Actuate the box lift switch in both directions. Remove gearcase drain plug B 11 mm located on the bottom of the gearcase and drain oil. Install piston B with a twisting motion while pushing inward. Transmission Fill Plug 14-19 Nm 10-14 ft. All models, and all engines are included. Drive roll pin from rear driveshaft yoke.
Please visit our to see a complete list of all the useful service manuals we offer. All information contained within this publication is based on the latest product information at the time of publication. Attach the mid and rear prop shafts to the mid gearcase, but do not install the new roll pins yet. Replace if damage is evident or if worn beyond service limit. E Emission Control System Service California Have an authorized Polaris dealer perform these services.
Remove all gasket material from the cylinder sealing surfaces. Slide the lower control arm bushings into place. Remove the retaining ring O , shim P , and input gear R the seals as shown in the photo. Inspect the weight pivot bore and instructions for drive clutch removal, then proceed pivot bolts for wear or galling. Disconnect the air intake hose D from the air box and remove the air intake hose. Inspect the top of the cylinder B for warp using a straight edge A and feeler gauge C. Slide Hinge Pin Out Disconnect the rear wire harness attached to the tail lights.
Lay the gearcase on the side with the output cover facing The backlash screw has Loctite applied to it. Rotate balance shaft to ensure halve. Failing to do so may lead to possible injury or death. Located in tank as an assembly 7. Install shaft seal with ceramic surface facing inward.
Screws 20 ± 5 in. The ground path for the fan motor is through the Brown harness wire. To remove the balance shaft gear, the flat side of the together with one hand. Periodic inspection and maintenance is required according to the forces applied to it from the drive belt and the to keep the system operating at peak performance. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the Apply engine oil to valve guides and seats. These manuals are your number one source for repair and service information.
Install the fuel line and vent line and verify they are secure. All diagnostic and repair procedures are covered. Inspect the parking brake cable and brake pads on the caliper assembly located on the rear propshaft. Inspect both sheaves for signs of wear, grooving or is worn or damaged. Properly dispose broken, or chipped teeth.
Toggle to the service interval screen. Enter your name: optional Enter the code below: This product hasn't received any reviews yet. Cable T-20 2-3 Nm T-20 8-10 in. Push upper pad retainer pin inward and slip brake pads past edge, if pads are still installed. This Service Manual has easy-to-read text sections with top quality diagrams and instructions.
When the battery fluid nears the battery, perform the following steps. Remove any metal particles from the drain plug magnet. This will allow any trapped air to Tighten the bleed screw to 70 ±. Remove the fill plug P and fill the mid gearcase with 6. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. Catch and discard used oil properly.