In addition, there will be lists of necessary tools, parts and safety equipment, which will help you throughout your repair. You will also find specific part numbers within the ATV repair manual that you can use to order new parts from your authorized ATV dealer or from a trusted website.
The manual is the most-excellent resource for Polaris Trail Boss owners to refer to for instructions on care, maintenance and repairs. By following the directions in the repair manual, you will be able to make sure your four-wheeler has the longest life possible. Inevitably, however, something will go wrong with your quad. When this happens, you can turn to your Polaris Trail Boss repair manual which will give you step-by-step instructions on how to fix the issue at hand.
It is important to remember that these manuals are written for people who have enough knowledge and skills, as well as the appropriate tools, to service their ATV. 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. 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. Adapter Number Ten 3. Install nut onto puller rod and hand tighten against installation tool. Turn clutch sheave counterclockwise until bushing is seated. Belt burnt, thin -Abuse continued throttle application when -Caution operator to operate machine within guidelines. Front Spindle Nut 40 Ft. Rear Hub Retaining Nut 80 Ft. Be sure machine is secure before be- ginning this service procedure. Wear eye protec- tion when removing bearings and seals.
Place a shop towel on hub to protect surface. Carefully pry seal out of hub. Using a brass drift, tap bearing spacer to one side Tap spacer to side to expose inner bearing race.
Drive bearing out using a drift through opposite side of hub and discard. Drive or press one new bearing into hub using a 1. Tube PN 14 oz. Inspect spindle seal and bearing surface for wear or damage.
Inspect and Grease 2. Apply grease to spindle. Install hub on spindle. Apply grease to washer and install with domed side out. Cone Washer 5. Securely support rear of machine with rear wheels off the floor. Remove rear wheels and hubs. Remove snap ring A , lock sleeve B and foam seal C from axle.
Support rear caliper with wire or a tie strap. Do not hang caliper by brake line. Slide axle assembly out left side. Remove rear axle. See page 7. Remove snap ring, collar, and foam seal. Remove nut, brake disc assembly, and stop ring. Install stop ring in groove on left side of axle. Stop Ring Groove in spline 2. Install foam seal and axle nut lock sleeve with taper toward nut. Install snap ring to retain the Foam Seal lock sleeve. Snap Ring Lock Sleeve Tapered side toward nut 7.
Torque wheel nuts to 50 ft. Lubricate eccentric housing through grease fitting with Polaris Premium All Season Grease until grease is purged on each side of eccentric.
Remove sprocket hub. Note sealing O-ring between sprocket hub and bearing. Remove brake caliper mounting bracket. Remove brake caliper pivot bushing from stud. NOTE: Flange inward as shown. Remove rear housing. Remove seals from housing. Seal Bearing 2. Remove bearings. Drive bearing race out from opposite sides. Inspect housing for cracks or wear.
Replace if damaged. Transmission Disassembly. Remove seat, cab and air box. Remove right side heat and reservoir bracket. Remove rear PVT bracket. Remove gear position switch. Place bellcrank in neutral position. Remove sprocket retaining clip and sprocket.
Remove the transmission cover bolts. Remove shift assembly and gear as an assembly. NOTE: Direction of shift fork. Inspect shift fork surface for wear or damage. Remove shift fork guide pin. Mark orientation of bellcrank to the shift fork shaft. Remove bellcrank. Use a small puller if necessary. Remove snap ring and washer. Pull down and rotate shift fork shaft back and forth to remove.
Inspect shift fork shaft O-ring. Lubricate O-ring to ease in reassembly and to protect O-ring during assembly. Remove input shaft bearing. Inspect gears for galling and wear on teeth and bearing surface. Remove bearing from other end of input shaft. Remove two snap rings and gear. Inspect gear bushing. Inspect output shaft gear, sprocket and bearing. Output Shaft Bearing Sprocket Stretch chain tight on a flat surface and measure the length of 8 pitches in a minimum of three places on chain.
Replace chain if measurement is longer than 3. Assemble input shaft assembly. Sprocket cogs face the dog gear. Thrust Washer 2.
Prior to reinstalling the cover make sure the mating cover surfaces are clean and dry. Reinstall cover and torque bolts in a cross pattern in 3 steps to 12 ft. Brake System Service Notes Brake Pad Kits. There are a few things to remember when replacing disc brake pads or performing brake system ser- vice to ensure proper system function and maximum pad service life.
If cleaning does not reduce the occurrence of brake noise, Permatext Disc Brake Quiet available from most auto parts stores can be applied to the back of the pads. Polaris brake fluid is sold in 5. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture. The caliper pistons are T-shaped, which allows both hand and foot brake to use the same caliper piston, but remain separated by seals.
