polaris atv repair manual

7/23/2019 Polaris ATV Repair Manual

http://slidepdf.com/reader/full/polaris-atv-repair-manual 1/24

6

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]umtj`h) Mbcfhcrs iùhtck `h tac sumtj`h sjkc `d f p``bs puip fhk djbtcr systci(Urcssurc) Mbcfhcrs iùhtck `h tac rcturh sjkc `d f p``bs puip fhk djbtcr systci fhk ify usc f o``stcr

puip d`r cxtrf prcssurc([ac U`bfrjs F[T js f sumtj`h mbcfhcr(

]umtj`h Mbcfhcr[ac F[T js f =)waccb sumtj`h mbcfhcr taft vfmuuis o`ta jh d`rwfrk fhk rcvcrsc( Jt wfs `rjljhfbby s`bk fs tac

U`bfrjs =;5( Jt wfs uplrfkck fhk ocmfic tac U`bfrjs F[T ! Fbb [crrfjh Tfmuui* [ac =;5 mfh oc jkchtjdjck oyf kfrg obuc t`p fhk s`bjk waccbs( [ac F[T afs sp`gc waccbs fhk f bjlat obuc t`p( I`st pfrts frc

jhtcrmafhlcfobc octwcch tac tw` uhjts( [ac tjrcs frc h`t([̀ tfgc tajs mùrsc yù wjbb hcck f F[T mbcfhcr fs wcbb fs f Uajbbjps acfk fhk strfjlat cklc smrcw krjvcr( Jt js

rcmìichkck taft yù ̀ otfjh fhk rcfk tac U`bfrjs F[T @whcr‚s Ifhufb" [B)=55(

Fppbjmftj`h D`r fbb jh)lrùhk p``bs !luhjtc" vjhyb" tjbc" `r djocrlbfss*(• H` o``stcr puip `r cbcmtrjmfb w`rg rcqujrck(

• Jhstfbbs jht` f kckjmftck 6)6?/ sumtj`h mbcfhcr bjhc `r sgjiicr

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• Fuxjbjfry jhbct prcvchts puip mfvjtftj`h• Oypfss k``r rcbcfscs mbcfhcr drì afhl)ups

• Futìftjm rcvcrsc krjvc ofmgs ùt `d m`rhcrs• K`whd`rmc dfh lchcrftcs 45 LUI mjrmubftj`h fhk chafhmcs mbcfhcr stfojbjty

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`r smruoocrs*• ;? dcct `d a`sc pfmgflck jh tac o`x

@pcrftj`h fhk Ucrd`rifhmcF[T js f uhjquc sumtj`h mbcfhcr" i`vjhl frùhk f p``b jh spcmjfb mymbc r`bbjhl `h tarcc waccbs( Jt vfmuuis jh

o`ta d`rwfrk fhk rcvcrsc" fs wcbb fs `pchs f oypfss k``r wajma orcfgs sumtj`h b`hl chùla d`r tac mbcfhcr t`rci`vc trfppck kcorjs fhk m`htjhuc `h tarùla tac mymbc( [ac F[T mymbc js fs d`bb`ws>• D`rwfrk

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surdfmc d`r p``b mbcfhcrs t` trfvcb `vcr wjtaùt òstrumtj`h(Fvfjbfobc>• -31?5 \ajtc

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Jhstfbbftj`h[acrc frc scvcrfb `ptj`hs t` jhstfbbjhl f F[T( Jt js f sumtj`h mbcfhcr fhk tacrcd`rc ify oc jhstfbbck cjtacr

tarùla f kckjmftck sumtj`h bjhc fttfmack t` tac sumtj`h sjkc `d tac p``b puip" `r jhstfbbck jh f p``b sgjiicr(Ocmfusc tacrc frc ifhy p`ssjobc wfys `d jhstfbbjhl tac F[T tac lrùp `d djttjhls" sa`wh ocb`w" frc pfmgck jh

f ofl wjta cvcry F[T(

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Jhstfbbftj`h\ach jhstfbbjhl tac a`sc d`r tac F[T jh f kckjmftck sumtj`hbjhc" tac a`sc ify djt shul `h jts `wh( Jd h`t tac a`sc wjbbdfbb ùt cvcry tjic tac puip sauts `dd( Jh tajs mfsc usc tac

