Place shift selector in neutral and set parking brake. Replace all O-rings, seals, and worn components. Loosen three camshaft sprocket bolts. No more messy manuals that you have to keep replacing or cant use any more due to wear and tear. Start new bushing evenly in moveable sheave. Clean the seal cavity to remove all traces of old sealer. Valve Spring Free Length Valve Spring Length: Std: 1.
Install and tighten rocker arm shaft locating bolt. Check for movement of the driven clutch shaft in the one-way clutch. Apply Loctite 680 retaining compound to the back side of new bushing. You will not be dissatisfied. Replace if damage is evident or if worn. Remove the two 6 mm cylinder base bolts.
The plunger should move smoothly in and out of the tensioner body. Torque cover bolts evenly to specification. Never substitute or mix oil brands. As the armature plate is engaged, it should contact the outer magnet pole seal sleeve and the inner magnet pole. Place tensioner cam on front spacer and tensioner shoe on rear spacer. Inspect the crankshaft main bearings, balancer shaft bearings, and pump shaft bearing. Remove front output ring gear.
Measure height of each cam lobe using a micrometer. Pull cam chain tensioner plunger outward to the end of its travel. Start bearing carrier on drive shaft. Can be saved to your computer forever. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque. Closely spaced coils toward cylinder head 6. There are a few things to remember when replacing disc brake pads or performing brake system ser- vice to ensure proper system function and maximum pad service life.
Seal this edge to cover on engine side 2. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. Continue to screw front housing in, making sure O-ring enters housing without damage. Tap cover with soft face Remove all bolts hammer to remove.
Seal Retaining Ring Shim s Bearing Housing Shaft 27. Remove camshaft end cap and O-Ring. Separate crankcase by tapping with a soft faced hammer in reinforced areas. Use the point of maximum advance when checking ignition timing. Outer Feed Rotor to Pump Body Clearance: Std:. Measure in two directions, front to back and side to side.
However if you get stuck and need any technical help Im always on hand. Stop the engine and inspect for leaks. Measure free length of spring with a Vernier caliper. Install clutch in holding fixture and loosen the spider counterclockwise using spider removal tool. If front axle sleeves become damaged and leak fluid they are replaceable.
Check hub coils, related wiring, and mechanical system for fault and repair as necessary. Separate A-arm from ball joint. Be sure vents in cover are clean and unobstructed. Inspect electrodes for wear and carbon buildup. Remove complete airbox assembly transmission vent line.
With inside of cover toward vise, slide cover onto puller. Remove Phillips screws from bottom of headlight pod at each front corner. . Remove all traces of old gasket material. Remove ignition timing inspection plug from recoil housing.
Polaris recommends using a rigid hone or arbor honing machine which also has the capability of oversizing. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. The 1993-2012 Polaris Sportsman four wheeler repair manuals are in pdf format, no special software is needed to download and view a manual. If the spring is removed, it will become over stressed and will require replacement. Apply Loctitet 609 evenly to bushing bore inside sheave moveable sheave. This is a very important step.