FREE DOWNLOADS,Polaris 50cc 90cc Scrambler ATV Print Service Manual By Cyclepedia
Polaris Sportsman ATV's The service manual downloads for the above listed models describes the service procedures for the complete vehicle. Follow the Maintenance Schedule recommendations to ensure that the all-terrain vehicle (ATV) is in peak operating condition and the emission levels are within the standards set by the your states/county Resources Board Polaris ATVs: Service Repair Manuals & Owner's Manual PDF. See also: Polaris snowmobiles service manuals. Title. File Size. Download Links. Polaris ATV and Light Utility Vehicle Polaris ATV – Service Manual Download Yamaha YANMAR Polaris ATV Polaris Sportman , & Series ATV Service Repair Manual Polaris Sportman Owner's Manuals | Polaris Sportsman Owner's Manuals Select a vehicle type, model year and model of vehicle below to view and download the vehicle owner's manual * Brand * Model Polaris ATV service manuals are available for immediate download. This service is available for only $ per download! If you have a dirty old paper copy of this manual or a PDF copy of ... read more
Aerosol 50 ml. ATV Angle Drive Fluid 8 oz. cartridge 24 Count number in the table above indicates the number of Premium All Season Grease units that are shipped with each order. cartridge 10 Count Starter Drive Grease 12 Count Premium U-Joint Lube 3 oz. thereafter; Change more often in extremely dirty 2 conditions, or short trip cold weather operation. Change Engine Coolant Page 2. coolant every 2 years. Fill reservoir between MAX Fill as required. Change Brake Fluid Page 2. brake fluid every 2 years. Transmission AGL Synthetic Gearcase Add lube to bottom of fill Page 2. Locate grease fittings on the upper and lower A-arms of Control Arm Pivot Polaris Premium All Season the front and rear suspension Page 2.
Locate the shift cable in the rear LH wheel well area. Replace if worn or damaged. or loose nuts, bolts or fasteners 3. Frame, Nuts, Bolts, and Fasteners Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. Lower Jam Nut 4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH H gear and PARK P. Thread the upper or lower jam nut as required to obtain proper cable adjustment. NOTE: This procedure may require a few attempts to obtain the proper adjustment. Once the proper adjustment is obtained, place the shift 2. Be sure fuel line is routed properly. cable and upper jam nut into the mount. Tighten the lower jam nut against the mount. IMPORTANT: Make sure line is not kinked or pinched. Replace fuel line every two years.
Start engine and shift through all gears to ensure the shift cable is properly adjusted. The EFI RZR engine uses a non-serviceable, high-volume, 2 high-pressure, fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator. FUEL SYSTEM AND AIR INTAKE Fuel Pump Asm Fuel System WARN I N G Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not overfill the tank. Do not fill the tank neck. If you get gasoline in your eyes or if you swallow NOTE: Neither filter is servicable.
gasoline, seek medical attention immediately. If you spill gasoline on your skin or clothing, Fuel Pump Asm immediately wash it off with soap and water Located in Fuel Tank and change clothing. Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time. Never drain the fuel when the engine is hot. Fine Filter Severe burns may result. Fuel Line Preliminary Filter 1. Check the quick-connect fuel line for signs of wear, deterioration, damage or leakage. Replace if necessary. Injector Rail NOTE: For all other information related to the EFI Fuel Line Connector System, refer to Chapter 4. Vent Lines 1. Check fuel tank, front gear case, rear gear case and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years. Fuel Pump Connector 2. Be sure vent lines are routed properly and secured with cable ties.
IMPORTANT: Ensure lines are not kinked or pinched. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster. If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be erratic. Boot Lock Nut Adjuster 4. Loosen the adjuster lock nut. Throttle Pedal NOTE: While adjusting, lightly flip the throttle pedal up and down. Tighten the lock nut. Check the throttle pedal play periodically in accordance with the 7. Squeeze the end of the rubber boot and slide it over the Periodic Maintenance Chart and adjust the play if necessary. cable adjuster to its original position. Throttle Freeplay Adjustment Air Filter Service Inspection It is recommended that the air filter be inspected as part of pre-ride inspection.