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4

Jhstfbbftj`h> @ptj`h -? ]gjiicr\ach jhstfbbjhl tac F[T jh f kcmg

sgjiicr" yù ify hcck tac ShjvcrsfbFkfptcr fs wcbb jd tac a`sc k`cs h`t djtshul `h jts `wh( Jd tacrc js t`` iuma

sumtj`h yù ify fbs` hcck t` jhstfbbtac Db`w _clubft`r( [ajs js fknustfobc

t` fbb`w wftcr drì frùhk tacrclubft`r t` db`w jht` tac a`sc" s` taft

yù ify fknust tac pr`pcr sumtj`h t``pcrftc tac F[T(

@ptj`hfb DjttjhlsFs tacrc frc ifhy kjddcrcht stybcs `d

p``b sgjiicrs jh tac ifrgct( [acrc jsfbs` f ;3 kclrcc !UH 3)<?35* fhk :5

kclrcc !UH 3)<?55* cbo`w jh tacdjttjhl ofl d`r usc t` jhstfbb tac a`sc(

M`hhcmtjhl tac A`sc6* ]ct fsjkc tac bcfkcr a`sc fhk tac `hc stfhkfrk a`sc scmtj`h taft afvc f wcjlat `h taci(

?* M`hhcmt rcifjhjhl a`sc scmtj`hs pusajhl mudds scmurcby t`lctacr uhtjb a`sc rcfmacs drì tac wfbb djttjhl t`tac dfrtacst cklc ̀ d tac p``b(

=* Fkk tac stfhkfrk a`sc scmtj`h wjta tac wcjlat(;* H`w fkk tac bcfkcr a`sc wjta tac wcjlat `h jt(

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[cst fhk Fknust \ftcr Db`wDjbb tac a`sc wjta wftcr( Fttfma tac Db`w _clubft`r jhmbukck jh tac djttjhl oflt` tac chk `d tac bcfkcr a`sc( A`bk tac db`w rclubft`r uhkcr wftcr fhk turh

tac p``b puip ̀ h( [ac tfrlct frcf ̀ h tac db`w rclubft`r rcprcschts tacm`rrcmt wftcr db`w rfhlc(

Ur`pcr Db`wJd tacrc js t`` bjttbc db`w>

6* Tcrjdy taft tac p``b djbtcr fhk puip ofsgct frc mbcfh(?* Tcrjdy taft fbb sumtj`h bjhcs frc mb`sck cxmcpt tac `hc utjbjzck oy tac db`w jhkjmft`r(

=* Macmg a`sc mudds fhk m`hhcmtj`hs d`r bcfgs taft mùbk mfusc db`w b`ss(;* D`r kckjmftck sumtj`h bjhc jhstfbbftj`hs" fknust vfbvc ft cqujpicht taft m`htr`bs tac kckjmftck sumtj`h bjhc(

Macmg d`r Ur`pcr \accb _UI[ac pr`pcr rcv`butj`hs pcr ijhutc !_UI* ̀ d tac

U`bfrjs F[T js =5 t` =;(Ifrg f tjrc ̀ h tac ̀ utcr cklc" suoicrlc tac F[T

fhk rci`vc fjr drì tac a`sc( A`bkjhl tac mbcfhcruhkcr tac wftcr" turh tac puip `h fhk mùht tac

waccb rcv`butj`hs( Jd tac _UI js h`t wjta jh rfhlcmacmg d`r tac pr`pcr db`w flfjh fhk ifgc tacm`rrcmt fknustichts(

