Output Pinion Shaft Shim Pack Requirement:Measured Distance + 0.3mm-0.4mm

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Transmission Reassembly

1. To reassemble the transmission, reverse the disassemblyprocedures. During reassembly, install the shift indicatorspring and pin assembly into the shift shaft. Use assemblylube to “stick” the parts together for easier assembly intothe case half. Assemble the transmission components inthe neutral position. Assemble the shift detent in thebottom of the transmission case, but do not fully install atthis time, leaving just enough tension on the detent to keepthe shift shaft from moving out of neutral.

2. Once all the components are installed and the transmissionis in neutral, install a new gasket and the cover. Torque thenine (9) bolts evenly in a criss-cross pattern to specification.

3. After the transmission components have been installed,torque the internal detent ball assembly and verify that theexternal shift cam and internal detent are synchronized.Torque the hex bolts to specification.

Transmission Shift Detent Service

IMPORTANT: To prevent difficult shifting, verify theinternal detent and external shift arm aresynchronized to the same position upon reassembly.

1. The detent assembly consists of a hex head retainer, springand ball assembly. These components should be inspectedanytime there is a problem shifting or if the transmission isbeing repaired.

2. Remove the hex head retainer. Inspect the spring, ball andshift cam for signs of wear or damage. Replace anydamaged components.

3. Verify the transmission is in neutral. Reassemble theexternal detent components, verifying the components arealigned with the shift shaft in the neutral position (internaldetent). Torque all fasteners to 6-8 ft. lbs. (9-11 Nm).

= T

Transmission Cover Bolt Torque:6-8 ft. lbs. (9-11 Nm)

Neutral

= T

Shift Detent Bolt Torque:6-8 ft. lbs. (9-11 Nm)Par

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ELECTRICAL

9.1

CHAPTER 9

ELECTRICAL

9

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2ELECTRICAL SYSTEM SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

DIAGNOSING ELECTRICAL PROBLEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2ELECTRICAL COMPONENTS EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3TRANSMISSION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4INSPECTION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5IGNITION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5RPM LIMITER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6ELECTRONIC THROTTLE CONTROL (ETC) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 9.7ETC OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7IGNITION COIL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8CDI OUTPUT TEST USING PEAK READING ADAPTOR. . . . . . . . . . . . . . . . . . . . . . . . 9.8PULSE COIL OUTPUT / RESISTANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8IGNITION SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9CHARGING SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9MAIN FUSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10STATOR / ALTERNATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10ALTERNATOR OUTPUT TEST (AC AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11

HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12PHOENIX HEADLIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12PHOENIX HEADLIGHT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12

TAILLIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13BRAKE LIGHT SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13TAIL LIGHT / BRAKELIGHT LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13

HANDLEBAR POD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14INDICATOR LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14

STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14STARTER MOTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14STARTER SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15STARTER SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16

BATTERY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17BATTERY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17BATTERY INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17BATTERY OFF SEASON STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18

SEALED LOW MAINTENANCE BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18BATTERY SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19BATTERY TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20BATTERY CHARGING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20

CONVENTIONAL BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20BATTERY ACTIVATION / SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21BATTERY TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23BATTERY CHARGING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23

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SPECIAL TOOLS ELECTRICAL SYSTEM SERVICE NOTES

Diagnosing Electrical Problems

Reference the following notes when diagnosing electricalproblems.

• Refer to wiring diagram for stator and electricalcomponent resistance specifications.

• When measuring resistance of a component that has alow resistance value (under 10 Ohms), remember tosubtract meter lead resistance from the reading.Connect the leads together and record the resistance.The resistance of the component is equal to tested valueminus the lead resistance.

• Become familiar with the operation of the meter. Besure leads are in the proper jack for the test beingperformed (i.e. 10A jack for current readings). Refer tothe owner’s manual included with the meter for moreinformation.

• Voltage, amperage, and resistance values included inthis manual are obtained with a Fluke™ 77 DigitalMultimeter (PV-43568). This meter is acceptable foruse when diagnosing electrical problems. Readingsobtained 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 betested. Disconnect it from the wiring harness or powersupply.

PART NUMBER TOOL DESCRIPTION

PV-43568Fluke™77 Digital

Multimeter

2870836 Battery Hydrometer

2870630 Timing Light

8712100 or 8712500 Tachometer

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9

ELECTRICAL COMPONENTS EXPLODED VIEW

Electrical Bracket(located on bulkhead)

Voltage Regulator

Ignition Switch

CDI Unit

Neutral Indicator Light

Reverse LightHarness

Battery Cable

Battery

Main Harness

Starter Relay

Ignition Coil

Spark Plug

Flywheel Stator

Note: CDI components are not compatible with any other type of ignition

Fuse

ETC Jumper Harness

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TRANSMISSION SWITCH

Removal

1. Remove the CVT cover. The indicator switch will bevisible between the drive and driven clutch. Refer toChapter 8 for CVT cover removal and install.

2. Remove the screws that retain the indicator switch.

Inspection / Testing

1. With the switch installed, use an ohmmeter to test forcontinuity between the switch leads and engine ground.First, shift the transmission into Neutral and test forcontinuity between the GRY wire and ground. Then shiftthe transmission into Reverse and test for continuitybetween the BLU wire and ground. In both tests youshould have continuity to ground. Replace the switch if nocontinuity or high resistance is found.