Add brake fluid to the indicated MAX level inside reservoir. Begin bleeding procedure with the caliper that is Forward farthest from the master cylinder. Slowly pump brake lever D until pressure builds and holds. 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. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components.
Place a shop towel under brake line connection at master cylinder. Remove cover and diaphragm from master cylinder and dispose of the fluid properly. Vent Slots 2. Be sure vents in cover are clean and unobstructed. Remove brake lever. Cover 4. Clean surfaces of the reservoir and master cylinder body. Clean the master cylinder assembly with clean Dot 3 brake fluid, brake parts cleaner, or denatured alcohol.
Dry thoroughly. Inspect the bore for nicks, scratches or wear. Replace if damage is evident or if worn. Dip piston in clean DOT 3 brake fluid, attach spring to piston, and install assembly into installation tool. Do not allow the lip of the seals to turn in- side out or fold. Fill reservoir with DOT 3 fluid. Follow bleeding procedure on pages 9. Check all connections for leaks and repair if necessary. Elevate and support front of machine. Severe injury may occur if machine tips or falls.
Remove the front wheel. Loosen pad adjuster screw turns. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. Compress mounting bracket and make sure dust boots are fully seated. Install wheels and torque wheel nuts. It is recommended 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.
Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. Remove bolts and disc. Clean mating surface of disc and hub. Remove brake pads. See page 9. Using a line wrench, loosen and remove brake line to caliper. Remove piston, dust seal and piston seal.
Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE: Be sure to clean seal grooves in caliper body. Page Front Caliper Assembly Piston should slide in and out of bore smoothly, with light resistance. Lubricate the mounting bracket pins with Polaris Premium All Season Grease, and install the rubber dust seal boots. Install caliper on hub strut, and torque mounting bolts.
Front Caliper Mounting Bolt Torque 18 ft. Install brake line and tighten securely with a line wrench. Remove caliper mounting bolts and lift caliper off of disc. NOTE: When removing caliper, be careful not to dam- age brake line. Support caliper so as not to kink or bend brake line. Push caliper pistons into caliper bore slowly with pads installed. Install new pads in caliper body. Be sure to put aluminum spacer between pads. Install caliper and torque mounting bolts.
DH Brake Caliper Torque 18 ft. Slowly pump the brake lever until pressure has been built up. Clean caliper area before removal. Using a flare nut wrench, remove hand brake inner and Remove inner auxiliary brake outer lines.
Place a container to catch and outer brake fluid draining from brake lines. Inspect caliper piston bore for scratches, severe corrosion, or galling and replace if necessary. Inspect surface of caliper piston for nicks, scratches, or damage and replace if necessary.
Install new O-rings in caliper body 2 piston seals per caliper half. Install brake pads in caliper body with friction material facing each other. If equipped with a pad spacer, install the spacer between the pads.
Install retaining pin through outer pad, pad spacer and inner pad. Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. Use a s micrometer and measure disc thickness at 8 different points around perimeter of disc. Rear Brake Replace disc if worn beyond service limit. Reservoir 18 ft. PN Strobe Timing Light PN Hydrometer. Use the following procedure: 1. Page 2. Using a small flexible tube such as an oil delivery hose grasp the burned out lamp and remove it.
Replace the removed lamp with a Polaris PN Replace the indicator light cover. NOTE: Check all lights daily for proper operation replace or repair if necessary. Remove the check plug. NOTE: The ignition timing marks are stamped on the outside of the flywheel. Use the point of maximum advance when checking ignition timing. Do not use the cast mark to determine flywheel application. Be sure to always use the correct CDI box part number.
Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting. A peak reading voltmeter must be used to perform the tests. Page Battery Service 6. Check specific gravity of each cell with a hydrometer to assure each has a reading of 1. See Battery Installation on page Inspect the battery fluid level.
When the battery fluid nears the lower level, the battery should be removed and distilled water should be added to the upper level line. To remove the battery: 1. Page Differences of more than. Install battery in vehicle with positive terminal toward the front.
Coat threads of battery bolt with a corrosion resistant Nyogelt grease. Using a multitester set on D. It should be Damage will occur to light bulbs and speed limiter. Connect an ammeter in series with the negative battery cable.
Check for current draw with the key off. If the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated. SMaximum alternator output will be indicated on the meter. It is not necessary to increase engine RPM above idle. SPlace the red lead on the tester in the 10A jack. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system.
A digital multitester must be used for this test. Some solvents may leave a residue or damage inter- nal parts and insulation. Note the alignment marks on both ends of the starter motor casing. Get your eManual now! This service is available for only. We use the most popular portable document format file viewer called google docs.
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