When riding in extremely dusty conditions, 1. Place the transmission in the P Park position. apply grease to the seal under the air box cap. In extremely dusty 2. Start the engine, and warm it up thoroughly. conditions, air filter replacement will be required more often. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Removal Adjustment 1. The air box is located just above the rear LH wheel in the 1. Remove the seat and rear service panel. wheel well area. Locate the throttle cable adjuster just above the PVT cover. Unlatch the 2 clips and remove the air box cap. Inspect the seal. It should adhere tightly to the cover and seal all the way around. Throttle Cable Adjuster Air Box Location 2.
Remove air filter assembly and remove the pre-filter sleeve. Installation 4. Inspect the main air filter element and replace if necessary. Clean the air box thoroughly. Do not clean the main filter, the filter should be replaced. Install a new or clean pre-filter over the main air filter NOTE: If the filter has been soaked with fuel or oil it element. must be replaced. Reinstall the filter into the air box. Be sure the filter fits 5. Wash pre-filter in warm soapy water and allow it to air dry. NOTE: If unable to clean the pre-filter, replace it. tightly in the air box. Install air box cap and secure with clips. Secure Clips Cap Pre-Filter Sleeve Air Filter NOTE: Service more frequently if vehicle is operated in wet conditions or at high throttle openings for extended periods. Intake Box Air Box Foam Seal Intake Duct Foam Seal Air Intake Duct Breather Filter Breather Seal Hose Fitting Cap T-MAP Seal Sensor Air Filter Boot Pre-Filter Clip 2 Sleeve Clamps Air Box Can 2.
To check the oil level follow the procedure listed below. Dipstick SAFE ADD 8 OZ Dipstick 6. Reinstall the dipstick completely, but do not lock it. NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of dipstick consistent. Position vehicle on a level surface. Remove the dipstick and check the oil level. Maintain the 2. Place the transmission in PARK P. Add oil as indicated by the level on the dipstick. Do not overfill see NOTE below. Be sure the machine has sat for awhile before removing the dipstick. NOTE: Due to the dipstick entry angle into the crankcase, the oil level will read higher on the IMPORTANT: Do not run the machine and then check bottom side of the dipstick.
Proper level indication the dipstick. is determined on the upper surface of the dipstick as it is being removed, regardless of the level marks 4. Remove both seats and the rear service panel. being on top or on bottom see the next illustration. Stop engine and lift the lever lock. Remove dipstick and wipe dry with a clean cloth. Dipstick Always read top side of dipstick to properly check oil level in crankcase Dipstick Lever Lock NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full mark, change the oil immediately. Reinstall the dipstick and seat the lever lock. Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter 8. Reinstall drain plug and torque to 16 ft. whenever changing the engine oil. Remove both seats and rear service panel. Place shop towels beneath oil filter. Hot oil can cause burns or skin damage.
Oil Filter Recommended Engine Oil: Premium 4-Cycle Synthetic OW PN Quart Ambient Temperature Range ° F to ° F 1. Using a clean dry cloth, clean filter sealing surface on the crankcase. Start the engine. Allow it to idle for two to three minutes until warm. Stop the engine. Lubricate O-ring on new filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition. Clean area around oil drain plug at bottom of engine. Remove dipstick and fill sump with 2 quarts 1. Crankcase Drain Plug Torque: NOTE: Drain plug is accessed 16 ft. Verify the transmission is still positioned in PARK P. Oil may be hot. Do not allow hot oil to come into Start the engine and let it idle for one to two minutes. contact with skin, as serious burns may result. Stop the engine and inspect for leaks. Place a drain pan beneath engine crankcase and remove the Re-check the oil level on the dipstick and add oil as drain plug. necessary to bring the level to the upper mark on the 6.
Allow oil to drain completely. Replace the sealing washer on drain plug. Dispose of used oil and oil filter properly. Low engine compression is rarely a factor in running condition The engine is equipped with a breather hose. Inspect the problems above idle speed. breather hose for possible kinks or wear. The hose is form fit- A cylinder leakdown test is the best indication of engine ted for a proper fit. Follow the breather hose from the side of condition. Follow manufacturer's instructions to perform a the airbox to the engine valve cover. cylinder leakage test never use high pressure leakage testers, as crankshaft seals may dislodge and leak. engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components.