2. Inspect the shift indicator contacts, shift drum, pin andspring. Verify the pin is not sticking in the drum or isdamaged. Replace any worn or damaged components.

Installation

1. Once repairs are completed, reinstall the shift pin andspring into the shift drum (arrow). NOTE: assembly lubecan be used to “stick” parts together for ease of assembly.

2. Install the indicator switch and o-ring (arrow), routing thewires in the same manner as during disassembly.

3. Install the retaining screws. Torque to specification.

Transmission -Shift DrumSwitch

INSPECT

= T

Transmission Switch Screw Torque:39-52 in. lbs (4.5-6Nm)

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9

IGNITION SYSTEM

Ignition System Testing

Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean and tight.Use the following pages as a guide for troubleshooting. The resistance values are also given on the specification pages.

Condition: No spark or intermittent spark.

Verify 12 VDC power is present on both BRN and GRN/Y wires at the CDI with the brake applied.

Disconnect the W and BRN/W wire at the CDI module to isolate the limiter portion of the module. This test will isolate the transmission switch circuit

Verify that a minimum of 10.5 VDC is getting tothe CDI module BRN wire during cranking. Referto the wiring schematic for connection locations. Is the DC voltage output within specifications?

Check coil ground connection between engine and coil mount using an ohmmeter. The coil mount shouldhave good continuity to ground on the engine (0-.2 Ω).

Disconnect the BLK and BLK/GRN wires from the ignition coil and check resistance:

Primary - Measure between the Primary andGround Wire Tabs on the coil: 0.2 to 0.6 OhmsSecondary - Measure between High Tension Wire and engine ground (Cap Installed): 7KΩ - 9KΩ

Are these values within specs?

If all of the above tests are within specifications, and all grounds, connections, and wire color codinghave been inspected, perform voltage output tests on following page before replacing the CDI module.

- Test the ETC switch circuit and the transmission switch circuit for shorts to ground.- Check connectors for moisture, wire color matching or corrosion.

Inspect battery condition, connec- tors, wiring and grounds to the component in question. Replacethe component if a wiring problem

Clean coil mounting area.Repair ground wire connections.

Replace the ignition coil.

No

Yes

Yes

Yes

Yes

No

No

No

and the ETC switch circuit.

Does it have spark?

cannot be found.

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9

RPM Limiter Specifications

NOTE: The CDI box reads the RPM signal from the stator. The CDI box acts as a limiter when peak RPM ismet. In reverse gear, the CDI box limits RPM once the CDI box receives a ground path from the transmissionswitch indicating the ATV is in reverse. The CDI box can also receive a ground path from the ETC switchcausing the CDI box to limit RPM if the throttle cable becomes slack or stuck.

To Regulator

Rectifier

E.T.C. Switch

Reverse Gear

Signal to CDI

To Reverse

Over-ride

Switch

LH Switch Assembly

Reverse Lamp

Neutral Lamp

Foot Brake

12 VDC

Key On

12 VDC

CDI Output

To Ignition Coil

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9

Electronic Throttle Control (ETC) Switch

The Electronic Throttle Control (ETC) system is designed tostop the engine of an ATV in the event of a mechanical problemwith the throttle mechanism. The ETC switch is mountedindependently of the throttle actuator lever inside the throttleblock assembly. This is a normally closed switch, and is held inthe open position (contacts are separated (as shown below)) bythrottle cable tension. The contacts are “open” during normaloperation regardless of throttle lever position. In the event of amechanical problem in the throttle mechanism (cable tension islost), the switch contacts close, connecting the CDI black wireto ground, which prevents ignition spark. This is the same asturning the key or engine stop switch “OFF”.

Test the ETC switch at the harness connector. Adjust throttlecable freeplay (ETC switch) and make sure throttle mechanismis functioning properly before testing the switch.

NOTE: Refer to Maintenance Chapter 2 foradjustment procedure. See “Electronic ThrottleControl / Throttle Cable Adjustment”.

ETC Operation Test

Remove throttle block cover by carefully releasing all tabsaround edge of cover.

Place transmission in neutral and apply parking brake.

Start engine and open throttle lever slightly until engine RPM isjust above idle speed.

Hold throttle cable with fingers at point “A” as shown below andrelease throttle lever. If the ETC system is functioning properly,the engine will lose spark and stop.

Electronic Throttle Control (ETC) Switch(Composite Throttle Housing)

ETC switch contactsare closed in a faultcondition (throttle cable slack)

Switch contacts are openduring normal operation

A

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Ignition Coil Testing

CDI Output Test Using Peak Reading Adaptor

Re-connect all CDI wires to stator wires. Disconnect CDImodule wire from ignition coil primary terminal. Install thePeak Reading Adaptor (PV-39991) to your meter and connectone meter lead to engine ground and the other to the BLK/GRNignition coil primary wire leading from the CDI module. Setmeter to read DC Volts. Crank engine and verify CDI output tothe ignition coil. When finished, reconnect the CDI output wireto ignition coil.

Pulse Coil Output / Resistance Tests

Disconnect pulse coil harness from CDI module. Install thePeak Reading Adaptor (PV-39991) to your meter and connectone meter lead to the BLK/W wire and the other to the GRNwire. Set meter to read DC Volts. Crank engine and verify pulsecoil output.

If readings are within specifications, test the resistance value ofthe pulse coil. When finished, reconnect the pulse coil harnessto the CDI module.

