Check drain plug for proper torque. However if you get stuck and need any technical help Im always on hand. Remove the gas tank cover vent hose. Check the lifters for wear or scores. Tip hub outward and remove shaft from hub.
The new bolts contain patch lock, so Loctitet is not needed on the new bolts. Remove the gear, split bearing, and washer from 17. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. Mark the detent gear with a white pen. Remove the bearing from the input shaft with a puller. Add grease through large end of boot. The flat side of the roller pin faces downward when the shaft side is laying flat on the bench.
Never use high pressure leakage testers, as crankshaft seals may dislodge and leak. Place the shaft in a press to remove the bearing. Replace the disc if Front Wheel Nut Torque runout exceeds specifications. Maintenance Interval whichever comes first Miles Km Pre-Ride. Install the cam assembly helix over the shaft. Remove low gear 33T and the needle bearing.
Front Brush Guard Mount J. Always stop the engine and refuel outdoors or in a well ventilated area. Loosen the hub retaining nut. Drain whenever grease to the sealing edges of the filter before deposits are visible in the clear tube. Install the other output hub B and thrust bearing C into the output cover. Measure the gap between the two rotor tips as shown below.
Pushrods Bushing Do not expansion plug install more than 1. Place a container to catch brake fluid draining from brake lines. Be sure to catch the excess oil from the crankcase. Using a funnel, slowly add coolant through the radiator filler neck. Disconnect battery negative - black cable first, followed by the positive + red cable.
Proceed at a steady rate of speed and throttle opening. Install the sector gear in the bushing pocket on the left side. Slowly rotate the disc and read total runout on the dial indicator. This should occur after just a few seconds of flame treating. All service must be performed by your authorized Polaris dealer.
Slide off the shift dogs and wave springs. Leave the transmission in forward and shut off the engine. We stand behind our products and have had hundreds of satisfied customers. Use the following pages as a guide for troubleshooting. Always use genuine Polaris parts.
Shift weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance, clutch balance, engagement and shifting characteristics. If adjustment is necessary, bend the tongue slightly. The transmission drain plug 3 , is located on the bottom left-hand side of the gearcase. Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud. Rear Hub Nut Torque: 12. Transmission Case Bolts 27--34 37--46 Oil Deflector Screws 16--30 2--3. Install water pump cover R with new O-ring seal.
Brush Spring Though Bolt 3. Check your surroundings and determine your path of travel. Bolt Lower Pivot Ball 21 Nm Spring Retainer Lubrication Fitting Spring Hubstrut Bearing. If there is no tension, Accent the Timing Marks check the springs inside of the cam gear assembly. Inspect caliper piston bore for scratches, severe 2.
Visually inspect each cam lobe for wear, chafing or damage. Install the pads as Front Caliper Mounting Bolt: shown on Page 9. G Check vent hose to be sure it is routed properly and unobstructed. See page 114 for the part numbers of Polaris products. Install snap ring into groove. Always install a new filter when changing the oil.