2009 Polaris Outlaw 450 525 Service Manual
User Manual: 2009 Polaris Outlaw 450 525 Service Manual
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GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION 1 VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 GENERAL: DETAILED: DETAILED: DETAILED: 2009 OUTLAW 450 “MXR” / 525 “S” / 525 “IRS” . . . . . . . . . . . . . . . . . . . . . 1.4 2009 OUTLAW 450 “MXR”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 2009 OUTLAW 525 “S” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2009 OUTLAW 525 “IRS”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 “CHASSIS” SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 “KTM ENGINE” SPECIAL TOOL CROSS-REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 KTM ENGINE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 MISC. NUMBERS / CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 COVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 1.1 GENERAL INFORMATION VEHICLE IDENTIFICATION Engine Serial Number Location Model Identification The engine serial number is stamped into the casing on the lower left side of the crankcase (2). The machine model number must be used with any correspondence regarding warranty or service. } } } } Machine Model Number Identification A 09 GP 52 AA Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation 2 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Engine Designation Numbers ES045KLE013 - Single Cylinder, Liquid Cooled, SOHC 4-Stroke, Electric Start, 5-Speed Manual. ES051KLE015,16 - Single Cylinder, Liquid Cooled, SOHC 4-Stroke, Electric Start, 5-Speed Manual. VEHICLE INFORMATION VIN Identification Paint Codes World Mfg. ID Vehicle Identifier Vehicle Descriptor Body Style Emissions Engine Powertrain } } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A G P 5 2 A * 9 P 0 0 0 0 0 0 Model Year Plant No* PAINTED PART COLOR NUMBER Frame Matte Black P-458 Replacement Keys Individual Serial Number Check Digit* * This could be either a number or a letter Vehicle Identification Number (VIN) Location Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary. Whenever corresponding with Polaris about a particular issue, the machine model number and serial number (VIN) are important for vehicle identification. The serial number (VIN) is stamped on the left side of the frame tube (1). 1 1.2 SERIES # PART NUMBER 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 GENERAL INFORMATION Publication Numbers YEAR MODEL MODEL NO. OWNER’S MANUAL PN PARTS MANUAL PN 2009 OUTLAW 450 “MXR” A09GJ45AA 9921801 9921802 2009 OUTLAW 525 “S” A09GJ52AA 9921801 9921804 2009 OUTLAW 525 “IRS” A09GP52AA 9922079 9921808 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m NOTE: Additional Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. Standard Torque Specifications The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS, refer to exploded views provided in the appropriate chapter. There are exceptions in the steering, suspension, and engine chapters. 1.3 1 GENERAL INFORMATION SPECIFICATIONS MODEL: 2009 OUTLAW 450 “MXR” MODEL NUMBER: A09GJ45AA ENGINE MODEL: ES045KLE013 Category Length Specification 71.5 in. / 182 cm Width 47 in. / 119 cm Height 45 in. / 114 cm Minimum Turing Radius Wheel Base 5 in. / 13 cm P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Ground Clearance 67 in. / 170 cm 50.5 in. / 128 cm Dry Weight 360 lbs. / 163 kg Maximum Weight Capacity 215 lbs. / 98 kg Oil Capacity 1.7 qts. / 1.6 ltr Coolant Capacity 2.25 qts. / 2.1 ltr Fuel Capacity 3.1 gal. / 11.8 ltr MODEL: 2009 OUTLAW 525 “S” MODEL NUMBER: A09GJ52AA ENGINE MODEL: ES051KLE016 Category Specification Length 71.5 in. / 182 cm Width 47.5 in. / 121 cm Height 45 in. / 114 cm Minimum Turing Radius 67 in. / 170 cm Wheel Base Ground Clearance 50.5 in. / 128 cm 5 in. / 13 cm Dry Weight 370 lbs. / 168 kg Maximum Weight Capacity 215 lbs. / 98 kg Oil Capacity 1.7 qts. / 1.6 ltr Coolant Capacity 2.25 qts. / 2.1 ltr Fuel Capacity 3.1 gal. / 11.8 ltr MODEL: 2009 OUTLAW 525 “IRS” MODEL NUMBER: A09GP52AA ENGINE MODEL: ES051KLE015 Category Specification Length 71.5 in. / 182 cm Width 47.5 in. / 121 cm Height Minimum Turing Radius Wheel Base 45 in. / 114 cm 67 in. / 170 cm 50.5 in. / 128 cm Ground Clearance 11.5 in. / 29 cm Dry Weight 390 lbs. / 177 kg Maximum Weight Capacity 215 lbs. / 98 kg Oil Capacity 1.7 qts. / 1.6 ltr Coolant Capacity 2.25 qts. / 2.1 ltr Fuel Capacity 3.1 gal. / 11.8 ltr 1.4 GENERAL INFORMATION 2009 OUTLAW 450 “MXR” Drivetrain Transmission Type MODEL NUMBER: A09GJ45AA ENGINE MODEL: ES045KLE013 Engine KTM Liquid-cooled, single cylinder, SOHC, 4-stroke engine Platform / Design Engine Model Number ES045KLE013 Engine Displacement 448 cc 1 Bore & Stroke (mm) 89 x 72 mm Counter Sprocket - # Tooth 14 Rear Sprocket - # Tooth 38 Primary Ratio 2.516 Gear Ratio : 1st 2nd 3rd 4th 5th Rev 2.500 1.941 1.579 1.333 1.130 2.429 Chain Size / Deflection 520 O-ring / 1/4-3/8” (6-8mm) Clutch Type P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Number of Cylinders Manual 5-Speed w/Reverse Compression Ratio 11:1 Compression Pressure Steering / Suspension n/a Cooling System Liquid 50/50 Front Suspension Style / Shock Thermostat Opening 158°F (70°C) Front Travel Engine Idle Speed 1700-1800 RPM Overheat Warning High Temp Light Lubrication System Dry Sump / Internal Reservoir Lubrication Function Pressure Circulation Lubrication with 2 Rotor Pumps Oil Requirements PS-4 Plus (2W-50 Synthetic) Exhaust System 2 to 1 canister style Carburetion Carburetor model 138 Pilot Jet 45 Slow Air Jet 70 Jet Needle OBDVR Needle Clip #3 Pilot Screw n/a Float Height Parallel to Bowl Sealing Surface Fuel Delivery Impulse Fuel Pump Premium 91 Octane (minimum) Electrical Alternator Output Voltage Regulator Lights : Main Headlight 12V / 200W @ 3000 RPM 3-Phase LED Brake LED Ignition System RPM Limit Ignition Timing Spark plug / Gap 11 in. / 28 cm Threaded shock adjustment with Spanner Wrench Turning Radius 67 in. / 170 cm 0 - 1/16 in / .0 - .159 mm Wheels / Brakes Front Wheel Size / Offset / Bolt Pattern 10x5 / 28.3 mm - 4/156 Rear Wheel Size / Offset / Bolt Pattern 9x8 / 58.8 mm - 4/110 Front Tire Make / Model / Size Maxxis / RAZR-MX / 20x6-10 Rear Tire Make / Model / Size Maxxis / RAZR-MX / 18x10-9 Recommended Air Pressure Front / Rear 4 psi (27.6 kPa) Brake - Front Hydraulic Disc, Dual Bore Brake - Rear Hydraulic Disc Parking Brake Hydraulic Lock, Front Wheel JETTING CHART AMBIENT TEMPERATURE Altitude DC/CDI Kokusan Ignition 10000 / Reverse 6000 25o + 3o BTDC @ 3500 RPM NGK DCPR8E / .024 in. (0.6 mm) Maintenance-Free 9 Amp Hr Circuit Breakers (Amps) Main-10 / Fan-10 / Ignition-5 Instrument Cluster Shock Preload Adjustment Front and Rear 1 Watt (ea.) Battery / Model / Amp Hr Starting Rear Travel Single / High-Low / 50 Watts Tail Neutral / Hot / Reverse 10 in. / 25 cm Swing Arm / FOX™ PODIUM X Compression & Rebound Adjustable Shock Rear Suspension Style / Shock Keihin FCR-MX 39mm Fuel Requirement Dual A-arm / FOX™ PODIUM X Compression Adjustable Shock Toe Out Main Jet Wet Multi Disc Meters (Feet) Below 40° F Below 5° C +40° F + Above +5° C + Above 0-1800 (0-6000) Main Jet: 148 Clip Position: #3 Main Jet: 138 Clip Position: #3 above 1800 (above 6000) Main Jet: 138 Clip Position: #2 Main Jet: 125 Clip Position: #2 Electric - Standard N/A 1.5 1 GENERAL INFORMATION 2009 OUTLAW 525 “S” Drivetrain Transmission Type MODEL NUMBER: A09GJ52AA ENGINE MODEL: ES051KLE016 Engine KTM Liquid-cooled, single cylinder, SOHC, 4-stroke engine Platform / Design Engine Model Number ES051KLE016 Engine Displacement 510cc 1 Bore & Stroke (mm) 95 x 72 mm Counter Sprocket - # Tooth 14 Rear Sprocket - # Tooth 38 Primary Ratio 2.516 Gear Ratio : 1st 2nd 3rd 4th 5th Rev 2.500 1.941 1.579 1.333 1.130 2.429 Chain Size / Deflection 520 O-ring / 1/4-3/8” (6-8mm) Clutch Type Wet Multi Disc P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Number of Cylinders Manual 5-Speed w/Reverse Compression Ratio 11:1 Compression Pressure Steering / Suspension n/a Cooling System Liquid 50/50 Front Suspension Style / Shock Thermostat Opening 158°F (70°C) Front Travel Engine Idle Speed 1700-1800 RPM Overheat Warning High Temp Light Lubrication System Dry Sump / Internal Reservoir Lubrication Function Pressure Circulation Lubrication with 2 Rotor Pumps Oil Requirements PS-4 Plus (2W-50 Synthetic) Exhaust System 2 to 1 canister style Carburetion Carburetor model 138 Pilot Jet 45 Slow Air Jet 100 Jet Needle OBDVS Needle Clip #4 Pilot Screw n/a Float Height Parallel to Bowl Sealing Surface Fuel Delivery Impulse Fuel Pump Premium 91 Octane (minimum) Electrical Alternator Output Voltage Regulator Lights : Main Headlight 12V / 200W @ 3000 RPM 3-Phase LED Brake LED Ignition System Ignition Timing Spark plug / Gap 10000 / Reverse 6000 25o + 3o BTDC @ 3500 RPM NGK DCPR8E / .024 in. (0.6 mm) Maintenance-Free 9 Amp Hr Main-10 / Fan-10 / Ignition-5 1.6 Threaded shock adjustment with Spanner Wrench Turning Radius 67 in. / 170 cm 0 - 1/16 in / .0 - .159 mm Wheels / Brakes Front Wheel Size / Offset / Bolt Pattern 10x5 / 28.3 mm - 4/156 Rear Wheel Size / Offset / Bolt Pattern 9x8 / 58.8 mm - 4/110 Front Tire Make / Model / Size Maxxis / RAZR-R / 21x7-10 Rear Tire Make / Model / Size Maxxis / RAZR-R / 20x10-9 Recommended Air Pressure Front / Rear 4 psi (27.6 kPa) Brake - Front Hydraulic Disc, Dual Bore Brake - Rear Hydraulic Disc Parking Brake Hydraulic Lock, Front Wheel JETTING CHART AMBIENT TEMPERATURE Altitude DC/CDI Kokusan Ignition Circuit Breakers (Amps) Instrument Cluster 11 in. / 28 cm Shock Preload Adjustment Front and Rear 1 Watt (ea.) Battery / Model / Amp Hr Starting Rear Travel Single / High-Low / 50 Watts Tail Neutral / Hot / Reverse Swing Arm / FOX™ PODIUM X Compression & Rebound Adjustable Shock Rear Suspension Style / Shock Toe Out Main Jet RPM Limit 10 in. / 25 cm Keihin FCR-MX 39mm Fuel Requirement Dual A-arm / FOX™ PODIUM Electric - Standard N/A Meters (Feet) Below 40° F Below 5° C +40° F + Above +5° C + Above 0-1800 (0-6000) Main Jet: 148 Clip Position: #4 Main Jet: 138 Clip Position: #4 above 1800 (above 6000) Main Jet: 138 Clip Position: #3 Main Jet: 128 Clip Position: #3 GENERAL INFORMATION 2009 OUTLAW 525 “IRS” Drivetrain Transmission Type MODEL NUMBER: A09GP52AA ENGINE MODEL: ES051KLE015 Engine KTM Liquid-cooled, single cylinder, SOHC, 4-stroke engine Platform / Design Engine Model Number ES051KLE015 Engine Displacement 510cc 1 Bore & Stroke (mm) 95 x 72 mm Counter Sprocket - # Tooth 14 Rear Sprocket - # Tooth 38 Primary Ratio 2.516 Gear Ratio : 1st 2nd 3rd 4th 5th Rev 2.500 1.941 1.579 1.333 1.130 2.429 Chain Size / Deflection 520 O-ring / 1/4-3/8” (6-8mm) Clutch Type P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Number of Cylinders Manual 5-Speed w/Reverse Compression Ratio 11:1 Compression Pressure Steering / Suspension n/a Cooling System Liquid 50/50 Front Suspension Style / Shock Thermostat Opening 158°F (70°C) Front Travel Engine Idle Speed 1700-1800 RPM Overheat Warning High Temp Light Lubrication System Dry Sump / Internal Reservoir Lubrication Function Pressure Circulation Lubrication with 2 Rotor Pumps Oil Requirements PS-4 Plus (2W-50 Synthetic) Exhaust System 2 to 1 canister style Carburetion Carburetor model 148 Pilot Jet 45 Slow Air Jet 100 Jet Needle OBDVS Needle Clip #4 Pilot Screw n/a Float Height Parallel to Bowl Sealing Surface Fuel Delivery Impulse Fuel Pump Fuel Requirement Premium 91 Octane (minimum) Electrical Alternator Output LED LED Neutral / Hot / Reverse Ignition Timing Spark plug / Gap Toe Out 67 in. / 170 cm 0 - 1/16 in / .0 - .159 mm Wheels / Brakes Front Wheel Size / Offset / Bolt Pattern 10x5 / 28.3 mm - 4/156 Rear Wheel Size / Offset / Bolt Pattern 10x8 / 55.3 mm - 4/110 Front Tire Make / Model / Size Maxxis / RAZR-R / 21x7-10 Rear Tire Make / Model / Size Maxxis / RAZR-R / 20x10-10 Recommended Air Pressure Front / Rear Brake - Front 4 psi (27.6 kPa) Hydraulic Disc, Dual Bore Parking Brake Hydraulic Disc Hydraulic Lock, Front Wheel JETTING CHART AMBIENT TEMPERATURE Altitude Below 40° F Below 5° C +40° F + Above +5° C + Above 0-1800 (0-6000) Main Jet: 158 Clip Position: #4 Main Jet: 148 Clip Position: #4 above 1800 (above 6000) Main Jet: 148 Clip Position: #3 Main Jet: 138 Clip Position: #3 1 Watt (ea.) 10000 / Reverse 6000 o 25 + 3o BTDC @ 3500 RPM Meters (Feet) NGK DCPR8E / .024 in. (0.6 mm) Maintenance-Free 9 Amp Hr Circuit Breakers (Amps) Main-10 / Fan-10 / Ignition-5 Instrument Cluster 10 in. / 25 cm Threaded shock adjustment with Spanner Wrench Turning Radius DC/CDI Kokusan Ignition Battery / Model / Amp Hr Starting Shock Preload Adjustment Front and Rear 3-Phase Brake RPM Limit Rear Travel Single / High-Low / 50 Watts Tail Ignition System 10 in. / 25 cm Independent A-Arm / FOX™ Compression Adjustable Shock Brake - Rear 12V / 200W @ 3000 RPM Voltage Regulator Lights : Main Headlight Dual A-arm / FOX™ PODIUM Rear Suspension Style / Shock Keihin FCR-MX 39mm Main Jet Wet Multi Disc Electric - Standard N/A 1.7 1 GENERAL INFORMATION SPECIAL TOOLS “Chassis” Special Tools TOOL DESCRIPTION CHAPTER TOOL USED IN PV-39951-A 2870975 PA-48282 2200421 2871352 2871351 2871352 2872429 2871071 7052069-A 2201639 2201640 PV-43568 2870630 Engine Tachometer Mity Vac Pressure Test Tool Rear Hub Tool Gas Shock Recharging Kit (FOX™) Shock Rod Holding Tool (FOX™) Shock IFP Depth Tool (FOX™) Shock Rod Holding Tool - 1/2” Shock Rod Holding Tool - 5/8” Shock Body Clamp Charging Needle Seal Bullet Tool Seal Bullet Tool Fluke 77 Digital Multimeter Timing Light 2, 7 4, 6 5 5 5 5 5 5 5 5 5 5 7 7 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m PART NUMBER* *Special Tools can be ordered through a Polaris Dealer or SPX Corporation (1-800-328-6657). “KTM Engine” Special Tool Cross-Reference POLARIS PART NUMBER* KTM PART NUMBER** TOOL DESCRIPTION PA-46502 PA-48700 PA-48674 PA-48675 PA-48676 PA-48677 PA-48678 PA-48680 PA-48681 PA-48682 PA-48928 PA-48683 PA-48684 PA-48685 PA-48686 n/a n/a 503.29.050.000 151.12.018.100 590.29.026.006 n/a 590.29.005.010 580.12.009.000 584.29.037.037 590.29.018.000 580.12.015.089 580.12.015.095 590.29.018.050 590.29.003.100 590.29.020.000 Valve Spring Compressor Adaptor, Valve Spring Compressor Hydraulic Clutch Bleeder Internal Gear Puller (18-23 mm) Valve Guide Limit Gauge Crankshaft Locking Tool Water Pump Seal Installer Flywheel Puller Main Bearing Removal Tool Valve Guide Installation Tool Piston Ring Compressor (89 mm) Piston Ring Compressor (95 mm) Valve Guide Reamer Clutch Holder Riveting Tool for Cam Chain *Special Tools can be ordered through a Polaris Dealer or SPX Corporation (1-800-328-6657). **KTM special tool part numbers are provided as a cross-reference for any existing KTM dealer that is already equipped with KTM special tools. 1.8 GENERAL INFORMATION KTM Engine Special Tools P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1 1.9 GENERAL INFORMATION MISC. NUMBERS / CHARTS Decimal Equivalents 1/64 SAE Tap / Drill Sizes 3/64 Thread Size / Drill Size 1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 11/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 1 1/8-7 63/64 1 1/8-12 1 3/64 1 1/4-7 1 7/64 1 1/4-12 1 11/64 1 1/2-6 1 11/32 1 1/2-12 1 27/64 1 3/4-5 1 9/16 1 3/4-12 1 43/64 2-4 1/2 1 25/32 2-12 1 59/64 2 1/4-4 1/2 2 1/32 2 1/2-4 2 1/4 2 3/4-4 2 1/2 3-4 2 3/4 5/64 7/64 9/64 11/64 13/64 .0156 .0312. . . 1 mm= .0394" .0469 .0625 .0781. . . 2 mm = .0787" .0938 .1094. . . 3 mm =.1181" .1406 .1563. . . 4 mm = .1575" .1719 .1875. . . 5mm= .1969" .2031 .2188 .2344. . . 6 mm = .2362" P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Thread Size/ Drill Size #0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/16-20 25/64 ................. 1/32 . . . . . . . . . . . . . ................. 1/16 . . . . . . . . . . . . . ................. 3/32 . . . . . . . . . . . . . ................. 1/8 . . . . . . . .1250 ................. 5/32 . . . . . . . . . . . . . ................. 3/16 . . . . . . . . . . . . . ................. 7/32 . . . . . . . . . . . . . ................. 1/4 . . . . . . . .25 ................. 9/32 . . . . . . . . . . . . . ................. 5/16 . . . . . . . . . . . . . ................. 11/32 . . . . . . . . . . . . ................. 3/8 . . . . . . . .375 ................. ................. ................. 7/16 . . . . . . . . . . . . . ................. 15/32 . . . . . . . . . . . . ................. 1/2 . . . . . . . .5 ..... ................. 17/32 . . . . . . . . . . . . ................. 9/16 . . . . . . . . . . . . . ................. 19/32 . . . . . . . . . . . . ................. 5/8 . . . . . . . .625 ... ................. 21/32 . . . . . . . . . . . . ................. 11/16 . . . . . . . . . . . . ................. 23/32 . . . . . . . . . . . . ................. 3/4 . . . . . . . .75 ................. 25/32 . . . . . . . . . . . . ................. 13/16 . . . . . . . . . . . . ................. 27/32 . . . . . . . . . . . . ................. 7/8 . . . . . . . .875 ................. 29/32 . . . . . . . . . . . . ................. 15/16 . . . . . . . . . . . . ................. 31/32 . . . . . . . . . . . . ................. 15/64 17/64 19/64 21/64 23/64 25/64 13/32 27/64 29/64 31/64 33/64 35/64 37/64 39/64 Metric Tap / Drill Sizes Tap Size Drill Size 3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6x1.00 7x1.00 8x1.00 8x1.25 9x1.00 9x1.25 10x1.25 10x1.50 11 x 1.50 12x1.50 12x1.75 #39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32 1.10 41/64 Decimal Equivalent 0.0995 0.0937 0.1285 0.125 0.166 0.161 0.196 0.234 0.277 0.265 0.3125 0.3125 0.3437 0.339 0.375 0.406 0.406 Nearest Fraction 3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32 43/64 45/64 47/64 49/64 51/64 53/64 55/64 57/64 59/64 61/64 63/64 1 . . . . . . . . . . 1.0 .2656. . . 7 mm = .2756" .2813 .2969 .3125. . . 8mm= .3150" .3281 .3438. . . 9 mm = .3543" .3594 .3906. . . 10 mm = .3937" .4063 .4219. . . 11 mm =.4331" .4375 .4531 .4688. . . 12 mm = .4724" .4844 . . . . . . . 13mm = .5118" .5156 .5313 .5469. . . 14 mm = .5512" .5625 .5781. . . 15 mm = .5906" .5938 .6094 . . . . . . . 16mm=. 6299" .6406 .6563. . . 17 mm =.6693" .6719 .6875 .7031. . . 18 mm = .7087" .7188 .7344. . . 19 mm = .7480" .7656 .7813. . . 20 mm = .7874" .7969 .8125. . . 21 mm =.8268" .8281 .8438 .8594. . . 22 mm = .8661" .8906. . . 23 mm = .9055" .9063 .9219 .9375. . . 24 mm = .9449" .9531 .9688. . . 25 mm = .9843" .9844 GENERAL INFORMATION Coversion Table Unit of Measure Multiplied by 1 Converts to 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 9.807 = 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 = Kilo pascals (kPa) Kilo pascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilo pascals (kPa) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilo pascals (kPa) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m ft. lbs. 2 ð(3.14)xR xH (height) = Cylinder Volume °C to °F: °F to °C: 9/5 (°C + 32) = °F 5/9(°F - 32) = °C 1.11 GENERAL INFORMATION Glossary of Terms P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 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 grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO. 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 the chassis). 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 is converted 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. PVT: Polaris Variable Transmission (Drive Clutch System) 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. 1.12 MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 BREAK-IN PERIOD / MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PRE-RIDE MAINTENANCE INTERVAL / RECOMMENDED FLUID LEVEL CHECKS . . 2.4 10 - 60 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 45 - 90 HOUR GREASE LUBRICATION MAINTENANCE INTERVAL . . . . . . . . . . . . . . 2.6 90 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 2 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m LUBRICANTS AND SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10 PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 FUEL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 CARBURETOR GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 THROTTLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 THROTTLE CABLE / ETC ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 CHOKE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 AIR FILTER SERVICE (“MXR” / “S”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 AIR FILTER SERVICE (“IRS”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 AIR BOX DRAIN TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 ENGINE AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 ENGINE OIL AND FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 CYLINDER LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 EXHAUST PIPE / SPARK ARRESTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 ENGINE MOUNT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 LIQUID COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 RECOVERY BOTTLE / COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 2.20 RADIATOR / COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 COOLING SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 RADIATOR SCREEN REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 FINAL DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 HYDRAULIC CLUTCH LEVER ADJUSTMENT / OIL LEVEL INSPECTION . . . . . . . . . 2.21 HYDRAULIC CLUTCH SYSTEM BLEEDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 REVERSE LOCK-OUT LEVER INSPECTION AND CABLE ADJUSTMENT. . . . . . . . . 2.23 SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 DRIVE CHAIN INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 DRIVE CHAIN TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 DRIVE CHAIN ADJUSTMENT (“MXR” / “S”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24 DRIVE CHAIN ADJUSTMENT (“IRS”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 REAR DRIVESHAFT BOOT INSPECTION (“IRS”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 DRIVESHAFT BOOT PRESSURE EQUALIZING (“IRS”). . . . . . . . . . . . . . . . . . . . . . . . 2.26 2.1 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 BATTERY INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 BATTERY TERMINALS / BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 SPARK PLUG REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 CONTROLS / HANDLEBAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 STEERING INSPECTION / TIE ROD ENDS AND HUBS . . . . . . . . . . . . . . . . . . . . . . . 2.30 TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 SUSPENSION (450 “MXR” / 525 “S”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m FRONT SUSPENSION SET-UP / SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . 2.32 FRONT SHOCK COMPRESSION ADJUSTMENT (“MXR”). . . . . . . . . . . . . . . . . . . . . . 2.33 REAR SUSPENSION SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 REAR SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 REAR SHOCK COMPRESSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 REAR SHOCK REBOUND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 SUSPENSION (525 “IRS”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 FRONT SUSPENSION SET-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 FRONT SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 REAR SUSPENSION SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 REAR SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 REAR SHOCK COMPRESSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE LEVER POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE PEDAL TESTING / BRAKE LIGHT OPERATION . . . . . . . . . . . . . . . . . . . . . . . 2.38 WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 WHEEL REMOVAL: FRONT OR REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 TIRE PRESSURE / TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40 2.2 MAINTENANCE PERIODIC MAINTENANCE CHART Periodic Maintenance Overview Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition • Frequent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low speed, heavy load operation • Extended idle • Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer. Break-In Period Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both. The breakin period consists of the first three hours of operation, or the time it takes to use 5-6 gallons (20 liters) of fuel. Do not allow engine speed to exceed 7000 RPM during the break-in period. Follow the break-in period with an additional 12 hours of cautious operation, with engine speed below 75% of capacity. See “Owner’s Manual” for additional break-in information. Maintenance Chart Key The following symbols denote potential items to be aware of during maintenance: = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer. = SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). • = Use Polaris Premium All Season Grease. ! = Perform After the 3 Hour Break-In Period. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. 2.3 2 MAINTENANCE Pre-Ride Maintenance Interval Periodic Maintenance Chart Maintenance Interval (whichever comes first) Hours Calendar Fuel Used in gallons (liters) Pre-Ride - Item Steering Front / Rear Suspension - Pre-Ride - Tires Brake Systems Fluid level / Lever travel Wheels / Frame Fasteners - Pre-Ride - - Pre-Ride - P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Remarks E E - Pre-Ride - Engine Oil Level - Pre-Ride - Drive Chain Throttle Fuel Lines - Pre-Ride Pre-Ride Pre-Ride - Check operation Check for leaks Clutch System / Oil - Pre-Ride - Check operation, adjustment, oil level Engine Stop Switch - Pre-Ride - Check operation Air Filter Element - Pre-Ride - Inspect; clean often - Pre-Ride - Drain deposits when visible Coolant - Pre-Ride - Head Lamp / Tail Lamp - Pre-Ride - A-arm Ball Joint - Pre-Ride Rear Shaft Assembly - Pre-Ride Post-Ride Air Box Sediment Tube E Make adjustments as needed. - Check level daily, change coolant every 2 years Check operation; apply dielectric grease if replacing Check freeplay daily; have dealer replace if wheel moves excessively Check pre-ride for tears, punctures, leaking. Check post-ride for bulging / ballooning. Replace if damaged. Burp if bulging. 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. • Use Polaris Premium All Season Grease. Recommended Pre-Ride Fluid Level Checks ITEM Engine / Trans Oil Coolant / Level Brake Fluid TYPE NOTES Polaris PS-4 Plus (2W-50 Synthetic) Check crankcase site glass for proper oil level. Polaris Premium 60/40 Pre–mixed Allow engine and cooling system to cool completely Antifreeze/Coolant or a 50/50 and check level in radiator. Fill to top of filler neck. If mixture high quality antifreeze/ reservoir was empty or extremely low, fill radiator coolant and distilled water before filling reservoir tank to full line. Fill to indicated level inside reservoir. Polaris DOT 4 Brake Fluid Use the sight glass to ensure the proper fluid level. NOTE: Quick reference lubricants and maintenance product part numbers are listed on page 2.9 2.4 SEE PAGE 2.15 2.20 2.38 MAINTENANCE 10 - 60 Hour Maintenance Interval Periodic Maintenance Chart Item Remarks Brake Pad Wear 10 H Monthly - Inspect regularly Battery Rear Sprocket Bolts 10 H 10 H Monthly Monthly - Check terminals; clean; test Check; torque 2 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Maintenance Interval (whichever comes first) Hours Calendar Fuel Used in gallons (liters) E E ! Air Filter Element 15 H Weekly - Inspect; clean, replace as needed Engine Oil and Filter Change 15 H 6M 26 (100) Drain and change the oil and oil filters; perform a break-in oil change after the first 3 hours of operation 15 H 6M 26 (100) Remove and clean the short and long oil screens; perform during the break-in oil change after the first 3 hours of operation 15 H 6M 26 (100) Check lines for damage or bends 15 H 15 H 15 H 15 H 15 H 30 H 30 H 6M 6M 6M 6M 6M 6M 6M 26 (100) 26 (100) 26 (100) 26 (100) 26 (100) 52 (200) 52 (200) Check for cracks and leaks Check; adjust as needed Check; torque Check; adjust Check; torque Check discs for wear Replace; inspect plug cap Engine E Oil Screens / Drain Plug ! E Engine Oil Lines ! ! Carb Adaptor Boot ! Idle Speed ! Engine Mounting Bolts ! Valve Clearance ! Shift Lever Bolt Wet Clutch E Spark Plug • General Lubrication 45 H 6M 78 (300) Lubricate all fittings, pivots, cables, etc. 45 H 6M 78 (300) E Carburetor Float Bowl Throttle Cable / ETC Switch Drive Chain 45 H 6M 78 (300) 45 H 6M 78 (300) Drain bowl periodically and prior to storage Inspect; adjust; lubricate or replace if necessary Adjust and lubricate as needed 45 H 6M 78 (300) 45 H 6M 78 (300) 45 H 6M 78 (300) 45 H 60 H 60 H 6M 12 M 12 M 78 (300) 104 (400) 104 (400) ! Brake Pad Replacement Cooling System Front / Rear Suspension Steering Clutch Springs Cam Chain Tensioner To be performed by a Polaris MSD trained technician Inspect coolant strength seasonally Inspect; tighten fasteners; grease (especially after washing or driving in high water levels) See page 2.6 Lubricate Check spring length Check ratchet teeth for wear ! Perform after the 3 hour break-in period. 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. • Use Polaris Premium All Season Grease. 