Pulse Coil Testing

Ignition System Troubleshooting

No Spark, Weak or Intermittent Spark

• No 12 volt power or ground to CDI

• Spark plug gap incorrect

• Fouled spark plug

• Faulty spark plug cap or poor connection to hightension lead

• Related wiring loose, disconnected, shorted, orcorroded

• Engine Stop switch or ignition switch faulty

• ETC switch misadjusted or faulty

• Poor ignition coil ground (e.g. coil mount loose orcorroded)

• Faulty stator (measure resistance of all ignition relatedwindings)

• Incorrect wiring (inspect color coding in connectorsetc)

• Faulty ignition coil winding (measure resistance ofprimary and secondary)

• Worn magneto (RH) end Crankshaft bearings

• Sheared flywheel key

• Flywheel loose or damaged

• Excessive crankshaft runout on magneto. (RH) endshould not exceed .005”

• Faulty CDI module

Wire Description Resistance

Ignition Coil Primary Winding 0.2 - 0.6 Ohms

Ignition Coil Secondary Winding (With Cap Installed)

7K - 9K Ohms

Output Test Connect Meter Wires To: Reading

CDI Output BLK/GRN to Engine Ground 160 - 200DC Volts

Measure Between

Primary reading.the two wire tabs for

Voltage TestConnect

Meter Wires To:

Reading(With Peak Reading

Adapter)

Pulse Coil BLK/W to GRN5 DC Volts minimum @

cranking RPM

Ohm TestConnect

Meter Wires To:Ω Reading

Pulse Coil BLK/W to GRN 120-180 Ohms

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9

CHARGING SYSTEM

Charging System Testing

Whenever charging system problems are suspected, proceed with the following system checks:

Using a multitester set on D.C. volts, mea-sure the battery open circuit voltage (seeprocedure later in chapter). It should be 12.4 volts or more. Is it?

Meter Setting: DC VoltsWith the transmission in neutral, start theengine and increase RPM to between 3000and 4000. Read battery voltage with thea voltmeter. Readings should be between

13.0 and 14.6 V D.C.

Meter Setting: DC AmpsPerform system “Break Even Amperage”

test outlined on Page 9.13.

Does charging occur as specified?

Meter Setting: AC Amps Disconnect the wires leading from the regu- lator/rectifier. Using a multitester, perform an Alternator Output (AC Amp) Test. See test procedure on Page 9.12 for procedure.

Meter Setting: DC Volts Reconnect the alternator wires. Note: Red wire must be connected to harness. Battery voltage must be present on red wire terminalon harness side of voltage regulator connector.

Is it?

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.

Yes

No

No

Yes

Yes

Remove the battery and properly ser-vice. Reinstall the fully charged battery or a fully charged shop battery.

No

Check Key off Current Draw. Yes

Check for owner modification, anddiscuss operating habits. The batterywill continually discharge if operatedbelow the “Break Even” RPM. Con-tinued problems would call for battery

inspection.

Yes

Inspect the wiring harness be-tween the panel and the stator for damage. If no damage is found, remove the recoil and flywheel.Inspect the flywheel magnets, sta- tor coils and stator wire harness for damage. Repair or replace any damaged components.

No

Check regulator/rectifier connectionsand ground, battery connections, cir- cuit breaker and connecting wires. Repair or replace faulty wiring or

components.

No

Is it?

Is output above 5 amps?

Refer to Page 9.13.

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ELECTRICAL

Main Fuse Assembly

The main fuse assembly is located under the seat and has a 15amp capacity.

NOTE: Use only the recommended fuse capacity, asuse of a higher amperage fuse to correct blown-fusesituations could lead to electrical componentdamage.

Stator / Alternator Tests

Three tests can be performed using a multimeter to determinethe condition of the stator (alternator).

TEST 1: RESISTANCE VALUE OF EACH STATOR LEG

1. Measure the resistance value of each of the three statorlegs: Y1 to Y2, Y1 to Y3, and Y2 to Y3. Each shouldmeasure 0.7-1.0 ohms.

NOTE: If there are any significant variations inohm’s readings between the three legs; it is anindication that one of the three stator legs may beweak or failed.

TEST 2: RESISTANCE VALUE OF STATOR LEG TOGROUND

1. Measure the resistance value of each of the stator legs toground: Y1 to Ground, Y2 to Ground, Y3 to Ground.

NOTE: Any measurement other than Infinity (open)will indicate a failed or shorted stator leg.

TEST 3: MEASURE AC VOLTAGE OUTPUT OF EACHSTATOR LEG AT CHARGING RPM WITH AVOLTMETER SET TO VOLTS AC.

1. Turn the dial selector to the Volts AC position.

2. Start the engine and let it idle.

3. Separately test each ’leg’ of the stator by connecting themeter leads to the wires leading from the alternator (Y1 toY2, Y1 to Y3, Y2 to Y3). Alternator Current OutputReading should be no less than 30-40V AC above 2000RPM on each ’leg’.

NOTE: If one or more of the stator leg output ACvoltage varies significantly from the specified value,the stator may need to be replaced.

Alternator Output Test (AC amp)

This test measures AC amperage from the alternator.

• Maximum alternator output will be indicated on themeter. It is not necessary to increase engine RPM aboveidle.