F[T [rùobcsa``tjhlTcrjdy \accb ]pcck• =5 ” =; drcc ?1 ” =? ruhhjhl `h db``r

Tcrjdy A`sc Bchlta• ? t` = scmtj`hs pfst tac durtacst p`jhtTcrjdy Ubfmcicht `d tac A`sc \cjlats

• Sp t` 4 dt( kccp ” `hc wcjlat ; dt( ofmg• 4 t` 1 dt( kccp ” `hc = dt( $ `hc 4 dt( ofmg

• Tcrjdy tac Mbcfhcr Mymbcs Ur`pcrby• Tcrjdy taft tac Ur`pcbbcr js drcc drì kcorjs

• Tcrjdy taft tac Tfm Jhbct js drcc `d kcorjs• Tcrjdy taft tac ]wjvcb i`vcs drccby

Jd t`` iuma db`w>6* D`r kckjmftck sumtj`h bjhc jhstfbbftj`hs" fknust vfbvc ft cqujpicht taft m`htr`bs tac kckjmftck sumtj`h bjhc(?* D`r sgjiicr jhstfbbftj`hs" ifgc surc tac db`w rclubft`r js jhstfbbck( [urh ghò ̀ h db`w rclubft`r

mùhtcrmb`mgwjsc uhtjb pr`pcr wftcr db`w js jhkjmftck(

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[uhc Sp Gjt3):;35 F[T [uhc)up Gjt jhmbukcs fbb wcfr pfrts out k`cs h`tjhmbukc f t`p `r o`tt`i(

_coujbk Gjt

3):;?5 F[T _coujbk Gjt jhmbukcs fbb wcfr pfrts fhk jhmbukcs tac t̀ p fhk o t̀t̀ i(

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[cfr K`wh> F[T

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_ci`vc tac F[T [`p[acrc frc tw` smrcws iùhtck ̀ h tac t`p ̀ d tac F[T( _ci`vc

tacsc smrcws fhk tfgc tac t`p `dd(

_ci`vc tac Ur`pcbbcr@hmc tac t`p js `dd" rci`vc tac pr`pcbbcracbk `h oy `hc smrcw `h tac t`p(

@hmc tac t`p fhk pr`pcbbcr afvc occh

rci`vck" turh tac uhjt ̀ vcr( [acrc frc 3smrcws ̀ h tac o`ttì( Zù k` h`t hcck t`

rci`vc tac ? jh tac ijkkbc h`w( Out jdkcorjs wcrc mfulat jh f uhjt jh tac djcbk"

tacsc tw` mùbk oc rci`vck t` tfgc ̀ dd tac

o`ttì pbftc t` rci`vc tac kcorjs(



66

_ci`vc tac O`ttì[̀ rci`vc tac o`ttì" rci`vc tac = smrcwsfhk pubb tac o`ttì ̀ dd tac uhjt(

_ci`vc tac Ocbt ̀ h tac Kùobc \accb]jkcNust bjgc f ojmymbc mafjh" ft tac obuc rcvcrsckrjvc" pubb tac ocbt t` tac sjkc( _ci`vc tac ocbt

_ci`vc Ocbt drì ]jhlbc \accb ]jkc

Flfjh" bjgc f ojmymbc mafjh" stfrtjhl ft tac obucrcvcrsc krjvc" pubb tac ocbt t` tac sjkc fhkkjsm`hhcmt jt(

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_ci`vc Krjvc I`kubc[acrc frc tarcc smrcws taft a`bk

tac krjvc i`kubc jh pbfmc( _ci`vctacsc tarcc smrcws fhk pubbi`kubc ̀ ut ̀ d uhjt( Ubcfsc h`tc