2.5 MAINTENANCE 45 - 90 Hour Grease Lubrication Maintenance Interval Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Fuel Used in gallons (liters) 45 H 6M - 45 H 6M - Inspect; tighten fasteners; grease (also after washing ATV or driving in water) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Upper Steering Post (A) • Front A-arms (B) • Stabilizer Bar (C) • Rear Axle Housing (D) • Rear Control Arm Needle Bearings (E) • Rear Bearing Carrier Needle Bearings (F) • Remarks 45 H 6M - 45 H 6M - 90 H 12 M - 90 H 12 M - Inspect; grease (also after washing ATV or driving in water) Disassemble, clean, inspect bearings and seals, grease, reassemble ! Perform after the 3 hour break-in period. 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. • Use Polaris Premium All Season Grease. F B A F B D 2.6 E C E MAINTENANCE 90 - 300 Hour Maintenance Interval Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Fuel Used in gallons (liters) Remarks 90 H 12 M 156 (600) Pressure test system annually Coolant System Pressure Test Cooling Hoses 90 H 12 M 156 (600) Radiator 90 H 12 M 156 (600) 2 90 H 12 M 156 (600) Cylinder and Piston Piston Pin Circlip Groove Compression Ring Oil Scraper Ring Camshaft Camshaft Bearings Valve Springs Valve Spring Cap Valve Seats / Guides 90 H - 156 (600) 90 H - 156 (600) Visual inspection for wear 90 H - 156 (600) 90 H 90 H 90 H 90 H 90 H - 156 (600) 156 (600) 156 (600) 156 (600) 156 (600) Rocker Arm / Rollers 90 H - 156 (600) Timing Chain Cam Chain Tensioner Bearings (Connecting Rod, Balance Shaft, Crankshaft Main) Crankshaft Run-Out Oil Pressure Valve 90 H 90 H - 156 (600) 156 (600) Measure ring gap and replace if at or above service limit. See “Engine Manual”. Visual inspection for wear Replace Measure free length; replace as needed Visual inspection for wear Measure for wear; replace as needed Measure radial clearance; replace as needed Replace Check ratchet teeth for wear 90 H - 156 (600) Replace 90 H 90 H - 156 (600) 156 (600) Transmission 90 H - 156 (600) Measure; adjust as needed Measure spring; replace as needed Check entire transmission / bearings for wear; replace as needed Ignition Timing - 12 M - Inspect; adjust as needed Hydraulic Clutch Fluid Exhaust Pipe 90 H 100 H 12 M 12M - Wiring 100 H 12M - 180 H 180 H 300 H 12 M 24 M 24 M 36 M - Bleed as needed; change yearly Inspect Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc. Clean and adjust 300 H 36 M - P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Fuel System Inspect for leaks Inspect; clean external surfaces; change coolant every 2 years Check for leaks at tank cap, lines, fuel valve, filter, and carburetor. Replace lines every 2 years Inspect; measure; replace as needed E E ! Carburetor Jet Needle / Needle Jet Brake Fluid Spark Arrestor Wheel Bearings Front / Rear Toe Adjustment - Headlight Aim - Replace Clean out Inspect; replace as needed Inspect periodically; adjust when parts are replaced Adjust as needed 2.7 MAINTENANCE Maintenance References 4. Brake Fluid (Right hand and Foot Brake Master Cylinder) 2. Clutch Oil 1. Engine Oil and Filters P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Oil Filters Sight Glass 3. Rear Drive Chain Fill to Indicated Level III. # Item Lube Rec. Method Frequency* 1. Engine Oil / Transmission Polaris PS-4 Plus 2W-50 Synthetic View the oil level through the sight glass on the right side of the engine. Perform break–in oil / filter change at 3 hours; change oil every 15 hours. ** 2. Clutch Oil Hydraulic Clutch Oil Check fluid level, fill to 4 mm below upper edge of reservoir. Bleed as required. Change oil annually * 3. Drive Chain Polaris Chain Lube Apply to chain link plates and rollers. As required * 4. Brake Fluid Polaris DOT 4 Brake Fluid Fill master cylinder reservoirs As required. Change fluid every to indicated level inside 2 years or 180 hours. *** reservoir. * More often under severe use, such as operation in mud, water, sand or under severe loads. ** Every 15 hours of operation (refer to Maintenance Schedule for additional information). Change more often in extremely dirty conditions, such as continuous operation in water, mud or sand, continuous hot, cold, or short trip cold weather operation. NOTE: Excessive clutch plate residue will accelerate oil change intervals. *** Every 24 months or 180 hours of operation (refer to Maintenance Schedule for additional information). More often under severe conditions such as continuous operation in water, mud or sand. 2.8 MAINTENANCE LUBRICANTS AND SERVICE PRODUCTS Polaris Lubricants, Maintenance and Service Products PART NO. DESCRIPTION 2 ENGINE LUBRICANT 2876244 PS-4 Plus Engine Oil (Quart) 2W-50 Synthetic (4-Cycle) 2876245 PS-4 Plus Engine Oil (Gallon) 2W-50 Synthetic (4-Cycle) GREASE / SPECIALIZED LUBRICANTS Premium All Season Grease (3 oz. cartridge) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 2871322 2871423 Premium All Season Grease (14 oz. cartridge) 1350046 Rear Shaft Grease 2871460 Starter Drive Grease 2871312 Grease Gun Kit 2871329 Dielectric Grease 2876335 Hydraulic Clutch Oil (Quart) 2872348 Chain Lube, Aerosol (16 oz.) COOLANT 2871323 60/40 Coolant (Gallon) 2871534 60/40 Coolant (Quart) ADDITIVES / SEALANTS / THREAD LOCKING AGENTS / MISC. 2870791 Fogging Oil (12 oz. Aerosol) 2871326 Premium Carbon Clean (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2870585 Loctite™ Primer N, Aerosol, 25 g 2872189 DOT 4 Brake Fluid 2871956 Loctite™ Thread Sealant 565 (50 ml.) 2871949 Loctite™ Threadlock 242 (50 ml.) 2871950 Loctite™ Threadlock 242 (6 ml.) 2871951 Loctite™ Threadlock 262 (50 ml.) 2871952 Loctite™ Threadlock 262 (6 ml.) 2871953 Loctite™ Threadlock 271 (6 ml.) 2871954 Loctite™ Threadlock 271 (36 ml.) 2870584 Loctite™ RC 680–Retaining Compound (10 ml.) 2870587 Loctite™ 518 Gasket Eliminator / Flange Sealant (50 ml.) 2871957 Black RTV Silicone Sealer (3 oz. tube) 2871958 Black RTV Silicone Sealer (11 oz. cartridge) 8560054 Silicone Sealer (14 oz. cartridge) 2871557 Crankcase Sealant, 3–Bond 1215 2872893 Engine Degreaser 2.9 MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE FUEL SYSTEM AND AIR INTAKE Fuel System Pre-Ride / Daily Inspection WARNING Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. Gasoline is extremely flammable and explosive under certain conditions. • Tires – check condition and pressures • Always stop the engine and refuel outdoors or in a well ventilated area. • Chain - check tension, lubricate, adjust as needed P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m • Fuel Tank – fill tank to proper level; Check for leaks • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. • All Brakes – check operation and fluid level • Throttle – check for free operation • Do not overfill the tank. Do not fill the tank neck. • Headlight / Taillight / Brakelight – check operation of all lights, indicator lamps and switches • If you get gasoline in your eyes, or if you swallow gasoline, seek medical attention immediately. • Engine Stop Switch / Key Switch – check for proper function • If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing. • Wheels – check for loose wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins • Air Cleaner Element – check for dirt or water; clean or replace • Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can result in loss of consciousness or death in a short period of time. • Steering – check for free operation, noting any unusual looseness in any area • Never drain the float bowl when the engine is hot. Severe burns may result. • Loose Parts – visually inspect vehicle for any damaged or loose nuts, bolts or fasteners • Engine Coolant – check for proper level at the recovery bottle 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 with cable ties. Frame, Nuts, Bolts, and Fasteners Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. CAUTION Make sure lines are not kinked or pinched. 3. 2.10 Replace all fuel lines every two years. MAINTENANCE Vent Lines 5. Reverse the procedures to install the fuel valve. Check engine, fuel tank, and carburetor vent lines for signs of wear, deterioration, damage, or leakage. Replace every two years. Be sure vent lines are routed properly and secured with cable ties. 6. Turn valve on, start engine and inspect for leaks. CAUTION Make sure lines are not kinked or pinched Carburetor General Maintenance The Keihin FCR-MX 39 mm carburetor should be cleaned and properly adjusted on an annual basis. Refer to the “KTM Engine / Carburetion” section in the back of this service manual for carburetion maintenance details. Normal wear from engine vibrations may cause the carburetor to supply an overly rich fuel mixture. Replace the jet needle and the needle jet after every 180 hours of operation. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Fuel Valve The fuel valve is located on the right side under the front fender. Carburetor Draining Fuel Valve The carburetor float bowl should be drained periodically, or before extended periods of storage, to remove moisture or sediment from the bowl. NOTE: The bowl drain screw is located on the bottom left side of the float bowl. ON 1. Turn fuel valve to the “OFF” position. 2. Place a suitable container under the carburetor float bowl to collect the drained fuel. 3. Remove the hex plug (A). Allow the fuel to completely drain. OFF RES Service / Replacement: 1. Turn the valve to the “OFF” position and remove the phillips head screw and adjustment knob from the valve. 2. Remove the retaining nut and pull the valve out far enough to access the fuel lines. Remove Nut A 3. Clamp the fuel lines with an appropriate fuel line pinch tool to prevent fuel leakage and remove the line clamps and the (3) fuel lines from the valve. 4. Inspect the valve for damage or debris. Replace if needed. 4. Inspect the drained fuel for water or sediment. 5. Reinstall the hex plug securely. 6. Turn fuel valve to “ON” position. 7. Start machine and check for leaks. NOTE: All tubes attached to the carburetor must be checked for pinching or blockage, as this will affect engine performance. 2.11 2 MAINTENANCE Idle Speed Adjustment To remove the ETC cover: The carburetor idle speed strongly influences the starting performance and engine responsiveness when accelerating. If idle speed does not meet specification, use the following procedure to make adjustments: 1. Use a medium flat blade screwdriver and insert blade into the pocket of the cover starting on the #1 position 2. Twist screwdriver slightly while lifting on the cover to release snap. 3. Repeat procedure at the other five locations as shown. NOTE: Adjusting the idle speed affects throttle cable freeplay and electronic throttle control (ETC) adjustment. Always check throttle cable freeplay after adjusting idle speed and adjust if necessary. 2 3 1 Start engine and warm it up thoroughly. 2. Adjust idle speed by turning the idle speed adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. 6 5 4 Idle Speed Screw NOTE: Do not attempt to remove cover until all latch points are released. Throttle Cable / Electronic Throttle Control (ETC) Adjustment Idle Speed 1700-1800 RPM 1. Slide boot off throttle cable adjuster and jam nut. 2. Place shift selector in neutral and set parking brake. 3. Start engine and set idle to 1700-1800 RPM. Throttle Inspection Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must 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 speed increases at any point in the turning range, inspect throttle cable routing and condition. Adjust cable tension as needed until lock-to-lock turning can be accomplished with no rise in engine rpm. 5. Replace the throttle cable if worn, kinked, or damaged. 6. Inspect ETC cover seal and switch cavity by removing the cover. Verify that no dirt, water or mud is present. 2.12 NOTE: Be sure the engine is at operating temperature. See Idle Speed Adjustment. 4. Loosen lock nut on in–line cable adjuster. Lock Nut Boot Adjuster Sleeve Boot MAINTENANCE 5. Turn adjuster until 1/16” to 1/8” (2-3mm) freeplay is achieved at thumb lever. After making adjustments, quickly actuate the thumb lever several times and reverify freeplay. If smooth choke operation is not obtainable, remove the choke slide piston. The slide piston should not have any deep score marks or deposits. Also check the condition of the rubber boot, spring, and the choke lock. If any damage or excessive wear is found, replace the choke slide as an assembly. 2 Inspect the Slide Piston P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Direction of Travel Freeplay 1/16”-1/8” (2-3 mm) 6. Tighten lock nut securely and slide boot completely in place to ensure a water–tight seal. 7. Turn handlebars from left to right through the entire turning range. If idle speed increases, check for proper cable routing. If cable is routed properly and in good condition, repeat adjustment procedure. Inspect the Boot and Spring Air Filter Service (“MXR” / “S”) It is recommended that the air filter be inspected frequently. When riding in extremely dusty conditions, cleaning is required more often. Choke Operation Removal: The choke knob is located on the left side of the carburetor. The choke should operate smoothly. 1. Unlatch and remove the seat. 2. Release the four air box cover clips (A) and remove the cover (B). 3. Remove the wing nuts (C) securing the filter to the air box. 4. Pull the air filter assembly out of the air box. 5. Remove the spring clamp (D) and the foam filter element (E) from the internal cage (H). Choke Knob A B F A E D H C G 2.13 MAINTENANCE Cleaning: Cleaning: 6. Separate the foam filter element. 6. Separate the foam filter element. 7. Wash the foam filter element (E) in soapy water, then rinse and let dry (see previous illustration). 7. Wash the foam filter element (L) in soapy water, then rinse and let dry. 8. Apply a commercially available foam filter oil thoroughly on the foam filter element. 8. Apply a commercially available foam filter oil thoroughly on the foam filter element. Installation: Installation: 9. 9. Inspect the air box cover seal (F) for damage (see previous illustration). Replace as needed. Inspect the air box cover seal (N) for damage. Replace as needed. 10. Assemble and reinstall air filter assembly into air box along with the filter clamp (J). 11. Reinstall the air box cover (B) and secure the cover with the four clips (A) as shown in the previous illustration. 11. Securely tighten the filter clamp. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 10. Assemble and reinstall the air filter assembly into the air box and secure it with the wing nuts. 12. Check the boot (G) for cracks, deterioration, abrasion, or leaks. Replace as needed. Air Filter Service (“IRS”) It is recommended that the air filter be inspected frequently. When riding in extremely dusty conditions, cleaning is required more often. Removal: 1. Unlatch and remove the seat. 2. Release the two air box cover clips (H) and remove the cover (I). 3. Loosen the filter clamp (J). 4. Remove the filter assembly from the air box. 5. Remove the spring clamp (K) and the foam filter element (L) from the internal cage (M). 12. Reinstall the air box cover (I) and secure the cover with the two clips (H). 13. Check the boot (P) for cracks, deterioration, abrasion, or leaks. Replace as needed. Air Box Drain Tube Periodically check the air box drain tube located on the bottom side of the air box. Be sure the drain tube is not obstructed by mud or sand. Whenever deposits are visible, clean out the tube. “IRS” Model Shown Here I L N Drain Tube K H M NOTE: The drain tube will require more frequent inspection if the vehicle is operated in severe conditions. J P 2.14 MAINTENANCE ENGINE AND TRANSMISSION Engine Oil and Filter Service Engine Oil Level IMPORTANT: Polaris PS-4 Plus (2W-50 Synthetic) engine oil is recommended for use in the KTM engine. This engine oil was specifically designed for the KTM engine and clutching system. Other oils do not contain the needed additives to prolong engine life and provide proper lubrication to the KTM clutch and transmission components. Check the oil level before each use of the ATV. If the engine is cold, the oil level should be visible at the lower edge of the sight glass. If the engine is warm, the oil level should be visible in the middle of the sight glass. CAUTION P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended engine oil. Never mix brands. Sight Glass Fill Plug 1. Position the ATV on a level surface. 2. View the oil level through the sight glass on the right side of the ATV. NOTE: It is very important to maintain the proper engine oil level. High oil levels can cause excessive engine operating temperatures, which may lead to engine overheating. Engine damage may result. IMPORTANT: Always change both oil filters and clean both oil screens whenever changing oil. 1. Position the ATV on a level surface. 2. Start the engine. Allow it to idle for two to three minutes until warm, then stop the engine. 3. Clean the area around the crankcase drain plug with clean shop towels. WARNING Hot oil can cause serious burns to the skin. Do not allow hot oil to contact skin. 4. Place a drain pan beneath the crankcase and remove the drain plug. Warm Level Cold Level 3. Remove the fill plug and add the recommended oil as needed. 4. Reinstall the fill plug. Sealing Ring Drain Plug 15 ft. lbs. (20 Nm) 5. Allow the oil to drain completely. 6. Clean the crankcase sealing surface and the drain plug (with magnet) thoroughly. 2.15 2 MAINTENANCE NOTE: The sealing surface on the drain plug and crankcase should be clean and free of burrs, nicks or scratches. 7. Cleaning the Long Oil Screen 14. Remove the long screen plug, located on the left side of the engine near the engine serial number. Replace the sealing ring and reinstall the drain plug. Torque to 15 ft. lbs. (20 Nm). Cleaning the Short Oil Screen Strike the head of the oil screen plug with a suitable hammer before you attempt to remove it. This “shocks” the threads of the plug and makes it easier to remove. 9. Remove the plug at the bottom of the engine. See illustration below: P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 8. Plug Remove Plug Long Screen 15. Remove the oil screen. Clean the screen thoroughly and blow clean with low pressure compressed air. 16. Check the O-rings. If damaged, install new O-rings. 17. Place the long oil screen on a pin-type wrench or long screwdriver of about 12 inches (300 mm) in length. NOTE: The large opening of the oil screen should face in towards the inner case. Crankcase Drain Plug 10. Remove the short oil screen. Clean the screen thoroughly and blow clean with low pressure, compressed air. Pin-Type Tool 18. Insert the tool through the opening and into the bore of the opposite engine casing wall. Push the oil screen into the casing as far as possible. Remove the tool. O-rings Short Screen 11. Check the O-rings. If damaged, install new O-rings. 12. Reinstall the screen to the plug. 13. Lubricate the threads and reinstall the plug. Torque to 7.5 ft. lbs. (10 Nm). 2.16 MAINTENANCE CAUTION 23. Thoroughly clean the engine casing, filter covers and O-ring sealing surfaces. Replace the filter cover O-rings. O-ring The oil screen is mounted slightly downward in the crankcase. If installed incorrectly, the screen will not function properly and can lead to increased engine wear. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m O-ring 19. Reinstall the plug. Torque to 11 ft. lbs. (15 Nm). 24. Soak new oil filters in fresh engine oil before installation. Changing Oil Filters 25. Install new oil filters. Insert the long oil filter in the front and the short oil filter in the rear of the housing. 20. Place a drain pan under the engine. 21. Remove the (4) oil filter screws and remove the covers. 26. Lubricate the filter cover O-rings with engine oil and install both covers. Torque to cover screws to 54 in. lbs. (6 Nm). 27. Remove the fill plug and add 1.7 quarts (1.6 liters) of the recommended engine oil. Reinstall the fill plug. Sight Glass Fill Plug 22. Using a circlip or snap ring pliers, pull the oil filter inserts out of the engine case. Oil Filter Inserts = Polaris PS-4 Plus 2W-50 Synthetic Engine Oil 1.7 Qts (1.6 Liters) 28. Start the engine and allow it to idle for at least one minute to fully distribute the new oil. Stop the engine. 29. Check for leaks at all threaded connections and at the oil filter covers. 30. View the oil level in the sight glass. Correct the oil level if necessary. 2.17 2 MAINTENANCE Cylinder Leakdown Test NOTE: This engine has built-in decompression components. Due to the auto-decompression mechanism, a cranking compression test is not an accurate measure of engine condition. NOTE: If necessary, blow debris from screen with compressed air. 3. Inspect the screen for wear or damage. Replace the arrestor if found to be worn or damaged. A cylinder leakdown test is the best indication of engine condition. Follow the manufacturer’s instructions provided with the leakdown tester to perform a cylinder leakage test. D B P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Cylinder Leakdown Service Limit: 10% (Inspect for cause if leakage exceeds 10%) C A Valve Clearance Adjustment Refer to page 6-13 of the “KTM Engine / Carburetion” section in the back of this service manual for valve clearance adjustment procedure. Valve Clearance Specification .005” (.127 mm) Exhaust Pipe / Spark Arrestor WARNING 4. Torque retaining screw (A) to 25 in. lbs. (3 Nm). Engine Mount Locations Inspect engine mounts and frame for cracks or damage. Periodically check engine fastener torque. M14 Swing arm through-bolt: 85-105 ft. lbs. (115-142 Nm) M10 Through-bolts: 30 ft. lbs. (41 Nm) M8 Bolts: 17 ft. lbs. (23 Nm) M10 / M14 Failure to follow these warnings could result in serious personal injury or death. • 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. M10 M10 • Wear eye protection and gloves. • Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time. Periodically clean the spark arrestor to remove accumulated carbon. 1. Remove the retaining screw (A) and remove the arrestor (B) and reducer (C) from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen (D). A synthetic brush may melt if components are warm. 2.18 M8 M8 MAINTENANCE LIQUID COOLING SYSTEM Cooling System Hoses Cooling System Overview Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary. The engine coolant level is maintained by the recovery system. The recovery system consists of the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose. 2 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator. • Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels often during the break–in period. • Overheating of engine could occur if air is not fully purged from system. • Polaris Premium 60/40 anti-freeze is premixed and ready to use. Do not dilute with water. Coolant Strength / Type Test the strength of the coolant using an antifreeze hydrometer. 1. Check tightness of all hose clamps. 2. Do not over–tighten hose clamps at radiator or radiator fitting may distort, causing a restriction or leak. Radiator hose clamp torque is 36 in .lbs. (4 Nm). Antifreeze Hydrometer • A 50/50 or 60/40 mixture of antifreeze and distilled water will provide the optimum cooling, corrosion protection, and antifreeze protection. • Do not use tap water. Tap water contains minerals and impurities which build up in the system. Do not add straight antifreeze or straight water to the system. Straight water or antifreeze may cause the system to freeze, corrode, or overheat. Polaris 60/40 Anti-Freeze / Coolant (PN 2871323) 2.19 MAINTENANCE Recovery Bottle / Coolant Level Inspection Radiator / Coolant Level Inspection The recovery bottle is located on the right side of the vehicle under the front fender. The fluid level in the recovery bottle must be maintained. WARNING Never remove the radiator pressure cap when the engine is warm or hot. Escaping steam and fluid can cause severe burns. The engine must be allowed to cool before removing the pressure cap. Check radiator external air flow passages for restrictions or damage. 2. Carefully straighten any bent radiator fins. 3. Remove any obstructions with compressed air or low pressure water. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Recovery Bottle If coolant level is low, perform the following steps: 1. 1. If the recovery bottle has run dry, inspect the level in the radiator and add coolant if necessary. The radiator pressure cap is located on the left side of the vehicle under the front fender. 1. Remove recovery bottle cap. Verify the breather foam is in place and the inner splash cap vent hole is clear and open. 2. Fill the recovery bottle with Polaris Premium 60/40 AntiFreeze / Coolant (PN 2871323) or a mixture of anti-freeze and distilled water as required for freeze protection in your area. 3. Fill the recovery bottle up to the visible level, then add an additional 6 oz. (175 ml) of coolant. Remove the pressure cap. Pressure Cap Maintain above the visible level 2. Using a funnel, slowly add coolant as necessary through the radiator filler neck. 3. Reinstall the pressure cap. NOTE: Use of non-standard pressure cap will not allow the recovery system to function properly. Cooling System Bleeding 4. Reinstall the cap. NOTE: If overheating is evident, allow system to cool completely and check coolant level in the radiator. Inspect for signs of trapped air in system. 2.20 Bleeding the cooling system is required only if the system has been drained for maintenance and/or repair. Always allow the engine to cool sufficiently before removing the radiator pressure cap. MAINTENANCE 1. Loosen the M6 coolant bleed screw located in the top right-hand side of the cylinder head, 2-3 turns. FINAL DRIVE Hydraulic Clutch Lever Adjustment Turn the adjusting knob counterclockwise to move the lever closer to the handlebar. Turn the adjusting knob clockwise to move the lever away from the handlebar. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Loosen M6 Screw The hydraulic clutch lever is located on the left handlebar. The clutch is self-adjusting, but the lever position can be changed to fit the operator’s hand. 2. Remove radiator cap and slowly add coolant until the coolant escapes out of the cylinder head bleed screw. 3. Tighten the M6 bleed screw and continue filling the radiator to the bottom of filler neck. 4. Fill coolant reservoir tank to full mark. 5. Install radiator cap half-way and gently squeeze coolant hoses to force any trapped air out of system. 6. Again, remove radiator cap and slowly add coolant to the bottom of fill neck if required. 7. Start engine and observe coolant level in the radiator. Allow air to purge and top off as necessary. Reinstall radiator cap and bring engine to operating temperature. After engine is cool, check level in reservoir tank and add coolant if necessary. NOTE: Should the reservoir tank become empty, it will be necessary to refill at the radiator and repeat the bleeding procedure. Radiator Screen Removal 1. Remove the 4 screws retaining the radiator screen for access to the radiator fins when cleaning. Adjusting Knob NOTE: The adjustment range is limited. Never apply excessive force to the knob. Always turn the knob by hand. If the lever does not operate smoothly, check the fluid level at the master cylinder. See “Hydraulic Clutch Oil Level Inspection”. If the lever feels unresponsive, bleed the clutch system. See “Hydraulic Clutch System Bleeding”. Hydraulic Clutch Oil level Inspection The clutch oil master cylinder is located on the left handlebar. Check the fluid level in the reservoir before each ride. The level should be 4 mm below the upper edge of the reservoir. Do not overfill. NOTE: Use only the recommended clutch oil. 1. Position the ATV on a level surface. 2. Turn the handlebar until the master cylinder is in a horizontal position. 2.21 2 MAINTENANCE 3. Remove the two cover screws, the cover and the rubber boot. 4. Fill the Hydraulic Clutch Bleeder Syringe (PA-48674) with the recommended hydraulic clutch oil. 5. Remove the bleeder screw and cap from the slave cylinder. Screws PA-48674 Cover Bleeder Screw w/Cap Boot Hydroclutch Slave Cylinder P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 4 mm 6. 4. Press fluid into the system until the fluid runs out of the hole in the master cylinder without producing any bubbles. Add the recommended oil as needed. = Polaris Hydraulic Clutch Oil (Quart) PN 2876335 CAUTION Add fluid with syringe until there are no more bubbles Do not use brake fluid. Do not mix clutch fluid with any other hydraulic fluids. 5. Reinstall the cover, boot and screws securely. Hydraulic Clutch System Bleeding Always bleed the clutch system at the intervals outlined in the “Periodic Maintenance Chart”. Always bleed the clutch system any time the clutch lever feels unresponsive. NOTE: Use only the recommended clutch oil. 1. Position the vehicle on a level surface. 7. When finished, remove the Hydraulic Clutch Bleeder Syringe. 2. Turn the handlebar until the master cylinder is in a horizontal position. 8. Reinstall the bleeder screw. 3. Remove the two cover screws, the cover and the rubber boot. 9. Add or remove fluid as needed to maintain the level 4 mm below the top edge of the master cylinder reservoir. 10. Reinstall the cover, boot and screws securely. 2.22 MAINTENANCE Reverse Lock-Out Lever Inspection and Cable Adjustment Check for smooth lever operation and ensure that the lever returns freely without binding (1). Drive Chain Inspection / Replacement Inspect the drive chain for missing or damaged O–Rings, link plates, or rollers. Do not wash the chain with a high pressure washer, gasoline or solvents; do not use a wire brush to clean the chain as damage to the O–Rings may occur. Clean chain with hot soapy water and a soft bristled nylon brush. Polaris ATV drive chains are equipped with O–ring sealed, permanently greased, pins and rollers. The sprockets and outer rollers require periodic lubrication. Lubricate the chain with Polaris Chain Lubricant (PN 2872073). P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Never allow battery acid to contact the drive chain. Adjust the reverse cable freeplay to 0.08 - 0.12 in. (2-3 mm) by adjusting the cable jam nuts (2). The chain must be replaced when it reaches 3% elongation. 