Allow Engine and Transmission Mount Locations components to cool sufficiently before proceeding. Periodically inspect engine and transmission mounts for cracks Wear eye protection and gloves. or damage. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very Rear Mount short time. Periodically clean the spark arrestor to remove accumulated carbon. Remove the retaining screw and remove the arrestor from the end of the muffler. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm. Inspect the screen for wear and damage. Replace if needed. Reinstall the arrestor and torque the screw to ft. Arrestor LH Mount Screen RH Mount Compression and Leakdown Test Muffler NOTE: This engine does NOT have decompression components.
Compression readings will vary in Retaining proportion to cranking speed during the test. Screw 2. gearcase maintenance intervals described in the Periodic Maintenance Chart. Regular fluid level 2. Remove the fill plug. inspections on these components should be 3. Remove the level check plug. performed as well. Add the recommended fluid through the fill plug hole until Transmission Specifications it begins to flow out the level check plug hole. Specified Lubricant: AGL Synthetic Gearcase Lubricant Fill Plug PN Approximate Capacity at Change: Main Gearcase - 24 oz. Reinstall the level check plug and torque to in.
changed in accordance with the maintenance schedule. Reinstall the fill plug and torque to ft. checking or changing fluid. Maintain the fluid level even with the bottom of the fill plug hole. Check the fluid level. Transfer Case Drain Plug Main Gearcase Drain Plug Transfer Case Lubricant Change: 1. Place a drain pan under the transfer case drain plug. Remove the drain plug and allow to drain completely. Clean the drain plug. Reinstall the drain plug with a new o-ring and torque to in. Add the recommended fluid through the fill plug hole until it begins to flow out the check plug hole. Do not overfill. Level Check Plug Main Gearcase Lubricant Change: 4. If fluid level is not at fill plug hole, add the recommended 9. Place a drain pan under the main gearcase drain plug. Transmission Lubricant Change: Reinstall the drain plug with a new o-ring and torque to The lubricant change procedure is relatively the same for the in.
main gearcase and the transfer case. To minimize confusion, Add the recommended fluid through the fill plug hole. perform the lubricant change on only one gearcase at a time. Maintain the fluid level at the bottom of the fill plug hole Access the drain plugs through the drain holes in the skid plate. when filling the Main Gearcase. Check for leaks. Discard the used lubricant properly. The front gearcase lubricant level should be checked and 2. Remove the fill plug and check the fluid level. Add the recommended fluid as needed. The drain plug is located on the bottom of the gearcase. Front Gearcase Specifications ft. Fill Plug Nm Specified Lubricant: Premium Demand Drive Fluid LT PN Capacity: 6. The fill plug is located on the bottom right side of the front Nm gearcase. Maintain the lubricant level even with the bottom threads of the fill plug hole.
Place a drain pan under the drain plug. Remove the drain plug and allow fluid to drain completely. Inspect the O-ring and replace if damaged. Reinstall the drain plug; torque to ft. Add the recommended fluid. Reinstall the fill plug; torque to ft. Fill Plug ft. Specified Lubricant: ATV Angle Drive Fluid PN Capacity: 18 oz. Maintain the fluid level even with the bottom of the threads of the fill plug hole. Drain Plug Fill Plug 1. Remove the drain plug and allow the lubricant to drain completely. Maintain Level at Bottom of Threads 5. Reinstall the drain plug with new O-ring and torque to in. Position the vehicle on a level surface. The lubricant level should be even with the bottom of the Fill Plug threads of the fill plug hole. Add the recommended lubricant as needed. Add the recommended lubricant. Maintain the fluid level even with the bottom threads of the fill plug hole.
Discard used lubricant properly. If the coolant level is below the MIN line, inspect the coolant level in the radiator. Cooling System Overview NOTE: If overheating is evident, allow system to The engine coolant level is controlled, or maintained, by the cool completely and check coolant level in the recovery system. The recovery system components are the radiator and inspect for signs of trapped air in system. recovery bottle, radiator filler neck, radiator pressure cap and connecting hose. As engine coolant engine is warm or hot. Escaping steam can temperature decreases the contracting cooled coolant is drawn cause severe burns. The engine must be cool back up from the tank past the pressure cap and into the radiator. before removing the pressure cap. NOTE: Some coolant level drop on new machines is 5. Remove the pressure cap. Using a funnel, add coolant to normal as the system is purging itself of trapped air. the top of the filler neck.
