Thoroughly clean the lifters in cleaning solvent and wipe them with a clean, lint-free cloth. E Emission Control System Service California Have an authorized Polaris dealer perform these services. Pull knob off the shifter. Install piston assemblies into cylinder aligning the piston engine oil. Tighten nut slightly if necessary to align cotter pin holes. Part Description Part removal process. Inspect both sheaves for signs of wear, grooving or is worn or damaged.
Partially install the piston pins into the pistons. Use extreme caution with solvent. Check brake system for fluid leaks. Inspect the weight pivot bore instructions for drive clutch removal, then proceed and pivot bolts for wear or galling. Now, you dont have to rely on your mechanic for the simplest repair. Remove the bearing from the lower portion of the differential assembly. Remove the 2 screws that attach the gear position sensor to the shift housing.
Install the cam helix assembly over the shaft. If you have any doubt as to your ability to perform any of the procedures outlined in this service manual, contact an authorized Polaris dealer for service. Remove the 2 Torx screws and 2 push rivets that retain the front and rear portions of the dash assembly and remove the dash assembly from the vehicle. Torque to train is assembled. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.
Refer to Chapter 7 for more information on the rear differential mechanical operation. Put Install a new bearing onto the output shaft using a press. Carefully pull the rail away harness for the fuel injector s up over the air box to allow from the injectors and remove the injector s from the fuel injector removal. Odometer Mode The odometer records the miles or kilometers traveled by the vehicle. Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
Inspect inner clutch cover-to-engine seal. Install adapter reducer Item 9. Replace starter drive if gear teeth are cracked, worn, or broken. Before replacing the bulb s , use a digital multi-meter to test the Remove the O-rings A from the headlamp brackets on harness to ensure the lamp is receiving 12 volts and that a ground both sides of the headlamp. Replace the disc if any deep scratches are evident. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. Piston should slide in and out of bore smoothly, with light resistance.
Lift up on the floor and remove the panduit strap retaining 20. Each manual provides step-by-step instructions based on the complete disassembly of the machine. Remove the front output pinion shaft assembly. Remove all gasket material from the cylinder sealing surfaces. Note and record the number and thickness of shims and replace as needed. Add Polaris Premium Antifreeze to the radiator filler neck if the level goes down.
Stator Mark Upper Connector Jam Nut Lower Jam Nut 33. Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate. Pry the shift lever cover using a suitable tool and remove the screw. Remove Thoroughly clean the brake caliper before disassembly and prepare a clean work area to disassemble the caliper. Install the reverse clutch assembly onto the park flange.
Stop engine and place gear selector in Park. Use compressed air to blow out any debris. Replace fuel line every two years. Step-by-step procedures and detailed illustrations guide you almost anything task you would ever need to perform on your unit. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the Apply engine oil to valve guides and seats. Remove the four bolts with a hex need to be removed.