1. Stretch the chain tightly in a straight line. 2. Measure the length of 20 pitches (pins) from pin center to pin center, and compare to the specification. Replace the chain if the length exceeds the wear limit. 2 Sprocket Inspection Drive Chain Wear Limit, 20 Pitch Length: Std: 12.5″(32 cm) Wear Limit: 12.875” (32.7 cm) Inspect the sprocket for worn, broken or bent teeth. To check for wear, pull upward on the chain at the area indicated (arrow). Replace sprocket if chain movement exceeds 1/4” (6 mm). 3. When replacing or reinstalling drive chain, install the closed end of the splice link clip as shown, with the closed end leading in forward operation. There should be a .003-.005” (.076-.127 mm) gap between the side plate of the chain and the splice link clip. See the following illustrations. Proper Spacelink Clip Opening Position .003” - .005” (.076- .127 mm) Gap after installation “IRS” Inspect the sprocket for excessive wear, missing teeth, etc. “MXR” / “S” 2.23 2 MAINTENANCE If a gap is noticed between the outside edge of the master link and plate, back the plate out and close the gap. Drive Chain Adjustment (“MXR” / “S”) 1. Loosen the two rear axle housing pinch bolts. Master Link P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Do not press plate in too far 2. Insert a pin punch into the rear axle housing. 3. Roll the vehicle ahead or back to adjust chain slack to the proper dimension. 4. Tighten the rear axle housing pinch bolts to 35 ft. lbs. (47 Nm). Drive Chain Tension CAUTION Never adjust or operate vehicle with rear drive chain too loose or too tight. Severe damage to transmission and drive components can result. BREAK-IN: It is extremely important to maintain proper chain tension to ensure the best possible chain life. There is a chain break–in period of approximately 100 miles or two (2) tanks of fuel. During this time chain tension should be watched very closely and loads to the chain should be kept light. CHECKING CHAIN TENSION: 35 ft. lbs. (47 Nm) Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain. Steps 1 and 2 should be used to check chain tension on “MXR” and “S” solid rear axle models. 1. Collapse the rear suspension with a trailer tie down strap. Fasten the strap around the axle and rear grab bar. 2. Tighten the strap until the axle, swing arm pivot, and counter shaft, are centered on a single plain (this establishes the tightest chain position). 3. At the center point of the top side of the chain there should be 1/4” - 3/8” (6-9 mm) deflection. NOTE: The chain has a press-on master link. A chain tool must be used if it’s necessary to remove the chain for service. 2.24 CAUTION Do not over-tighten rear axle housing pinch bolts. Pre-mature bearing failure may result. MAINTENANCE Drive Chain Adjustment (“IRS”) Rear Driveshaft Boot Inspection (“IRS”) 1. Before Operating Loosen the upper and lower pivot mounting bolts (1). Inspect the boots before operating the vehicle. If a boot is torn, punctured or leaking fluid, replacement is required. 2 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m OK 1 2. Thread the chain adjusting bolt (2) inward or outward to adjust chain slack to the proper dimension. After Operating Inspect the boots after operating the vehicle. If a boot is bulging or ballooned, perform the boot “pressure equalizing” procedure. 2 1 3. Torque the pivot mounting bolts to 30 ft. lbs. (41 Nm). 4. Torque the chain adjusting bolt to 20 ft. lbs. (27 Nm). 2.25 MAINTENANCE Driveshaft Boot Pressure Equalizing (“IRS”) ELECTRICAL AND IGNITION SYSTEM 1. Battery Maintenance Using a needle nose pliers or boot clamp removal tool, remove the small boot clamp (1) from the inboard boot. NOTE: Do not use any tools that may damage the boot. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 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. 2. Slide the free end of the boot two inches toward the center of the vehicle and lift the boot away from the shaft to allow excess air to escape. 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. NOTE: The Outlaw battery is a Low Maintenance design and construction. Before placing the battery into service, check the battery condition and charge accordingly. Use of Conventional Lead-Acid batteries is not recommended. New Batteries: Batteries must be fully charged before use or battery life will be reduced by 10–30% of full potential. Charge battery for 3-5 hours at a current equivalent of 1/10 of the battery’s rated amp/hour capacity (i.e. 9 amp hr x.10 =.9 amp charging). Do not use the alternator to charge a new battery. 3. Wipe excess grease from the shaft before returning the boot to the boot groove. Use caution not to allow excess air back into the system when reinstalling the boot. 4. Reinstall the boot clamp. Maintenance-Free batteries are sealed at the factory. The use of lead-calcium instead of lead-antimony allows the battery acid to be fully absorbed by the plates. Therefore, a Maintenance-Free battery case is opaque and the sealing caps are not removable, since there is no need to check electrolyte level. IMPORTANT: Never attempt to add electrolyte or water to a Maintenance-Free battery. Doing so will damage the case and shorten the life of the battery. 2.26 MAINTENANCE Battery Inspection / Removal 4. Clean battery cables and terminals with a stiff wire brush. Corrosion can be removed using a solution of one cup water and one tablespoon baking soda. Rinse well with clean water and dry thoroughly. Test battery for condition and charge accordingly (refer to the “Electrical” chapter for battery testing). 5. If required, charge battery at 1/10 of its amp/hour rating. Example: 1/10 of 14 amp battery = 1.4 amp 6. Reinstall battery, attaching positive (+) red cable first and then the negative (–) black cable. 7. Coat terminals and bolt threads with Dielectric Grease (PN 2871329). 8. Reinstall battery holder strap and reassemble the ATV. “MXR” / “S” Models The battery is located under the LH rear fender of the ATV. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Battery Battery Terminals / Bolts “IRS” Models The battery is located in front of the engine on the lower portion of the main frame. Ensure battery terminals are clean of corrosion. Use Polaris corrosion resistant Dielectric Grease (PN 2871329) on battery bolts. Off Season Storage To prevent battery damage during extended periods of non–use, the following basic battery maintenance items must be performed: Battery • Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water. Rinse with fresh water after cleaning. • Using a wire brush or knife, remove any corrosion from the cables and terminals. • Never add water to a sealed maintenance free battery. To remove the battery: 1. Disconnect battery negative (–) black cable first, followed by the positive (+) red cables. 2. Disconnect the battery holder strap. CAUTION • Charge at a rate no greater than 1/10 of the battery’s amp/hr capacity until the open circuit voltage is 12.9V or greater. • Store the battery either in the machine with the cables disconnected, or store in a cool place. 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. 3. Remove the battery. 2.27 2 MAINTENANCE Charging Procedure (“MXR” / “S”) NOTE: The battery may be charged removing the battery from the vehicle. 1. Charging Procedure (“IRS”) without Attach the positive (+) charging cable to the starter solenoid lead terminal (A), which is directly wired to the positive battery terminal. NOTE: The battery may be charged removing the battery from the vehicle. 1. without Attach the positive (+) charging cable to the (+) battery terminal (A) and negative (-) charging cable to the (-) battery terminal (B). P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m A B A B 2. Attach the negative (-) battery charging cable to the negative (-) battery terminal (B). IMPORTANT: When attaching to the positive (+) terminal, take care to stay clear of the frame. 3. Charge with a charging output no greater than 1/10 of the battery's amp/hr rating. Charge as needed to raise the open circuit voltage to 12.9 V or greater. 2. Charge with a charging output no greater than 1/10 of the battery's amp/hr rating. Charge as needed to raise the open circuit voltage to 12.9 V or greater. WARNING WARNING To avoid the possibility of explosion or sparks, connect positive (red) cable first and negative (black) cable last. To avoid the possibility of explosion or sparks, connect positive (red) cable first and negative (black) cable last. Spark Plug Removal / Inspection 1. 2.28 Access the spark plug at the right side of the engine. MAINTENANCE 2. 3. 4. Remove spark plug high tension lead. Clean plug area so no dirt and debris can fall into engine when plug is removed. STEERING Remove spark plug and inspect electrode for wear and carbon buildup. The insulator tip should be a light tan color, indicating good combustion. Look for a sharp outer electrode edge with no rounding or erosion. The steering components should be checked periodically for loose fasteners, worn tie rod ends, ball joints, and damage. Also check to make sure all cotter pins are in place. If cotter pins are removed, they must not be re–used. Always use new cotter pins. If needed, clean spark plug with electrical contact cleaner or a glass bead spark plug cleaner only. Replace any worn or damaged steering components. Steering should move freely through the entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m NOTE: Wire brushes or coated abrasives should not be used. General Steering Information 5. Measure gap with a wire gauge. Refer to specifications for proper spark plug type and gap. Adjust gap if necessary by bending the side electrode carefully. NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts. WARNING Spark Plug Gap 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 MSD certified technician when replacing worn or damaged steering parts. Use only genuine Polaris replacement parts. .024″ (0.6 mm) 6. If necessary, replace spark plug with proper type. Recommended Spark Plug: NGK DCPR8E Spark Plug Torque: 14 Ft. Lbs. (19 Nm) Controls / Handlebar Check controls for proper operation, positioning and adjustment. If desired, the handlebars can be adjusted for rider preference. WARNING CAUTION Improper adjustment or incorrect tightening torque of the adjuster block bolts can cause limited steering, which could result in loss of control and serious injury or death. Severe engine damage may occur if the incorrect spark plug is used. 7. 8. Apply a small amount of anti–seize compound to the spark plug threads. Install spark plug and torque to specification. Reverse steps as needed for reassembly. 1. Loosen the four bolts and adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right. 1 11 ft. lbs. (15 Nm) 2.29 2 MAINTENANCE 2. Torque the front two bolts to 11 ft. lbs. (15 Nm), then torque the rear two bolts. A gap of up to 1/8” will remain at the rear bolts. Steering Inspection / Tie Rod Ends and Hubs • To check for play in the outer tie rod ends, grasp the steering tie rod, pull in all directions feeling for movement. Toe Alignment Inspection One of two methods can be used to measure toe alignment. The string method and the chalk method. If adjustment is required, refer to “Toe Adjustment” for procedure. METHOD 1: USING A STRAIGHTEDGE OR STRING WARNING • Repeat inspection for the inner tie rod ends at the steering post. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Severe injury or death can result from improper toe alignment and adjustment. 1. Position the vehicle on a level surface. Ensure the vehicle is at the proper ride height by placing a rider on the vehicle. 2. Place the handlebars in a straight-ahead position and secure the handlebars in this position. 3. Tie a length of string between two stands as shown in the following illustration. Position the stands so the string is flush or parallel with the side of the rear tire. • Elevate front end of machine so front wheels are off the ground. Check for any looseness in front hub / wheel assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward. • If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (possible loose wheel nuts or loose front hub components). Check for Loose Wheel or Hub • Refer to Chapter 5 “Body / Steering / Suspension” for service procedures. Figure 2-30 NOTE: If available, you may use a long straight-edge instead of a string. 2.30 MAINTENANCE 4. 5. Measure the distance from the string to the rim at the front (1) and rear (2) of the front rim (see Figure 2-30). The rear measurement should be 0-1/16’(0-1.6 mm) more than the front measurement to obtain the recommended toe out alignment. Toe Adjustment Repeat the measurement procedure on the other side of the vehicle. NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment. If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting. NOTE: If you discover improper toe out alignment, refer to “Toe Adjustment” procedure. METHOD 2: USING A CHALK LINE Position the vehicle on a level surface. Ensure the vehicle is at the proper ride height by placing a rider on the vehicle. 2. Set handlebars in a straight ahead position and secure handlebars in this position. NOTE: The steering post arm “frog” can be used as an indicator of whether the handlebars are straight. The frog should be centered with equal clearance between the steering stops. 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. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. CAUTION 3. To adjust toe alignment: • Hold tie rod to keep it from rotating. Place a chalk mark on the center line of the front tires as close to the hub/axle center line as possible, or measure to a specific distance from the floor. NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement. • Loosen jam nuts at both ends of the tie rod. 4. Measure the distance between the marks and record the measurement. Call this measurement “A”. 5. Rotate the tires 180o by moving vehicle forward or backward. Position chalk marks even with the hub/axle centerline or the specified floor measurement. • IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly. 6. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. Recommended toe alignment is: 0 to 1/16” (0 to 1.6 mm) toe out. This means the measurement at the front of the tire (A) should be 0 to 1/16” (0 to 1.6 mm) wider than the measurement at the rear (B). • Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in Method 1 or Method 2 of Toe Alignment Inspection. • After alignment is complete, torque jam nuts to specification. 12–14 ft. lbs. (16–19 Nm) Steering Knuckle Tie Rod Assembly Hold rod end parallel to steering knuckle while nut is tightened Chalk Line Measurement (A) Chalk Line Measurement (B) 2.31 2 MAINTENANCE SUSPENSION (450 “MXR” / 525 “S”) Front Spring Preload Adjustment Front Suspension Set-Up The front suspension spring preload may be adjusted to suit different conditions and operator weight. 1. Position the vehicle on a level surface. 2. Stop the engine. 3. Elevate the front of the vehicle by placing a suitable jack stand under the frame. WARNING Uneven adjustment may cause poor handling of the ATV, which could result in an accident and serious injury or death. Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments. NOTE: The tires should barely touch the ground and the suspension should be at full rebound. Measure the distance from the ground to the bottom of the front frame portion. Note this measurement for later use. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 4. 1. Raise and safely support the front of the ATV off the ground to allow the suspension to fully extend. 2. Loosen the upper jam nut adjustment ring. Turn the lower adjustment ring (1) clockwise to increase preload or counter-clockwise to decrease preload. Decrease Preload Spring Spacer 5. Remove the support stand and have a rider sit comfortably on the seat with hands on the handlebars. 6. Place the transmission in neutral and slowly roll the machine forward and backward at least ten feet (3 m) without lifting or pushing down on the suspension. 7. Turn the handlebars fully to the left and right. 8. With the rider still on the vehicle, repeat the measurement performed in step 4. 9. Subtract the step 8 measurement from the step 4 measurement. The difference should be between the following measurements: • 450 “MXR” 3.625 - 3.875 inches (9.21 - 9.84 cm) • 525 “S” 3.5 - 3.75 inches (8.89 - 9.53 cm) 10. If the number is less than 3.625” (450) or 3.5” (525), decrease the front spring preload and repeat all steps (see “Front Spring Preload Adjustment”). If the number is higher than 3.875” (450) or 3.75” (525), increase spring preload and repeat all steps. 2.32 Decrease Preload Spring Spacer 1 Increase Preload Ride-In Spring “MXR” Models 1 Increase Preload Ride-In Spring “S” Models MAINTENANCE 3. 4. Once you have obtained the correct preload, hold the lower adjustment ring while tightening the upper adjustment ring to lock them in place. Rear Suspension Set-Up 1. Position the vehicle on a level surface. Measure the spring preload of RH shock and LH shock to ensure they are equal. Adjust if necessary. 2. Stop the engine. 3. Elevate the rear of the vehicle by placing a suitable jack stand under the frame. Front Shock Compression Adjustment (“MXR”) 4. Measure the distance from the ground to the bottom of the rear grab bar. Note this measurement for later use. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The compression damping adjustment is located on top of the shock ‘Piggyback’ reservoir of each front shock. NOTE: The tires should barely touch the ground and the suspension should be at full rebound. Use a flat blade screwdriver to make damping adjustments. NOTE: When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position. Turn the clicker clockwise to increase compression damping. Turn the clicker counter-clockwise to decrease compression damping. NOTE: The factory setting is 10 clicks from closed (see “Front Compression Adjustment Table”). Increase Compression Damping Decrease Compression Damping Clicker Adjuster “MXR” Models Front Compression Adjustment Table Setting Compression Damping Softest 20 clicks from closed Factory 10 clicks from closed Firmest 2 clicks from closed 5. Remove the support stand and have a rider sit comfortably on the seat with hands on the handlebars. 6. Place the transmission in neutral and slowly roll the machine forward and backward at least ten feet (3 m) without lifting or pushing down on the suspension. 7. Turn the handlebars fully to the left and right. 8. With the rider still on the vehicle, repeat the measurement performed in step 4. 9. Subtract the step 8 measurement from the step 4 measurement. The difference should be between the following measurements: • 450 “MXR” 5.125 - 5.375 inches (13.02 - 13.65 cm) • 525 “S” 5.0 - 5.25 inches (12.7 - 13.34 cm) 10. If the number is less than 5.125” (450) or 5.0” (525), decrease the rear spring preload and repeat all steps (see “Rear Spring Preload adjustment”). If the number is higher than 5.375” (450) or 5.25” (525), increase spring preload and repeat all steps. 2.33 2 MAINTENANCE Rear Spring Preload Adjustment Rear Shock Compression Adjustment The rear suspension spring preload may be adjusted to suit different riding conditions and operator weight. The compression damping adjustment is located on top of the shock ‘Piggyback’ reservoir of the rear shock. 1. Raise and safely support the rear of the ATV off the ground to allow the suspension to fully extend. Remove the seat to access the compression adjustment screw. Loosen the upper jam nut adjustment ring. Turn the lower adjustment ring (1) clockwise to increase preload or counter-clockwise to decrease preload. NOTE: When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position. 2. Turn the clicker clockwise to increase compression damping. Turn the clicker counter-clockwise to decrease compression damping. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1 Use a flat blade screwdriver to make damping adjustments. Decrease Preload Increase Preload NOTE: The factory setting is 10 clicks from closed (see “Rear Compression Adjustment Table”). Increase Compression Damping Spring Spacer Decrease Compression Damping Progressive Spring Clicker Adjuster 3. Once you have obtained the correct preload, hold the lower adjustment ring while tightening the upper adjustment ring to lock them in place. Rear Compression Adjustment Table Setting 2.34 Compression Damping Softest 20 clicks from closed Factory 10 clicks from closed Firmest 2 clicks from closed MAINTENANCE Rear Shock Rebound Adjustment SUSPENSION (525 “IRS”) The rebound damping adjustment is located between the lower spring seat and lower shock eyelet mount of the rear shock. Front Suspension Set-Up 1. Position the vehicle on a level surface. 2. Stop the engine. 3. Elevate the front of the vehicle by placing a suitable jack stand under the frame. Use a flat blade screwdriver to make damping adjustments. NOTE: When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position. NOTE: The tires should barely touch the ground and the suspension should be at full rebound. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Turn the clicker clockwise to increase rebound damping. Turn the clicker counter-clockwise to decrease rebound damping. 2 NOTE: The factory setting is 10 clicks from closed (see “Rear Rebound Adjustment Table”). 4. Measure the distance from the ground to the bottom of the front frame portion. Note this measurement for later use. 5. Remove the support stand and have a rider sit comfortably on the seat with hands on the handlebars. 6. Place the transmission in neutral and slowly roll the machine forward and backward at least ten feet (3 m) without lifting or pushing down on the suspension. 7. Turn the handlebars fully to the left and right. 8. With the rider still on the vehicle, repeat the measurement performed in step 4. 9. Subtract the step 8 measurement from the step 4 measurement. The difference should be between 3.75 and 4.0 inches (9.5 - 10.2 cm). Clicker Adjuster Increase Rebound Damping Decrease Rebound Damping Rear Rebound Adjustment Table Setting Rebound Damping Softest 23 clicks from closed Factory 10 clicks from closed Firmest 2 clicks from closed 10. If the number is less than 3.75” (9.5 cm), decrease the front spring preload and repeat all steps (see “Front Spring Preload Adjustment”). If the number is higher than 4.0” (10.2 cm), increase spring preload and repeat all steps. 2.35 MAINTENANCE Front Spring Preload Adjustment Rear Suspension Set-Up The front suspension spring preload may be adjusted to suit different conditions and operator weight. 1. Position the vehicle on a level surface. 2. Stop the engine. 3. Elevate the rear of the vehicle by placing a suitable jack stand under the frame. WARNING NOTE: The tires should barely touch the ground and the suspension should be at full rebound. 4. Measure the distance from the ground to the bottom of the rear lower control arm pivot bolt. Note this measurement for later use. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Uneven adjustment may cause poor handling of the ATV, which could result in an accident and serious injury or death. Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments. 1. Raise and safely support the front of the ATV off the ground to allow the suspension to fully extend. 2. Loosen the upper jam nut adjustment ring. Turn the lower adjustment ring (1) clockwise to increase preload or counter-clockwise to decrease preload. 1 Decrease Preload Spring Spacer 3. 4. Increase Preload Ride-In Spring Once you have obtained the correct preload, hold the lower adjustment ring while tightening the upper adjustment ring to lock them in place. Measure the spring preload of RH shock and LH shock to ensure they are equal. Adjust if necessary. 5. Remove the support stand and have a rider sit comfortably on the seat with hands on the handlebars. 6. Place the transmission in neutral and slowly roll the machine forward and backward at least ten feet (3 m) without lifting or pushing down on the suspension. 7. Turn the handlebars fully to the left and right. 8. With the rider still on the vehicle, repeat the measurement performed in step 4. 9. Subtract the step 8 measurement from the step 4 measurement. The difference should be between 4.25 and 4.5 inches (10.8 - 11.43 cm). 10. If the number is less than 4.25” (10.8 cm), decrease the rear spring preload on both shocks and repeat all steps (see “Rear Spring Preload adjustment”). If the number is higher than 4.5” (11.43 cm), increase spring preload and repeat all steps. 2.36 MAINTENANCE Rear Spring Preload Adjustment Rear Shock Compression Adjustment The rear suspension spring preload may be adjusted to suit different conditions and operator weight. The compression damping adjustment is located on the bottom of each rear shock. 1. Raise and safely support the rear of the ATV off the ground to allow the suspension to fully extend. Use a flat blade screwdriver to make damping adjustments. 2. Loosen the upper jam nut adjustment ring. Turn the lower adjustment ring (1) clockwise to increase preload or counter-clockwise to decrease preload. NOTE: When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Turn the clicker clockwise to increase compression damping. Turn the clicker counter-clockwise to decrease compression damping. 1 Decrease Preload Spring Spacer NOTE: The factory setting is 8 clicks from closed (see “Rear Compression Adjustment Table”). Increase Preload Ride-In Spring 3. Measure the spring preload of RH shock and LH shock to ensure they are equal. Adjust if necessary. 4. Tighten jam nuts. Compression Adjustment Location Rear Compression Adjustment Table Setting Compression Damping Softest 24 clicks from closed Factory 8 clicks from closed Firmest 2 clicks from closed 2.37 2 MAINTENANCE BRAKE SYSTEM Brake Pedal Testing / Brake Light Operation Brake System Inspection Check for proper brake light operation before each use. The following checks are recommended to keep the brake system in good operating condition. Service life of brake system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride. • “IRS” models are equipped with a mounted brake light switch (A) that can be adjusted for proper operation. “IRS” A • Keep fluid level in the master cylinder reservoir to the indicated level on or inside the reservoir. • Use Polaris or DOT 4 Brake Fluid. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Parking Brake Lock 2 1 Brake Lever Position Adjuster Reservoir Sight Glass Front Master Cylinder Reservoir “IRS” • “MXR” and “S” models are equipped with a built-in brake light switch (B) that is part of the rear master cylinder banjo bolt. No switch adjustment is required. “MXR” & “S” B “MXR” / “S” 2 1 Rear Master Cylinder • Check brake system hoses for cracks, deterioration, abrasion and fluid leaks. Replace worn or damaged components as needed. • Check brake for excessive travel or spongy feel. • Check friction pads for wear, damage or looseness. • Check surface condition of the disc. • Inspect thickness of brake pad friction material. The foot brake pedal (1) should be checked for proper operation. When applied, the brake power should be sufficient enough to stop the wheels under most conditions. If brake operation is poor, two things must be examined: Free Play: Brake pedal free play should be 1/8” – 1/4” (3.2 – 6.35 mm). If free play is excessive, inspect pedal (1), linkage, and master cylinder (2) for wear or damage and replace any parts as needed. Brake Pad Inspection Bleeding: Refer to Chapter 6 “Brakes” for brake pad service information. If free play is correct, and brake pedal travel is still excessive, air may be trapped somewhere in the system. Bleed the hydraulic auxiliary brake system in a conventional manner, following the procedure outlined in Chapter 6 “Brakes”. Brake Lever Position Adjustment Refer to Chapter 6 “Brakes” for adjustment procedure. 2.38 MAINTENANCE WHEELS AND TIRES Tire Pressure Wheels CAUTION Inspect all wheels for runout or damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts. Wheel, Hub, and Spindle Torque Table Item Specification 30-35 ft. lbs. (41-47 Nm) Rear Wheel Nuts 30-35 ft. lbs. (41-47 Nm) Front Spindle Nut 40 ft. lbs. (55 Nm) Rear Hub Nut (“MXR” / “S”) 80 ft. lbs. (109 Nm) Rear Hub Nut (“IRS”) 90 ft. lbs. (122 Nm) Wheel Removal: Front or Rear Wheel Removal 1. 2. 3. 4. Stop the engine, place the transmission in gear and lock the parking brake. Loosen the wheel nuts slightly. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. Remove the wheel nuts and remove the wheel. Wheel Installation 1. 2. 3. 4. