Replace starter drive if gear teeth are cracked, worn, or broken. Replace crankshaft seal. It must be clean and have adequate spring pressure in order to seal properly.
Remove cap bolt, sealing washer, spring, and relief valve from MAG side crankcase. Measure rotor tip clearance with a feeler gauge. Separate crankcase by tapping with a soft faced hammer in reinforced areas. Rotor Tip Clearance: 3.
Watch the gap along the crankcase mating Std:. Use a feeler gauge to measure the connecting rod 2. Measure the width of the connecting rod at the big big end side clearance. Connecting Rod Width: Std:. Visually inspect bearing journal for scoring, damage or excessive wear. Inspect the crankshaft main bearings. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel.
Look for signs of discoloration, scoring or galling. Turn the outer race of each bearing. The bearings should turn smoothly and quietly. Measure the distance from the MAG side crankcase mating surface to the main bearing using a dial caliper and a straight edge. Remove all traces of gasket sealer from the crankcase mating surfaces. Inspect the surfaces closely for nicks, burrs or damage.
Install oil pump cover. Torque screws to specified torque. Install the crankshaft into the PTO side crankcase. Install the tensioner blade and tighten the mounting bolt to specified torque. Tensioner Blade Mounting Bolt Torque: Apply clean engine oil to oil filter gasket. Apply clean engine oil to the piston rings, ring 2.
Apply clean engine oil liberally to the cylinder bore lands, piston pin bore, piston pin, and piston skirt. Install the Lubricate the connecting rod both ends and cylinder with a slight rocking motion until the rings crankshaft main bearing area.
Lubricate 1. Slowly rotate engine two to three revolutions and re-check cam timing once chain is tight. Release the ratchet pawl A and push the tensioner plunger B all the way into the NOTE: The stator, flywheel, starter drive, and recoil tensioner body. Install flywheel, washer, and nut.
Torque flywheel to specification. Assemble rocker arms, rocker shaft and wave washer into rocker cover. Flywheel Nut Torque: 2. Install and tighten rocker shaft block plug. Apply engine assembly lube to the cam lobes and ft.
Insert a. Remove ratchet pawl with spring and inspect. A face shield or eye protection is required during this procedure. Replace any parts found to be worn or damaged. Slowly and carefully remove reel from recoil To reinstall an old spring: housing making sure the spring remains in the 1. Hook outer tab in place in recoil housing and wind housing. Inspect the reel hub and bushing A for spring in a counterclockwise direction one coil at a wear. Fuel Pump Exploded View Fuel Tank Asm.
Exploded View Fuel Flow Diagram. Screw 3. Throttle Valve 4. Cover, Diaphragm 5. Jet Block Assembly 6. Spring 7. Diaphragm Assembly 8. Ring 9. Ring Needle Jet Cover O-Ring Fuel Pump Assembly 2. Diaphragm, Gasket Set 3. Screw and Washer Assembly 4. Screw and Washer Assembly 5.
Screw and Washer Assembly 6. Pressure Regulator 7. Fuel Inlet 8. Fuel Outlet Gasoline powered engine ft. As the fuel fills the float chamber, the float 1 rises and forces the inlet needle against the seat, shutting off the orifice in the seat. Consequently the vacuum slide 2 moves upward. The fuel in float chamber 3 is metered by main jet 4 , and the metered fuel enters needle jet 5 , in which it mixes with the air admitted through main air jet 6 to form an emulsion. Remove carburetor diaphragm chamber cover with a ratchet style screwdriver.
DO NOT use an impact driver to remove the screws or carburetor may be permanently damaged. Take appropriate safety measures during these procedures. Safety glasses and chemical resistant Inspect this area gloves are required. Should you get cleaner in your eyes or if you swallow cleaner, seek medical attention immediately. Replace parts in proper order. Spacer washer D must be Inspect the diaphragm A for holes, deterioration, or installed below the E-Clip.
If adjustment is necessary, bend the tongue slightly. Place the carburetor on a level surface as shown Float arms even at right to remove weight from float arm. In this position, the float tongue will rest lightly on the inlet needle valve pin without compressing the spring. The pump diaphragms must be replaced.
A fuel level test can be performed on some models if the drain hose fitting is accessible. Be sure to re-attach the bowl drain hose after performing the Fuel Lines Steering Assembly, Exploded View Torque Specifications and Special Tools. The steering post arm bolt B points up; the rod end bolts A point down. Remove seat. Grasp rear of panel near rear cab. Bushing Cotter Pin 8 ft. Loosen front wheel nuts slightly.
Elevate and safely support machine under 1. Hold strut rod and remove top nut. Insert new ball joint E into driver F. Drive new joint into strut housing until fully seated. This bearing is attached to the post using a radial riveting method and is a non--serviceable item.
PVT System Torques This also from the drive belt increases, resulting in the belt will prevent water and other contaminants from rotating up toward the outer diameter of the drive Page 10 seconds.
PVT seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. Remove driven clutch retaining bolt and driven clutch. NOTE: Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. See Page 6. Driven Clutch Puller PN 1.
To control clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM.
These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.
All PVT system maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual. Because of Refer to bushing re- placement in this chapter.
