Where usage is not obvious the tool is shown in use. Clamp or pinch off the vent line 1 approximately 2I from the oil tank 2 , between the end of the oil tank vent fitting and the vent. Accessory outlets are available for all models. The rear step is measured as well Install new O-rings in the slide bolt bushing holes. Shift Shaft Cover Remove Roll Pin Detent Pawl Case. Remove the front housing cover, shim, thrust button, and 24.
Install rear rack onto rear frame and cab. Remove the park lock engagement dog. Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption. Field test machine at low speed before putting into service. Install a new o-ring on the backlash pad 2 stem. Inspect the spider dampener E for wear and replaced if needed. Turn the back of the headlight harness 1 counterclockwise and pull the harness assembly away from the headlight assembly.
To maintain the finish and X2-Touring not applicable prevent corrosion, periodic maintenance is required. Shifter Turn bleeder valves counter-clockwise to loosen. Rotate one-way clutch clockwise as viewed from the cover plate side. Support caliper so as not to kink Support the machine. Providing that the service schedules are respected, the customers can be sure of obtaining the maximum satisfaction and best result from his car. Coat the edges of the verify alignment of the sight hole circled and piston mark piston cavities. We recommend the use of Polaris Premium Demand Drive Hub Fluid.
Periodic inspection and maintenance is required to keep the system operating at peak performance. Follow the instructions on the container for the recommended amount. Steering post removal may be required for lock service or repair. Inspect the grease carefully for contamination, and clean the joint thoroughly if necessary. Remove the T27 screws that secure the output gear 21 with a T27 hex socket or driver. This manual for: 2003 Sportsman 500, 2001 Sportsman 500, 2000 Sportsman 500, Sportsman 500 2000, Sportsman 500 1999, Sportsman 500 1996, Sportsman 500 1997, Sportsman 500 1998, 1998 Sportsman 500, 2002 Sportsman 500, 1999 Sportsman 500, 1996 Sportsman 500, 1997 Sportsman 500, Sportsman 400 1996, Sportsman 400 2002, Sportsman 400 1997, Sportsman 400 1999, Sportsman 400 2000, Sportsman 400 2003, Sportsman 400 1998.
Slide off the shift dogs and wave springs. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. Practice on smaller hills before attempting large hills. Press shaft into the new bearing. Install new compression ring on drive shaft.
If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease. This information is for Sportsman models equipped with a winch in the front. Your safety is involved when these words and symbols are used. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown or press out using a hydraulic press. Remove the steering tie rod ends from the steering bracket. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Try to move the wheel component repair and adjustment be performed by and hub by pushing inward and pulling outward.
As long as the gauge is in the diagnostic mode, the wrench icon will remain lit. Press inside insert A until it snaps into place. Be sure the rubber grommet inside the pod is fully installed and that the indexing key is in the headlight pod keyway. The reading should be infinite no Remove terminal nut with lock washer, flat washer, large continuity. Remove the two screws B that secure the front cab to the frame in the fuel tank mount area. Keep both feet on the footrests. Slide the cam the cover using the designated pry points.
Polaris dealers are equipped with the proper diagnostic tools to further diagnose the blink code. Before reusing, take the battery to your dealer for testing and recharging. Check controls for proper operation, positioning and adjustment. Replace the disc if any deep scratches are evident. Cover every aspect of repair from complete engine overhaul to basic maintenance , includes troubleshooting information for diagnosing problems. Follow the procedures in this manual carefully and completely. Remove the bearing from the reverse shaft using a puller.
This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. Inspect all cables and lubricate with Polaris Cable Lubricant. Place the bellcrank in neutral position. Inspect the backlash pad 2 for excessive wear. Inspect the top of the cylinder B for warp using a straight edge A and feeler gauge C. Refer to the steps below for fuel line removal. It should adhere tightly to the cover and seal all the way around.
Step 3 Side Panel Removal Side panel removal is quick and easy, use the following instructions for removal and installation. Information on the construction and function are included. Fuel Filter if equipped - not shown 6. Pin 24 senses when the brake is applied. Beginners should receive training from a certified instructor. Different types of Battery electrolyte is poisonous. 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.