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. Attach the wheel nuts and finger tighten them. Lower the vehicle to the ground. Tighten wheel nuts to the proper torque listed in the table. CAUTION 2 Tire Pressure (PSI - Cold) Front 4 Rear 4 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Front Wheel Nuts Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle. Tire Inspection • Improper tire maneuverability. inflation may affect ATV • When replacing a tire always use original equipment size and type. • The use of non–standard size or type tires may affect ATV handling. Tire Tread Depth Always replace tires when tread depth is worn to 1/8” (3 mm) or less. WARNING Operating your ATV with worn tires, improperly inflated tires, non - standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the ATV decal and in the owner’s manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Improperly installed wheels could affect vehicle handling and tire wear. Make sure the flat side of the flange nut faces the wheel. 1/8″ (.3 cm) Flat side against wheel 2.39 MAINTENANCE MAINTENANCE LOG Service Date Hours Service Performed / Comments Dealer / Technician 3 Hours (Break-In) 15 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 30 45 60 75 90 2.40 ENGINE CHAPTER 3 ENGINE ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 KTM 450/525 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 GENERAL ENGINE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 3 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 ES45KL / ES51KL ENGINE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 COOLANT TEMPERATURE SENSOR (DUAL TEMP THERMAL SENSOR) . . . . . . . . . 3.7 COOLING SYSTEM FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 3.1 ENGINE ENGINE SERVICE Engine Removal KTM 450/525 Engine 1. Thoroughly clean the ATV engine and chassis. Chapter 3 covers basic engine information including engine removal / installation and the cooling system. 2. Place ATV in a clean work area. 3. Disconnect battery cables, starting with the negative (–) cable first. 4. Remove the (2) screws that retain the front cover (see Chapter 5). 5. Remove the seat and front cab assembly (see Chapter 5). Chapter 9 (KTM Engine/Carburetion) details the service procedures for the KTM 450/525 engine and Keihin carburetor. Refer to Chapter 9 for any engine service specifications or service procedures. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m GENERAL ENGINE INFORMATION Special Tools See Chapter 1 for a complete listing of special tools to service the KTM 450/525 engine. Accessible Components The following components can be serviced or removed with the engine installed in the frame: • Alternator / Stator 6. Remove the air box assembly. 7. Turn the fuel valve “Off” and remove the fuel lines from the fuel tank fittings (see Chapter 4). 8. Remove the fuel tank from the ATV. NOTE: Remove the engine skid plate to prevent excessive spills when draining the engine oil and coolant. The skid plate is attached by (4) screws on the bottom side of the plate. • Cam Chain and Sprockets 9. • Camshaft / Components 10. Remove the engine oil drain plug and allow oil to completely drain from the engine (see Chapter 2 for oil change procedure). Reinstall the drain plug when finished draining. • Clutch Assembly • Cylinder • Cylinder Head / Valves • Flywheel • Oil Pump Rotors Place a suitable catch container under the engine. 11. Remove the coolant drain screw from the cylinder under the coolant bypass hose. Open radiator cap to help vent the cooling system when draining. • Piston / Rings • Starter Motor / Starter Drive • Water Pump Impeller / Water Pump Seal Carrier The following components require engine removal for service: • Crankshaft • Crankshaft Main Bearings • Connecting Rod Coolant Drain Screw • Counterbalance Shaft or Bearing(s) • Transmission Gears and Bearings 12. Allow coolant to completely drain and then remove the bypass hose from the front of the cylinder. 3.2 ENGINE 13. Remove coolant return line from right side of cylinder. Breather Hose CAUTION Fuel will leak if carb is turned upside down. Coolant Return Line 17. Remove the rear header pipe clamp. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 3 14. Remove the water pump outlet line from the top of the cylinder head at the water pump housing. Top of Engine Coolant Outlet Line 18. Remove the exhaust springs that attach the header pipe to the cylinder head. Springs 15. Disconnect the throttle position sensor (TPS) connector and remove the carburetor from the engine. In most instances, the carburetor will not have to be disconnected from the throttle cable or fuel line for engine removal. Insert a shop towel into the engine carburetor flange to prevent dirt from entering the intake of the engine. 19. Slide header pipe forward and remove it from the engine. TPS Connector 16. Unplug the (2) vent lines from the carburetor that run along the frame tubes. 3.3 ENGINE 20. Disconnect all electrical connections from the engine. Connections include: the starter motor positive (+) wire, the spark plug high tension lead, the pulser coil, stator/ alternator, and transmission switch wire connectors on the left hand side of the ATV. 22. Remove the rear bolt from the front chain guard and remove the guard. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Pulser Coil Stator / Alternator Transmission Switch 23. Loosen the drive chain tension and disconnect or remove the chain. An acceptable alternative is to remove the engine counter sprocket and chain as one. 21. Remove the 3 bolts retaining the hydraulic clutch slave cylinder and remove the slave cylinder as an assembly. Hydraulic Clutch Slave Cylinder 24. Disconnect and remove the reverse cable from the engine. NOTE: Removing the banjo bolt from the clutch slave cylinder will require bleeding the hydraulic clutch system. Remove the slave cylinder as an assembly to prevent having to bleed the clutch system. Remove Cable and Bracket Disconnect Cable 3.4 ENGINE 25. Remove the front engine mount through-bolt. 29. Finally, remove the rear engine mount through-bolt. IMPORTANT: Do not completely remove the swing arm through-bolt on “MXR” / ”S” models. Leave it in far enough to hold the swing arm in place. Another pin should be inserted on the opposite side to also hold the swing arm in place. “MXR” / “S” 3 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Front Engine Mount 26. Remove the LH front engine mount from the frame to allow the engine to be pulled out the LH side. Rear Engine Mount “IRS” LH Frame Mount Rear Engine Mount 27. Loosen both the lower and rear engine mount throughbolts. 28. Remove the lower engine mount through-bolt while using the rear through-bolt as a pivot. NOTE: The rear engine mount through-bolt uses a bushing. Retain the bushing in the engine so it’s not lost during engine disassembly. 30. With an assistant helping you, remove the engine by tilting forward and turning to exit through the left side of frame. 31. Refer to the “KTM Engine / Carburetion” section in the back of this service manual for engine disassembly procedures. To reinstall the engine, reverse the procedures. Refer to engine installation notes on Page 3.6. Lower Engine Mount 3.5 ENGINE Engine Installation Notes • Adjust chain tension according to procedure provided in Chapter 2. After the engine is installed in the frame, review the following checklist and perform all steps that apply: Exhaust • Replace exhaust seal if necessary. Engine Mounting Torque “MXR” / “S” Models • Torque the front LH frame mount M8 bolts to 17 ft. lbs. (23 Nm). • Torque (lower / front) M10 through-bolts to 30 ft. lbs. (41 Nm). Bleed Cooling System NOTE: Refer to Page 3.7 for hose routing. Bleeding is generally necessary after repairs to purge any air that may remain in the system during filling. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m • Torque (rear) M14 swing arm bolt to 85-105 ft. lbs. (115-142 Nm) • Verify all fasteners are in good condition and torqued properly. “IRS” Models • Torque the front LH frame mount M8 bolts to 17 ft. lbs. (23 Nm). 1. Loosen the M6 coolant bleed screw located in the top right-hand side of the cylinder head, 2-3 turns. • Torque (rear / lower / front) M10 through-bolts to 30 ft. lbs. (41 Nm). Loosen M6 Screw M10 / M14 Reinstall “star” washer to ensure a good ground path between engine & chassis. M10 M10 M8 General Items • Fill engine with recommended amount of engine oil. 2. Remove radiator cap and slowly add coolant until the coolant escapes out of the cylinder head bleed screw. 3. Tighten the M6 coolant bleed screw and continue filling the radiator to the bottom of filler neck. 4. Fill coolant reservoir tank to full mark. 5. Install radiator cap half-way and gently squeeze coolant hoses to force any trapped air out of system. 6. Again, remove radiator cap and slowly add coolant to the bottom of fill neck if required. 7. Start engine and observe coolant level in the radiator. Allow air to purge and top off as necessary. Reinstall radiator cap and bring engine to operating temperature. After engine is cool, check level in reservoir tank and add coolant if necessary. = PS-4 Plus 2W-50 Synthetic Engine Oil 1.7 qts (1.6 L) • Install previously removed components using new gaskets, seals, and fasteners where applicable. • Perform checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily pre–ride inspection checklist (refer to Chapter 2 or the Owner’s Manual). 3.6 NOTE: Should the reservoir tank become empty, it will be necessary to refill at the radiator and repeat the bleeding procedure. ENGINE Engine Break-In Period ENGINE COOLING SYSTEM No single action on your part is as important as a proper breakin period. Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both. Perform the following procedures carefully. Coolant Temperature Sensor (Dual Temp Thermal Sensor) 3 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The break-in period for the KTM engine is defined as the first three hours of operation, or the time it takes to use 5-6 gallons (20 liters) of fuel. Do not allow engine speed to exceed 7000 RPM during the break-in period. Follow the break-in period with an additional 12 hours of cautious operation, with engine speed below 75% of capacity. The Dual Temp Thermal Sensor provides a ground path for the “Hot Light” and the fan motor. See Chapter 7 for further electrical information. New and rebuilt engines require a break-in oil change after 3 hours of engine operation. OIL RECOMMENDATION Polaris PS-4 Plus 2W-50 synthetic oil is specially formulated for the KTM wet-clutch transmission. Never substitute or mix oil brands. Serious engine damage can result. 1. 2. Fill fuel tank with unleaded fuel which has a minimum pump octane number of 91= (R+ M)/2. Torque to: 18 ft. lbs. (25 Nm) Cooling System Flow Chart Check oil level as indicated through the sight glass. Add oil if necessary. 3. Drive slowly at first to gradually bring engine up to operating temperature. 4. Vary throttle positions. Do not operate at sustained idle or sustained high speed. 5. Perform regular checks on fluid levels, controls and all important areas on the vehicle. 6. Pull only light loads during initial break in. 7. Change break-in oil and filters after 3 hours of operation. ES45KL / ES51KL Engine Lubrication Oil Type: Polaris PS-4 Plus 2W-50 Synthetic (PN 2876244) Capacity: Approximately 1.7 qts (1.6 L) Oil Filters: (Long PN 2520754) (Short PN 2520755) (Cover O-Ring PN 5413254) FLOW Radiator Remote Thermostat Water Pump Bypass Cylinder Cylinder Head WARNING Never remove radiator cap when engine is warm or hot. The cooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing. Drain Plug: 15 ft. lbs. (20 Nm) 3.7 ENGINE Cooling System Pressure Test Cooling System Specifications 1. Remove pressure cap and pressure test the cooling system using a commercially available pressure tester. 2. The system must retain 10 psi for five minutes or longer. If pressure is lost within five minutes, check radiator, all hoses and clamps, and water pump seal for damage. Radiator Pressure Cap Test Description Temperature / Spec. Fan Switch On 185° F (85° C) ± 3° Hot Light On 221° F (105° C) ± 3° System Capacity 2.25 Quarts (2.1 L) Radiator Cap Relief Pressure 20 psi WARNING P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Recommended Coolant Type Never remove radiator cap when engine is warm or hot. The cooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing. 1. Remove radiator pressure cap and test the cap using a cap tester (commercially available). 2. The radiator cap relief pressure is 20 psi. Replace if cap releases at less than 20 psi. Coolant Flow Diagram Remote Thermostat Dual Temp Thermal Sensor From Water Pump Pressure Cap To Cylinder Bypass 3.8 Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area. IMPORTANT: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. FUEL SYSTEM CHAPTER 4 FUEL SYSTEM CARBURETOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 KEIHIN FCR-MX 39 MM CARBURETOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 JETTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 CARBURETOR JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 KEIHIN OPTIONAL JET PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 KEIHIN FCR-MX 3900 CARBURETOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 LOCATION / OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 SERVICE / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 4 4.1 FUEL SYSTEM CARBURETOR SERVICE Keihin FCR-MX 39 mm Carburetor Chapter 4 covers basic fuel system information including exploded views of the carburetor, a listing of optional jets and jetting guidelines. Carburetor Jetting IMPORTANT: The following guidelines must be followed when establishing a main jet setting: 1. Select the lowest anticipated temperature at which the machine will be operated. 2. Determine the lowest approximate altitude at which the machine will be operated. 3. Select the correct jet from the specification chart listed in Chapter 1. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Chapter 9 (KTM Engine/Carburetion) details the service procedures for the KTM 450/525 engine and Keihin carburetor. Refer to Chapter 9 for any carburetor service specifications or service procedures. Polaris ATV carburetors are calibrated for an altitude of 0–6000 ft. (0–1800 meters) and ambient temperatures above +40° F (+26° C). Carburetors must be re–calibrated if operated outside this temperature and/or altitude range. The jetting installed in production is not intended for all altitudes and/or temperatures. In addition, air screw / pilot screw adjustments may be required to suit operating conditions. GENERAL INFORMATION Jetting Guidelines 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. Keihin Optional Jet Part Numbers MAIN JETS PILOT JETS 3050235-120 3050219-35 3050235-122 3050219-38 3050235-125 3050219-40 3050235-128 3050219-42 3050235-130 3050219-45 3050235-132 3050219-48 3050235-135 3050219-50 3050235-138 3050219-52 3050235-140 3050219-55 3050235-142 3050219-58 3050235-145 3050219-60 3050235-148 3050219-62 3050235-150 3050219-65 3050235-152 3050235-155 3050235-158 If you spill gasoline on your skin or clothing, immediately wash with soap and water and change clothing. Changes in altitude and temperature affect air density, which is essentially the amount of oxygen available for combustion. In low elevations and cold temperatures, the air is more dense and has more oxygen. In higher elevations and higher temperatures, the air is less dense with reduced oxygen. 4.2 3050235-160 3050235-162 FUEL SYSTEM KEIHIN FCR-MX 3900 CARBURETOR Exploded View Ref Description Ref Main Jet Pilot Jet Cover, Carburetor Top Seal, Carburetor Cover Shaft, Throttle Spring, Throttle Arm, Link Throttle Valve Valve, Throttle Roller, Throttle Valve Seal, Throttle Valve Plate, Throttle Valve Clip, Needle 13 14 15 16 17 18 19 20 21 22 23 24 Description Ref Screw, Needle Seat 25 26 27 28 29 30 31 32 33 34 35 36 Carburetor Needle and Jet Starter Jet Slow Air Jet Kit, Pilot Screw Plate, Buffer Float, Carburetor Pin, Float Clip, Float Valve Float Needle and Seat Bowl, Float Seal, Float Bowl Description Plug, Float Bowl Drain O-Ring, Plug Screw Kit, Accelerator Pump Bowl Valve, Choke Kit, Breather Hoses Cover, Throttle Seal, Throttle Cover Fitting, Fuel Inlet O-Ring, Fuel Inlet Fitting, Breather Hose Kit, Idle Speed Screw Kit, Throttle Position Sensor P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1 2 3 4 5 6 7 8 9 10 11 12 4 13 3 36 4 14 12 11 8 28 10 35 9 32 24 31 23 33 16 22 30 7 6 5 21 18 34 20 19 26 2 15 14 17 1 25 27 29 Refer to Page 4.2 for Optional Jet Part Numbers 4.3 FUEL SYSTEM FUEL TANK Exploded View Screws Cap Gasket P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Vent Line Fuel Tank To Carb U-Type Nut To Carb Fuel Fittings Impulse Line Flex Conduit Fuel Valve On / Off / Reserve Fuel Pump To Main Fitting Knob Screw Flex Conduit Screws To Reserve Fitting Nut FUEL FLOW Tank Vent Fuel Tank Fuel Screen(s) (Fuel Inlet Tubes) Carburetor Vents Fuel Valve 4.4 Fuel Pump Carburetor Engine FUEL SYSTEM Fuel Tank Removal Remove the seat, front cover, side panels and front cab (see Chapter 5 “Body Component Removal”). 2. Install the fuel cap. 3. Disconnect the fuel lines from the tank fittings. 4. Disconnect the vent line. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. Vent Line 4 Fuel Lines 5. Remove the (2) T27/8mm Hex-head screws from the rear portion of the fuel tank. 6. Lift the fuel tank out from the frame. 7. Reverse this procedure to reinstall. Refer to Chapter 5 “Body Component Removal” during body assembly. 4.5 FUEL SYSTEM FUEL PUMP Service / Replacement Location / Operation 1. Remove the (2) T27/8mm Hex-head screws and front cover from the ATV. The fuel pump is located under the front cover. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Fuel Pump The fuel pump operates off crankcase impulses via the impulse line located on the front left side of the carburetor. 2. Turn the fuel valve to the “OFF” position. 3. Pull the RH side panel out of the way and remove the (2) T27/8mm Hex-head screws retaining the fuel pump. Impulse Line 4.6 Inlet Outlet Impulse 4. Pull out the fuel pump and note the fuel line orientation on the pump. 5. Remove the clamps and fuel lines from the pump. 6. Remove the fuel pump and service / replace. 7. Reverse this procedure to reinstall the fuel pump. BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING KNUCKLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BALL JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 5.3 5.4 5.6 5.7 5.7 5.9 WHEEL HUB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 WHEEL HUB DISASSEMBLY / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11 WHEEL HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 FRONT SUSPENSION EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT A-ARM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SUSPENSION EXPLODED VIEW (“IRS”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR A-ARM REPLACEMENT (“IRS”). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR HOUSING (“IRS”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13 5.14 5.15 5.16 5.18 HOUSING REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19 HOUSING DISASSEMBLY / SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23 5 REAR BEARING CARRIER (“IRS”). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24 CARRIER REMOVAL / DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 5.24 CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26 REAR DRIVE CV JOINT (“IRS”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27 CV JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27 CV JOINT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28 CV JOINT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29 REAR SUSPENSION SERVICE (“MXR” / “S”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30 REAR AXLE SERVICE (“MXR” / “S”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31 REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31 INSTALLATION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 AXLE RUN-OUT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35 REAR AXLE HOUSING / AXLE (“MXR” / “S”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT SHOCK EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOX™ PODIUM SHOCK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36 5.37 5.38 5.40 5.42 FOX™ FRONT SHOCK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43 FOX™ FRONT SHOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 SHOCK EYELET REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49 FOX™ PODIUM X SHOCK SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 FOX™ PODIUM X SHOCK REBUILD INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 5.51 FOX™ PODIUM X SHOCK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52 FOX™ PODIUM X SHOCK REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.54 FOX™ PODIUM X SHOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.55 FOX™ PODIUM-C SHOCK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.58 FOX™ PODIUM-C REBUILD INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.59 FOX™ PODIUM-C SHOCK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.60 FOX™ PODIUM-C SHOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.62 5.1 BODY / STEERING / SUSPENSION GENERAL INFORMATION Torque Specifications COMPONENT TORQUE VALUE Front Suspension 33 ft. lbs. (45 Nm) 40 ft. lbs. (54 Nm) 40 ft. lbs. (54 Nm) 15 ft. lbs. (20 Nm) 33 ft. lbs. (45 Nm) 33 ft. lbs. (45 Nm) Front A–Arm Attaching Bolts TORQUE VALUE Torsion Bar Pivot Plate Bolts (“IRS”) Shock Bolts (top & bottom) (“IRS”) 9 ft. lbs. (12 Nm) 33 ft. lbs. (45 Nm) Shock Bolts (top & bottom) (“MXR” / “S”) 36 ft. lbs. (49 Nm) Serviceable Components Rear Pivot Housing Mounting Bolts (“IRS”) Rear Pivot Housing Mount Plate (“IRS”) Rear Sprocket Bolts (“MXR” / “S”) Rear Sprocket Bolts (“IRS”) Brake Disc Caliper Mounting Bolts 30 ft. lbs. (41 Nm) 17 ft. lbs. (23 Nm) 29-35 ft. lbs. (39-47 Nm) 32 ft. lbs. (43 Nm) 18 ft. lbs. (24 Nm) 30-35 ft. lbs. (41-47 Nm) 33 ft. lbs. (45 Nm) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Front A–Arm Ball Joint Stud Nut COMPONENT Front Spindle Nut Tie Rod End Jam Nut Tie Rod End Attaching Nut Shock Bolts (top & bottom) Steering Master Cylinder Mount Bolts Handlebar Adjuster Block Steering Post Bushing Nuts Steering Post Retainer Nuts 45–55 in. lbs. (5.2–6.3 Nm) 11 ft. lbs. (15 Nm) 17 ft. lbs. (23 Nm) 17 ft. lbs. (23 Nm) Wheel Nuts Foot Peg Special Tools PART NUMBER PA - 48282 Rear Suspension 2200421 Rear Axle Nut (“MXR” / “S”) Rear Axle Nut Pinch Bolt (“MXR” / “S”) Rear Axle Housing Pinch Bolts (“MXR” / “S”) Rear Hub Nut (“MXR” / “S”) Swing Arm Pivot Bolt / Rear Engine Mount (“MXR” / “S”) Rear A–Arm Attaching Bolts (“IRS”) Rear Hub Nut (“IRS”) Rear Hub Carrier Bolts (“IRS”) Upper Torsion Bar Bolts (“IRS”) 5.2 8-10 ft. lbs. (11-14 Nm) 50 in. lbs. (6 Nm) 35 ft. lbs. (47 Nm) 80 ft. lbs. (109 Nm) 95 ft. lbs. (129 Nm) 33 ft. lbs. (45 Nm) 90 ft. lbs. (122 Nm) 30 ft. lbs. (41 Nm) 33 ft. lbs. (45 Nm) 2871352 2201640 2201639 2871351 TOOL DESCRIPTION Rear Drive Hub Tool (“IRS”) Gas Shock Recharging Kit (FOX™) Shock Rod Holding Tool (FOX™) Shock Seal Installer .620” / 15.7 mm (FOX™) Shock Seal Installer .498” / 12.6 mm (FOX™) Shock IFP Depth Tool (FOX™) BODY / STEERING / SUSPENSION BODY ASSEMBLY Exploded View I. Grab Bar J. Seat Latch Lever K. Frame L. Foot Peg M. Rock Guard N. Front Bumper P. Sub-Frame Support A. Seat B. Seat Latch Pin C. Rear Cab D. Side Panel E. Front Cover F. Front Cab G. Heel Pocket H. Seat Latch Housing A B P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m C H J G 5 D G F D E I I K K M L L P “IRS” Frame “MXR” / “S” Frame L N M L M N 5.3 BODY / STEERING / SUSPENSION BODY COMPONENT REMOVAL Front Cab Seat 1. Remove the seat and front cover. 2. Remove the (4) T27/8mm Hex-head screws and push rivet retaining the front cab/side panels on each side. The seat latch is located underneath the tail light. 2. Remove the seat by pulling the seat latch outward and lifting up on the rear of the seat. Once the rear of the seat is loose, disengage the front by pulling the seat back towards the rear of the ATV. 3. Install the seat by engaging the front portion first, then pulling the seat latch out while setting the seat down and into place. Lift up on the seat to verify it is latched down. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. 3. Remove the retaining nut and wave washers from the key switch and remove the switch from the front cab. Front Cover 1. Key Switch Location Remove the (2) T27/8mm Hex-head screws. Disconnect HERE 2. Pull the front cover forward to disengage the tabs and remove it from the ATV. 5.4 4. Remove the fuel cap and lift up on the front cab assembly to disconnect the indicator panel as shown. 5. Remove the front cab and side panels as an assembly. 6. Reinstall the fuel cap. 7. Reverse the removal steps to reinstall the front cab assembly. BODY / STEERING / SUSPENSION Side Panels 1. Refer to the “Front Cab” procedure to remove the front cab and side panels as an assembly. 2. Slide each side panel forward to disengage the tabs from the front cab and remove them. 3. Reverse the removal steps to reinstall the side panel and refer to “Front Cab” procedure to reinstall the front cab.. 6. Remove both seat grommets (B) from the rear cab and completely remove the rear cab. B Rear Cab A Remove the seat. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. 2. Remove the (2) T27/8mm Hex-head screws from the rear portion of the side panels. 3. Remove the (2) T27/8mm Hex-head screws retaining the rear cab to the heel pockets. 4. Remove the (2) T27/8mm Hex-head screws retaining the rear cab to the frame. 7. Reverse the removal steps to reinstall the rear cab. • Lubricate the rubber grommets to aid assembly • Route tail light harness through rear cab upon assembly. Heel Pocket 5. 1. Remove the (2) T27/8mm Hex-head screws retaining the heel pocket to the foot peg. 2. Remove the (2) T27/8mm Hex-head screws retaining the inner portion of the heel pocket to the frame. 3. Remove the T27/8mm Hex-head screws retaining the rear cab to the heel pocket and remove them from the ATV. 4. Repeat this procedure to remove the other heel pocket. 5. Reverse the removal procedure to reinstall the heel pocket. Disconnect the tail light (A). 5.5 5 BODY / STEERING / SUSPENSION STEERING ASSEMBLY EXPLODED VIEW A. Handlebar B. Block Clamps C. Steering Bushings D. Steering Post E. Zerk Fitting F. Cotter Pin G. Tie Rod Assembly H. Steering Knuckle A 11 ft. lbs. (15 Nm) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m B 33 ft. lbs. (45 Nm) H D G C 17 ft. lbs. (23 Nm) F E 33 ft. lbs. (45 Nm) 15 ft. lbs. (20 Nm) 17 ft. lbs. (23 Nm) 33 ft. lbs. (45 Nm) F NOTE: APPLY ANTI-SEIZE COMPOUND ONTO SPINDLE BEFORE HUB INSTALLATION 5.6 F BODY / STEERING / SUSPENSION STEERING KNUCKLE Removal 1. 2. Follow the steps in the “FRONT HUB REMOVAL” section to remove the hub, if needed. Remove the upper and lower ball joint cotter keys and castle nuts. Tap down on the lower A-arm to move the lower ball joint from the steering knuckle. 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 knuckle. 3. Install the washers and 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. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Castle Nuts 4. BALL JOINT SERVICE Removal 1. 3. The A-arm must be removed to perform this procedure, Refer to “A-ARM REPLACEMENT” on Page 5.14. Ball Joint Carefully tap on the upper A-arm near the top ball joint while lifting up on the upper A-arm. Upper A-arm Retaining Ring 2. Remove the retaining ring from the ball joint. Upper A-arm Shown 5.7 5 BODY / STEERING / SUSPENSION 3. A driver must be used for the removal of the ball joints. Use the dimensions below to fabricate or locate the correct size driver to use in the following process. Installation 1. Driver Dimensions 1.375 in. (3.49 cm) Place the A-arm in the correct position for ball joint installation. Face the A-arm end flat on top of the driver. Carefully drive the ball joint into place until the ball joint is properly installed. 3 in. (7.62 cm) Press into the A-arm in this direction P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1.75 in (4.45 cm) * Outside diameter of driver cannot be any larger than 1.75 in. Inside diameter cannot be any smaller than 1.375 in. Driver must be 3 in. or taller. 4. Use a press and correct size driver to remove the ball joint from the A-arm. Press out of the A-arm in this direction Upper A-arm Shown 2. After the new ball joint is installed into the A-arm, install a NEW retaining ring. Upon A-arm installation onto the steering knuckle, install a NEW cotter key. Nut & Washer NEW Retaining Ring NEW Cotter Key Lower A-arm Upper A-arm Shown NOTE: The driver must fit the inside diameter of the A-arm. This will allow the ball joint to be properly pressed out of the A-arm without damaging the Aarm. Ball Joint Correct Driver Placement Ball Joint The driver must fit the inside diameter of the A-arm end. Lower A-arm Shown Upper A - arm NEW Retaining Ring Nut & Washer NEW Cotter Key 5.8 BODY / STEERING / SUSPENSION FRONT WHEEL HUB Exploded View 12 15 19 13 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 8 10 11 7 6 5 2 3 4 14 18 5 9 17 1 REF. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. QTY. 2 2 2 2 2 2 2 8 2 2 2 2 2 8 2 2 8 2 2 16 DESCRIPTION Nut, Castle Pin, Cotter Washer Spacer, Outer Seal Bearing, Ball, Sealed Hub, Wheel, Front, Indy Red Stud Spacer, Tapered Bearing, Ball Seal Disc, Brake Spacer, Inner Bolt Rim, Front Valve, Rim Nut, Flange Tire, Front, 21x7–10 Guard, Disc, Outer 5.9 BODY / STEERING / SUSPENSION Wheel Hub Removal 1. 5. Remove outer brake disc guard, cotter pin, front spindle nut, and washer. Elevate front end of ATV and safely support machine under footrest / frame area. CAUTION 2. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 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. Check bearings for side play by grasping tire / wheel firmly (top and bottom, side to side) and checking for movement. It should rotate smoothly without binding or rough spots. 6. Remove the outer spacer from the spindle. Inspect outer spacer for wear, replace if needed. Outer Spacer 3. Remove wheel nuts and wheel. 4. Remove the two brake caliper bolts and the brake caliper. Use mechanic’s wire or other suitable material to support the caliper assembly. Do not allow caliper assembly to hang by the brake line! 7. Remove the hub from the spindle. Remove the inner spacer from the spindle. Inspect the inner spacer for wear, replace if needed. Inner Spacer Brake Caliper Mount Bolts 8. 5.10 Rotate each bearing inside the hub by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Replace bearing if moisture, dirt, corrosion, or roughness is evident. BODY / STEERING / SUSPENSION Wheel Hub Disassembly Wheel Hub Assembly 1. 1. Place a shop towel on hub to protect surface. Carefully pry seal out of hub. Drive or press one new bearing into hub using a bearing driver. Seals (2) Hub Seal P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Tapered Spacer Bearings (2) 2. CAUTION Using a brass drift, tap bearing spacer to one side to expose inner bearing race. Drive bearing out using a drift through opposite side of hub and discard. Do not drive on the inner race of the bearing. Tap Spacer to the side 3. Premium All- Season Grease (PN 2871322) (3 oz. Tube) (PN 2871423) (14 oz. Tube) 2. Coat bearing spacer with grease and install into hub. Drive or press the other bearing into hub until seated against spacer. 3. Install seal into hub (with numbers facing out) until flush with end of seal bore. Remove spacer. Drive other bearing out and discard. Seal 4. Clean hub and spacer thoroughly. 5. Inspect spacer for wear or damage. Measure the tapered spacer for wear, replace as needed. Tapered Spacer .774 + .005 .797 + .005 5.11 5 BODY / STEERING / SUSPENSION Wheel Hub Installation 1. 2. 6. Bend both ends of cotter pin around end of spindle in different directions. Apply anti-seize compound to spindle area, this will aid in wheel removal in the future. 7. Rotate hub. It should rotate smoothly without binding, rough spots or side play. Inspect spindle and bearing surface for wear or damage. Install the inner spacer. 8. Install brake caliper. Tighten bolts to 38 ft.lbs. (52 Nm). Inner Spacer P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 38 ft. lbs. (52 Nm) Apply anti-seize compound 3. Install hub on spindle. Install the outer spacer. 9. Outer Spacer 4. Install the washer and spindle nut. Torque the spindle nut to 40 ft. lbs. (54 Nm). Front Wheel Torque Front Wheel Nuts (4) 30-35 ft. lbs. (41-47 Nm) Front Spindle Nut 40 ft. lbs. (54 Nm) 5. Install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes. 5.12 Install the brake disc guard. 10. Install the wheel and four wheel nuts finger tight. Lower the ATV and torque the wheel nuts to 30-35 ft. lbs. (41-47 Nm). BODY / STEERING / SUSPENSION FRONT SUSPENSION EXPLODED VIEW Use new cotter pins upon reassembly. Install with open end toward rear of machine. C P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m I J H C E D G L 33 ft. lbs. (45 Nm) 5 B F L D J M I B A 40 ft. lbs. (54 Nm) K A 40 ft. lbs. (54 Nm) 33 ft. lbs. (45 Nm) A. Springs B. Front Shock C. Upper A-Arm D. Lower A-Arm E. A-Arm Shaft F. Bushings G. Bolt H. Flange Nut I. Steering Knuckle J. Ball Joints K. Cotter Pins L. Retainer Rings M. Inner Disc Guard 5.13 BODY / STEERING / SUSPENSION FRONT A-ARM REPLACEMENT 6. Examine A–arm shafts (I). Replace if worn. Discard hardware. A-arm Removal and Inspection Elevate and safely support vehicle. Remove the front wheel(s). 2. Remove the upper and lower ball joint cotter pins (A) from the ball joint studs (B & C) at wheel end of A–arm. Remove the ball joint nuts until the nuts are flush with end of the ball joint studs. 3. Push up on the upper A-arm (D) to remove the A-arm from the steering knuckle (E). Push down on the lower A-arm (F) to remove the A-arm from the steering knuckle (E). Refer to “Steering Knuckle - Removal” procedure on page 5.7. I P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. H G B D E A-arm Installation A F C 1. Insert A–arm shaft (I) into the new A–arm (D & F). 2. Install new A–arm assembly onto vehicle frame (upper and lower). Torque bolts to 33 ft. lbs. (45 Nm). 3. Attach upper A-arm (D) and lower A–arm (F) to steering knuckle (E). Attach shock with bolts (G). Tighten all fasteners to 33 ft. lbs. (45 Nm). If ball joint cotter pin holes are not aligned, tighten nut slightly to align. Install a new cotter pin with open ends toward rear of machine (upper and lower). Bend ends in opposite directions around nut. 4. Locate grease fittings at the end of each A–arm tube and pump A–arm ends full of grease. WARNING 4. Remove the lower shock bolt (G) from the lower A-arm and remove the shock from the A-arm. Upon A–arm installation completion, test vehicle at low speeds before putting into regular service. 5. Loosen two bolts on the A–arm tubes (H) (upper and lower A-arms) until A–arm can be removed. A-arm Attaching Bolt Torque: Ball Joint Stud Nut Torque: Front Shock Bolt Torque: 33 ft. lbs. (45 Nm) 5.14 BODY / STEERING / SUSPENSION REAR SUSPENSION EXPLODED VIEW (“IRS”) C 33 ft. lbs. (45 Nm) H G D P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 30 ft. lbs. (41 Nm) C 33 ft. lbs. (45 Nm) G 33 ft. lbs. (45 Nm) H A 5 G G B 9 ft. lbs. (12 Nm) H D H G H 33 ft. lbs. (45 Nm) F B E 30 ft. lbs. (41 Nm) 33 ft. lbs. (45 Nm) A. Hub Carrier Assembly B. Torsion Bar Assembly C. Upper A-Arm D. Lower A-Arm E. Bolt F. Flange Nut G. Needle Bearing H. Bearing Seals 5.15 BODY / STEERING / SUSPENSION REAR A-ARM REPLACEMENT (“IRS”) 7. A-arm Removal NOTE: Rear A-arm mounts contain needle bearings 1. Elevate and safely support vehicle. Remove the rear wheel(s). 2. Remove the lower shock bolt from the lower A-arm hole (A) and remove the shock from the A-arm. F H G E Loosen the upper and lower bearing carrier bolts at the wheel end of A–arms. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 3. Examine A–arm shafts (E), needle bearings (F), seals (G), and thrust washers (H). Replace if worn or damaged. D C H G F E F E G H D D E A A-arm Inspection 1. B 4. Remove bolt (B) on the lower A–arm tube and pry the hub carrier up and away from the A-arm. 5. Remove bolt (C) on the upper A–arm tube and pry the hub carrier down and away from the A-arm. 6. Remove remaining bolts (D) from A-arms and remove Aarms from the frame. 5.16 Disassemble, clean and inspect the upper A-arm. Closely inspect the thrust washers, needle bearing, seals, and shaft. Replace components as required. BODY / STEERING / SUSPENSION 2. Disassemble, clean and inspect the lower A-arm. Closely inspect the thrust washers, needle bearings, seals and shafts. Replace components as required. NOTE: Apply grease to the inside of the needle bearings before inserting shaft. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Inspect 6. 3. Inspect needle bearing performance by rotating the shaft inside the bearing (circled). If replacement is required, press the bearings out from opposite sides using a drift punch or other suitable tool. 4. Press needle bearings from the A-arms using a drift punch or other suitable tool. Do not re-use bearings once they have been removed. Insert A–arm shafts, seals and thrust washers into the A– arm mounting bores. A-arm Installation 5. Press new needle bearings into the A-arms, centering bearing in the bore. Press only on the outside diameter of the bearing. Verify that an equal amount of space remains on each side to allow for seal installation. 1. Install A–arm assemblies onto vehicle frame (upper and lower). Torque mounting bolts to 33 ft. lbs. (45 Nm). 2. Attach upper A-arm and lower A–arm to the bearing carrier. Tighten both fasteners to 30 ft. lbs. (41 Nm). WARNING Upon A–arm installation completion, test vehicle at low speeds before putting into regular service. 5.17 5 BODY / STEERING / SUSPENSION REAR HOUSING (“IRS”) Exploded View H G F E P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m D C I B B A D CV Ball / Cage Assembly Individual Parts Not Available - Order Hub Assembly A. CV Boot Retaining Ring (2) B. Inner CV Boot (2) C. Sprocket Hub D. Bearing (2) E. Rear Axle Housing F. O-Ring G. Rear Brake Disc Hub H. Brake Hub Retaining Ring 5.18 A BODY / STEERING / SUSPENSION Housing Removal With ATV on the ground, loosen wheel nuts and hub nuts. 2. Safely lift and support the rear of the ATV under the main frame. 3. Remove both rear wheels and hubs. 4. Loosen rear housing mounting bolts and chain adjustment. 5. Remove drive chain. 6. Remove rear caliper and secure out of the way. Remove the brake disc from the rear housing. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. 9. NOTE: Do not allow the caliper to hang by the brake line. Brake line damage may result. 7. 8. Remove both upper carrier bolts and secure upper a-arms out of the way. Tilt each hub carrier outward while pulling rear CV shaft end from carrier assembly. 10. Bend the tabs of the bolt retainer plate away from the bolt heads. 5 11. Remove the bolts and rear drive sprocket from the rear housing. 12. Remove rear housing mounting bolts and chain adjustment components. 13. Lift and rotate rear housing at an angle and remove it from the ATV frame, exiting the frame from either side. NOTE: Removal of rear shock may be necessary to gain adequate clearance for rear housing removal. 5.19 BODY / STEERING / SUSPENSION Housing Disassembly / Service Place housing in a suitable holding fixture. 2. Remove both boot clamps from their locations. 3. Using a flat blade screwdriver, carefully pry the retaining ring from each boot. 4. 5. Using a flat blade screwdriver, carefully pry the retaining rings from both CV ball cages. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. 6. 7. Remove the CV ball cage retaining rings from the housing. 8. Remove the inner CV joints and shaft assemblies from the carrier housing. Remove the retaining rings from both inner boots of the rear housing. Remove both inner boots by pulling outward on boot. A blunt prying tool may be required to break the sealing area. NOTE: Inner CV joint parts are not replaceable. Order new hub assembly if damaged beyond serviceable condition. NOTE: Inner CV boots are sealed to housing. Use caution during removal. Boot damage may result. 5.20 BODY / STEERING / SUSPENSION 9. To disassemble the inner CV joint, place the CV end on a vise and use a punch to tap the driveshaft out. 11. To reassemble the inner CV joint, use special Hi Temp CV joint grease to allow the rollers to “stick” to the cage. Insert the rollers into the outer cage, then insert the inner joint sideways 180 degrees into the cage assembly and turn the inner joint to capture the rollers. The chamfered end should be facing toward the drive shaft. 12. Using a soft faced hammer, tap the drive shaft into the chamfered end of the inner CV assembly until it locks in place. Lubricate the inner CV assembly liberally with joint grease before housing reassembly. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 13. Before pressing the brake and sprocket hubs apart, remove the sprocket hub snap ring. IMPORTANT: Note the orientation of the parts for reassembly. Inner CV joint parts are not replaceable. Replace hub assembly if joints are damaged 5 NOTE: Drive shaft inserts into chamfered end 14. Using Special Tool PN PA-48282, press the rear hub assembly apart to access the carrier bearings. 10. The inner CV joint can be disassembled by rotating the inner joint approximately 180 degrees and pulling out. Clean and inspect the joint and rollers for cracks or rough surfaces. Replace the hub assembly if damage is found. Brake Hub Assembly 180° Rear Hub Tool PA - 48282 5.21 BODY / STEERING / SUSPENSION 15. Using a suitable holding fixture, press or tap the carrier bearings out the opposite end of each housing. 3. Using Special Tool PN PA-48282, press the rear hub assembly together. Verify o-ring is seated properly during reassembly. NOTE: Do not reuse the bearings if removed. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Bearing Rear Hub Tool PA - 48282 Assembly 1. Using a suitable holding fixture, press or tap the carrier bearings into the housing. 4. Install the sprocket hub snap ring. 5. Pack the housing assembly and inner boots with a total of 8.75 oz. of Hi-Temperature CV joint grease. Distribute grease evenly. NOTE: Do not reuse the bearings if removed. Bearing 2. Apply sealant to the sprocket hub splines before assembly. Sprocket Hub Assembly O-ring CV GREASE NOTE: Use Special Hi-Temp CV Grease 8.75 oz. (248.05 grams) 5.22 BODY / STEERING / SUSPENSION Rear Housing Hi-Temp CV Grease Capacity: 8.75 oz. (248.05 grams) Install the inner CV ball cage and retaining rings. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 6. NOTE: Before tightening boot clamp on inboard joints, make sure any air pressure which may have built up in joint boot has been released using the boot ‘burping’ process. The air should be released after the plunging joint has been centered properly. Tighten boot clamps using boot clamp pliers. 7. 8. Ensure the retaining ring is seated properly in the rear housing groove. 5 Installation 1. Reverse the steps described in the Removal/ Disassembly procedure. 2. Attach the rear housing mounting bolts, chain adjustment components and brackets. Torque brackets to 17 ft. lbs. (23 Nm). Do not tighten chain adjustment or housing bolts until chain adjustment has been completed. 3. Attach the brake disc and drive sprocket to rear housing. 4. Install and torque the brake disc bolts to 18 ft.lbs. (24 Nm). 5. Install and torque the drive sprocket bolts to 32 ft. lbs. (43 Nm). Using a flathead screwdriver, bend up the tabs of the bolt retainer plate at each bolt head. 6. Install each rear CV shaft end into hub carrier and attach the upper a-arm to the hub carrier. Clean and apply a thin coat of sealant to both the boot and sealing surface before installing inner boots. Install retaining rings. Apply sealant before assembly 9. Install boot clamps. 5.23 BODY / STEERING / SUSPENSION 7. Insert and torque the a-arm mount bolts to 30 ft. lbs. (41 Nm). Carrier Disassembly / Inspection Remove outer snap ring. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. Carrier Bolt Torque: 2. 30 ft. lbs. (41 Nm) 8. Follow chain adjustment procedures. 9. Torque remaining rear housing fasteners to 30 ft. lbs. (41 Nm) after completion of chain adjustment. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown. 10. Install rear hubs, cone washer and nut. Verify cone washer domed side faces outward. Torque hub nut to 90 ft. lbs. (122 Nm) and install cotter pin. REAR BEARING CARRIER (“IRS”) Carrier Removal 1. Remove rear wheel and hub. 2. Remove upper carrier bolt and secure upper A-arm out of the way. Tip hub carrier outward and remove shaft end from carrier. Remove lower carrier bolt. NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. 3. Inspect bearing. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race. 4. 5.24 Inspect bearing housing for scratches, wear or damage. Replace housing if damaged. BODY / STEERING / SUSPENSION 5. Disassemble, clean and inspect the upper A-arm thrust washers, needle bearing, seals and shaft. Replace components as required. Thrust Washer Needle Bearing Carrier Assembly 8. Install needle bearings by pressing the bearings into the housing using a suitable tool. Bearing Installation Thrust Washer Shaft Seal P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Seal 6. Disassemble, clean and inspect the lower A-arm thrust washers, needle bearings, seals and shaft. Replace components as required. 9. Apply grease and install the shafts. Install the seals in the upper and lower portion of the carrier. Shaft Thrust Washer Seal Thrust Washer Seal Thrust Washer Shaft Shaft Seal Needle Bearings 7. Seal Inspect needle bearing performance by rotating the shaft inside the bearing. If replacement is required, press the bearings out from opposite sides using a drift punch or other suitable tool. Thrust Washer 10. Support bottom of bearing carrier housing and start bearing in housing. Bearing Removal 5.25 5 BODY / STEERING / SUSPENSION 11. Press bearing into place until outer race bottoms on housing. Upper / Lower Control Arm Bolt Torque: 33 ft. lbs. (45 Nm) Pull drive shaft outward and install hub onto driveshaft splines. 7. Install cone washer domed side facing outward. 8. Install retainer nut, wheel and wheel nuts. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 6. 9. CAUTION Remove jackstand and torque hub nut and wheel nuts to specification. 90 ft. lbs. (122 Nm) Use an arbor press and only press on the outer race of the bearing. Failure to do so, will result in bearing damage. 12. Install snap ring into groove. Carrier Installation 1. Insert bearing carrier on drive shaft. 2. Align bottom of carrier housing and lower control arm. Grease and slide lower control arm bushings into place, securing corner housing. 3. Install both lower control arm bolts. 4. Lift bearing carrier until top aligns with upper control arm. 5. Install and torque upper control arm bolt and torque to specification. Torque lower control arm bolts to specification. 5.26 New Cotter Pin Hub Nut Torque: 90 ft. lbs. (122 Nm). 10. Install a new cotter pin. Tighten nut slightly to align holes if required. Wheel Nut Torque: 30-35 ft. lbs. (41-47 Nm). BODY / STEERING / SUSPENSION REAR DRIVE CV JOINT (“IRS”) CV Joint Removal Elevate and safely support the rear of the ATV. 2. Remove the rear wheel hub nut and remove the rear wheel and hub assembly from the rear bearing carrier. 3. Remove upper carrier bolt and secure upper A-arm out of the way. Tip hub carrier outward and remove shaft end from carrier. NOTE: Shaft is shown out of rear carrier P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. NOTE: If the drive shaft has been removed from the ATV, place the shaft assembly in a soft-jawed vise and remove the CV joint using the same procedure with a soft-faced hammer. 7. Pull the CV joint and boot off the end of the shaft. Make sure the circlip remains on the shaft and not left in the joint. NOTE: Shaft is shown out of rear carrier Circlip NOTE: CV joint can be serviced without removing the driveshaft from the rear carrier housing. 4. Remove the clamps from the rubber boot(s) using the proper boot clamp pliers. 5. Slide the boot down the shaft and wipe the grease away from the face of the joint. NOTE: Shaft is shown out of rear carrier 6. Support the drive shaft and strike the inner race of the CV joint using a soft-faced hammer to drive the joint off the shaft. 5.27 5 BODY / STEERING / SUSPENSION CV Joint Service Install a NEW circlip on the end of the shaft. CAUTION Circlip Complete disassembly of the CV joint is NOT recommended. The internal components are a precision fit and develop their own characteristic wear patterns. Intermixing the internal components could result in looseness, binding, and/or premature failure of the joint. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m IMPORTANT: If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. Inspect the grease CAUTION The grease provided in the replacement kit is specially formulated for wear resistance and durability. DO NOT use substitutes or mix with other lubricants. NOTE: The amount of grease that’s provided with the boot kit is pre-measured, so use all the grease. CV Boot Replacement Kit 1. 2. Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly. 3.5 oz. Visually inspect the joint for damage. Replace if needed. NOTE: Shiny areas in ball tracks and on the cage spheres are normal. Do not replace CV joints because parts have polished surfaces. Replace CV joint only if components are cracked, broken, worn or otherwise unserviceable. 3. Grease Pack Small Clamp CV Joint Grease Included with Boot Replacement Kit: 3.5 oz. (99 g) Slide the small boot clamp and boot (small end first) onto the drive shaft and position the boot in its groove machined in the shaft. 5.28 Boot Large Clamp 4. Grease the inner and outer joint races. Fully compress the joint and push the drive shaft into the inner race of the CV joint. 5. Align the circlip with the lead-in chamfer. 6. Use a soft-faced hammer to assemble the shaft into the inner race of the CV joint. Tap on the joint until the shaft “clicks” into place. BODY / STEERING / SUSPENSION 7. Pull on the joint to test that the circlip is seated and that the joint is securely fastened to the shaft. 8. Add any remaining grease to the boot and remove any excess grease from the CV joint’s external surfaces. 9. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. CV Joint Installation 1. Slide shaft assembly into bearing carrier hub. 10. Tighten the large clamp using an appropriate clamp pliers. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 11. Fully extend the CV joint by pulling on the shaft and slide a straight O-ring pick or small screwdriver between the small end of the boot and the shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life. Before you remove your instrument, be sure the small end of the boot is in its correct location on the shaft. 2. Apply anti-seize compound to splines of shaft. 3. Lift bearing carrier into place and install bolt to upper control arm. Torque bolt to 33 ft. lbs. (45 Nm). 12. Install the small clamp on the boot and tighten using an appropriate clamp pliers. 4. CAUTION Install the rear wheel and hub assembly onto the rear drive shaft and bearing carrier. Torque rear hub castle nut to 90 ft. lbs. (122 Nm). Install new cotter pin. Be careful not to cut through the bridge of the clamp when tightening. 90 ft. lbs. (122 Nm) New Cotter Pin 5.29 5 BODY / STEERING / SUSPENSION REAR SUSPENSION SERVICE (“MXR” / “S”) Swing Arm Removal / Installation 36 ft. lbs. (49 Nm) 36 ft. lbs. (49 Nm) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m A. Chain Slide B. Swing Arm Bolt C. Spacer (2) D. Seal (4) E. Needle Bearing (4) F. Thrust Bushing (2) G. Washer (2) H. Nylok Nut I. Chain Guide J. Swing Arm Guard K. Carrier Pinch Bolt (2) L. Chain Roller A Swing Arm K F I G C F H B G 95 ft. lbs. (129 Nm) E L D J Removal / Disassembly 1. Safely support the rear of the machine under the main frame. Remove both rear wheels. 2. Remove drive chain. 3. Remove rear caliper. IMPORTANT: Do not allow the caliper to hang by the brake line. Brake line damage may result. 4. 5. 6. 7. 8. Remove rear wheels and/or hubs Remove lower shock bolt. Remove the foot brake assembly. Remove the nylok nut (H) and washers (G) from the mount bolt (B). Remove the mount bolt (B) from the swing arm. 5.30 NOTE: Be careful not to damage the seals (D) and bearings (E) during swingarm removal. 9. Remove swingarm from the frame. 10. If needed, remove the thrust bushings (F) and swingarm seals (D) from swingarm. 11. If needed, remove the needle bearings from the swingarm (E). 12. Clean and inspect parts for wear. Replace worn parts. Installation 1. Reverse the steps above in the Removal / Disassembly procedure. Add grease to pivot bearings before assembly. 2. Torque mount nut (H) on bolt (B) to 95 ft. lbs. (129 Nm). 3. Torque the top and bottom rear shock bolts to 36 ft. lbs. (49 Nm). BODY / STEERING / SUSPENSION REAR AXLE SERVICE (“MXR” / “S”) 4. Removal / Disassembly 1. Loosen the hex screw (A) to loosen the axle nut. Turn the axle nut (D) counter clockwise with a 1 3/4” wrench (PN 2870772) until the retaining ring (B) is visible for removal. Securely support rear of machine with rear wheels off the floor. Remove rear wheels and hubs. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m D A 5. 2. B 5 Remove the brake caliper bolts and remove the brake caliper. 6. 3. Remove retaining ring (B) from next to the axle nut. Remove the master link from the drive chain. Remove the drive chain. Remove the four bolts that secure the brake disc (C) to the rear disc hub and remove the brake disc. NOTE: It is not necessary to remove the brake disc at this time. Only remove if needed. C 5.31 BODY / STEERING / SUSPENSION 7. Loosen and remove the axle nut (D). 10. Remove the four bolts that secure the sprocket. D NOTE: Only remove sprocket if replacing with a new sprocket. 8. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Bolts Remove the retaining ring (E) and caliper mounting bracket (F). 11. Slide the sprocket off the axle, if needed. E 12. Loosen the concentric clamp bolts (H). Slide the axle through the rear axle housing on the sprocket side. F 9. Remove the O-ring (G) from the axle assembly. H G 13. With the axle out, remove the retaining ring (J) and sprocket hub (K) from the axle. K J 5.32 BODY / STEERING / SUSPENSION Installation / Assembly 1. 5. Slide the sprocket hub (A) onto the sprocket side of the axle. Install the retaining ring (B) onto the axle and into the groove of the axle. Apply Anti-Seize to the splines of the axle. C Install the mounting bracket (E) and retaining ring (F). Be sure to properly align the bracket (E) and bushing (I) upon installation. I A F P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 29-35 ft. lbs. (39-47 Nm) B Groove E 6. 2. Slide the axle into the rear axle housing. 3. Install the sprocket (C) onto the sprocket hub (A). Torque the four sprocket nuts to 29-35 ft. lbs. (39-47 Nm). 4. Apply grease to the O-ring (D) and install the O-ring on the sprocket side of the axle. Install the axle through the housing. Install the O-ring into the axle housing on the brake side. D 7. Install the axle nut hub (G) and retaining ring (H). Thread the axle nut hub onto the axle until there is enough room to install the retaining ring into the groove in the axle. Groove Turn the axle nut hub (G) outward with the 1 3/4” wrench (PN 2870772) until the end of the axle nut (G) just covers the retaining ring (H). The retaining ring should still be visible under the axle nut from an angle. G H 5.33 5 BODY / STEERING / SUSPENSION 8. Torque the axle nut hex bolt to 8-10 ft. lbs. (11-14 Nm). Torque the hex pinch bolt to 50 in. lbs. (6 Nm). 9. Install the brake disc if previously removed. Torque the brake disc nuts to 16-19 ft. lbs. (22-26 Nm). 13. Install rear wheels and torque wheel nuts to 30-35 ft. lbs. (41-47 Nm). 80 ft. lbs. (109 Nm) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 16-19 ft. lbs. (22-26 Nm) 50 in. lbs. (6 Nm) 10. Reinstall the chain and masterlink. To verify proper chain tension, refer to Chapter 2 for procedure. Torque the two axle housing pinch bolts to 35 ft. lbs. (47 Nm). 35 ft-lb (47 Nm) 11. Install the brake caliper and torque the mounting bolts to 18 ft. lbs. (25 Nm). 12. Apply Anti-Seize lubricant to the axle splines. Install the rear wheel hubs on both sides. Torque the wheel hub nuts to 80 ft. lbs. (109 Nm). Install a new cotter pin. 5.34 30 - 35 ft. lbs. (41 - 47 Nm) 14. Lubricate the axle housing through the grease fitting with Polaris All Season Grease (PN 2871423). BODY / STEERING / SUSPENSION Axle Run-Out Inspection Park the vehicle on a flat surface and apply the parking brake. 2. Place a jack under the axle skid plate and raise until the rear wheels are off the ground. 3. Strap the vehicle securely to the ground so that the machine is held solid and will not wiggle. 4. Remove the rear wheels. 5. Remove the rear hubs (discard the used cotter pin). 6. Check that the swing arm bolt is properly torqued to 95 ft.lbs. (129 Nm). 7. Wipe the axle clean with a shop rag. Pay special attention to clean the splines at the end of the axle and the small cylindrical surface next to the splines. 8. Using a large screw driver, gently pry the brake pads apart so that the axle will spin freely. 9. Grab the end of the axle with your hand and try to move the axle up and down and side to side in the eccentric housing. The axle should not move. If the axle does not move, proceed to step 12. If movement is still detected after completing step 12, carrier bearings should be inspected and/or replaced before continuing. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. 10. Back the socket headed locking screw in the large cast axle nut out several turns. Using a large wrench, loosen the large axle nut by turning counter clockwise 2 turns. 11. Retighten the large nut by turning clockwise until there is no more axle play. Do not over tighten! The axle should still spin freely. 12. Torque the socket headed locking screw to 10 ft.lbs. (14 Nm). 13. Grease the eccentric using Polaris all season grease. Stop when grease starts to seep out from the eccentric seals. 14. Wipe away any excess grease. Use Polaris Brake and Clutch cleaner on the brake caliper and disc to clean any grease off the brakes. 15. Secure a dial indicator to the work surface and the measuring point on the small cylindrical surface next to the spline on the end of the axle. 16. With the vehicle in neutral, slowly spin the axle one full rotation and measure the total run out (total dial movement). Be very careful not to bump the machine or dial indicator while performing the measurement. 17. Repeat on the other end of the axle. If the measurement is over 0.040” (1.01mm) on either side, the axle needs to be replaced. Reassembly: 18. Reinstall the hubs making sure the concave side of the conical washer is facing the hub. 19. Torque the hub nut to 80 ft.lbs. (108 Nm) and install a new cotter pin. 20. Reinstall the rear wheels and torque the wheel nuts to 30-35 ft.lbs. (41-47 Nm). 