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Download polaris service manual
Polaris Atv Repair Manual. Download polaris service manual
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Polaris Breeze Owner's Manual. Polaris Hawkeye Owner's Manual. Polaris Magnum 2x4 Service Manual. References Admin. There are illustrations in the repair manual of component breakdown. Do you have a sportsman Polaris Scrambler 50 cc parts manual.
There are part-breakdown diagrams and schematics in the repair manual. Body Assembly, Exploded View Page Body Assembly Exploded View - projex inbox. Pull release lever at the rear of the seat Lift and pull seat rearward, disengaging seat from tabs at the rear of the fuel tank Side panels See page 5.
Page Headlight Pod Exploded View - projex inbox. Page Side Panel Removal - projex inbox. Remove seat. Grasp rear of side panel near rear Step 1. Page Steering Assembly, Exploded View - projex inbox. The steering post arm bolt B points up; the rod end bolts A point down. Page A-Arm Replacement - projex inbox. Elevate and safely support vehicle with weight removed from front wheel s. Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud.
Page Rear Suspension Assembly - projex inbox. Page Strut Assembly - projex inbox. Upper Pivot Ball 25 Nm 15 ft. Page Front Strut Cartridge Replacement - projex inbox.
Hold strut rod and remove top nut. Compress spring using strut spring compressor tools. Page Ball Joint Replacement - projex inbox. Loosen front wheel nuts slightly. Page Steering Post Assembly - projex inbox. Hand tighten. Align cotter pin hole. Install cotter pin. Bend both ends of cotter pin around nut in opposite directions. Page Pvt System - projex inbox. PVT System Operation The internal components of the drive clutch and driven clutch control clutch engagement for initial vehicle movement , clutch upshifting and backshifting.
Periodic inspection and main- tenance is required to keep the system operating at peak performance. The following list of items should be in- spected and maintained to ensure maximum performance and service life of PVT components.
Page Pvt Overheating 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. For inspection of clutch components, please contact your Polaris dealer. Poor engine performance. Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Page Pvt Disassembly - projex inbox. Refer to the appropriate parts manual for proper fasteners and fastener placement. See page 6.
Remove or loosen rear cab fasteners as necessary to gain access to PVT outer cover. Remove driven clutch retaining bolt and driven clutch. Use puller if necessary.
Driven Clutch Puller PN 8. Remove driven clutch offset spacers from the transmission input shaft. Keep Spacers In Order 9. Page Pvt Assembly - projex inbox. Inspect PVT inner cover-to engine seal. Replace if cracked or damaged. Seal this edge to cover on engine side 2.
Place a new foam seal on transmission input shaft. Apply RTV silicone sealant to outside edge of inner cover-to-engine seal, to ensure a water tight fit between the seal and the cover on engine side. This is accomplished through weights and a spring inside the unit which react to the centrifugal force applied to the clutch from the engine RPM.
Page Drive Clutch Spring Specifications - projex inbox. To control clutch engagement Gold RPM. The springs which have a higher rate when the clutch is in Silver neutral Page Shift Weights - projex inbox. These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.
Page Shift Weight Inspection All PVT system maintenance repairs must be per- formed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual. Page Drive Clutch Inspection - projex inbox. Page Drive Clutch Disassembly - projex inbox. Using a permanent marker, mark the cover, spider, Mark and moveable and stationary sheaves for reference. Remove cover bolts evenly in a cross pattern, and remove cover plate.
Page Spider Removal - projex inbox. Install clutch in holding fixture and loosen the spider counterclockwise using spider removal tool. Inspect all rollers, bushings and roller pins by pulling a flat metal rod across the roller. Turn roller with your finger. If you notice resistance, galling, or flat spots, replace rollers, pins and thrust washers in sets of three.
Page Drive Clutch Assembly - projex inbox. The Teflon bushings are self-lubricating. Do not apply oil or grease to the bushings. Page Drive Belt Tension - projex inbox. Torque cover bolts evenly to specification. Spider Torque: ft. Mark drive belt direction of rotation so that it can be installed in the same direction. NOTE: Normally positioned so part numbers are easily read. Page Drive Belt Installation - projex inbox. Measure belt length with a tape measure around the outer circumference of the belt.
Belts which measure longer than nominal length may require driven shimming or engine adjustment for a longer center distance to obtain proper belt deflection. Page Drive Clutch Bushing Service - projex inbox. Part Description Part No.
Turn sheave puller barrel together counterclockwise on puller rod until bushing is removed. Remove nut from puller rod and set aside. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard. Install main adapter Item 8 on puller.
From outside of clutch cover, insert removal tool Item 3 into cover bushing. With inside of cover toward vise, slide cover onto puller. Apply Loctite retaining compound to the back side of new bushing.
Working from inside of cover, insert bushing and bushing installation tool into center of clutch cover. One must always be installed. Apply and hold downward pressure on the helix, or place driven clutch in compressor tool PN Check alignment of tabs on spring. Replace the spring if tabs are misaligned or the spring coils are distorted. Tabs Aligned 6. Inspect ramp buttons in the moveable sheave and replace if worn.
Re- fer to bushing replacement in this chapter. Page Driven Clutch Assembly - projex inbox. Install moveable sheave with spacer washers. Important: At least one spacer washer must be installed. Teflon bushings are self-lubricating. Install spring, inserting spring tab into proper hole in moveable sheave. In order to remove the bushing it will be necessary to apply heat. A press can be used to remove and install some of the bushings.
Working from the top, install bushing removal tool Item 5 into center of clutch sheave with smaller diameter toward bushing to be removed. Bushing Removal Tool 5 6. Working from the top, insert adapter number ten onto puller. See illustration at right. Start new bushing evenly in moveable sheave. Install nut onto puller rod and hand tighten against installation tool.