Observe coolant levels often during the break-in period. Reinstall the pressure cap. NOTE: Use of a non-standard pressure cap will not NOTE: Overheating of engine could occur if air is allow the recovery system to function properly. not fully purged from system. Remove recovery bottle cap and add coolant using a funnel. Do not dilute with water. The pressure cap and recovery bottle are located under the front 9. Reinstall the recovery bottle cap. hood of the vehicle. The coolant level must be maintained between the minimum and maximum levels indicated on the If coolant was required, start engine and check for leaks. recovery bottle.
Make sure radiator fins are clean to prevent overheating. Tap water contains minerals and impurities which build up in the system. If not, perform the following procedure. freeze, corrode, or overheat. Remove the hood by lifting it straight up from the front cab to allow the inserts to disengage from the grommets. PN 3. View the coolant level in the recovery bottle. Carefully straighten any bent radiator fins. Refer to Chapter 3 for cooling system pressure test procedure. Remove any obstructions with compressed air or low pressure water. Cooling System Hoses 1. Inspect all hoses for cracks, deterioration, abrasion or leaks. CAU T I ON Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators effectiveness. Use of a high-pressure washer is not recommended. Remove the front hood. T-Connector WARN I N G Never drain the coolant when the engine and radiator are warm or hot.
Hot coolant can cause 2. Check tightness of all hose clamps. severe burns. Allow engine and radiator to cool. Slowly remove the pressure cap to relieve any cooling CAU T I ON system pressure. Do not over-tighten hose clamps at radiator, or 3. Place a suitable drain pan underneath the T-fitting on the radiator fitting may distort, causing a restriction front RH side of the vehicle. to coolant flow. Radiator hose clamp torque is 4. Drain the coolant from the radiator by removing the lower 36 in. engine inlet hose from the T-fitting. Properly dispose of the coolant. Radiator T-Fitting 1. Check radiator A air passages for restrictions or damage. A Drain Here 5. Allow coolant to completely drain. Flush radiator fins in this direction 2. Remove the front bumper see Chapter 5. Wheel, Hub, and Spindle Torque Table 2.
Remove the upper engine outlet hose and recovery hose from the top of the radiator. Item Nut Type Specification 3. Remove the 2 upper radiator retaining bolts and the 4 bolts retaining the lower radiator mount bracket. Remove Aluminum Wheels Cast Lug Nut 1 90 ft. Steel Wheels Flange Nut 27 ft. Disconnect the fan motor and remove the radiator from the 90 ft. Take care not to damage the cooling fins. NOTE: Do not lubricate the stud or the lug nut. Reverse procedure for installation. Recovery Fan Motor Asm. Hose Wheel Removal 1. Inserts 2. Place the transmission in PARK P and stop the engine. Radiator 3. Loosen the wheel nuts slightly. If wheel hub removal is T-Fitting Engine required, remove the cotter pin and loosen the hub nut Outlet Hose slightly. Screws 4. Elevate the appropriate side of the vehicle by placing a suitable stand under the frame. Remove the wheel nuts and remove the wheel. Grommets Engine 6. If hub removal is required, remove the hub nut and washers.
Inlet Hose Wheel Installation 1. Verify the transmission is still in PARK P. Install the wheel hub, washers, and hub nut, if previously removed. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. Attach the wheel nuts and finger tighten them. Carefully lower the vehicle to the ground. Operating a RANGER with worn tires will 7. If hub nut was removed, install a new cotter pin after the increase the possibility of the vehicle skidding hub nut has been tightened. easily with possible loss of control. Use a new Worn tires can cause an accident. Tire Pressure Hub Nut CAU T I ON Maintain proper tire pressure. Refer to the warning tire pressure decal Valve stem applied to the vehicle. Wheel Nuts 4 facing outward Tire Pressure Inspection Cold CAU T I ON Front Rear 8 psi 55 kPa 8 55 kPa If wheels are improperly installed it could affect vehicle handling and tire wear.
On vehicles with tapered rear wheel nuts, make sure tapered end Drive Shaft Boot Inspection of nut goes into taper on wheel. Inspect the front and rear drive shaft boots for damage, tears, wear, or leaking grease. If the rubber boots exhibit any of these Tire Inspection symptoms, replace the boot s. Refer to Chapter 7 for drive shaft boot replacement. Battery Maintenance Keep battery terminals and connections free of corrosion. If Battery cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean 2 shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into the battery WARN I N G Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water.
