Replace if worn past service limit. Remove six cylinder head bolts using a 12 mm socket. Fill selector body with Polaris 0W-40 All Season Synthetic motor oil. Route the wires smoothly and away from any moving parts and secure in place with tie straps. If all of the previous tests indicate a good condition, but the charging voltage does not rise above battery voltage at the connector or terminal board, replace the voltage regulator.
Mark Faces Up Polaris Sales Inc. It is important to note that spring pressure is very light. The tab must be positioned in the notch on the side of the piston as shown A. Clean and reinstall drain plug using a new sealing washer. Insert a pin punch through the sprocket hub and into Alternate Adjustment Method -- Pin Punch the eccentric axle housing. Pour a small amount of clean, high flash point solvent into the intake port and check for leakage around each intake valve.
Install driven clutch spacer and dust seal s. Replace entire tensioner assembly if any part is worn or damaged. Caliper Body Torque 18 ft. Remove hub nut, domed washer and flat washer. Polaris Premium 4 All Season 2.
Note location of chain tensioner cam. Return all wires to the proper terminal on the terminal board according to color after testing. Lubricate front housing O-ring thoroughly with Polaris All Season grease. Reinstall right front and rear mud flap bolt in footrest. Install battery in vehicle with positive terminal toward the front. Brake Caliper Torque: 18 ft.
In order to avoid serious burns, wear some type of insulated gloves for the rest of the removal process. This will provide access to remove transmission out right side of frame. Inspect bearings for smooth operation. Inspect the return spring for distortion or damage. Remove cotter pin and nut. Refer to Illustration on following page.
Electrical tape can be applied to all shafts to protect seals during installation. Remove nut, disc assembly, and stop ring. Remove electrical tape and liberally apply anti-seize compound to the threads of the front output housing. In some applications, such as the engine, warranty coverage may become void if other brands are substituted. Adjust air screw for best throttle response and smooth idle. Change fluid every 2 years. Remove nut from puller rod and set aside.
Operate vehicle at a speed greater than indicated on speedometer past point where needle is stuck. Screw and Washer Assembly 6. Remove brush terminal end of housing while holding other two sections together. One Way Valve Spring Free Length: Std: 1. If you have your machine torn apart and are needing to order parts this is the book that includes the part numbers for each item as well as detailed illustrations showing what parts you need and how it goes back together. Refer to the chart on next page to perform voltage drop tests on the starter system. Ring Gear Flat Washer Lock Plate Polaris Sales Inc.
Install spark plug and torque to 14 ft. Subtract the thickness of the existing shim from. Ignition Generating Coil: Exciter coil, primary charge coil. Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion. Apply silicone to splines of brake disk and reinstall disk. See Caution with step 3 above.
Bearing Cotter Pin Wheel Nut O-Ring Hub Cap 40 ft. Watt: Unit of electrical power. Reinstall rear cab assembly and seat. When installation is complete, Yokes must pivot freely in all directions without binding. Inspect drive gear teeth for cracks, damage or excessive wear.
Turn transmission so shafts are pointing down. Another 30g 60g total if joint is cleaned. Grease fittings 3 and 4. Remove 4 axle tube bolts from rear gearcase. Pull the seat back and free of the tabs. Inner splash cap vent hole must be clear and open.