(3 Stator Wires are Yellow)

VOLTAGEREGULATOR

Y1 Y2 Y3

CAUTION

This test simulates a “full load” on the alternator. Do not perform this test longer than required to

obtain a reading or the alternator stator windings may overheat. Do

not exceed idle rpm during this test.

Alternator Current Output:Minimum of 5 AC Amps

To Calculate Available Alternator Output

I = P 150 WE 12 V

= 12.5 Amps

I = Current in AmpsP = Power in WattsE = Electromotive Force (Volts)

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9

• Place the red lead on the tester in the 10A jack.

• Turn the selector dial to the AC amps (A~) position.

• Connect the meter leads to the wires leading from thealternator (see schematic for proper wiring colors).

• Start the engine and let it idle. Reading should be aminimum of 5A at idle.

Current Draw - Key Off

Connect an ammeter in series with the negative battery cable.Check for current draw with the key off. If the draw is excessive,loads should be disconnected from the system one by one untilthe draw is eliminated. Check component wiring as well as thecomponent for partial shorts to ground to eliminate the draw.

Charging System “Break Even” Test

The “break even” point of the charging system is the point atwhich the alternator overcomes all system loads (lights, etc.)and begins to charge the battery. Depending on battery conditionand system load, the break even point may vary slightly. Thebattery should be fully charged before performing this test.

• Clamp an inductive ammeter or connect an ammeter(set to DC amps) in series between the negative batterycable and terminal.

• Connect a tachometer according to manufacturer’sinstructions.

• With engine off and the key and kill switch in the ONposition, the ammeter should read negative amps(battery discharge). Reverse meter leads if a positivereading is indicated

• Shift transmission into neutral and start the engine. Ifusing an ammeter in series, start engine with kick startonly.

• Turn headlight on high beam and apply the brake light.Increase engine RPM while observing ammeter andtachometer.

• Note RPM at which the battery starts to charge(ammeter indication is positive).

• With lights and other electrical load off, this shouldoccur at approximately 1500 RPM or lower.

• Turn the lights on and lock parking brake to keep brakelight on.

• Repeat test, observing ammeter and tachometer. Withlights on, charging should occur at or below 2000 RPM.

CAUTION

Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will

occur to light bulbs and speed limiter.

Current Draw - Key Off:Maximum of .02 DCA (20mA)

CAUTION

Do not connect or disconnect the battery cable or ammeter with the engine running.

CAUTION

Never use the electric starter with an ammeter connected in series, as damage to the meter or

meter fuse may result. Do not run test for extended period of time. Do not run test with

high amperage accessories.

Current Drain Inspection Key Off

Less Than 9 mADo not use electric start.

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HEADLIGHT

Phoenix Headlight Adjustment

The headlight beam can be adjusted up and down and side toside.

1. Place the vehicle on a level surface with the headlightapproximately 25’ (7.6 m) from a wall.

2. Measure the distance from the floor to the center of theheadlight and make a mark on the wall at the same height.

3. Shift transmission to neutral, start the engine and turn theheadlight switch to high beam.

4. Observe headlight aim. The most intense part of theheadlight beam should be aimed 2” (5.1 cm) below themark placed on the wall in Step 2.

NOTE: Rider weight must be included on the seat

5. Adjust beam to desired position by moving headlight.

Phoenix Headlight Replacement

NOTE: Allow lamp to cool before proceeding. Do nottouch a halogen lamp with bare fingers. Oil fromyour skin leaves a residue, causing a hot spot whichwill shorten the life of the lamp. Hold the bulb by thebase only.

Headlight Assembly Removal

1. To access the headlight assembly without removing thefront cover, reach up under the front cab.

2. Rotate the socket (2) counterclockwise and pull it awayfrom the headlight assembly.

3. Install the new headlamp.

4. Reinstall all components.

Lamp Center Height25’ (7.6 m)

2” (5.1 cm)

1

2

Headlamp Installation

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9

TAILLIGHT

Brake Light Switches

Each brake lever utilizes an electrical brake switch to send asignal to the tail light.

1. Locate the brake switches on each of the brake levers orpedal.

2. Disconnect wire harness from brake switch.

3. Connect an ohmmeter across switch contacts or two switchwires. Reading should be infinite (•).

4. Apply brake the brake lever(s) and check for continuitybetween switch contacts. Replace switch if there is nocontinuity or greater than .5 ohms resistance when the brakeis applied with slight pressure.

Tail Light / Brakelight Lamp Replacement

If the taillight/brakelight does not work the lamp assembly mayneed to be replaced.

1. From the rear of the taillight remove two screws (1)holding lens cover in place and remove lens cover.

2. Remove lamp (2) and replace it with recommended lamp.Apply Dielectric Grease (PN 2871329).

3. Reinstall the lens cover removed in Step 1.

4. Test the taillight/brakelight.

LH Brake Switch

RH Brake Switch

Foot Brake Switch

To CDI

To OtherLamps

Tail Light

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HANDLEBAR POD SERVICE

Indicator Lamp Replacement

1. Remove the two screw covers (A) and screws from the podassembly (B).

2. Disconnect the bullet connectors (2) to the appropriatelamp being replaced.

3. To remove defective lamp, turn the hex nut counter-clockwise. Once the nut is removed the lamp should pullout of the top of the pod.

4. Reverse the above steps for installation.

STARTER SYSTEM

Starter Motor Service

The starter motor is a complete service part. If it is determinedthat the starter motor is the failed part, replace as needed. See theparts manual for correct part numbers.