Disconnect the black negative battery cable. Internal: Drink large quantities of water or milk. Disconnect the red positive battery cable. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Remove the rubber strap and lift the battery out of the vehicle. Eyes: Flush with water for 15 minutes and get prompt medical attention. CAU T I ON Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. To reduce the chance of sparks: Whenever Ventilate when charging or using in an enclosed removing the battery, disconnect the black space. Always shield eyes when negative cable first. When reinstalling the working near batteries. battery, install the black negative cable last. KEEP OUT OF REACH OF CHILDREN. It can also hinder vehicle performance. Do not use the alternator to charge a new Follow the battery charging procedure before battery.
installing the battery. Ensure the battery is fully charged. Place the battery in the battery holder and secure with rubber strap. Connect and tighten the red positive cable first. Connect and tighten the black negative cable last. Remove both driver and passenger seats. more, remove the battery from the vehicle, ensure that it's fully 2. Remove the rear service panel. charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. WARN I N G NOTE: Battery charge can be maintained by using a A hot exhaust system and engine can cause serious Polaris battery tender charger or by charging about burns. Allow engine to cool or wear protective once a month to make up for normal self-discharge. gloves when removing the spark plugs Battery tenders can be left connected during the storage period, and will automatically charge the 3.
The PTO side spark plug can be accessed with the service battery if the voltage drops below a pre-determined panel removed. The MAG side spark plug can be accessed point. through the rear RH wheel well area. Remove both spark plug caps. Battery Charging Sealed Battery The sealed battery is already filled with electrolyte and has been sealed at the factory. Never pry the sealing strip off or add any type of fluid to this battery. The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure the DC voltage at the battery terminals. Check the battery voltage with a voltmeter or multimeter. The battery voltage should read If the voltage is less than When using a constant current 5. Clean plug area so no dirt and debris can fall into engine charger, follow the guidelines in the following table: when plugs are removed.
Remove spark plugs. STATE OF CHARGE VOLTAGE ACTION 7. Inspect electrodes for wear and carbon buildup. Look for CHARGE TIME a sharp outer edge with no rounding or erosion of the None, check electrodes. Clean with electrical contact cleaner or a glass bead spark charge plug cleaner only. CAUTION: A wire brush or coated Needs Charge abrasive should not be used. Measure gap with a wire gauge. Adjust gap if necessary by carefully bending the side Steering Inspection electrode. The steering components should be checked periodically for Spark Plug Gap loose fasteners, worn tie rod ends, ball joints, and damage. Also check to make sure all cotter pins are in place.
If cotter pins are removed, they must not be re—used. Always use new cotter pins. Steering should move freely through the entire range of travel without Gap -. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the NOTE: Whenever steering components are incorrect spark plug is used. replaced, check front end alignment. Apply anti-seize compound to the spark plug threads. Install spark plug and torque to specification. WARN I N G Recommended Spark Plug: Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component Champion RC7YC3 repair and adjustment be performed by an authorized Polaris MSD certified technician when replacing Spark Plug Torque: worn or damaged steering parts.
Steering Wheel Freeplay Engine To Frame Ground Check the steering wheel for specified freeplay and operation. Inspect engine ground cable connection. Be sure it is clean and tight. The ground cable runs from the engine starter motor to the 1. Position the vehicle on level ground. Lightly turn the steering wheel left and right. Ground 3. There should be 0. Terminal Location 4. If there is excessive freeplay or the steering feels rough, inspect the following components. Place machine on a smooth level surface. tie rod and pull in all directions feeling for movement. Set steering wheel in a straight ahead position and secure the steering wheel in this position. Check for any looseness in front hub and wheel measurement. assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel 4. Measure the distance between the marks and record the and hub by pushing inward and pulling outward. Check for Loose Wheel or Hub 5. Rotate the tires ° by moving vehicle forward or backward.
Again measure the distance between the marks and record. wheel assembly to determine the cause possible loose wheel nuts or loose front hub components. vehicle center and each wheel. This will tell you which tie rod needs adjusting. Raise and safely support the front or rear of the vehicle off NOTE: Be sure steering wheel is straight ahead before determining which tie rod s need the ground to allow the suspension to fully extend. NOTE: The tires should not be touching the ground. To adjust the suspension, use the adjustment cam located CAU T I ON near the bottom of the shock. During tie rod adjustment, it is very important that the following precautions be taken when Shock Spanner Wrench tightening tie rod end jam nuts.
