Polaris disc brake systems are light weight, low maintenance Dispose of brake fluid properly. The in-line filter is similar in appearance to a fuel filter, and is visible on the left side Location A. Inspect the pinion gear C for chipped, broken, or missing teeth. Remove cam chain drive sprocket and woodruff key from crankshaft. Be careful not to damage the crankcase crankcase.
Use a suitable container to catch the brake fluid. Factory highly detailed repair manual's, with complete instructions and illustrations, wiring schematics and diagram's to completely service and repair your vehicle. See Chapter 2 for proper fill procedures and Torque Specifications. Replace all O-rings, seals, and worn components. Safety glasses or a face shield are required. Never substitute or mix oil brands.
If needed, remove the seal from the front of the snorkel shaft snorkel tube 11. Slide the cam the cover using the designated pry points. The gap should be Re-connect all wires. Align the pin A in the top block with the middle hole B in the bottom block for proper installation. Install the cylinder with a slight rocking motion until the rings are captive in the sleeve. Head temperature can be checked with a pyrometer or a welding temperature stick. To remove the bearing, simply press the bearing from the shaft.
The reverse shaft should slide out of the silent chain 4 to 26. In order to remove bushings it will be Place main adapter Item 8 on puller. It will save you a lot and know more about Polaris Manual in the long run. Subtract this measurement from the maximum cylinder measurement obtained in Step 5 above. This information is for Sportsman models equipped with a winch in the front. Be sure that the armature plate tabs are fully engaged into the roll cage assembly. Fuel Flow throttle valve closed or slightly opened.
The setting will increase by one hour each time the button is pressed. Inspect mating surface of crankcase and oil pump. The rear step is measured as well Install new O-rings in the slide bolt bushing holes. Use a feeler gauge to measure the connecting rod big end Inspect the balancer drive gear and pump shaft drive gear. How to change spark plug on a 2007 polaris sportsman 500 free repair manual for a 2003 sportsman polaris 500 free manual book on atv sportsman 500 polaris 2000 fix it and repair download polaris 500 sportsman repair manuals download 99 polaris 500 sportsman repair manuals diagram electric polaris sportsman 500 change the brakes on a 2006 polaris sportsman 500 carbuert adjustment for 500cc polaris 4wheeler 2003 can a 500 engine fit into a 300 polaris sportsman 99 polaris sportsman 500 manual 97 polaris sportsman 500 4x4 blows black smoke. This will tell you which tie rod needs adjusting. All-wheel braking is integrated into the foot brake and hand brake systems and allows 4 wheel braking from either control separately, or at the same time.
Description Bolt Vent Tube Oil Seal Plug Input Cover Plate Asm. Disconnect spark plug wire from the spark 0. . Inspect the bearing for wear. To remove the remaining bearing on the snorkel shaft 15 , Inspect the output gear assembly 1 , replace bearings if remove the retaining ring and press the bearing off. Torque the slide pin to specification.
Inspect the magnetic coil A in the outer cover plate 13. Remove and Remove the armature plate. Use a micrometer and measure disc thickness at 8 different points around perimeter of disc. Install new cover o-ring 1 on the cover plate assembly 14. Torque the nut to 12-18 ft. Install the small clamp on the boot.
Install a new o-ring on the backlash pad 2 stem. Remove the steering tie rod ends from the steering bracket. Remove the slide pin clips from the slide bolt. Winch Connector Winch Connecting Splash Guard for Contactor mount Harness. The fuel injector mounts into the intake manifold, and the fuel rail attaches at the top end. Pilot Screw Base Setting Set at Factory Float Bowl Height: 13-14 mm Factory Specification: 2. Fuel Pump Testing To test the fuel pump: Turn fuel off.
Refer to the standard fastener torque values in Chapter 1 during Remove the four bolts attaching the rear of the cargo box assembly. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. Throttle lever operation should be smooth and lever Slide boot off throttle cable adjuster and jam nut. Valve Guide Installed Height Place 46 cutter on the pilot and make a light cut. Using suitable pry tools, remove 12. Replace the disc if any deep scratches are evident.