b`mftj`h `d scrjfb huiocr fhkstjmgcr wjta jhstrumtj`hs `h a`w t`

rcpbfmc ocbt `h k`uobc waccb sjkc(

]crjfb Huiocr

Ocbt Kjflrfi

[arcc smrcws t`rci`vc t` tfgc

i`kubc ̀ ut ̀ duhjt(

_ci`vc _cvcrsc Krjvc M`l[ac tw` rcvcrsc krjvcs frc b`mftck `h cjtacr sjkc `d tac i`kubc( [acy frc acbk jh pbfmc oy f m`l( \ajma mfhoc rci`vck wjta tac acbp `d f dbft cklc smrcw krjvcr( [ac m`l turhs out js acbk jh pbfmc oy tac tfo `h t`p `d tac

m`l( [ac mrcw krjvc wjbb acbp wajbc y`u turh t` lct pfst tac b`mgjhl kcvjmc d`r jt `h tac i`kubc( !]cc hcxt sbjkc*

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B`mgjhl tfo `h taci`kubc d`r tac m`l(

Kjrcmtj`h t` turh m`ljs mùhtcrmb`mgwjsc(

_ci`vc _cvcrsc Krjvc Icmafhjsi !_KI*_ci`vc tac smrcw taft a`bks tac _KI( Jt wjbb sbjkc ̀ dd( Zù ̀ hby wfht t` afvc ̀ hc _KI ̀ dd ft f tjic( O`ta ̀ dtac _KI frc iùhtck t` tac sfic safdt( Jd yù rci`vc o`ta ft tac sfic tjic" tac safdt wjbb sbjkc ̀ ut ̀ d tacuhjt(



6;

[jicr Mfi[ac tjicr mfi js cfsjcr t` wftma fhk vcrjdy `h tac bcdt

sjkc `d tac i`kubc fs jt js obuc(

[ac tjicr mfi saùbk mìpbctcf dubb =45 kclrcc fhk `pch tac

oypfss k``r(

Jd tac tjicr mfi kjk h`t turh"tac -3 lcfr hccks t` ocrcpbfmck( Jd jt ifkc tac dubb

turh" nust tac _KOI] hcck tòc rcpbfmck(

_ci`vc Dr`ht Ubftc ̀ h tac I`kubc[̀ fmmcss tac -3 Lcfr" rci`vc tac tarcc smrcws taft

a`bk tac dr`ht pbftc ̀ h tac i`kubc( _ci`vc tac dr`htpbftc(

H`tcs>



63

[ac -3 Lcfr js obfmg( Jt js tac i`st mrjtjmfb lcfr fswcbb fs tac ̀ hc taft mfh oc kfiflck(

Zù mfh fmmcss tac -3 lcfr wjtaùt f b`t `d w`rg( [ac

-6 mfh oc pusack fsjkc fs jt dbcxjobc( _ci`vc tac -<(H`w tac -3 js fmmcssjobc fhk mfh oc rci`vck fhkrcpbfmck(

[acrc js h` rcfs`h t` tfgc fhy i`rc `d tac i`kubc fpfrt( [ac i`kubc js fvfjbfobc fs f rcpbfmcicht pfrt fhk jd

i`rc w`rg js hcckck tafh _KI rcpbfmcicht fhk tac -3 Lcfr" dubb i`kubc rcpbfmcicht js rcmìichkck(



64

[ac i`kubc fbs` m`ics fs f rcpbfmcicht pfrt jh tac rcoujbk gjt(

_cpbfmc tac Dr`ht Ubftc `h tac I`kubc[acrc frc tarcc smrcws taft a`bk tac dr`ht pbftc

`h tac i`kubc( _cpbfmc tac smrcws fhk dr`htpbftc(

_cpbfmc tac _KI ! _cvcrsc Krjvc Icmafhjsi*



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_cpbfmc tac M`l[ac m`l h`w turhs mb`mgwjsc l`jhl `h ifgjhl surc

taft tac tfo `h tac t`p `d tac m`l l`cs pfst tacb`mgjhl tfo ̀ h tac i`kubc( [ajs wjbb prcvcht tac m`l

drì i`vjhl jh `pcrftj`h fhk a`bk tac _KI jh pbfmc(

_cpbfmc Krjvc I`kubcUbfmc tac i`kubc ofmg jh tac drfic( _cpbfmc tac tarcc smrcws taft a`bk jt jh pbfmc(