Turn clutch sheave counterclockwise until bushing is seated. Because of the critical nature and precise balance of components within the PVT system, it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures.
Page Ebs Exploded View - projex inbox. Rotate one-way clutch clockwise as viewed from the cover plate side. The clutch should rotate on the shaft with only slight amount of drag. There should not be any binding or rough spots. Page Moveable Sheave Bushing Inspection - projex inbox. Remove moveable sheave. Lift one-way clutch off shaft. Replace as an assembly if worn, damaged, or if problems were noted on page 6.
Inspect surface of shaft for pitting, grooves, or damage. Review all information below before proceeding. Push helix inward. Remove snap ring, washer, helix, and spring. The spring is a compression spring only and has no torsional wind. NOTE: Rotating the moveable sheave so that the roll- ers are not in contact with either helix ramp surfaces will lessen the effort needed to push helix inward.
Inspect moveable sheave bushing for wear. Check for movement of the driven clutch shaft in the one-way clutch. Place main adapter Item 8 on puller. Apply Loctitet evenly to bushing bore inside sheave moveable sheave. Install puller adapter Item 10 onto puller. See Ill. Install bushing removal tool Item E into center of clutch sheave. Install main puller adapter Item 8 onto puller. Install adapter reducer Item 9. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear.
Belt burnt, thin -Abuse continued throttle application when -Caution operator to operate machine within guidelines. Page Final Drive - projex inbox. AWD Operation Overview Front Hub Disassembly.
Front Hub Nut Refer to text for procedure Pg 7. Page Awd Operation Overview - projex inbox. If the rear wheels lose traction the front wheel rotational speed will decrease, causing the front drive axle speed to exceed front wheel speed.
Refer to the electrical chapter. Carefully lift and support the front end of the machine as shown with the jack stands under the front end of the foot rests. Thoroughly inspect the hub internally. If the hub bearing sleeve is damaged or shows signs of movement, the hub assembly must be replaced. When the sleeve is pressed into the hub it should be flush with the outside surface of the hub.
Remove fill check plug and rotate hole to either or position. NOTE: Do not force the oil into the hub under pressure. Page Awd Hub Seal Replacement It is very important that the brake disc be free of any oil or solvents. Reinstall the brake disc using genuine Polaris OEM bolts that have a pre-applied locking agent.
Do not substitute bolts or use old ones. Remove the front drive axle as described later in this chapter. Remove the seal sleeve from the strut casting using a drift punch and hammer, tapping evenly on each side until the sleeve slides off. Remove front hub. See page 7. Remove Hilliard clutch assembly. Disassemble the roller clutch and thoroughly clean all parts. If the spring is removed, it will become over stressed and will require replacement.
Page Awd Armature Plate Inspection - projex inbox. As the armature plate is engaged, it should contact the outer magnet pole seal sleeve and the inner magnet pole. Also, the armature plate must be flat when placed on a flat surface.
Bent armature plates should be replaced. Be sure machine is secure before beginning this service procedure. Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint. Driveshaft components are precision parts. Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life. Remove clamps from rubber boot using the proper boot clamp pliers.
Retaining ring 6. Remove the large end of the boot from the CV joint, slide the boot back and separate the wheel spindle and CV joint assembly from the axle shaft by pulling the shaft sharply outward, away from the CV joint.
Disassemble front hub. Refer to page 7. Remove the cotter pin and castle nut from the A- arm ball joint. Separate A-arm from ball joint. If front axle sleeves become damaged and leak fluid they are replaceable. Using a hammer and drift punch, remove the seal sleeve by driving it off evenly being careful not to nick or damage the sleeve mounting area A.
Slide prop shaft back and away from front housing. Pull sharply forward to remove from transmission shaft. Page U-Joint Disassembly - projex inbox. Remove internal or external snap ring from all bearing caps. NOTE:If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting and mark inner and outer yoke for correct re-positioning dur- ing installation.
Page U-Joint Assembly - projex inbox. Force U-joint cross to one side and lift out of inner yoke. Install new bearing caps in yoke by hand.
Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Install outer yoke, aligning marks made before disassembly. Repeat steps to install bearing caps on outer yoke. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown. Page Awd Front Housing Removal - projex inbox. Stop engine, place machine in gear and set parking brake. Loosen right front wheel nuts slightly.
Remove output shaft assembly, large shim, and thrust button with its small shim. Clean all parts and inspect spacers for wear. Inspect ring gear for chipped, broken, or missing teeth. Page Awd Front Housing Assembly - projex inbox. Replace all O-rings, seals, and worn components. Press pinion shaft seal into pinion cover until flush with sealing surface. Polaris Sportsman Service Manual. View and download your vehicles owner's manual by selecting the brand, model year and model of your vehicle.
Polaris Sportsman Xplorer Repair Service Manual PS This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. Written from hands-on experience gained from the complete strip-down and rebuild of a vehicle, Haynes can help you.
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Read Polaris Sportsman Service Repair Manual by km9idisodkmzv on Issuu and browse thousands of other publications on our platform. And after more than two decades out there, your Polaris ATV or is showing some, shall we say, character.
Most of the recounted accidents connected to ATVs are a direct and indirect end result of the ATV rider's negligence, abuse of alcoholic stuff and indiscipline. Written from hands-on experience gained from the complete strip-down and rebuild of a vehicle, Haynes can Clear and easy to follow page layout Full procedures written from hands-on experience.
Polaris Sportsman Xplorer Repair Service Manual PS This manual presented for you in electronic format you can just print out the page you need then dispose of it when. Owner's Manuals. Password is: Polaris Sportsman Service Manual.
Sportsman Keep this book handy in the toolbox. Pizzahutblog: Polaris Sportsman Parts pizzahutblogss. Free Manuals : link at the bottom.
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