Voltage Drop Test

The Voltage Drop Test is used to test for bad connections. Whenperforming the test, you are testing the amount of voltage dropthrough the connection. A poor or corroded connection willappear as a high voltage reading. .

Voltage drop shown on the meter when testing connectionsshould not exceed .1 VDC per connection or component

To perform the test, place the meter on DC volts and place themeter leads across the connection to be tested. Refer to the charton next page to perform voltage drop tests on the starter system.

A

B

To Remove Nut

Voltage should not exceed.1 DC volts per connection

Starter Motor

O-ring

StarterGear Assy.

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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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Starter System Testing

Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testingof starter system. A digital multitester must be used for this test.

With the tester on the VDC position, place theblack meter lead on the battery negative and the red

meter lead on the battery positive.

Reading should be 12.4 volts or greater.

Disconnect Blue/White engagement wire fromthe starter solenoid. Connect tester black wire tobattery ground. Connect red tester lead to Blue/White harness wire at solenoid.Turn on ignition switch and depress the starter button. Tester should read battery voltage.

No

Yes

Remove battery and properly service.

Install fully charged shop battery tocontinue test.

Check voltage on both sides of circuit break- er, ignition switch/engine stop switch and starter button and brake switches.The voltage on both sides should be the same. NOTE: The ignition switch and engine stop switch must be on, the starter button and brake depressed.Replace the defective

No

Test starter solenoid coil by connecting an ohmmeter between the coil leads Resistance should be 3.4Ω + 1. Check solenoid ground path by measuring

Reconnect the solenoid. Connect the tester blacklead to the battery positive and the red lead to the solenoid end of the battery-to-solenoid wire. Depress starter button. Reading should be less than .1 V D.C.

Voltage Drop TestingSee Page 9.15 for instructions.

Connect the black tester lead to solenoid end of battery-to-solenoid cable. Connect red tester leadto solenoid end of solenoid-to-starter cable. Depress starter button. Reading should be less than .1 V D.C.

Yes

Connect the black tester lead to solenoid end ofthe solenoid-to-starter cable. Connect the red tester lead to the starter end of the same cable. Depress the starter button.

Yes

Yes

Reading should be less than .1 V D.C.

If all of these indicate a good condition, yet the starter still fails to turn, the starter must be removed for static testing and inspection.

Yes

Clean the battery-to-solenoid cable ends or replace the cable.No

Replace the starter solenoid.No

Clean the solenoid-to-starter cable ends or replace the cable.

No

component.

resistance between the G/Y harness wire and battery negative terminal (-).

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BATTERY INFORMATION

Battery Identification

NOTICE: It is important to identify what type of battery youhave installed in your ATV. Different types of batteries requiredifferent service procedures. Proper servicing and upkeep ofyour battery is very important for maintaining long battery life.

Your ATV may have a Conventional Battery or a Sealed LowMaintenance Battery. To identify which type of battery yourATV has, refer to the illustration below and follow the correctservice and charging procedures that follow in the manual.

Battery Inspection / Removal

The battery is located under the seat.

1. Disconnect holder strap.

2. Disconnect battery negative (-) (black) cable first, followedby the positive (+) (red) cable.

3. Remove the battery.

Battery Installation

1. Clean battery cables and terminals with a stiff wire brush.Corrosion can be removed using a solution of one cupwater and one tablespoon baking soda. Rinse well withclean water and dry thoroughly.

2. Route the cables correctly.

3. Reinstall battery, attaching positive (+) (red) cable first andthen the negative (-) (black) cable. Coat terminals and boltthreads with Nyogel™ Grease (PN 2871329).

4. Reinstall the holder strap.

CONVENTIONAL BATTERY

RemovableCaps

Top View

Electrolyte LevelIndicator

Side View

SEALED LOW MAINTENANCE BATTERY

No Caps(Non-removablesealed Top)

Top View

Side View

No ElectrolyteLevel Indicator

CAUTION

Whenever removing or reinstalling the battery, disconnect the negative (black) cable first and

reinstall the negative cable last!

Battery Location

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Battery Off Season Storage

To prevent battery damage during extended periods of non-use,the following basic battery maintenance items must beperformed:

• Remove the battery from the machine and wash thecase and battery tray with a mild solution of bakingsoda and water. Rinse with lots of fresh water aftercleaning.

• Using a wire brush or knife, remove any corrosion fromthe cables and terminals.

• Charge at a rate no greater than 1/10 of the battery’samp/hr capacity until the voltage reaches 13.0 VDC orgreater.

• Store the battery either in the machine with the cablesdisconnected, or store in a cool place.

NOTE: Stored batteries lose their charge at the rateof up to 1% per day. Recharge to full capacity every30 to 60 days during a non-use period. If the batteryis stored during the winter months, electrolyte willfreeze at higher temperatures as the batterydischarges. The chart below indicates freezingpoints by specific gravity.

SEALED LOW MAINTENANCEBATTERY

Battery Service

NOTE: All Low Maintenance batteries are fullycharged and tested at the factory before installation.Expected shelf life varies upon storage conditions.As a general rule before placing the battery intoservice, check the battery condition and chargeaccordingly.

Battery Check:

1. Check the date label on the side of the battery to calculatewhen to check voltage. The battery should be checkedevery 3 months.