If the rod end is positioned incorrectly it will not PN pivot, and may break. Rotate the adjustment cam clockwise to increase spring tension or counter-clockwise to decrease spring tension. Damage may not be immediately apparent if done incorrectly. preload to the spring over the primary position. WARN I N G Uneven adjustment may cause poor handling of the vehicle, which could result in an accident and serious injury or death. Always adjust both the left and right spring preloads equally. Check the brake pads for wear, damage, or looseness. Brake Fluid Inspection Always check the brake pedal travel and inspect the brake fluid 2. Inspect the brake pad wear surface for excessive wear. reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only. Pads should be changed when the friction material is worn to.
Brake fluid should be changed every two years. The fluid should also be changed anytime the fluid becomes contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown. The brake fluid master cylinder reservoir can be accessed through the left front wheel well. Measure Pad Material Thickness Service Limit: 2. View the brake fluid level in the reservoir. The level should be between the MAX and MIN level lines. If the fluid level is lower than the MIN level line, add brake 4. Check surface condition of the brake discs. fluid until it reaches the MAX level line. Measure the thickness of the front and rear brake discs. Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage 6. The disc s should be replaced if thickness is less than. Measure Brake Disc Thickness Rear Front Maximum Disc Disc Minimum Service Limit:.
Tighten any loose fittings and replace any worn or damaged parts. Nm ft. Nm Camshaft Gear 8 mm 22 ± 2 30 ± 3 Camshaft Thrust Plate 6 mm ± 12 13 ± 1. The system must maintain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check the Cooling System Specifications radiator, hoses, clamps and water pump seals for leakage. Pressure Cap Test Condition Specification Thermostat Open ° F 82° C WARN I N G Thermostat Full Open Lift 6 mm at ° F 95° C Thermostat Closed ° F 77° C Never remove pressure cap when engine is warm or hot. The cooling system is under System Capacity 4. Pressure Cap Relief 13 PSI Allow the engine and cooling system to cool before servicing. Remove pressure cap and test cap using a commercially Polaris Premium Antifreeze available pressure cap tester.
The pressure cap relief pressure is 13 psi. Replace cap if it does not meet this specification. Pressure Cap CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Cooling System Pressure Test 1. Remove pressure cap and pressure test the cooling system using a commercially available pressure tester. Remove Cap Test Here 3. Remove pressure cap and top off coolant. Remove recovery bottle cap and fill bottle to the full line. WARN I N G Recovery Bottle Always wear safety glasses and proper shop clothing when performing the procedures in this manual. Failing to do so may lead to possible Pressure Cap injury or death. CAU T I ON Use caution when performing these procedures. Coolant may be hot and may cause severe injury or burns. NOTE: If the coolant level is LOW in the radiator, or if there are leaks in the system, the coolant system will not draw coolant from the reservoir tank.
Leave the cap off of the radiator to allow any possible air to escape. NOTE: Use this procedure when a unit overheats and no apparent leaks in the cooling system are 6. Start the engine and let it idle for minutes or until the found. thermostat opens and allows coolant to flow through the system. Drive the vehicle onto a slight incline and use properly weight rated ramps. If an incline is not available, slightly 7. Slightly loosen the bleed screw C on the thermostat cover elevate the front of the vehicle. to let air escape. If no air is present, a steady stream of coolant will stream out. If air is present, the screw will 2. Place the vehicle in Park and block the rear wheels. bubble and sputter as the air escapes.
Top LH Side Pressure Cap of Engine C 8. Tighten the bleed screw to 70 ± 10 in. Squeeze the coolant lines by hand to help purge the system of air. Be sure the engine has cooled and no pressure is built up in the cooling system before removing NOTE: If there is air in the system you will see air the pressure cap. The coolant may be hot and bubbles forming through the radiator filler neck. could cause severe injury or burns. Add Polaris Premium Antifreeze to the radiator filler neck GENERAL ENGINE SERVICE if the level goes down. Capacity - Approximately 2 U. Quarts 1. Oil Type - Polaris Premium 0W Synthetic Filter Wrench - PV or equivalent Stop the engine and let cool, top off the radiator filler neck with coolant. coolant has been pulled into the system; Fill the recovery bottle only after you have completely filled the cooling system at the radiator filler neck. Accessible Engine Components Repeat this procedure, if overheating still occurs.