_cpbfmc tac ocbt ̀ h tac kùobc waccb sjkc( [ac kjflrfi d`r

tac ocbt js ̀ h tac o`ttì ̀ d tac i`kubc(

Jt js cfsjcst t` pbfmc tac ocbt jh tac m`rrcmt p`sjtj`h `h fbbpubbcys cxmcpt tac ofmg waccb djrst( [ach prcss ̀ vcr tac

pubbcy `h tac ofmg waccb(



61

Fknust Ocbt [chsj`h Kùobc \accb ]jkc[acrc js f obfmg fxbc ob`mg ft cfma waccb( Cfma afstw` smrcws( [` fknust tac ocbt tchsj`h b``sch tac

smrcws( \jta f dbft acfk smrcw krjvcr ocajhk tacfxbc" pjmg up tac tchsj`h(

[jlatch tac tw` smrcws k`wh( Zù saùbk oc fobc t`

prcss k`wh `h tac ocbt wjta yùr djhlcr fhk afvc ¹’pbfy(

Fxbc Ob`mg ]mrcwsFxbc Ob`mg ]mrcws

_cpbfmc tac Ocbt ̀ h tac ]jhlbc \accb ]jkcUbfmc tac ocbt `h tac obuc rcvcrsc krjvc djrst" bcfvjhltac ocbt ̀ dd tac waccb pubbcy( [ach i`vc jt ̀ h t` tac

waccb pubbcy(

Fknust Ocbt [chsj`h ̀ h ]jhlbc \accb ]jkc[acrc frc tw` smrcws `h tac obfmg fxbc ob`mg( B``schtac mrcws( \jta f dbft cklc smrcw krjvcr ocajhk tac

fxbc ob`mg pjmg up tac ocbt tchsj`h oy i`vjhl tacob`mg d`rwfrk(

[jlatch k`wh tac fxbc smrcws( [ajs ocbt saùbk octjlat wjta bjttbc ̀ r h` pbfy(

Fxbc Ob`mg ]mrcwsFxbc Ob`mg ]mrcws

H`tcs>



6:

_cpbfmc tac O`ttì[̀ rcpbfmc tac o`ttì" tacrc frc = smrcws(

_cpbfmc tac Ur`pcbbcr[acrc js `hc smrcw `h tac t`p `d tac pr`pcbbcr taftmrcws jht` tac safdt(

_cpbfmc tac F[T [`p[acrc frc tw` smrcws iùhtck ̀ h tac t`p ̀ d tac F[T(

H`tcs>



?5

_cpbfmc [jrcs

[̀ rcpbfmc tjrcs" nust pubb ̀ dd tac waccb(

[̀ rci`vc waccbs( _ci`vc tac auomfp( Cfma auo mfp afs fh `pchsp`t ̀ h taci taft f dbft acfk smrcw

krjvcr wjbb djt( [ach p`p taci `dd(\ach puttjhl auo mfps ofmg `hifgc surc tacy shfp jht` pbfmc(

@hmc tac auo mfp js `dd" f waccb ify oc rci`vck(

\accbs frc acbk `h t` tac fxbc wjta c)mbjps( F dbft acfksmrcw krjvcr wjbb pry tac c)mbjp `dd tac fxbc( [acrc js flr``vc `h tac fxbc d`r tac c)mbjp(

\ach rcpbfmjhl c)mbjps tfgc mfrc t` lct taci dubby jht`

p`sjtj`h fhk prcssck fbb tac wfy jht` tac lr``vc



?6

]crjfb Huiocr js b`mftck `h taco`tt`i ̀ d tac i`kubc fhk uhkcrtac afhkbc ̀ h tac t`p(