2. Check the voltage with a voltmeter or multimeter. A fullycharged battery should be 12.8 V or higher.

3. If the voltage is below 12.8 V, the battery will need to berecharged.

New Batteries: Batteries must be fully charged before use orbattery life can be reduced by 10-30% of full potential. Chargebattery for 3-5 hours using a variable rate charger. Do not use thealternator to charge a new battery. A high rate battery chargercan cause battery damage.

Low Maintenance batteries are permanently sealed at the time ofmanufacture. The use of lead-calcium and AGM technologyinstead of lead-antimony allows the battery acid to be fullyabsorbed. For this reason, a Low Maintenance battery case isdark and the cell caps are not removable, since there is no needto check electrolyte level.

Electrolyte Freezing Points

Specific Gravityof Electrolyte

FreezingPoint

1.265 -75° F

1.225 -35° F

1.200 -17° F

1.150 +5° F

1.100 +18° F

1.050 +27° FPar

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NEVER attempt to add electrolyte or water to a LowMaintenance battery. Doing so will damage the case and shortenthe life of the battery.

NEVER attempt to add electrolyte or water to a LowMaintenance battery. Doing so will damage the case and shortenthe life of the battery.

How To service a Low Maintenance battery:

1. Remove battery from the vehicle.

2. Test battery with a voltage meter or load tester to determinebattery condition. This will determine the length of timerequired to charge the battery to full capacity. Refer tocapacity table.

3. Charge battery using a variable rate charger.

Battery Charging

If battery voltage is 12.8 Volts or less, the battery may needrecharging. When using an automatic charger, refer to thecharger manufacturer’s instructions for recharging. When usinga constant current charger, use the following guidelines forrecharging.

NOTE: Always verify battery condition before and 1-2 hours after the end of charging.

Battery Charging Reference Table

Battery Testing

Whenever a service complaint is related to either the starting orcharging systems, the battery should be checked first.

Following are three tests which can easily be made on a batteryto determine its condition: OCV Test, Specific Gravity Test andLoad Test.

Open Circuit Voltage Test

Battery voltage should be checked with a digital multitester.Readings of 12.8 volts or less require further battery testing andcharging. See charts and Load Test.

NOTE: Lead-acid batteries should be kept at or neara full charge as possible. If the battery is stored orused in a partially charged condition, or with lowelectrolyte levels, hard crystal sulfation will form onthe plates, reducing the efficiency and service life ofthe battery.

NOTE: Use a voltmeter or multimeter to test battervoltage.

WARNINGAn overheated battery could explode, causing severe injury or death. Always watch charging

times carefully. Stop charging if the battery becomes very warm to the touch.

Allow it to cool before resuming charging.

State ofCharge

Voltage ActionCharge Time

(*See note below)

100% 12.8-13 V

None, check voltage at 3 mos. after manufacture date

None Required

75-100% 12.5-12.8 VMay need slight charge

3-6 hours

50-75% 12.0-12.5 V Needs Charge 5-11 hours

25-50% 11.5-12.0 V Needs ChargeAt least 13 hours, verify state of charge

0-25% 11.5 V or less Needs Charge At least 20 hours

OPEN CIRCUIT VOLTAGE

State ofcharge

Maintenance FreeLow Maintenance

Type

100% 13.0 V 12.70 V

75% Charged 12.80 V 12.50 V

50% Charged 12.50 V 12.20 V

25% Charged 12.20 V 12.0 V

0% Charged less than 12.0 V less than 11.9 V

* At 80° FNOTE: Subtract .01 from the specific gravity reading at 40° F.

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Battery Load Test

NOTE: This test can only be performed on machineswith electric starters. This test cannot be performedwith an engine or starting system that is not workingproperly.

A battery may indicate a full charge condition in the OCV testand the specific gravity test, but still may not have the storagecapacity necessary to properly function in the electrical system.For this reason, a battery capacity or load test should beconducted whenever poor battery performance is encountered.To perform this test, hook a multitester to the battery in the samemanner as was done in the OCV test. The reading should be 12.6volts or greater. Engage the starter and observe the batteryvoltage while cranking the engine. Continue the test for 15seconds. During cranking the observed voltage should not dropbelow 9.5 volts. If the beginning voltage is 12.6 volts or higherand the cranking voltage drops below 9.5 volts during the test,replace the battery.

Battery Charging Procedure

1. Remove the battery from the ATV to prevent damage fromleaking or spilled acid during charging.

2. Charge the battery with a variable rate charging output.Charge as needed to raise the voltage to 12.8 VDC orgreater.

3. Install battery in vehicle with positive terminal toward thefront. Coat threads of battery bolt with a corrosion resistantNyogel™ Grease (PN 2871329).

4. Route cables so they are tucked away in front and behindbattery.

5. Connect battery cables.

6. After connecting the battery cables, install the cover on thebattery and attach the hold down strap.

CONVENTIONAL BATTERY

Battery Activation / Service

To ensure maximum service life and performance from abattery, perform the following steps.

NOTE: This section contains information for bothConventional Lead-Acid batteries and Sealed LowMaintenance batteries. Before service, identify thebattery type in the vehicle. Use the section thatapplies to the battery.

NOTE: New Battery: Battery must be fully chargedbefore use or battery life will be significantlyreduced 10-30% of the battery’s full potential.

To activate a new battery:

1. Remove vent plug from vent fitting. Remove cell caps.

CAUTION

To prevent shock or component damage, remove spark plug high tension leads and

connect securely to engine ground before proceeding.