21. Unstrap the vehicle and remove the jack. NOTE: If vibration in the rear end persists, the rims may be bent or out of balance due to wear. Axle Run-out Inspection with V-Blocks Run-out must not exceed .040” (1.01 mm) Maximum 5.35 5 BODY / STEERING / SUSPENSION REAR AXLE HOUSING / AXLE (“MXR” / “S”) Exploded View 1. Seal 2. O-ring 3. Bearing, Cone, Taper 4. Bearing, Cup, Taper 5. Housing, Axle, Rear 6. Fitting, Lubrication 7. Axle, Rear 8. Nut, Nylok 9. Sprocket 10. Hub, Sprocket 11. Bolt 12. Ring, Retaining 13. Chain 14. Link, Connector 15. Bushing, Caliper 16. Bracket, Caliper Mount 17. Ring, External 18. Nut, Nylok 19. Disc, Brake 20. Hub, Rear Disc 21. Screw 22. Screw 23. Nut, Axle 24. Ring, Retaining P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 8 6 4 3 9 11 2 1 5 2 3 15 16 17 21 20 18 24 5.36 13 7 4 1 12 10 23 22 19 14 BODY / STEERING / SUSPENSION DECAL REPLACEMENT WARNING P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m The following procedure involves the use of an open flame. Perform this procedure in a well ventilated area, away from gasoline or other flammable materials. Be sure the area to be flame treated is clean and free of gasoline or flammable residue. WARNING Do not flame treat components that are installed on the vehicle. Remove the component from the vehicle before flame treating. 5 The side panels, front and rear fender cabs are plastic polyethylene material. Therefore, they must be “flame treated” prior to installing a decal to ensure good adhesion. A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a 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 quickly over the area where the decal is to be applied until the surface appears slightly glossy. This should occur after just a few seconds of flame treating. Do not hold the torch too close to the surface (2-3 inches from the flame tip is recommended). Keep the torch moving to prevent damage. 2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 5.37 BODY / STEERING / SUSPENSION FRONT SHOCK EXPLODED VIEWS P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m FOX™ PODIUM X ‘Piggyback’ Front Shock (450 “MXR”) Preload Ring 10 ft. lbs. (14 Nm) Ref. Qty Description Ref. Qty Description 1. 1 Rebuild Kit 16. 1 Preload Ring 1 Bumper 17. 1 Screw Asm. 4 Eyelet Bushing 18. 1 Body Cap 1 Nut 19. 1 Piston, Floating 1 Decal 20. 1 Top-Out Plate - Shock Oil (2870995) 21. 1 Back-Up Plate 2. 3. 4. 5. 6. 7. 1 Wire Retaining Ring 22. 1 Piston, Damping 8. 2 Wire Retaining Ring 23. 1 Eyelet Asm. 9. 1 Body 24. 1 Bearing Asm. 10. 1 Eyelet Sleeve 25. 1 Air Valve Ball 11. 1 Eyelet Sleeve 26. 1 Screw 12. 1 Reservoir 27. 1 Air Valve Ball 13. 1 Shaft 28. 1 Reservoir End Cap 14. 1 Spring Guide 29. 1 Damping Adjustment Asm. (Cartridge) 15. 1 Preload Ring 30. 1 Damping Adjustment Asm. (Piston) 5.38 BODY / STEERING / SUSPENSION P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m FOX™ PODIUM Front Shock (525 “S” / 525 “IRS”) Ref. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Qty 1 1 1 1 1 1 1 4 1 1 1 1 Description Shaft Body Body Cap Asm. Air Valve Asm. Screw Asm. Shock Oil (2870995) Decal Sleeve Eyelet Bushing Eyelet Asm. Bumper Piston Asm., Floating Valving Asm. Ref. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Qty 1 1 1 1 1 1 1 1 2 1 1 1 5 Description Bearing Asm. Bumper Preload Ring Preload Ring Nut Bearing, External Bearing, External Screw Wire Retaining Ring Spring Guide Rebuild Kit Eyelet Sleeve 5.39 BODY / STEERING / SUSPENSION REAR SHOCK EXPLODED VIEWS P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m FOX™ PODIUM X ‘Piggyback’ Rear Shock (450 “MXR” / 525 “S”) Ref. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Qty Description Ref. Qty Description 1 Rebuild Kit 20. 1 End Cap, Reservoir 1 Preload Ring 21. 1 Piston, Damping Adjust Asm. 1 Preload Ring 22. 1 Cartridge, Damping Adjust Asm. 2 Bearing 23. 1 Needle, Parabolic w/O-Ring 1 Bumper 24. 2 Air Valve Ball 1 Nut 25. 1 Adjustment Retainer 1 Decal 26. 1 Slotted Screw Adjustment Knob - Shock Oil (2870995) 27. 1 Tapered Adjustment Screw 4 Retaining Ring 28. 1 Eyelet 1 Body 29. 1 Air Valve Ball 1 Body Cap 30. 1 Screw 12. 1 Jet, Damping Adjust Port 31. 1 Shaft Spacer 13. 1 Metering Rod, Damping Adjust Port 32. 2 Shaft Spacer 14. 1 Reservoir 33. 1 Wire Retaining Ring 11. 15. 1 Shaft 34. 1 Air Valve Set Screw 16. 1 Screw Asm. 35. 1 Air Valve Ball 17. 1 Piston, Floating 36. 1 Reservoir End Cap Asm. 18. 1 Piston, Damping 37. 1 Air Valve Pellet 19. 1 Bearing Asm. 38. 1 Valving Asm. 5.40 BODY / STEERING / SUSPENSION P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m FOX™ PODIUM-C Rear Shock (525 “IRS”) Ref. Qty Description Ref. Qty Description 1. 1 Bearing, External 14. 1 Rebuild Kit 2. 1 Bearing, External 15. 1 Piston Asm., Floating 3. 1 Decal 16. 1 Valving Asm. 4. - Shock Oil (2870995) 17. 1 Bumper 5. 1 Body 18. 1 Shaft 6. 1 Screw Asm. 19. 1 Spring Guide 7. 1 Body Cap Asm. 20. 2 Wire Retaining Ring 8. 1 Nut 21. 1 Preload Ring 9. 1 Piston, Damping 22. 1 Preload Ring 10. 1 Bearing Asm. 23. 1 Jet, w/Needle Seat 11. 1 Eyelet Clevis 24. 1 Needle, Parabolic w/O-Ring 12. 2 Eyelet Bushing 25. 1 Metering Rod 13. 1 Eyelet Sleeve 26. 1 Slotted Screw Adjustment 5 5.41 BODY / STEERING / SUSPENSION FOX™ PODIUM SHOCK SERVICE General Service Information *Note direction of valve piston before disassembly. The side with the greater number of slots should face the IFP (nut end of the shaft). Changing oil on FOX™ Shocks is recommended annually and should be included when performing end of season storage preparation. For competition use, shocks should be disassembled, inspected and serviced more frequently. FOX™ PODUIM Front Shock Details Piston Orientation Toward Shaft (Fewer slots) Side with greater # of slots must face nut end (Toward nut &IFP) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Slots Orifice Piston* Orifice must be drilled to required size on replacement valve pistons FOX™ PODIUM Front Shock Standard Valving Piston Orifice = .136” COMPRESSION (525 “S” / “IRS”) REBOUND (525 “S” / “IRS”) 5.42 BODY / STEERING / SUSPENSION FOX™ Front Shock Disassembly Remove valve and sealing O–ring from body cap. Remove spring and bushings from shock eyes. Thoroughly wash shocks in a parts washer or with soap and water to remove dirt and other debris. Dry thoroughly with compressed air. Position and clamp body cap of shock in soft jaws (aluminum or brass) of vise. Remove Allen screw from pressure valve. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. 3. 4. 2. Extend shock shaft by pulling up on shock eyelet. Using a 1” (25 mm) or adjustable wrench, loosen shaft bearing cap. 5 With valve outlet pointed in a safe direction, insert red tip of safety needle assembly into recess in shock pressure valve. Depress safety pin on safety needle and push gauge and needle assembly slowly toward shock, inserting needle. Be sure to push needle completely into shock valve. Release nitrogen in a safe direction by turning T–handle clockwise (if equipped) or by depressing Schrader valve pin. 5. If body of shock starts to unscrew from body, tighten and try again. To keep body from turning, it may be necessary to use Body Clamp Tool clamped lightly around body in soft jaws of vise. CAUTION It is possible for some residual pressure to remain in the shock regardless of the gauge reading. Always completely remove valve from body cap before further disassembly of shock. Shock Body Clamp Tool (PN 2871071) 5.43 BODY / STEERING / SUSPENSION NOTE: Position body clamp at least 1 1/2" below bearing cap. 6. Valve Nut Torque Pull shock rod and piston straight out to avoid seal or valve damage. Be prepared to catch piston ring when removing the damper rod/valve piston. 12 ft. lbs. (17 Nm) 7. If bearing cap and/or seals are to be replaced, remove nut, washer, and valve piston with valving washers and set aside. Keep washers in order and note orientation of slots in piston for proper re–installation. The side with the greater number of slots must face the damper rod nut (toward IFP). P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 9. Remove shock from vise and dispose of used oil properly. Set shock body aside. SEAL REPLACEMENT 8. Mount damper rod in soft–jawed vise. Loosen valve nut and clean the valve piston and valving washers with electrical contact cleaner. Dry thoroughly with compressed air. Tighten nut and torque to 12 ft. lbs. (17 Nm). 5.44 1. Remove bearing cap from damper rod. Inspect seals, o– ring, and bushing inside cap. Inspect cap O–ring and replace if torn or damaged. 2. Using a small screwdriver or scribe, pry upper seal, main seal, and O–ring out of bearing cap. Use care to avoid scratching the seal cavity. BODY / STEERING / SUSPENSION Clean seal cavity and inspect bushing for wear or damage and replace bearing cap if necessary. 7. Inspect valve piston ring for wear. The outer surface of the ring should be even in color. Set aside damper rod assembly for reinstallation. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 3. 4. Lubricate new seals and O–ring with Polaris shock oil and install. Be sure the seals are seated completely in the seal cavity. 5. Inspect jounce bumper (where applicable) and replace if damaged. 6. Inspect damper rod for nicks, scratches or abrasion. Install bearing cap and thick backing washer on damper rod. Install compression valve washer stack in same order as disassembly. Install valve piston with greater number of slots facing damper rod nut (toward IFP). Install rebound stack, washer, and a new nut. Torque nut to 12 ft. lbs. (17 Nm). 8. Position shock in vise with Body Clamp Tool . Clean body clamp tool before installing. 5 Shock Body Clamp Tool (PN 2871071) 9. Using an open end or large adjustable wrench, unscrew the body cap from the body. 10. Inspect O–ring in body cap for damage. Valve Nut Torque 12 ft. lbs. (17 Nm) 5.45 BODY / STEERING / SUSPENSION 2. Compress flexible piston ring around valve piston and install piston into shock body. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 11. Note location of Allen screw in internal floating piston (IFP) for reassembly in body tube. Remove IFP through bottom body cap end (external threaded end) using IFP tool. Be prepared to catch piston ring and piston as it comes out. Remove Allen screw from center of piston. Inspect bleeder screw O–ring and IFP sealing O–ring for wear or damage. Replace O–rings upon reassembly. 3. Screw in bearing cap by hand until O–ring is fully seated. 4. Invert shock and mount bearing cap flats lightly in vise. Caution: Verify damper rod is fully extended. 5. Fill with shock fluid to approximately 1" (2.54cm) from end of body. 12. Carefully clean all parts thoroughly with electrical contact cleaner or solvent and dry with compressed air. Inspect shock body for scratches or wear. FOX™ Front Shock Assembly 1. Install bleeder screw in IFP until O–ring is lightly seated. NOTE: Bleeder screw must be positioned toward body cap (externally threaded) end of shock body. Gas Shock Oil - 5 wt. 2870995 - Quart 2872279 - 2.5 gallon 5.46 BODY / STEERING / SUSPENSION 6. Insert IFP. 10. Remove IFP bleeder screw. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Remove 7. Install body cap until O–ring is lightly seated. 8. Mount shock in vise by top eyelet as shown. Support shock and strike body cap end 2–3 times with a soft faced hammer to remove all air trapped inside the valve piston. Allow shock to stand for 3–5 minutes. 11. Set IFP tool to specified depth with a dial caliper as shown. 5 CAUTION Do not over–tighten vise or bearing cap may be damaged. 9. Unscrew body cap and remove. IFP Tool: (PN 2871351) 12. Insert IFP tool and slowly push IFP to specified depth. Place a shop towel over the end of IFP tool to catch any spilled shock oil. 5.47 BODY / STEERING / SUSPENSION 16. Install pressurizing valve with new O–ring and tighten securely. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 13. With the IFP set and the bleeder screw removed, slowly stroke shock to force air through piston orifice. Move the shock body slowly to prevent aeration of the oil. Allow all air to purge through the bleeder screw hole. 14. Install the bleeder screw with a new O–ring and tighten securely, using the flats on the tool to prevent the IFP from turning. Pour out excess oil. It is not necessary to completely clean all oil from the nitrogen chamber, a small amount of oil will lubricate the IFP. Verify the proper IFP depth to within ± .025” (.63mm) with a dial caliper. Be sure to measure to the flat portion of the IFP, not to the tapered outer edge. 17. Set the nitrogen tank pressure regulator to 200 – 205 PSI. 18. Insert the FOX™ Charging Needle (PN 7052069) and charge with nitrogen to 200 PSI. Pull the needle straight outward and remove from the pressurizing valve while holding the pressure hose on the fitting. Do not insert the needle again to check pressure as the volume inside the gauge will reduce pressure in the shock. 15. Reinstall body cap with a new O–ring and tighten by hand. Mount shock with body cap end down in the soft jaws of a vise. Torque bearing cap to 8–10 ft. lbs. (11–14 Nm). This will also tighten the body into the body cap. CAUTION Do not over tighten or damage to the bearing may result. Bearing Cap Torque 8 - 10 ft. lbs. (11- 14 Nm) 5.48 Shock Recharging Kit - PN 2200421 BODY / STEERING / SUSPENSION Gas Charge Pressure: 200 psi 19. As a final check, push the damper rod through a full stroke. The damper rod must bottom out at full travel, and then slowly rise to full extension. Shaft movement must be smooth and consistent throughout the entire compression and rebound stroke, without binding or loss of damping. Shock Eyelet Replacement Top Shock Eyelet Damper Rod Holding Tool (PN 2871352) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m If shock eyelet is removed for damper rod replacement, clean the threads of eyelet and damper rod thoroughly with LoctiteTM Primer N. Apply LoctiteTM 262 to threads before assembly. 5 20. To check for leaks, submerge the shock in water and look for bubbles or oil seepage around the bearing and body caps. 21. When reinstalling shocks on the machine, torque only to required specifications. If the shock is over tightened it will not pivot, possibly resulting in damage to shaft and seals. 22. When installing IFS shocks, tighten top mount first. Pivot shock body into lower mount and determine if spacer washers are necessary to prevent twist or side loading of shock. Suspension assemblies should always be moved through entire travel without springs to verify free movement and proper alignment of all components. 5.49 BODY / STEERING / SUSPENSION FOX™ PODIUM X SHOCK SERVICE SHOCK VALVING General Service Information Recommended Service Intervals FOX™ Racing Shocks will perform the best if serviced at regular intervals: • Every ride - Wash and dry the vehicle and suspension. • Every 100 hours - Visually inspect shock seals REBOUND 1.300 x 0.006 1.250 x 0.006 1.300 x 0.006 1.250 x 0.006 0.700 x 0.008 0.700 x 0.006 1.250 x 0.006 1.250 x 0.006 1.100 x 0.006 1.100 x 0.006 1.000 x 0.010 0.900 x 0.008 0.900 x 0.012 0.800 x 0.008 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m • Every 500 hours or Annually - Change shock oil and seals. COMPRESSION 0.800 x 0.008 0.700 x 0.008 1.230 x .082 Top-Out 0.620 x .093 Back-Up Piston Orifice: 0.078 Rear Shock Service Information (450 “MXR” / 525 “S”) SHOCK DESIGN DETAILS 5.03” Extended Length 450: 19.03” 525: 19.53” IFP Location 2.50” Nitrogen Pressure 200 psi Gas Shock Oil 2870995 (qt.) Body Material Steel SHOCK VALVING Front Shock Service Information (450 “MXR”) COMPRESSION REBOUND 1.600 x 0.010 1.425 x 0.010 SHOCK DETAILS 1.600 x 0.010 1.350 x 0.010 1.425 x 0.010 1.250 x 0.010 1.425 x 0.010 1.100 x 0.010 1.350 x 0.012 0.950 x 0.010 Travel 6.02” Extended Length 17.98” Compression Length 11.96” Dead Length 5.95” IFP Location 2.50” Nitrogen Pressure 200 psi Gas Shock Oil 2870995 (qt.) Body Material Aluminum 5.50 Travel 1.250 x 0.015 0.800 x 0.020 1.100 x 0.015 0.750 x .100 Back Up 1.100 x 0.015 0.950 x 0.015 1.570 x .128 Top-Out Piston Orifice 0.052 BODY / STEERING / SUSPENSION FOX™ PODIUM X Shock Rebuild Information When performing maintenance on FOX™ shocks, use the Gas Shock Recharging Kit (PN 2200421), as it contains the necessary valves, pressure gauge, and fittings to deflate and pressurize shocks. Special Tools Required: Body Holding Tool (PN 2871071) Charging Needle (PN 7052069-A) Gas Shock Recharging Kit (PN 2200421) FOX™ Shock IFP Tool (PN 2871351) Seal Installation Bullet Tool (PN 2201640) (PN 2201639) WARNING P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m FOX™ shocks contain high pressure nitrogen gas. Extreme caution must be used while handling and working with FOX™ shocks and related high pressure service equipment. The pressure must be released from the shock before disassembly. It is strongly recommended you wear safety glasses and ear protection during these procedures. TIP: Extreme cleanliness is very important during all disassembly and reassembly operations. This prevents dirt or foreign particles from entering the shock, which causes premature failure. 1. Safety Glasses 2. Latex Gloves 3. Lint Free Towels 4. Assembly Lube (lithium based grease) 5. Loctite #271 6. 12” Tie Wrap (Zip Tie) 7. MAPP Gas or Propane Torch 8. 1.834 TC Seal Kit 9. 5wt. Shock Fluid 5 10. IFP Depth Setting Tool 11. Seal Installation Bullet (5/8”) 12. Nitrogen Safety Needle 13. 5/8” Shaft Clamps 14. Adjustable Wrench 15. Pin Spanner Wrench (3/16” Pins) 16. 3/32” Hex Key (Allen Wrench) 17. 5/32” Hex Key (Allen Wrench) 18. Scribe or Dental Pick 19. 1/4” Flat Blade Screwdriver 20. #2 Phillips Screwdriver 21. 3/4” Open End Wrench 22. Standard Pliers 23. Small Needle Nose Pliers 24. Snap Ring Pliers 25. Socket 26. Torque Wrench 27. Torque Driver 28. Soft Faced Rubber Mallet 29. Nitrogen Tank w/ Regulator 30. Cleaning Solvent 31. Vise with soft jaws 32. Tape Measure 5.51 BODY / STEERING / SUSPENSION FOX™ Podium X Shock Disassembly Figure 2 NOTE: Read through all of these instructions first to familiarize yourself with the rebuild procedure. Make sure you have a clean work area, and all of the necessary tools are available. Always use proper safety equipment when working on shock absorbers. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m NOTE: Clean the entire shock assembly with soapy water. Try to remove as much dirt and grime as possible by scrubbing with a soft bristle brush. Never pressure wash your shock, as this can force water and debris inside which will damage the seals. Dry the shock assembly with compressed air, if available, or use clean towels. 1. If your shock DOES NOT have a spring installed, skip to Step #4. Measure the spring set length (Fig. 1). Record this number. 2. Back the preload adjustment ring off until spring is loose on the body. Remove the lower spring retaining clip. 3. Remove the spring. 4. If the shock has spherical bearings in the body cap or shaft eyelet, remove the reducer bushings and o-rings from both ends of the shock. If your shock has polyurethane bushings and sleeves, remove them from both ends of the shock (Fig. 1). 6. Clean the entire shock assembly with soapy water. Try to remove as much dirt and grime as possible by scrubbing with a soft bristle brush. Never pressure wash your shock, as this can force water and debris inside which will damage the seals. Dry the shock assembly with compressed air, if available, or use clean towels. 7. Use a 3/32” Hex Key to remove the button head screw from the FOX™ air valve in the reservoir end cap. 8. Securely clamp FOX™ Nitrogen Safety Needle in vise. CAUTION Figure 1 Point air valve away from face and body when charging or discharging any shock. 9. Insert the FOX™ Safety Needle squarely into center of gas valve (Fig. 3). Figure 3 5. Note and record the setting on the Compression Adjuster Screw. Using the Flat Blade Screwdriver, count the clicks as you turn the adjuster clockwise until it stops (Fig. 2). Once you have written this number down, turn the screw all the way counterclockwise until it stops. 10. Using a blunt object, depress the air valve core to release pressure. 11. When the shock is fully discharged, pull reservoir away from the FOX™ Safety Needle in a straight, smooth motion. 5.52 BODY / STEERING / SUSPENSION 12. Clamp the body cap of the shock securely in vise with shaft side up. 13. Gently tap the reservoir end cap with a rubber mallet to expose the wire retaining ring. Locate the end of the ring and push inward with fingertip. Remove the retaining ring. A scribe or dental pick can also be used for this step, but use extreme caution not to scratch the bore of the reservoir tube (Fig. 4). 17. Align the slot of the IFP Depth Setting Tool with the end of the IFP (Internal Floating Piston). Engage the IFP by rotating the tool 90 degrees (Fig. 6). Gently pull the IFP out of the reservoir tube using the IFP Depth Setting Tool, and place it on a clean, lint free towel. Remove the shock from the vise and pour shock oil from body and reservoir tubes into a proper disposal container. DO NOT RE-USE OLD SHOCK OIL. Figure 6 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Figure 4 14. Use pliers to grab flats of the gas valve of reservoir cap. Extract cap from reservoir tube using a rocking or twisting motion. Set reservoir cap aside on a clean, lint free paper towel. 15. Use the appropriate size wrench to loosen the bearing assembly (Fig. 5). Unscrew the bearing assembly completely from the body tube. Remove the shaft assembly from the body tube, and place on a clean, lint free paper towel. Remove the shock from the vise and pour shock oil from body tube into a proper disposal container. NOTE: DO NOT RE-USE OLD SHOCK OIL. Figure 5 5 18. Using the 1/8” Hex Tool, remove the IFP bleed screw from the IFP. 19. Clean the body tube, reservoir tube, and the IFP using solvent. Dry with compressed air in a well ventilated area. If compressed air is not available, dry parts using clean, lint free paper towels and let sit in a well ventilated area to allow the solvents to evaporate. 20. Set body assembly aside on a clean, lint free paper towel. 21. Clamp the shaft eyelet securely in vise with the piston end up. 22. Using a 9/16” wrench, remove the piston lock nut from the end of the shaft. 23. Hold the tip of a phillips head screwdriver against the end of shaft. Hold the piston assembly under the top-out plate and lift upwards (Fig. 7). Slide the piston assembly onto the shaft of the Screwdriver. Pull the Screwdriver away from shock shaft while supporting the piston assembly. Slide a 12” tie wrap through the entire piston assembly. Secure the two ends of the zip tie together and remove the screwdriver. There are many pieces to the piston assembly, and the assembly order of these pieces is critical to the proper performance of your shock. This step ensures that the proper order is kept. Place piston assembly on a clean, lint free paper towel. 16. Clamp the body cap of the shock securely in vise with the open end of the body tube pointing up 5.53 BODY / STEERING / SUSPENSION Figure 9 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Figure 7 24. Slide bearing assembly off of shaft. Use extreme caution not to scratch inside of the bearing assembly when passing it over the threads at end of shaft. 2. Thoroughly clean the bearing housing, and piston assembly with solvent. Dry with compressed air in a well ventilated area. If compressed air is not available, dry parts using clean, lint free paper towels and let sit in a well ventilated area to allow the remaining solvent to evaporate. FOX™ Podium X Shock Rebuild 3. Use a scribe or dental pick to remove the o-ring seal from the IFP. 4. Use a scribe or dental pick to remove the o-ring seals from the reservoir end cap. 5. Install the new, well lubricated, o-rings into the bearing housing. Correct placement of the shaft seal o-ring is in the groove next to the DU bushing. Check to make sure the seals are properly seated, and are not twisted. If a tool is required to aid in proper seating of o-ring, use the nonwriting end of a pen, or a similar soft, blunt object, to push it in. 6. Install the new U-cup seal into bearing. U-cup should be installed so the cupped end is facing the DU bushing inside of bearing. Check to make sure seal is properly seated. If a tool is required to aid in proper seating of U-cup seal, use the non-writing end of a pen, or a similar soft, blunt object, to push it in (Fig. 10). 1. Use a scribe or dental pick to remove the u-cup wiper (Fig. 8) and o-ring seals (Fig. 9) from the bearing housing. Be careful not to scratch the seal grooves or the DU bushing that is pressed into the bearing. Figure 8 IMPORTANT: Use extreme caution when using a scribe to remove seals. Always ”spear” the seal with the point of the scribe. Do not wedge the point of the scribe in behind the seal. This can scratch the surface of the seal groove which will compromise the performance and reliability of the shock absorber. Figure 10 5.54 BODY / STEERING / SUSPENSION 7. Install the scraper in the bearing housing. Check for proper orientation of the scraper in the bearing. The stepped side of the scraper should be visible. 8. Install the new, well greased o-ring onto the IFP 9. Replace the IFP bleed screw o-ring. 8. 10. Install the new, well greased o-rings into the reservoir end cap. Fill the reservoir to the retaining ring groove with the recommended oil. You should see bubbles rising to oil surface. Wait until bubbling slows or stops completely. If oil level has fallen, add more oil until level is at retaining ring groove. Insert IFP into reservoir. Use a smooth motion and push straight in until o-ring seats into the retaining ring groove. Use your free hand to wrap new piston band around IFP with the rounded edge out, and push the IFP into the reservoir. Shock oil will come up through the IFP bleed hole. FOX™ Podium X Shock Assembly Polaris Gas Shock Oil - 5 wt. PN 2870995 - qt. PN 2872279 - 2.5 gal. Clamp shaft eyelet securely in vise, and place seal bullet tool on end of shaft. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. 2. Lubricate the bearing assembly seals with an ample amount of assembly lube. Slide the bearing assembly onto shaft with the scraper facing the eyelet (Fig. 11). This should be done in a single smooth motion to avoid damaging the seals. Figure 11 9. Push the IFP into the reservoir until you have enough oil on top of the IFP so that the bleed hole is under the surface of the oil (Fig. 12). 5 Figure 12 3. Insert the shaft of a Phillips head screwdriver through the center of the piston assembly. The pointed end of the screwdriver should be on the same side as the top-out plate. Cut and remove the tie wrap that was holding the piston assembly together. 4. Hold the piston assembly from underneath the top-out plate and place the end of the screwdriver onto the end of the shock shaft. Slide the piston assembly onto the shaft end. Check to make sure the piston assembly is properly seated, then install the piston lock nut. Torque the nut to 22 ft. lbs. using the torque wrench and 9/16” socket. Remove shaft assembly from vise and set it aside on a clean, lint free paper towel. 5. Clamp the body cap of the shock securely in the vise, with the open end of the body facing up. 6. Using the flat blade screwdriver, turn the compression adjuster screw counter clockwise until it stops turning. 7. Lubricate the new IFP o-ring with an ample amount of assembly lube. 10. Quickly install the IFP Bleed Screw before the oil level drops and tighten it with the 1/8” Hex Tool (Fig. 13). NOTE: The IFP will spin in the reservoir when the screw bottoms. This is OK. Figure 13 11. Using the IFP Depth Setting Tool, push the IFP into the reservoir until it stops. 5.55 BODY / STEERING / SUSPENSION 12. Fill shock body to the bottom of the bearing threads with oil. 20. Add oil to the body tube until the surface of the oil is to the top of the threads inside the body tube. 13. Using the IFP Depth Setting Tool, slowly pull the IFP up to the mid point of the reservoir. Then push it down to the bottom again (Fig. 14). Be careful not to pull the IFP out completely. Also, be careful that the oil level in the shock body does not disappear below the bottom of the body and into the reservoir. If the oil does recede completely from the body, you must remove the IFP and go back to step 7 of reassembly. 21. Pull the damping piston up until it is just below the surface of the oil. Add more oil if necessary. 22. Hold the shaft eyelet with one hand. With other hand, slide the bearing assembly down the shaft until contact with the body is made. Oil will overflow from around the bearing (Figure 16). Figure 16 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Figure 14 14. As you push the IFP down, you should see bubbles rising to the surface inside the body tube. Repeat this process several times until you don’t see any new bubbles inside the body tube. 15. Pull the IFP up until it’s top is approximately 1” from the end of the reservoir and remove the IFP depth setting tool. Again, be sure the oil level in the shock body does not drop below the bottom of the body. If the oil does recede completely from the body, you must remove the IFP and go back to step 7 of reassembly. Add oil if necessary while pulling up on the IFP. 16. Using the flat blade screwdriver, turn the Compression Adjuster Screw clockwise until it stops turning. 