Start engine and allow it to reach operating temperature, monitoring gauge indicator. Unlike other manuals on the internet my manuals don't need a password to view or print and you can back them up any way you see fit to make sure it's aways there when you need it. Covers all models and versions of Polaris youth series including: Polaris Scrambler 50 Polaris Scrambler 90 Polaris Sportsman Covers all models and versions of Polaris youth series including: Polaris Predator 50 Polaris Scrambler 50 Polaris Scrambler 90 Polaris Predator 90 Polaris Sportsman Covers all models and versions of Polaris youth series including: Polaris Predator 50 Polaris Predator 90 Polaris Sportsman Covers all models and versions of Polaris youth series including: Polaris Predator 50 Polaris Outlaw 90 Polaris Sportsman Covers all models and versions of Polaris youth series including: Polaris Outlaw 50 Polaris Outlaw 90 Polaris Sportsman Need the RZR Manual?
Click Here. Covers all models and versions of including: Polaris 2x4 Series Polaris 4x4 Series Polaris 6x6 Series. Covers all models and versions of Polaris Trail Boss L including: Polaris Trail Boss 2x4 Polaris Trail Boss 4x4. Covers all carbureted and EFi models and versions including the Sportsman X2 and touring models. Toggle navigation Main Menu. Polaris ATV Manuals. Copyright com All Rights Reserved. Home » Contact. High Definition Keyword Searchable Factory OEM Manual - Pages Covers all models and versions of Polaris youth series including: Polaris Scrambler 50 Polaris Scrambler 90 Polaris Sportsman High Definition Keyword Searchable Factory OEM Manual - Pages Covers all models and versions of Polaris youth series including: Polaris Predator 50 Polaris Scrambler 50 Polaris Scrambler 90 Polaris Predator 90 Polaris Sportsman High Definition Keyword Searchable Factory OEM Manual - Pages Covers all models and versions of Polaris youth series including: Polaris Predator 50 Polaris Predator 90 Polaris Sportsman High Definition Keyword Searchable Factory OEM Manual - Pages Covers all models and versions of Polaris youth series including: Polaris Predator 50 Polaris Outlaw 90 Polaris Sportsman High Definition Keyword Searchable Factory OEM Manual - Pages Covers all models and versions of Polaris youth series including: Polaris Outlaw 50 Polaris Outlaw 90 Polaris Sportsman
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This is especially useful if you want to power up your Pi in headless mode that is without a connected monitor , and have it run a program without configuration or a manual start. The Spring Brake Thingy is a product designed to protect your SxS transmission. This brake is needed for all kinds of situations. If you are trailering, The inimitable Hypernaked offers two exciting choices. The Tuono V4 Factory confirms its reputation as the ultimate adrenalin machine, setting hearts thumping and pulses racing and delivering uncompromised, unbeatable fun both on the road and track.
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tone vs mood; qiskit Email address. Buy Car. Sell Car. Dealer Login. outdoor yoga pacific beach mack2happy Getty Images. How Long Does Pre-Workout Take to Kick In? When you start your workout, you want to hit the ground running. Coffee: A cup of black coffee with or without sugar before your workout is a great way to up your energy levels. With its 8 gallon capacity, this system is the perfect add-on to nearly double the range of your 4 seat Polaris RZR. It does not require any welding, keeps your stock fuel system intact and sits low so it doesn't affect your car's performance.
It also has an external port so you can fuel your friends when they run out of gas. Oct 25, · 1. With the tire removed and all components cleaned of mud and dirt, you want to loosen the small Allen hold-down set screw in the caliper first. A 15mm socket will loosen the caliper from the caliper bracket. You will need a Universal Joint or Swivel Joint for one of the bolts. This is the case for both the front and rear brakes on a RZR. Remove the brake caliper and tie it to the suspension with a wire without disconnecting it from the brake hose to avoid depressurizing the brake system. Caution, do not step on the brake pedal after removing the brake caliper.
Remove the brake pads and use the chance to measure the brake disc thickness. If you are having issues with your Polaris SXS not starting this could be your fix. Check your brake pressure switch. how to start a polaris rzr without key By temporary work in france By temporary work in francehow to start a polaris rzr without key. do gucci serial numbers have letters. nautical valances Jul This trail fix will work on all Polaris RZR XP models and rangers. I walk you Worked well unsupervised. Exercise 2. When you fi rst meet someone it can be difficult to know how to start a conversation, especially if your fi rst language is not English. When you turn this nut, the moveable jaw moves up or down, making the size bigger or smaller. Between the two jaws, there is a spring that helps get a good grip on the job. Strap Wrench. Source: housegrail. This kind of wrench is used on bolts and nuts that are too slippery for regular wrenches.