WARNING

To avoid the possibility of sparks and explosion, connect positive (red) cable first and negative

(black) cable last.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or

vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes etc. away. Ventilate when charging or using in an enclosed space.

Always shield eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

WARNING

The gases given off by a battery are explosive. Any spark or open flame near a battery can

cause an explosion which will spray battery acid on anyone close to it. Should there be contact with battery acid, wash the affected area with

large quantities of cool water and seek immediate medical attention.

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2. Fill battery with electrolyte to upper level marks on case.

3. Set battery aside to allow for acid absorption andstabilization for 30 minutes.

4. Add electrolyte to bring level back to upper level mark oncase. NOTE: This is the last time that electrolyte shouldbe added. If the level becomes low after this point, add onlydistilled water.

5. Charge battery at 1/10 of its amp/hour rating. Examples: 1/10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4amp; 1/10 of 18 amp battery = 1.8 amp (recommendedcharging rates).

6. Check specific gravity of each cell with a hydrometer toassure each has a reading of 1.270 or higher.

Battery Inspection

The battery is located under the seat and the right rear fender.

Inspect the battery fluid level. When the battery fluid nears thelower level, remove the battery and fill with distilled water onlyto the upper level line.

1. Disconnect holder strap and remove the battery.

2. Remove the filler caps and add distilled water only asneeded to bring each cell to the proper level. Do not overfillthe battery.

Refill using only distilled water. Tap water contains mineralswhich are harmful to a battery.

Do not allow cleaning solution or tap water inside the battery.Battery life may be reduced.Reinstall the battery caps.

3. Reinstall the battery caps.

Battery Location

Maintain between upperand lower levelmarks

CAUTION

Whenever removing or reinstalling the battery, disconnect the negative (black) cable first and

reinstall the negative cable last!

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Battery Testing

Whenever a service complaint is related to either the starting orcharging systems, the battery should be checked first.

Following are three tests which can easily be made on a batteryto determine its condition: OCV Test, Specific Gravity Test andLoad Test.

Open Circuit Voltage Test

Battery voltage should be checked with a digital multitester.Readings of 12.6 volts or less require further battery testing andcharging. See charts and Load Test on below.

NOTE: Lead-acid batteries should be kept at or neara full charge as possible. Electrolyte level should bekept between the low and full marks. If the battery isstored or used in a partially charged condition, orwith low electrolyte levels, hard crystal sulfation willform on the plates, reducing the efficiency andservice life of the battery.

Specific Gravity Test

A tool such as a Battery Hydrometer (PN 2870836) can be usedto measure electrolyte strength or specific gravity. As the batterygoes through the charge/discharge cycle, the electrolyte goesfrom a heavy (more acidic) state at full charge to a light (morewater) state when discharged. The hydrometer can measurestate of charge and differences between cells in a multi-cellbattery. Readings of 1.270 or greater should be observed in afully charged battery. Differences of more than .025 between thelowest and highest cell readings indicate a need to replace thebattery.

OPEN CIRCUIT VOLTAGE

State ofcharge

Conventional Lead-acid

Low Maintenance Type

100% Charged 12.60 V 12.70 V

75% Charged 12.40 V 12.50 V

50% Charged 12.10 V 12.20 V

25% Charged 11.90 V 12.0 V

0% Chargedless than 11.80 V

less than 11.9 V

SPECIFIC GRAVITY

State ofcharge*

Conventional Lead-acid

Low Maintenance

Type

100% Charged 1.265 1.275

75% Charged 1.210 1.225

50% Charged 1.160 1.175

25% Charged 1.120 1.135

0% Charged less than 1.100 less than 1.115

* At 80° F

NOTE: Subtract .01 from the specific gravity reading at 40° F.

1.10

1.15

1.20

1.25

1.30

Detail A

Battery Hydrometer (PN 2870836)

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Battery Load Test

NOTE: This test can only be performed on machineswith electric starters. This test cannot be performedwith an engine or starting system that is not workingproperly.

A battery may indicate a full charge condition in the OCV testand the specific gravity test, but still may not have the storagecapacity necessary to properly function in the electrical system.For this reason, a battery capacity or load test should beconducted whenever poor battery performance is encountered.To perform this test, hook a multitester to the battery in the samemanner as was done in the OCV test. The reading should be 12.6volts or greater. Engage the starter and observe the batteryvoltage while cranking the engine. Continue the test for 15seconds. During cranking the observed voltage should not dropbelow 9.5 volts. If the beginning voltage is 12.6 volts or higherand the cranking voltage drops below 9.5 volts during the test,replace the battery.

Battery Charging Procedure

1. Remove the battery from the ATV to prevent damage fromleaking or spilled acid during charging.

2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raisethe specific gravity to 1.270 or greater.

3. Install battery in vehicle with positive terminal toward thefront. Coat threads of battery bolt with a corrosion resistantdielectric grease.

4. Connect battery cables.

5. After connecting the battery cables, install the cover on thebattery and attach the hold down strap.

6. Install clear battery vent tube from vehicle to battery vent.WARNING: Vent tube must be free from obstructions andkinks and securely installed. If not, battery gases couldaccumulate and cause an explosion. Vent should be routedaway from frame and body to prevent contact withelectrolyte. Avoid skin contact with electrolyte, as severeburns could result. If electrolyte contacts the vehicle frame,corrosion will occur.