17. Fill the body tube with oil approximately 1/4” below the threads. Wrap the new piston band around the piston, making sure the rounded edges face out. Insert the shaft assembly into the body tube. Slowly push shaft into body until piston assembly is approximately 1” below oil surface. 18. Stroke the shaft up and down slowly over about a 1” range until no air bubble rise from the damping piston. Be careful to keep the damping piston at least 1/4” below the surface of the oil during this process. 19. Bring the damping piston up until it is approximately 1/4” below the surface of the oil. Using the mallet, give 2 - 3 sharp blows to the eyelet, driving the damping piston down into the shock body. This opens the valves on the damping piston. You will see the released air bubbles come to the surface of the oil. 5.56 23. Screw the bearing assembly into the body tube by hand, holding the shaft up so that the bearing is in contact with the bottom of the damping piston assembly. Be careful not to cross-thread the bearing assembly. When the bearing will no longer thread in by hand, turn the Compression Adjuster Screw all the way counter clockwise using the flat blade screwdriver. 24. Tighten the bearing assembly using the appropriate size open end wrench. 25. Set IFP depth tool to specified length for the correct IFP depth. Shock IFP Depth (Front & Rear): 2.50” ± .05” 26. Insert IFP depth setting tool into reservoir and engage IFP. Using a long 1/8” hex tool, remove the bleed screw from the center of the IFP. TIP: Apply grease to the end of the hex tool so that the bleed screw sticks to it. This will make it easier to remove it from the IFP. 27. Push the IFP down to the correct depth setting. As you do this, keep the open end of the IFP depth setting tool covered with your hand. Oil will stream through the bleed hole in the IFP as you push it further into the reservoir (Fig. 17). BODY / STEERING / SUSPENSION Figure 17 34. Continue charging with gas as you pull the reservoir away from the FOX™ Nitrogen Safety Needle using a smooth, straight motion. Keep the reservoir as straight as possible to prevent the safety needle from bending. As the safety needle is pulled free from the FOX™ air valve, a popping sound should be heard. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Figure 19 28. Install IFP bleed screw and tighten using the 1/8” hex tool. Remove the IFP depth setting tool. Pour the residual oil out of the reservoir tube into a proper disposal container. 29. Install the reservoir end cap with the FOX™ air valve facing the outside of the reservoir tube. Push down on the reservoir end cap using even pressure, until the retaining ring groove is exposed. Install the wire retaining ring, and check to make sure retaining ring is seated properly. 30. Push the shaft assembly completely into the body tube (Fig. 18). It should go all the way down smoothly and without interference. If it does not, disassemble and reassemble per this procedure. Do not attempt to pull the shaft assembly back out by hand. Figure 18 5 WARNING CHARGE THE SHOCK USING NITROGEN GAS ONLY. DO NOT FILL WITH ANY OTHER GASES. Doing so compromises the performance of the shock and may be EXTREMELY DANGEROUS! 35. Install the button-head screw into the FOX™ air valve, using a 3/32” hex key. 36. Remove the shock from the vise. 37. Clean all oil residue from the shock and reservoir with solvent, and dry with compressed air in a well ventilated area. If compressed air is not available, dry the shock and reservoir using clean, lint free paper towels and let sit in a well ventilated area to allow the solvents to evaporate. 38. Reinstall the spring and the spring retainer. 39. Thread the spring preload ring down against the spring, and set the preload to the measurement you took when you removed the spring. 31. If reservoir cap is not properly seated against the retaining clip, tap it gently with a rubber mallet until it snaps into place. Remove shock assembly from vise. 32. Securely clamp FOX™ Nitrogen Safety Needle in the vise. Be sure to point the air valve away from your face and body. 33. Insert the safety needle squarely into center of FOX™ air valve, and pressurize the reservoir. Continue filling until the shaft has fully extended and the reservoir pressure is at 200 psi (Fig. 19). 40. Using the flat blade screwdriver, turn the Compression Adjuster Screw all the way clockwise until it stops. Now turn it counter clockwise while counting the clicks until it matches the original setting which you wrote down during disassembly. 41. Remove the shock from the vise. 42. Reinstall spherical bearing o-rings and reducers or polyurethane bushings and sleeves. NOTE: After installation, be sure to RIDE SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 5.57 BODY / STEERING / SUSPENSION FOX™ PODIUM-C SHOCK SERVICE COMPRESSION (525 “IRS”) General Service Information *Note direction of valve piston before disassembly. The side with the greater number of slots should face the IFP (nut end of the shaft). Piston Orientation Toward Shaft (Fewer slots) Side with greater # of slots must face nut end (Toward nut &IFP) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Slots Orifice REBOUND (525 “IRS”) Piston* Orifice must be drilled to required size on replacement valve pistons FOX™ PODIUM-C Rear Shock Standard Valving Piston Orifice = .120” Changing oil on FOX™ Shocks is recommended annually and should be included when performing end of season storage preparation. For competition use, shocks should be disassembled, inspected and serviced more frequently. FOX™ PODIUM-C Rear Shock Details (525 “IRS”) 5.58 BODY / STEERING / SUSPENSION FOX™ PODIUM-C Rebuild Information SHOCK REBUILD SERVICE TOOLS 8 When performing maintenance on FOX™ shocks, use the Gas Shock Recharging Kit (PN 2200421), as it contains the necessary valves, pressure gauge, and fittings to deflate and pressurize shocks. 1 10 9 3 WARNING 7 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m FOX™ shocks contain high pressure nitrogen gas. Extreme caution must be used while handling and working with FOX™ shocks and related high pressure service equipment. The pressure must be released from the shock before disassembly. It is strongly recommended you wear safety glasses and ear protection during these procedures. TIP: Extreme cleanliness is very important during all disassembly and reassembly operations. This prevents dirt or foreign particles from entering the shock which causes premature failure. 5 4 2 4 6 1. Torque Wrench 2. IFP Depth Set Tool (PN 2871351) (FOX™ # 803-00-294) 3. Hex Keys 4. Seal Picks 5. Charging Safety Needle (PN 7052069-A) (FOX™ # 802-02-001-A) 6. Ruler 7. Seal Bullet Tool (PN 2201640), (PN 2201639) (FOX™ # 398-00-026-B) 8. Socket 9. Crows Foot (1 3/8”) 10. Body Cap Socket 5 Items not shown: Polaris Gas Shock Oil - 5 wt. (PN 2870995) Body Clamps (PN 2871071) (FOX™ # 803-00-287) Assembly Grease (FOX™ # 025-01-013) Gas Shock Recharging Kit (PN 2200421) 5.59 BODY / STEERING / SUSPENSION FOX™ PODIUM-C Shock Disassembly Remove the bushings and steel sleeves from the eyelet. 2. Clean the entire shock and set the compression adjuster to the fully open position. 3. Use a 3/32” Hex Key to remove the button head screw from the FOX™ air valve located on the shock body. 4. Using a 1 3/8” wrench, loosen and unscrew the bearing assembly from the shock body. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. 7. 8. Remove the shaft assembly from the body tube and place it on a clean, lint free rag or towel. 9. Dispose of the used shock oil. Securely clamp a FOX™ Nitrogen Safety Needle in the vice. Insert the safety needle squarely into the center of the gas valve discharging the nitrogen from the shock. 10. Clamp the shock body in the vice using a set of Body Clamps making sure not to crush the shock body. Use a propane torch to lightly heat the Body Cap so that the Loctite softens. IMPORTANT: Ensure that all pressure has been released. 5. Inspect the FAV2 nitrogen valve for signs of wear such as holes on the face of the rubber pellet. Replace if necessary. 6. Clamp the body end eyelet of the shock securely in a soft jawed vice with the shaft side up. IMPORTANT: Too much heat might damage the body or body cap. 5.60 BODY / STEERING / SUSPENSION 11. Use a crescent wrench or body cap socket to remove the body cap from the shock body. 17. Using a 9/16” wrench, remove the piston lock nut from the end of the shaft. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 18. Slide the piston assembly onto a T-Handle wrench or zip tie to preserve the shim stack / piston order. Remove and discard the step cut piston band. 12. Pull the IFP out of the shock body using the IFP depth setting tool. 5 19. Slide the bearing assembly off the shaft. 13. Remove the bleed screw from the IFP using a 1/8” THandle Hex Key. Discard the bleed screw O-ring, IFP O-ring and IFP band. 14. Clean and dry the IFP. 20. Remove and discard the body cap o-ring. Clean and dry the body cap. 15. Remove the body assembly from the vice and clean its internals. Set aside on a clean, lint free rag. 21. Remove all seals and wipers from the bearing housing, carefully not to damage the sealing surface. 16. Clamp the shaft clevis in the vice with the piston end up. 22. Check the condition of the shaft bumper, replace if necessary. 23. Proceed to “Shock Assembly” instructions. 5.61 BODY / STEERING / SUSPENSION FOX™ PODIUM-C Shock Assembly Install new wiper, seal and O-rings onto the bearing housing, lightly grease the new seals with FOX™ assembly grease before installing. 2. Place the shaft bullet tool onto the end of the shaft and apply FOX™ assembly grease to both the tool and shaft. Install the piston and shim stack assembly onto the end of the shaft. Torque the piston lock nut to specification. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. 5. =T Piston Lock Nut: 22 ft. lbs. (30 Nm) 3. Slide the bearing housing over the bullet tool, onto the shaft. Once bearing is installed, remove the bullet tool. 4. Install a new piston band on the piston. 5.62 6. Slide the shock body over the piston shaft assembly, ensure that the piston band is seated correctly. 7. Thread the bearing assembly into the shock body by hand until the O-ring is seated against the body. 8. With the shaft fully extended, clamp the shock in the vice by the shaft clevis. BODY / STEERING / SUSPENSION Fill the shock body with Polaris Gas Shock Oil (PN 2870995) to approximately ½ full. 13. Insert the IFP into the shock body with the dished side facing down. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 9. = 14. Using a ruler and the IFP Depth Set Tool, set the IFP depth, to 1.800" measured from the top of the body, you should feel slight resistance from the oil bleeding out from the IFP. Polaris Gas Shock Oil - 5 wt. 2870995 (Quart) 2872279 (Gallon) 10. Slowly stroke the shock body to purge the air from the piston shim stack, allow a few minutes for the air to escape. 11. Clamp the shock by the flats of the bearing housing in the vice with the open end of the body facing up. Fully extend the shaft and add oil as needed. IFP Depth: 1.80” 15. Lube and replace the IFP bleed screw O-ring. While holding the IFP with the depth setting tool, install the IFP bleed screw using a 1/8” T-Handle Hex Wrench. 12. Lube and install the IFP O-ring and piston band using the FOX™ assembly grease. 5.63 5 BODY / STEERING / SUSPENSION 16. Discard the excess oil that remains above the IFP. 20. Using a 1 3/8" wrench, torque the bearing cap to specification. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 17. Lube and install the new body cap O-ring. Apply Green Loctite 638 ® to the first two threads of the shock body. Thread the body cap onto the body and hand tighten. =T 18. Clamp the body in the vise using the body clamps. Try to find the location on the body where the IFP is located for higher clamping resistance. Do not over tighten. IMPORTANT: Too much damage the body tube. clamping force could Bearing Cap: 30 ft. lbs. (41 Nm) 21. Fill the shock reservoir with nitrogen to 200 PSI by inserting the safety needle squarely into the center of the FOX™ air valve. 19. Using a crescent wrench or body cap socket, torque the body cap to specification. Nitrogen Pressure: 200 PSI =T Body Cap: 75 ft. lbs. (102 Nm) 5.64 22. Install the button head screw into the FOX™ air valve using a 3/32” Hex Key. 23. Lube and install the bushings and steel sleeves into the clevis. BODY / STEERING / SUSPENSION P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 24. Set the compression adjuster to 12 clicks out from fully closed. 5 25. Ensure shock function before riding the vehicle. 5.65 BODY / STEERING / SUSPENSION P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m NOTES 5.66 BRAKES CHAPTER 6 BRAKES BRAKE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 BRAKE CALIPER EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 BRAKE SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m HYDRAULIC SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 FRONT BRAKE SYSTEM - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 REAR BRAKE SYSTEM (“MXR” / “S”) - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . 6.6 REAR BRAKE SYSTEM (“IRS”) - EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 BRAKE FLUID REPLACEMENT AND BLEEDING PROCEDURE. . . . . . . . . . . . . . . . . . 6.9 FRONT MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11 BRAKE LEVER POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 CALIPER REMOVAL AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 PAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18 6 FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18 DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18 DISC REMOVAL / REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18 REAR CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19 CALIPER REMOVAL (“MXR” / “S”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19 CALIPER REMOVAL (“IRS”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20 CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20 CALIPER INSPECTION / REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21 CALIPER INSTALLATION (“MXR” / “S”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22 CALIPER INSTALLATION (“IRS”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23 REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23 PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23 PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24 BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25 REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25 DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25 DISC REMOVAL / REPLACEMENT (“MXR” / “S”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26 DISC REMOVAL / REPLACEMENT (“IRS”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26 DISC INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 BRAKES SQUEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 POOR BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 LEVER VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 BRAKES LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 6.1 BRAKES BRAKE SPECIFICATIONS General Specifications FRONT BRAKE CALIPER Item Standard Service Limit Brake Pad Thickness .298″ / 7.6 mm .180″ / 4.6 mm Brake Disc Thickness .158” / 4.013 mm .140″ / 3.556 mm – .002″ / .051 mm P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Brake Disc Thickness Variance Between Measurements Brake Disc Runout – .010″ / .254 mm RH Handle Bar Master Cylinder I.D. – .551” / 14 mm REAR BRAKE CALIPER Item Standard Service Limit Brake Pad Thickness .298″ / 7.6 mm .180″ / 4.6 mm Brake Disc Thickness .158” / 4.013 mm .140″ / 3.556 mm Brake Disc Thickness Variance Between Measurements – .002″ / .051 mm Brake Disc Runout – .010″ / .254 mm Master Cylinder I.D. – Aux. Rear .500” / 12.7 mm Torque Specifications ITEM Front Caliper Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Front Master Cylinder Reservoir Cover Bolts Brake Line Banjo Bolts Brake Disc Mounting Bolts Wheel Mounting Nuts Front Master Cylinder Clamp Bolts Rear Caliper Bleed Screws Front Caliper Bleed Screws Front Spindle Nut Rear Hub Nut TORQUE (ft. lbs. except where noted) TORQUE (Nm) 38 18 8 11 (in. lbs.) 15 18 30-35 85 (in. lbs.) 47 (in. lbs.) 47 (in. lbs.) 40 90 52 24 11 1.24 20 24 41-47 9.6 5.3 5.3 54 122 NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures are used when torquing certain bolts and fasteners. Special Tools 6.2 Part Number Tool Description 2870975 Mity Vac™ BRAKES BRAKE CALIPER EXPLODED VIEWS Front Brake Caliper Assembly Apply Polaris DOT 4 Brake Fluid to Component 47 in. lbs. (5.3 Nm) B A C E Apply Polaris All Purpose Grease F G D P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m H J D A. Adjustment Set Screw B. Bleeder Screw C. Caliper Assy. D. Boot E. Square O-ring (thick) F. Square O-ring (thin) G. Piston H. Caliper Mount J. Brake Pads 6 Rear Brake Caliper Assembly K Apply Polaris DOT 4 Brake Fluid to Component J 47 in. lbs. (5.3 Nm) E H Apply Polaris All Purpose Grease F C A D A. Caliper Mount B. Brake Pads C. Piston D. Caliper Assy. E. Square O-ring (thick) F. Square O-ring (thin) G. Boot, Pin Bushing H. Boot, Pin Seal J. Bleeder Screw K. Adjustment Set Screw G B 6.3 BRAKES BRAKE SYSTEM OVERVIEW Hydraulic System Operation E C F B P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m A D G Typical Hydraulic Brake System The Polaris brake system consists of the following components or assemblies: brake lever; master cylinder; hydraulic hose; brake calipers (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 piston moves inward it closes a small opening (compensating port) (C) within the cylinder and starts to build pressure within the brake system. As the pressure within the system is increased, the piston (D) located in the brake caliper moves outward and applies pressure to the moveable brake pad. This pad contacts the brake disc and moves the caliper in its floating bracket, pulling the stationary side pad into the brake disc. The resulting friction reduces brake disc and vehicle speed. As the lever pressure is increased, the braking affect 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 further outward 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 feel spongy. 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 system changes, this port compensates for fluid expansion (heated fluid) or contraction (cooled fluid). During system service, be sure this port is open. Due to the high temperatures created within the system during heavy braking, it is very important that the master cylinder reservoir have adequate space to allow for fluid expansion. Never overfill the reservoir! Fill to 1/4” – 5/16” (.64 – .80 cm) from top 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 the cover. 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 expanding fluid may build pressure in the brake system leading to brake failure. When servicing Polaris ATV brake systems use only Polaris DOT 4 Approved High Temperature Brake Fluid. WARNING Once a bottle of brake fluid 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. 6.4 BRAKES Front Brake System - Exploded View A. Master Cylinder B. Brake Line C. Mechanical Brake Switch D. Front Spindle E. Banjo Bolt & Washers F. Caliper G. Caliper Mount Bolt P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m A B C E B 15 ft. lbs. (20 Nm) 6 B 38 ft. lbs. (52 Nm) 15 ft. lbs. (20 Nm) G D E F 6.5 BRAKES Rear Brake System (“MXR” / “S”) - Exploded View 18 ft. lbs. (24 Nm) C 15 ft. lbs. (20 Nm) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m B D M H K J B I F A G E L A. Caliper B. Sealing Washer C. Banjo Bolt D. Brake Line E. Clevis Pin F. Master Cylinder Asm. G. Cotter Pin H. Rear Brake Reservoir I. Hose Clamp J. Reservoir Hose K. Brake Pressure Switch L. Brake Pedal Spring M. Brake Line Retainer N. Bushing O. Foot Brake Pedal 6.6 N O BRAKES Rear Brake System (“IRS”) - Exploded View H 18 ft. lbs. (24 Nm) C 15 ft. lbs. (20 Nm) J B I D 15 ft. lbs. (20 Nm) P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m C F B A G K L 6 E M A. Caliper B. Sealing Washer C. Banjo Bolt D. Brake Line E. Clevis Pin F. Master Cylinder Asm. G. Cotter Pin H. Rear Brake Reservoir I. Hose Clamp J. Reservoir Hose K. Brake Switch L. Brake Switch Bracket M. Switch Spring N. Washer O. Bushing P. Torsion Spring Q. Foot Brake Pedal R. Large Washer S. Screw Q O S N O R P 6.7 BRAKES Service Notes Disc brake systems are light weight, low maintenance, and perform well in the conditions ATVs routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life. • Optional pads are available to suit conditions in your area. 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 levels after pad service. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m • Make sure atmospheric vent on reservoirs are unobstructed. • Test for brake drag after any brake system service and investigate cause if brake drag is evident. • Make sure caliper moves freely on guide pins. • Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely. • Perform a brake burnishing procedure after installing new pads to maximize service life. CAUTION Use only DOT 4 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 Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning does not reduce the occurrence of brake noise, check the backing of each pad for worn spots allowing metal to metal contact. See table below: Brake Noise Troubleshooting Possible Cause Dirt, dust, or imbedded material on pads or disc Remedy Spray 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 adjustment Insufficient lever or pedal clearance Master cylinder reservoir overfilled Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston(s) not returning Operator error (riding the brake / park brake applied) Adjust pad stop (front calipers) Check position of controls & switches Set to proper level Clean compensating port Inspect. Repair as necessary Clean 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 6.8 BRAKES Brake Fluid Replacement and Bleeding Procedure NOTE: Do not move brake lever when reservoir fluid level is low. NOTE: When bleeding the brakes or replacing the fluid always start with the caliper farthest from the master cylinder. CAUTION P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Always wear safety glasses during these procedures. CAUTION 5. Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. NOTE: This procedure should be used to change fluid or bleed brakes during regular maintenance. Polaris DOT 4 Brake Fluid 6. Front Brake Caliper Bleeding 1. Clean reservoir cover thoroughly. 2. Remove screws, cover, and diaphragm from master cylinder reservoir. Add brake fluid to the upper level mark on reservoir. Begin bleeding procedure with either front caliper. Install a box end wrench on the caliper bleeder screw. Attach a clean, clear hose to fitting and place the other end in a clean container. Be sure the hose fits tightly on fitting. Bleeder Screw NOTE: Fluid may be forced from compensation port when brake lever is pumped. Place diaphragm in reservoir to prevent spills. Do not install cover. 3. Inspect vent slots in the cover and remove any debris or blockage. 4. If changing fluid, remove old fluid from reservoir with a Mity Vac™ (PN 2870975) or similar tool. 7. Slowly pump brake lever until pressure builds and holds. 8. While maintaining lever pressure, open bleeder screw. Close bleeder screw and release brake lever. NOTE: Do not release lever before bleeder screw is tight or air may be drawn into caliper. 6.9 6 BRAKES 9. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir. Reservoir Cover Torque 11 in. lbs. (1.2 Nm) CAUTION Maintain at least 1/2” (1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder. 1. Remove the seat. 2. Clean rear brake fluid reservoir cover thoroughly. 3. Remove the cap and diaphragm from the reservoir. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 10. Tighten bleeder screw securely and remove bleeder hose. Torque bleeder screw to 47 in. lbs. (5.3 Nm). Rear Brake Caliper Bleeding Reservoir 11. Repeat Steps 5-10 for the remaining front caliper. 12. Add brake fluid to the proper level. “IRS” Location Reservoir Master Cylinder Fluid Level: Add to MAX level inside reservoir. Sight glass must look dark, if sight glass is clear, fluid level is too low “MXR” / “S” Location 13. Install diaphragm, cover, and screws. Torque the screws to 11 in. lbs. (1.2 Nm). 4. If changing fluid, remove old fluid from reservoir with a Mity Vac™ (PN 2870975) or similar tool. 5. Using a funnel, add brake fluid to the MAX level mark on reservoir. Polaris DOT 4 Brake Fluid 6.10 BRAKES 6. Install a box end wrench on the bleeder screw. Attach a clean, clear hose to fitting and place the other end in a clean container. Be sure the hose fits tightly on fitting. FRONT MASTER CYLINDER Brake Lever Position Adjustment Brake lever position can be changed to fit the operator’s hand. “MXR” / “S” Shown P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Loosen the jam nut and turn the adjuster screw in to move the lever closer to the handlebar. Turn the adjuster screw out to move the lever away from the handlebar. Jam Nut Bleeder Screw 7. Slowly pump foot brake lever until pressure builds and holds. 8. While maintaining lever pressure, open bleeder screw. Close bleeder screw and release brake lever. Adjuster Screw NOTE: Do not release lever before bleeder screw is tight or air may be drawn into caliper. Removal 9. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir. 1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components. 10. Tighten bleeder screw securely and remove bleeder hose. Torque bleeder screw to 47 in. lbs. (5.3 Nm). 2. Place a shop towel under brake line connection at master cylinder. Loosen banjo bolt (A); remove bolt and sealing washers. 11. Using a funnel, add brake fluid to the MAX level mark on reservoir. Rear Reservoir Fuild Level: Add to MAX level shown on the outside of the rear reservoir. A B 12. Field test machine at low speed before putting into service. Check for proper braking action and lever reserve. With lever firmly applied, lever reserve should be no less than 1/2” (1.3 cm) from handlebar. 13. Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion. Replace hose if wear or abrasion is found. CAUTION Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 3. Loosen the master cylinder clamp bolts (B) on the handlebar side of the master cylinder. 6.11 6 BRAKES 4. Remove master cylinder from handlebars. Installation 1. Install master cylinder on handlebars. Torque mounting bolts to 85 in. lbs. (9.6 Nm). Torque the top bolt first. Master Cylinder 15 ft. lbs. (20 Nm) Front Brake Line P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 85 in. lbs. (9.6 Nm) Banjo Bolt 15 ft. lbs. (20 Nm) Caliper Mount Bolt 38 ft. lbs. (52 Nm) 15 ft. lbs. Banjo Bolt (20 Nm) Caliper NOTE: To speed up the brake bleeding procedure the master cylinder can be purged of air before brake line is attached. Fill with DOT 4 Brake Fluid and pump lever slowly two to three times with finger over the outlet end to purge master cylinder of air. 2. Place new sealing washers on each side of banjo brake line. Install the brake line into the master cylinder. Torque the brake switch bolt to 15 ft.lbs. (20 Nm). Master Cylinder Assembly Brake Line Sealing Washers Torque to 15 ft. lbs. (20 Nm) Cover Screws 11 in. lbs. (1.24 Nm) Clamp Bolts 85 in. lbs. (9.6 Nm) Master Cylinder Mounting Clamp Bolt Torque: 85 in. lbs. (9.6 Nm) Banjo Bolt Torque: 15 ft. lbs. (20 Nm) 6.12 BRAKES 3. Fill reservoir with DOT 4 Brake Fluid. FRONT CALIPER SERVICE Caliper Removal and Disassembly 1. Clean caliper area before removal. 2. Elevate and support front of machine. Remove the front wheel. CAUTION P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. Polaris DOT 4 Brake Fluid 4. Follow bleeding procedure. Check all connections for leaks and repair if necessary. 3. Place a suitable container under caliper to catch brake fluid draining from brake line. 4. Using a wrench, loosen and remove brake line from caliper. 5. 6 Loosen pad adjuster screw 2-3 turns. 6.13 BRAKES 7. Remove the upper and lower caliper mounting bolts and remove the caliper assembly from the caliper mount. 9. Remove mounting bracket, pin assembly and dust boot. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 6. Push brake pad retainer pin inward and slip brake pads past the edge. 10. Thoroughly clean the brake caliper before disassembly and prepare a clean work area to disassemble the caliper. 11. Use low pressure, compressed air to remove the pistons from the caliper. CAUTION Use caution and always wear safety glasses when working with compressed air. 12. While holding the caliper and covering the pistons with a shop towel, carefully apply compressed air to the brake line inlet to force the pistons out from the caliper. IMPORTANT: Do not remove the caliper pistons with a pliers. The piston sealing surfaces will become damaged if a pliers is used. 8. Remove both brake pads from the caliper. 13. Once the pistons are removed, use a pick to carefully remove the square O-rings from the caliper. O-rings should be replaced during caliper service. 6.14 BRAKES 14. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. 2. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Clean Components Inspect piston for nicks, scratches, pitting or wear. Measure piston diameter and replace if damaged or worn beyond service limit. NOTE: Be sure to clean seal grooves in caliper body. = In. / mm. Caliper Piston O.D.: Std: 1.002” (25.45 mm) Service Limit: 1.000” (25.4 mm) Caliper Inspection 1. Inspect caliper body for nicks, scratches, pitting or wear. Measure bore size and compare to specifications. Replace if damaged or worn beyond service limit. 3. Inspect the brake disc and pads as outlined for brake pad replacement in this section. See “Brake Pad Inspection” earlier in this chapter. Caliper Assembly 1. Install new O-rings in the caliper body. Be sure the grooves are clean and free of residue or brakes may drag upon assembly. Seal Grooves = In. / mm. New O-Rings Caliper Piston Bore I.D.: Std: 1.004” (25.5 mm) Service Limit: 1.006” (25.55 mm) 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance. 6.15 6 BRAKES 3. Lubricate the mounting bracket pins with Polaris Premium All Season Grease (PN 2871423), and install the rubber dust seal boots. FRONT BRAKE PADS Pad Removal 1. Elevate and support front of ATV. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. Remove the front wheel. Loosen pad adjuster screw 2-3 turns. 3. Remove the upper and lower caliper mounting bolts and remove the caliper from the steering knuckle. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 4. 2. Compress the mounting bracket and make sure the dust seal boots are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. Caliper Installation 1. Install caliper and torque mounting bolts. 38 ft. lbs. (52 Nm) 15 ft. lbs. (20 Nm) 2. Install brake line and tighten securely with a line wrench. Torque the banjo brake lines to the proper torque specification. 3. Install the adjuster screw and turn until stationary pad contacts disc, then back off 1/2 turn. 4. Perform brake bleeding procedure as outlined earlier in this chapter. 5. Install wheels and torque wheel nuts to specification. NOTE: When removing caliper, use care not to damage brake line. Support caliper so to avoid kinking or bending brake line. 4. Push caliper piston into caliper bore slowly using a C-clamp or locking pliers with pads installed. NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 6.16 BRAKES 5. Push mounting bracket inward and slip outer brake pad past edge. Then remove inner pad. Pad Assembly Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. 6. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other. WARNING If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new, clean pads. 3. Install caliper onto steering knuckle and torque mounting bolts. 38 ft. lbs. (52 Nm) Measure Pad Thickness 4. Front Brake Pad Thickness New : .298”/ 7.6 mm Service Limit: .180” / 4.6 mm Slowly pump the brake lever until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 6.17 6 BRAKES 5. Install the adjuster screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). FRONT BRAKE DISC Disc Inspection 1. Visually inspect the brake disc for scoring, scratches, or gouges. Replace the disc if any deep gouges are evident. 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0–1” micrometer. Replace disc if worn beyond service limit. 1/2 Turn P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Measure Thickness 6. Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap. 7. Install wheels and torque wheel nuts. Front View NOTE: Refer to Torque Table at beginning of chapter for the front wheel nut torque. Brake Disc Thickness New: .158” (4.013 mm) Service Limit: .140” (3.556 mm) Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise. Start machine and slowly increase speed to 30 mph. Gradually apply brakes to stop machine. Allow pads and disc to cool sufficiently during the procedure. Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times. Side View Brake Disc Thickness Variance Service Limit: .002” (.051 mm) (difference between measurements) 3. Mount a dial indicator and measure disc runout. Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specifications. Brake Disc Runout Service Limit .010” (.254 mm) Disc Removal / Replacement 6.18 1. Remove the front wheel and front brake caliper (see “FRONT BRAKE PADS - Pad Removal”). 2. Remove the wheel hub cotter pin, castle nut, and washer. 3. Remove the wheel hub assembly from the spindle. 4. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. 5. Remove bolts and disc. BRAKES 6. Clean the wheel hub mating surface of disc and hub. REAR CALIPER SERVICE 7. Install new disc on hub. Caliper Removal (“MXR” / “S”) CAUTION 1. Clean caliper area before removal. 2. Using a line wrench, loosen and remove brake line to caliper. Place a container under caliper to catch fluid draining from brake line. Always use new brake disc mounting bolts. The bolts have a pre–applied locking agent which is destroyed upon removal. 8. Install new bolts and tighten to specified torque. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 18 ft. lbs. (24 Nm) 3. Loosen pad adjuster screw 2-3 turns. 6 Image shown with brake line attached. Line should be removed in Step 2. Front Brake Disc Mounting Bolt Torque 18 ft. lbs. (24 Nm) 9. Install wheel hub assembly, washer and castle nut. Torque the front hub castle nut to 40 ft. lbs. (54 Nm) and install a new cotter pin. 10. Install the front brake caliper and front wheel (see “FRONT BRAKE PADS - Pad Assembly”). 11. Field test the ATV for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when lever is released. If the brake drags, re-check assembly and installation. 4. Remove the upper and lower caliper mounting bolts and remove the caliper assembly from the caliper mount. Image shown with brake line attached. Line should be removed in Step 2. 6.19 BRAKES Caliper Removal (“IRS”) Caliper Disassembly 1. Clean caliper area before removal. 1. 2. Using a line wrench, loosen and remove the brake line. Place a container to catch brake fluid draining from brake line. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 3. Push upper pad retainer pin inward and slip brake pads past edge. 2. Remove mounting bracket, pin assembly and dust boot. 3. Remove dust seal and piston seal. Loosen pad adjuster screw 2-3 turns. Image shown with brake line attached. Line should be removed in Step 2. 4. Remove the upper and lower caliper mounting bolts and remove the caliper assembly from the rear housing mount. Image shown with brake line attached. Line should be removed in Step 2. 6.20 BRAKES 4. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. 2. Inspect piston for nicks, scratches, wear or damage. Measure diameter and replace if damaged or worn beyond service limit. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Clean Components 3. Inspect the brake disc and pads as outlined for brake pad replacement in this section. See “Brake Pad Inspection” in this chapter. NOTE: Be sure to clean seal grooves in caliper body. = In. / mm. Caliper Inspection 1. 6 Caliper Piston O.D.: Std: 1.186” (30.12 mm) Service Limit: 1.184” (30.07 mm) Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit. Caliper Reassembly 1. Install new O-rings (A) in the caliper body (B). Be sure groove is clean and free of residue or brakes may drag upon assembly. C = In. / mm. B D Caliper Piston Bore I.D.: Std: 1.192” (30.28 mm) Service Limit: 1.194” (30.33 mm) A 2. Coat piston with clean Polaris DOT 4 Brake Fluid (C). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance. 6.21 BRAKES 3. Lubricate the mounting bracket pins with Polaris Premium All Season Grease (PN 2871423), and install the rubber dust seal boots. Caliper Installation (“MXR” / “S”) 1. Install the caliper assembly over the brake disc and onto the caliper mount. Torque the mounting bolts to specification 15 ft. lbs. (20 Nm) 4. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 18 ft. lbs. (24 Nm) Compress the mounting bracket and make sure the dust seals are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. Brake Caliper Mounting Bolt Torque: 18 ft. lbs. (24 Nm) 2. Install brake line and tighten securely with a line wrench. Torque the brake line banjo bolt to specification. 3. Install the adjuster screw and turn until stationary pad contacts disc, then back off 1/2 turn. 1/2 Turn 4. Perform brake bleeding procedure as outlined earlier in this chapter. Rear Brake Master Cylinder Fluid Level Between MIN and MAX lines 6.22 BRAKES Caliper Installation (“IRS”) REAR BRAKE PADS 1. Pad Removal Install the caliper assembly over the brake disc and onto the rear housing caliper mount. Torque the mounting bolts to specification. 1. Loosen the pad adjuster screw 2-3 turns before removing the brake caliper. “MXR” / “S” Shown P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 15 ft. lbs. (20 Nm) 18 ft. lbs. (24 Nm) Brake Caliper Mounting Bolt Torque: 18 ft. lbs. (24 Nm) 2. Install brake line and tighten securely with a line wrench. Torque the brake line banjo bolt to specification. 3. Install the adjuster screw and turn until stationary pad contacts disc, then back off 1/2 turn. 2. Remove caliper mounting bolts and lift caliper off of disc. “MXR” / “S” Shown 6 NOTE: When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line. 3. 1/2 Turn 4. Perform brake bleeding procedure as outlined earlier in this chapter. With pads installed, push caliper piston into caliper bore (A) slowly using a C–clamp (B) or locking pliers. A B Rear Brake Master Cylinder Fluid Level Between MIN and MAX lines 6.23 BRAKES NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 4. Pad Installation 1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Push upper pad retainer pin inward and slip brake pads past edge. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m “MXR” / “S” Shown 2. 5. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other. “MXR” / “S” Shown WARNING If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new, clean pads. Measure Pad Rear Brake Pad Thickness New: .298” / 7.6 mm Service Limit: .180” / 4.6 mm 6.24 BRAKES 3. Install the caliper assembly over the brake disc and onto the caliper mount. Install the mounting bolts and torque mounting bolts to 18 ft. lbs. (24 Nm). “MXR” / “S” Shown 18 ft. lbs. (24 Nm) Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise. Start machine and slowly increase speed to 30 mph. Gradually apply brakes to stop machine. Allow pads and disc to cool sufficiently during the procedure. Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m REAR BRAKE DISC Disc Inspection 1. Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. Brake Caliper Mounting Bolt Torque: 18 ft. lbs. (24 Nm) 4. “MXR” “S” Install the adjuster screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn counterclockwise. Measure Thickness 6 “MXR” / “S” Shown “IRS” 2. 5. Slowly pump the foot brake lever until pressure has been built up. Maintain at least 1/2” (12.7 mm) of brake fluid in the reservoir to prevent air from entering the rear master cylinder. Use a 0–1” micrometer and measure disc thickness at 8 different points around perimeter of disc. Replace disc if worn beyond service limit. Brake Disc Thickness New: .158” (4.013 mm) Service Limit: .140” (3.556 mm) Auxiliary Brake Master Cylinder Fluid Level Between MIN and MAX lines Brake Disc Thickness Variance Service Limit: .002” (.051 mm) (difference between measurements.) 3. Mount dial indicator and measure disc runout. Replace the disc if runout exceeds specifications. Brake Disc Runout Service Limit: .010” (.25 mm) 6.25 BRAKES Disc Removal / Replacement (“MXR” / “S”) 7. Remove brake disc mounting bolts (4). Refer to Chapter 5 “REAR AXLE SERVICE - Removal / Disassembly” for rear brake disc removal. Disc Removal / Replacement (“IRS”) With ATV on the ground, loosen wheel nuts and hub nuts. 2. Safely lift and support the rear of the ATV under the main frame. 3. Remove right rear wheel and hub. 4. Remove rear caliper and secure out of the way. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. NOTE: Do not allow the caliper to hang by the brake line. Brake line damage may result. 5. 6. Remove right upper carrier bolt and secure upper a-arm out of the way. Tilt right hub carrier outward while pulling rear CV shaft end from carrier assembly. 6.26 8. Lift and rotate disc, slipping it over the hub assembly and off the drive shaft, exiting the frame from the side. Disc Installation 1. Install the disc by slipping it over the over the drive shaft and hub assembly. Disc mounting holes will be on the inside face of the hub assembly for correct installation. 2. Install brake disc mounting bolts. Torque mounting bolts to 18 ft. lbs. (24 Nm). 3. Install CV shaft into hub carrier. 4. Install upper a-arm, bolt and nut on to hub carrier. Torque mounting bolt to 33 ft. lbs. (45 Nm). 5. Install wheel hub, domed washer and nut (dome of washer facing out). Torque hub nut to 90 ft. lbs. (122 Nm). Install cotter pin. BRAKES TROUBLESHOOTING Brakes Squeal • Dirty/contaminated friction pads • Improper alignment • Worn disc • Worn disc splines • Glazed brake pads P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 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 6 • 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 6.27 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m BRAKES NOTES 6.28 ELECTRICAL CHAPTER 7 ELECTRICAL GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 SPECIAL TOOLS / ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 COMPONENT LOCATION (CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 LIGHTING AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 7.3 7.3 7.4 7.4 7.4 7.5 7.5 7.5 7.5 7.6 P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m TRANSMISSION SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB REPLACEMENT / HOUSING REPLACEMENT . . . . . . . . . . . . . . . HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLAMP SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAILLIGHT / BRAKELIGHT LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE LIGHT SWITCH TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TETHER SWITCH TEST (ACCESSORY OPTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDICATOR LAMP REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRONIC THROTTLE CONTROL (ETC) SWITCH / OPERATION TEST . . . . . . . . IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 IGNITION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 DC / CDI IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 CIRCUIT BREAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 CRANKING OUTPUT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 IGNITION SYSTEM BREAKOUT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 IGNITION SYSTEM TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 COMPONENTS OF DC / CDI IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 FAN CONTROL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 FAN SWITCH BYPASS TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 FAN SWITCH “HOT LIGHT” OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13 CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13 CURRENT DRAW – KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR TESTS (CHARGING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING SYSTEM TESTING FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13 7.13 7.14 7.15 7 BATTERY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16 BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OCV – OPEN CIRCUIT VOLTAGE TEST / LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . BATTERY TERMINALS / BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY MAINTENANCE / INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16 7.16 7.16 7.16 7.16 STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17 STARTING SYSTEM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEUTRAL START DIODE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER VOLTAGE DROP TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRUSH INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARMATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER ONE-WAY CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17 7.18 7.18 7.18 7.18 7.18 7.19 7.20 7.20 7.21 7.21 7.22 7.22 7.23 7.1 ELECTRICAL GENERAL INFORMATION COMPONENT LOCATION (CHASSIS) Special Tools 450 “MXR” / 525 “S” PART NUMBER TOOL DESCRIPTION PV-43568 Fluke™ 77 Digital Multimeter 2870836 Battery Hydrometer PV-39951-A Digital Tachometer P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Electrical Service Notes Keep the following notes in mind when diagnosing an electrical problem. • Refer to wiring diagram for stator and electrical component resistance specifications. • When measuring resistance of a component that has a resistance value under 10 Ohms, remember to subtract meter lead resistance from the reading. Connect the leads together and record the resistance. The resistance of the component is equal to tested value minus the lead resistance. • Become familiar with the operation of your meter. Be sure leads are in the proper jack for the test being performed (i.e. 10A jack for current readings). Refer to the Owner’s Manual included with your meter for more information. • Voltage, current, and resistance values included in this manual are obtained with a Fluke™ 77 Digital Multimeter (PV-43568). This meter is used when diagnosing electrical problems. Readings obtained with other meters may differ. • Pay attention to the prefix on the multimeter reading (K, M, etc.) and the position of the decimal point. • For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. • Ignition timing is non-adjustable. 7.2 525 “IRS” ELECTRICAL LIGHTING AND CONTROLS 4. Install the replacement bulb into the headlight housing and rotate firmly clockwise until it locks in place. Transmission Switch Test RED P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m BLK A B 1. Shift the transmission into 1st gear. The ohm meter should show no continuity or OL when testing at points A and B. 2. Shift the transmission into neutral and check for continuity at test point A. Continuity should be present. 3. Shift the transmission into reverse and check for continuity at test point B. Continuity should be present. NOTE: If there is no continuity at either of the wire connections with the transmission in neutral or reverse, remove the switch and inspect the shift drum contact pin and spring for proper function. If no problems are found, replace transmission switch. 5. Reinstall the wire harness to the back side of the headlight bulb. Headlight Housing Replacement 1. Remove the front cover and remove the T27/8mm Hexhead screws from the front portion of each side panel. 2. Lift up on the side panel and loosen the T27/8mm Hex-head screws retaining the headlight brackets and rotate them to free the headlight housing. 3. Remove adjuster screw and pull out the headlight housing. 4. Disconnect the wire harness from the bulb at the back side of the headlight housing. If removing the bulb, refer to “Headlight Bulb Replacement”. 5. Install the new headlight housing, placing it in the slots on the frame tabs. Secure the headlight housing with the retaining brackets. 6. Install adjuster screw, leaving it loose so it can be adjusted. 7. Reinstall wire harness to the back side of the headlight bulb. 8. Reinstall the front cover and adjust headlight as needed (see “Headlight Adjustment”), then tighten the adjuster screw. Headlight Bulb Replacement 1. Remove the front cover. 2. Disconnect the wire harness from the bulb at the back side of the headlight housing. Remove the headlight housing if having trouble gaining access to the bulb (see “Headlight Housing Replacement”). CAUTION Do not service bulb while headlight is hot. Serious burns may result. 3. Grasp the bulb housing and turn it counterclockwise to remove the bulb. IMPORTANT: When servicing a halogen bulb, avoid touching the bulb with bare fingers. Oil from your skin leaves a residue causing a hot spot that will shorten the life of the bulb. If your fingers touch the bulb, clean it with denatured alcohol. 7.3 7 ELECTRICAL Headlight Adjustment Headlamp Switch Test The headlight beam can be adjusted to varied positions by using the following procedures: Probe the headlamp plug wires at the back of the 3-wire connector. Turn headlight on. Test for battery voltage across the connections. 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. • Low Beam - Brown and Green • High Beam - Brown and Yellow 25 ft. (7.6 m) Lamp Center Height If no voltage is found, test for bad connections, switches, or broken wiring. Refer to wire diagram for harness connections. Taillight / Brakelight Lamp Replacement P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 2 in. (5.1 cm) If the taillight / brakelight does not work, disconnect the wire harness and try applying 12 Vdc and a known good ground directly to the LED lamp connector as shown below. NOTE: Vehicle shown is for general representation. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3. Start the engine and turn the headlight switch to high beam. 4. Observe headlight aim. The most intense part of the headlight beam should be aimed 2 in. (5.1 cm) below the mark placed on the wall in Step 2. NOTE: Rider weight must be included on the seat. On machines with separate low beam lights, the drop should be 8 in. (20.3 cm) in 25 ft. from the center of the low beam lamp. 5. Loosen the adjuster screw and adjust the beam to the desired position. If the LED still does not work, replace the LED lamp assembly. 1. Remove the seat and disconnect the taillight / brakelight wire harness (A). 2. Remove the two fasteners (B) retaining the lamp assembly. Adjuster Screw B 6. A B Tighten the screw and torque to 27 in. lbs. (3 Nm). 7.4 3. Remove the assembly and replace it with the recommended lamp. 4. Reinstall the assembly by reversing this procedure. 5. Test the taillight / brakelight after installation to verify proper function. ELECTRICAL Brake Light Switch Tests Foot Brake Switch 1. 2. Connect an ohmmeter across switch contacts. The circuit should have an open line or infinity reading. 3. Apply the clutch lever and check for continuity between switch contacts. Replace switch if there is no continuity or if continuity is greater than .5 ohms when the clutch lever is applied. Disconnect wire harness from switch and connect an ohmmeter across switch contacts. The circuit should have an open line or infinity reading. Tether Switch Test (Accessory Option) Disconnect wire harness from switch and connect an ohmmeter across switch contacts. The circuit should have an open line or infinity reading. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m 1. 2. Apply foot brake and check for continuity between switch contacts. Replace switch if there is no continuity or if continuity is greater than .5 ohms when the brake is applied with slight pressure. Hand Brake Switch 1. Disconnect wire harness from switch and connect an ohmmeter across switch contacts. The circuit should have an open line or infinity reading. 2. Pull tether boot from switch and check for continuity between switch contacts. Replace switch if there is no continuity or if continuity is greater than 0.5 ohms when tether is removed. 7 Indicator Lamp Replacement 1. Remove the fuel cap and carefully push the indicator panel through the front cab from the back side. Indicator Panel 2. Apply front brake lever and check for continuity between switch contacts. Replace switch if there is no continuity or if continuity is greater than .5 ohms when the brake is applied with slight pressure. Clutch Switch Test 1. Disconnect wire harness from switch. 2. Disconnect wire harness from indicator panel. 7.5 ELECTRICAL 3. Remove indicator lamp from the panel by turning the holder 1/4 turn with a screw driver (A). ETC Operation Test Remove throttle block cover by carefully releasing all tabs around edge of cover. Place transmission in neutral and apply parking brake. A Start engine and open throttle lever slightly until engine RPM is just above idle speed. Hold throttle cable with fingers at point “A” (as shown below) and release throttle lever. If the ETC system is functioning properly, the engine will lose spark and stop. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m B 4. Push a new lamp into holder assembly and insert into the indicator panel. Turn holder 1/4 turn to lock in place (B). 5. Reconnect wire harness and insert the indicator panel back into the front cab. Electronic Throttle Control (ETC) Switch (Composite Throttle Housing) ETC switch contacts are closed in a fault Switch contacts are open condition (throttle cable during normal operation slack) Electronic Throttle Control (ETC) Switch The Electronic Throttle Control (ETC) system is designed to stop the engine of an ATV in the event of a mechanical problem with the throttle mechanism. The ETC switch is mounted independent of the throttle actuator lever inside the throttle block assembly. This is a normally closed switch, and is held in the open position (contacts are separated) by throttle cable tension (as shown in the illustration). The contacts are “open” during normal operation regardless of throttle lever position. In the event of a mechanical problem in the throttle mechanism (cable tension is lost), the switch contacts close, connecting the CDI black wire to ground, which prevents ignition spark. This is the same as turning the key or engine stop switch “OFF”. Test the ETC switch at the harness connector. NOTE: Adjust throttle cable freeplay (ETC switch) and make sure throttle mechanism is functioning properly before testing the switch. Refer to Chapter 2 “Maintenance” for cable adjustment procedure. 7.6 A ELECTRICAL IGNITION SYSTEM DC / CDI Ignition Ignition System Troubleshooting Some of the advantages of DC ignition are: No Spark, Weak or Intermittent Spark • Stronger, more consistent spark at low rpm for better performance • No 12 volt power or ground to CDI • Easier starts • Spark plug gap incorrect • Simpler component design for ease trouble shooting and maintenance • Fouled spark plug Operation Overview: The DC/CDI system relies on battery power for ignition function. Instead of generating DC voltage via magnetic induction, a 12 volt DC current is supplied directly to the CDI unit from the battery. P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m • Faulty spark plug cap or poor connection to high tension lead • Related wiring loose, disconnected, shorted, or corroded • Faulty engine stop switch, ignition switch, or tether switch • ETC switch misadjusted or faulty • Poor ignition coil ground (e.g. coil mount loose or corroded) • Faulty pulse coil (measure resistance of value of pulse coil) • Incorrect wiring (inspect color coding in connectors etc) At the CDI, the supplied 12 volt DC current charges an internal capacitor to build up the initial ignition charge. A small AC signal from the Pulse coil closes a thyristor (located in the CDI) at a point pre-determined in the crankshaft rotation by magnets on the flywheel’s outer diameter. This signal releases the electrical charge which saturates the coil for ignition. Circuit Breakers The circuit breaker panel is located underneath the front cab. Access can be gained by removing the front cover and front cab. • Faulty ignition coil winding (measure resistance of primary and secondary) 7 • Sheared flywheel key • Flywheel loose or damaged • Excessive crankshaft runout on magneto (RH) end – should not exceed .005” • Faulty CDI module • Faulty 5 Amp or 10 Amp circuit breaker 10 Amp - System Main 10 Amp - Fan 5 Amp - CDI 7.7 ELECTRICAL Cranking Output Tests The following tests will measure the amount of output directly from each component. Test output from the CDI box and pulser coil and compare to the specification table. The following measurements are obtained when cranking the engine with the electric starter and with the spark plug installed. The starter system must be in good condition and the battery fully charged. 200 Watt 4 Stroke DC/CDI Ignition Connect Meter Wires To: Taken With Standard Volt Ohm Meter Pulser Coil Output Red and Green .13 - .14 VAC CDI Output White/Blue and Ground 200 VDC P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Test Pulser Coil Testing CDI Output Testing 7.8 ELECTRICAL Ignition System Breakout Diagram P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m Ignition Stop Circuits 7 CDI Box Wire Color Description TERMINAL WIRE COLOR TERMINAL DESCRIPTION TERMINAL WIRE COLOR TERMINAL DESCRIPTION P1 - N/A NOT USED P2 - N/A NOT USED P3 - YELLOW TPS SIGNAL P4 - N/A NOT USED P5 - RED PULSER COIL (+) INPUT P6 - N/A NOT USED P7 - BLUE TPS 5 VOLT REF. OUTPUT P8 - GREEN PULSER COIL (-) INPUT P9 - BLACK IGNITION STOP GROUND INPUT P10 - BROWN P11 - VIOLET REVERSE SIGNAL INPUT P12 - RED / WHITE BATTERY (+) VOLTAGE P13 - BROWN GROUND INPUT P14 - WHITE / BLUE CDI OUTPUT TO IGNITION COIL P15 - N/A NOT USED P16 - N/A TPS GROUND OUTPUT NOT USED 7.9 ELECTRICAL Ignition System Testing Whenever troubleshooting an electrical problem, first check all terminal connections to be sure they are clean and tight. Use the following flow chart as a guide for troubleshooting a “No Spark” condition. Condition: No spark or intermittent spark. 5HSODFHWKHVSDUN SOXJDQGUHFKHFN IRUVSDUN 9HULI\EDWWHU\YROWDJHLVSUHVHQWRQWKH5HG:KLWH ZLUHDWWKH&',ER[,VYROWDJHSUHVHQW" &KHFNYROWDJHDWEDWWHU\ ,QVSHFWZLULQJEHWZHHQ&',DQGFLUFXLWEUHDNHUV &KHFNWKHFRQGLWLRQRIWKH$PSFLUFXLWEUHDNHU 1R P a 87 rt 7- Sh 99 a r 9- k. 56 co 86 m
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