Compare to specifications on page 3. It is important to note that spring pressure is very light. Measure the thickness and compare to specification. Use the point of maximum advance when checking ignition timing. The driven clutch must be disassembled from the helix side or the one-way clutch seals may be damaged. Note position of spacers for assembly. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve.
Remove five crankcase bolts A indicated in the photo at right with a 12 mm socket. If the shaft can be moved laterally, or if the one-way clutch does not function properly as described in Step 1 and 2 on page 6. Install transmission and add Polaris Premium Synthetic Gear Case Lubricant recommended amount. If fully extended, chain is worn beyond service limit. Loosen rocker shaft retaining bolt A to remove shaft. Replace bearing if moisture, dirt, corrosion, or roughness is evident.
Measure pump end clearance using a feeler gauge and straight edge. To reduce backlash, rotate housing clockwise as viewed from front of housing. Check specific gravity of each cell with a hydrometer to assure each has a reading of 1. Be sure to install the bearings with the larger I. Bend back retainer tabs on three screws at the front of the inner cover where applicable.
Hold flywheel with holder tool and remove flywheel nut. Remove brake caliper pivot bushing from stud. Remove seals from transmission case. Install clear battery vent tube from vehicle to battery vent. Reinstall cover and torque bolts in a criss-cross pattern in 3 steps to 18 ft. Press bearing into place until outer race bottoms on housing. Rotate each bearing by hand and check for smooth rotation.
See Illustration 1 and 3. Remove right hand shock absorber. If the light is not on when neutral is selected, check the bulb. Ring Gear Flat Washer Lock Plate Polaris Sales Inc. Drive or press the seal into place using a 25mm. Do not apply heat to piston rings or loss of temper may result.
Remove snap ring A , lock sleeve B and foam seal C from axle. Remove nut from puller rod and set aside. Install wheel and wheel nuts and tighten evenly in a cross pattern to specified torque. Keep the torch moving to prevent damage. Bleed the hydraulic auxiliary brake system in a conventional manner, following the procedure outlined in the Brake chapter. Measure valve stem in several places. Turn sheave counterclockwise on puller rod until it comes free.
Lapping is not required with an interference angle. Place wheels on hubs and install wheel nuts with tapered side facing in. If the bulb is good, check the wiring, transmission switch, and lamp socket ground path. Piston Ring-to-Groove Clearance Refer to Specifications on Page 3. Start new bushing evenly in moveable sheave. Turn clutch sheave counterclockwise until bushing is seated. Install lower ball joint, torque nut to 25 ft.
Clean guides thoroughly with hot soapy water and a nylon brush. One Way Valve Spring Free Length: Std: 1. If yoke tool does not slide freely in both bores, replace yoke. Remove brake pad adjuster screw. Replace entire tensioner assembly if any part is worn or damaged. Remove screws and retainer plate.
Throttle Valve Jet Needle Air Jet By-pass Pilot Outlet Pilot Jet Needle Jet Main Jet Polaris Sales Inc. Remove the four bolts securing rocker shaft supports, and remove the supports, rocker shaft and rocker arms as an assembly, being careful not to drop the dowel pins into the engine. O-Ring Washer Spring Pilot Screw 5. Std ±15% Polaris Sales Inc. Clamp housing lightly in soft jawed vise. Inspect the drained fuel for water or sediment. Install snap ring to contain bearing cap just installed.
Fill selector body with Polaris 0W-40 All Season Synthetic motor oil. Add Polaris Premium Synthetic Gearcase Lubricant to proper level as described above. Torque strut rod nut to specification. Remove right side upper control arm. Install oil pump on crankcase and torque bolts to 6 ft. Align timing reference marks on the plate and crankcase. Subtract this measurement from the maximum cylinder measurement obtained in step 5 above.