7. Route cables so they are tucked away in front and behindbattery.

8. Reinstall battery, attaching positive (+) (red) cable first andthen the negative (-) (black) cable. Coat terminals and boltthreads with Dielectric Grease (PN 2871329).

9. (Conventional Lead/Acid Batteries Only) Install clearbattery vent tube from vehicle to battery vent. WARNING:Vent tube must be free from obstructions and kinks andsecurely installed. If not, battery gases could accumulateand cause an explosion. Vent should be routed away fromframe and body to prevent contact with electrolyte. Avoidskin contact with battery electrolyte, severe burns couldresult. If electrolyte contacts the vehicle frame, corrosionwill occur.

10. Route cables so they are tucked away in front and behindbattery.

11. Reinstall battery cover and holder strap.

Do not run the engine with the battery disconnected. Electricalcomponents can become damaged.

CAUTION

To prevent shock or component damage, remove spark plug high tension leads and

connect securely to engine ground before proceeding.

Dielectric Grease

(PN 2871329)

WARNING

To avoid the possibility of explosion, connect positive (red) cable first and negative

(black) cable last.

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NOTES

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QUADRICYCLE

CHAPTER 10

QUADRICYCLE

10

PHOENIX QUADRICYCLE BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2REAR BRAKE CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3REAR BRAKE DISC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3REAR AXLE - CALIPER MOUNT PLATE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

PHOENIX QUADRICYCLE SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

IMPORTANT: This chapter illustrates components that are unique to the Phoenix Quadricycle. Except where noted, any servicing of these components or other components

on the ATV can be done using this service manual’s procedures and illustrations.

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PHOENIX QUADRICYCLE BRAKE SYSTEM

Overview

The Phoenix Quadricycle brake system consists of a hydraulic brake system with a mechanical park brake. All-wheel braking isintegrated into the rear brake foot pedal (A). This allows 3 wheel disc braking. A mechanical brake lever (B) located on the lefthandlebar actuates the rear parking brake.

A cable (C) is linked to the two master cylinders (D) located by the foot brake. When the foot brake (A) is applied the master cylindersactuate the front and rear brake calipers. One brake line (E) runs to the rear caliper (F) located on the left rear axle tube. Anotherbrake line (G) runs to the front of the ATV to a junction block (H), where two brake lines split off to each front wheel. Brake fluidis routed through the junction block where the fluid is then routed to the front calipers (I). This gives the operator all wheel discbraking.

A

C

D

E

F

G

I

H

PHOENIX QUADRICYCLE

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1

Rear Brake Caliper Removal

NOTE: Refer to Chapters 7 and 9 for front brakeinformation, wheel, and axle removal.

1. Place ATV on a flat level surface. Be sure there is nopressure on any of the brake levers.

2. Jack up the rear of the ATV and remove the left rear tire(A). Refer to Chapter 5 in the Phoenix Service Manual.

3. Remove the park brake cable by removing the bolt from theactuator.

4. Loosen the two rear caliper bolts (B). Lift caliper (C) frommount.

Rear Brake Disc Service

1. With the rear left wheel removed, slide the spacer (A) andbrake disc from the axle (B).

2. Check the brake disc scoring, scratches, or gouges. Use amicrometer to measure disc thickness at eight differentpoints around the perimeter of the disc. Replace disc ifworn past the service limit.

3. Mount a dial indicator and measure brake disc runout. Ifbrake disc exceeds the specification, replace the disc.

4. Reverse steps for installation.

A

B C

A

B

= In. / mm.

Service Limit: 3.556mm (.140”)

= In. / mm.

Brake Disc Run-out: .254 mm (.010 in.)

Measure Brake Disc

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Rear Axle - Caliper Mount Plate Service

1. With the brake disc removed, remove the four studs (A)that secure the rear axle caliper mount (B) to the axle tube.

2. Remove the axle caliper mount (B) from the axle tube.

3. If replacing the bearings (C), remove the snap ring (D) fromthe axle caliper mount and press the bearings out.

4. Reverse the steps for installation. Torque the studs tospecification .

PHOENIX QUADRICYCLE SPEEDOMETER

Overview

The speedometer does not require any electrical power. Insteadthe speedometer head (E) operates off a mechanical drivemechanism located in the transmission. The shaft/gear (A)meshes with one of the transmission gears (See Pic 2). Theshaft/gear (A) then mesh with the meter gear (B), located in theback of the LH crankcase (F) . The meter gear (B) turns the jointgear (C), which is connected to the speedometer cable (D),which thereby turns the speedometer (E).

NOTE: To service the speedometer gear,transmission disassembly may be required. Pleaserefer to chapter 7 of the service manual fortransmission disassembly information.

= T

Brake Plate Stud (4) Torque: 40 ft.lbs. (54 Nm)

A

B

D

C

1. O-ring2. Snap Ring3. Bearings4. Stud5. Axle Mount6. Oil Seal7. Brake Disc Mount8. Brake Disc9. Brake Disc Bolt10. Collar Spacer

12

3

4

56

78

9

10

E

D

C

B

A

F

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Shaft/Gear (A) Meshes with Transmission Gear

A

Transmission Gear

Pic. 2

C

A

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NOTES

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WD-1

WIRE DIAGRAM

2009 PHOENIX 200 WIRE DIAGRAM

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WD-2

WIRE DIAGRAM

INTENTIONAL BLANK PAGE

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