A RZR is actually a cheap Chinese imitation of a real RZR and is made in China and imported by Polaris using often cheap inferior parts. The rear caliper as you probably already know, is a hydraulic rooms to rent in glasgow May The brake switch on the Polaris RZR. Do you need it? What ALL does it do? Find out all these answers and more in this video. Remove the wire plug. Hook a multi meter set to ohms, one lead to each of the terminals. Should have nothing. Now step on the brake pedal, meter should register continuity. Billet Gas and Brake Pedal Covers These billet pedal covers bolt to the stock steel pedals to give you a trick billet look. Let's start by checking the wire plug on the top of the fuel pump unit, which is located under the passenger-side seat. Remove the connector from the fuel pump head. Check the pins of the connector for proper seating and any corrosion. Clean any corrosion and ensure the pins make good contact. Retest your fuel gauge.
Hit the streets like never before with the SUPERR. The R boasts all of our most iconic features, like the powerful R-series drive system, two-piston hydraulic brakes, and dual suspension. TOP SPEED. I'm a "veteran" and love my Avata, but the motion controller without Goggles 2 which almost no one can actually use comfortably is just too limited for anything even half-serious. like if you enter a dark building or a thick forest and start pulling you forward or sideways no, the brake doesn't work either in that case. Does anyone know how to start a turbo rzr without brake pressure to get it out of the woods?
THE PROSTAR FURY 2. how to start a polaris rzr without key. Nov 06, · Join. What is your answer? TR Register Members. Location:West London. Posted Tuesday at AM. If yes - then reconnect and disconnect on the slave side - check for fluid flow. From a pre-run walk plan to a run-walk plan, here's how to get started. It involves only walking, to give your bones, muscles, tendons and fitness the base they need to progress to running without injury. I simply pick up this built at auction and they specify that it comes with keys and of course it didn't so I simply want it to start it so I can move it arou November 10, Continental announced it received its first major order in the third quarter for the mass production of its semi-dry brake system also known as Future Brake System or FBS tncm x plane 11 crack Starting your own business with no money or experience is possible. In that sense, this guide will show you how to prepare for a recession. This isn't the type of posts about starting a business without money in 3 simple steps.
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Polaris ATV,2004 – 2014 Polaris Sportsman 400, 450, 500 Carburated ATV Service Manual
Polaris ATV Manuals This is the BEST, most complete workshop repair and maintenance manual available anywhere on the internet! All of the manual listed below are full factory service Polaris ATV Manuals This is the BEST, most complete workshop repair and maintenance manual available anywhere on the internet! All of the manual listed below are full factory service Polaris ATV service manuals are available for immediate download. This service is available for only $ per download! If you have a dirty old paper copy of this manual or a PDF copy of WebPolaris ATV Service Manual - All Models - Free ebook download as PDF File .pdf), Text File .txt) or read book online for free. Scribd is the world's largest social reading and publishing site. Save Save Polaris ATV Service Manual - All Models For Later. 91% 91% found this document useful, Mark this document as useful WebPolaris Sportsman EFI EFI ATV Complete Workshop Service Repair Manual Thanks for taking the time to look Download USD WebPolaris Sportsman ATVs: 4 Wheelers & Quad Bikes ... read more
Wash the cylinder in a A finished cylinder should have a cross-hatch pattern to ensure solvent, then in hot, soapy water. Replace if necessary. spring tension offsetting the teeth between the two gears. High Definition Keyword Searchable Factory OEM Manual - Pages Polaris Outlaw 50 Polaris Outlaw 90 Polaris Sportsman Toggle navigation Main Menu. Remove the stator cover A and water pump cover B. Polaris Breeze Owner's Manual.
Ignition Coil PVT Duct Outlet Duct Stator Mark Upper Connector Jam Nut Lower Jam Nut Capacity - Approximately 2 U. Once the proper adjustment is obtained, place the shift 2. Built of Grade 50 steel and powder coated black you can rest assured that this mount will last season after season without fail.
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