Prime oil pump using procedure below. For inspection of clutch components, please contact your Polaris dealer. Re- fer to bushing replacement in this chapter. The steering post arm bolt B points up; the rod end bolts A point down. Inspect ramp buttons in the moveable sheave and replace if worn. Check brake system for fluid leaks. Do not store or use a partial bottle of brake fluid.
Ring Piston Ring-to-Groove Clearance Feeler Gauge Top Ring Std:. Inspect pinion gear for broken, chipped, or worn teeth. The plunger should move smoothly in and out of the tensioner body. Chain Pitch: Distance between chain link pins No. Important: At least one spacer washer must be installed.
Loosen all four oil pipe banjo bolts and then remove the bolts and eight sealing washers. Apply a light film of oil to the threads and flange surface of the cylinder mounting bolts. Before positioning the sprocket on the camshaft, check the position of the cam sprocket alignment pin. Install caliper on hub strut, and torque mounting bolts. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown.
Clean the gasket surfaces on the cylinder and crankcase. Place a drain pan beneath oil tank and remove drain Ambient Temperature Range: plug. Visually inspect each cam lobe for wear, chafing or damage. Install moveable sheave with spacer washers. Remove the cotter pin and castle nut from the A- arm ball joint. Remove the following parts as required.
Slide seal off shaft and remove snap ring and shims. Refer to the electrical chapter. Remove recoil housing bolts and remove housing. Apply cutting oil to valve seat and cutter. Measured end play will be between. Replace piston and rings if ring-to-groove clearance exceeds service limits.
Place gear selector in neutral and set parking brake. To install housing, reverse removal procedure. Start bearing carrier on drive shaft. All voltages are with reference to pin B ground. Engage tabs of stationary washer in drive end housing, holding it in place with a light film of grease. Measure rotor tip clearance with a feeler gauge.
Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Slide the Low gear in and out until needle bearing slides out of gear and can be removed. Remove carburetor diaphragm chamber cover with a ratchet style screwdriver. Remove pump body screw and feed chamber cover. Assemble rocker arms, rocker shaft, and shaft supports. Polaris recommends using a rigid hone or arbor honing machine which also has the capability of oversizing. In low elevations and cold temperatures, the air has more oxygen.
Check the oil pump and oil passage mating surfaces to be sure they are clean and not damaged. Be sure to put aluminum spacer between pads. Change fluid every 2 years. Internal: Drink large quantities of water or milk. Lubricate the mounting bracket pins with Polaris Premium All Season Grease, and install the rubber dust seal boots. Install center shaft brake disc shaft bushing using small end of bushing installation tool.
Check all front suspension components for wear or dam- age. Rear Brake Replace disc if worn beyond service limit. Can be saved to your computer forever. Be sure machine is secure before beginning this service procedure. Check for movement of the driven clutch shaft in the one-way clutch. Using a flare nut wrench, remove hand brake inner and auxiliary brake outer lines.