[ac scrjfb huiocr js f ofr m`kc(Jt jhkjmftcs tac pr`kumt(

[ac kftc tac pr`kumt wfs oujbt([ac huiocr ̀ d taft pr`kumt oujbt taft kfy(

]crjfb Huiocr

Ur`kumt

Kftc Oujbt Huiocr Oujbt taft Kfy

H`tcs>



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Mbcfhcr js h`ti`vjhl(

Mbcfhcr `hby

turhs jh `hckjrcmtj`h `r js

ruhhjhl jh mjrmbcs

Macmg d`r pr`pcr

waccb _UI

Macmg d`r or`gchocfrjhls `r ocbts(

Macmg d`r w`rh

tjrcs(

Ifgc surc taft tac

swjvcb turhs drccby(

Tcrjdy taft mbcfhcr jsmymbjhl pr`pcrby(

Macmg p`wcr i`kubc

pfrts(

Mbcfhcr js sb`w ̀ r

sbulljsa" ruhhjhlwjta bcss p`wcr

tafh h`rifb(

_ci`vc o`ttì

pbftc fhk vcrjdytaft tac jhtfgc

frcf js d rcc ̀ dkcorjs(

Jhspcmt pr`pcbbcr

d`r kcorjs `rkfiflc(

Mbcfh tac djbtcr

puip fhk puipofsgct(

Jhspcmt pr`pcbbcrd`r kcorjs ̀ r

kfiflc(

Macmg d`r pr`pcr

waccb _UI

Macmg d`r or`gch

ocfrjhls ̀ r ocbts(

Tcrjdy taft mbcfhcr js

mymbjhl pr`pcrby(Macmg p`wcr i`kubc

pfrts(

Ur`pcr Db`wJd tacrc js t`` bjttbc db`w>6* Tcrjdy taft tac p``b djbtcr fhk puip ofsgct frc mbcfh(

?* Tcrjdy taft fbb sumtj`h bjhcs frc mb`sck cxmcpt tac `hc utjbjzck oy tac db`w jhkjmft`r(=* Macmg a`sc mudds fhk m`hhcmtj`hs d`r bcfgs taft mùbk mfusc db`w b`ss(;* D`r kckjmftck sumtj`h bjhc jhstfbbftj`hs" fknust vfbvc ft cqujpicht taft m`htr`bs tac kckjmftck sumtj`h bjhc(

Jd t`` iuma db`w>6* D`r kckjmftck sumtj`h bjhc jhstfbbftj`hs" fknust vfbvc ft cqujpicht taft m`htr`bs tac kckjmftck sumtj`h bjhc(?* D`r sgjiicr jhstfbbftj`hs" ifgc surc tac db`w rclubft`r js jhstfbbck( [urh ghò ̀ h db`w rclubft`r

mùhtcrmb`mgwjsc uhtjb pr`pcr wftcr db`w js jhkjmftck(

Macmg d`r Ur`pcr \accb _UI[ac pr`pcr rcv`butj`hs pcr ijhutc !_UI* ̀ d tacU`bfrjs F[T js =5 t` =;(

Ifrg f tjrc ̀ h tac ̀ utcr cklc" suoicrlc tac F[Tfhk rci`vc fjr drì tac a`sc( A`bkjhl tac mbcfhcr

uhkcr tac wftcr" turh tac puip `h fhk mùht tacwaccb rcv`butj`hs( Jd tac _UI js h`t wjta jh rfhlc

macmg d`r tac pr`pcr db`w flfjh fhk ifgc tacm`rrcmt fknustichts(

F[T [rùobcsa``tjhlTcrjdy \accb ]pcck

• =5 ” =; drcc ?1 ” =? ruhhjhl `h db``rTcrjdy A`sc Bchlta

• ?)= scmtj`hs pfst tac durtacst p`jhtTcrjdy Ubfmcicht `d tac A`sc \cjlats

• Sp t` 4 dt( kccp ” `hc wcjlat ; dt( ofmg• 4 t` 1 dt( kccp ” `hc = dt( $ `hc 4 dt( ofmg

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