You will also find specific part numbers within the ATV repair manual that you can use to order new parts from your authorized ATV dealer or from a trusted website. The manual is the most-excellent resource for Polaris Trail Boss owners to refer to for instructions on care, maintenance and repairs.
By following the directions in the repair manual, you will be able to make sure your four-wheeler has the longest life possible. Inevitably, however, something will go wrong with your quad. When this happens, you can turn to your Polaris Trail Boss repair manual which will give you step-by-step instructions on how to fix the issue at hand.
The use of lead- -calcium and AGM technology instead of 1. Remove spark plug high tension lead. Clean plug lead- -antimony allows the battery acid to be fully area so no dirt and debris can fall into engine absorbed. Be sure it is clean and tight. It is recommended that the air filter and pre filter be replaced annually. When riding in extremely dusty Engine Ground Strap conditions, replacement is required more often. The pre filter should be cleaned before each ride using the following procedure: 1.
Page Engine Oil Level Ill. To further expel water from the cover and to dry Polaris Premium 4 All Season out the PVT system, shift the transmission to Synthetic, 0W PN neutral and rev engine slightly to expel the moisture and air-dry the belt and clutches. Page Oil And Filter Change Remove dipstick and fill tank with 2 quarts 1. Place gear selector in neutral and set parking brake. Remove the seat. Remove body panels and fuel tank as necessary to gain access to valve cover.
Try to move the wheel outlined in this chapter, Polaris recommends steering and hub by pushing inward and component repair and adjustment be performed by an pulling outward. Place machine on a smooth level surface. Drive chapter for more information. This will tell G Do not perform clean out immediately you which tie rod needs adjusting.
NOTE: Be sure after the engine has been run, as the ex- handlebars are straight ahead before determining haust system becomes very hot. Page Brake Pad Inspection Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks.
The sprockets outer Repeat this procedure several times to check different spots on the chain. Remove the wheel nuts and remove the wheel. Check controls for proper operation, positioning and adjustment. Tapered nuts - install with tapered side against wheel Brake control and switch must be positioned to allow brake lever to travel throughout entire Check that all cotter pins are in place.
Refer to specific fastener torques listed in each chapter. Torque Patterns. If the piston has an identification mark, follow the directions for piston placement Crankshaft below. Page Engine Installation Notes Change break-in oil and filter at 20 areas. Rinse thoroughly, dry with compressed air, hours or miles, whichever and oil the bore immediately with Polaris 4 Cycle comes first. Lubricant to prevent the formation of surface rust.
Engine Lubricant PN Remove cam chain tensioner plug, sealing washer, spring and pin. Maintain inward pressure while removing.
Remove the two 6x25 mm cam chain tensioner flange bolts. Measure free length of tensioner spring. Replace 4. Remove cylinder block plug using a 14 mm hex spring if excessively worn. Cylinder block plug Tensioner Spring Free Length: 5. Measure O. Inspect it for wear or damage. Remove cam shaft end plug A. Remove camshaft sprocket flange bolt and washer. Measure I. Compare to specifications.
Inspect cam sprocket teeth for wear or damage. Replace if necessary. Remove release lever shaft and return spring spacer. Inspect shaft for wear or galling. Thoroughly clean the cam shaft, making sure the oil feed holes are not obstructed. Measure height of each cam lobe using a 1. Loosen each of the four cylinder head bolts micrometer. Remove spring retainer and spring. Lay a straight edge across the surface of the cylinder. Remove valve seals. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.
Inspect split keeper groove for wear or flaring of the keeper seat area B. NOTE: The valves cannot be re-faced or end ground. If any of the above conditions exist, the valve seat must be reconditioned. See Valve Seat Reconditioning, Page 3. If the valve seat is cracked the cylinder head must be replaced. Follow the manufacturers instructions provided Reaming The Valve Guide with the valve seat cutters in the Valve Seat 9. Allow cylinder head to cool to room temperature.
Reconditioning Kit PN Abrasive stone Apply cutting oil to the reamer. Guides should be seat reconditioning equipment can also be used. Insert valve into guide and tap valve lightly into place a few times. Remove valve and check where the Prussian Bluet or black marker indicates seat contact on the valve face. Clean cylinder head, valves, and camshaft oil contact point on the valve will be very narrow, and is supply passage A thoroughly.
Look for an even and continuous contact point on the black marker, all the way around the valve face. Cylinder Removal Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head. Remove the top rail first followed by the bottom rail.
Remove the expander. Remove circlip. Note that opening for circlip access is on the intake side. Remove all gasket material from the cylinder sealing surfaces. Measure piston pin bore. Record measurements. If cylinder is tapered or out of round beyond. Cylinder Taper Limit:. Cylinder Out of Round Limit:. Standard Bore Size: 3. Measure connecting rod small end ID. Place each piston ring inside cylinder using piston to push ring squarely into place as shown.
Piston Ring. Inspect gear teeth on starter drive. Replace starter drive if gear teeth are cracked, worn, or broken. Replace crankshaft seal. It must be clean and have adequate spring pressure in order to seal properly.
Remove cap bolt, sealing washer, spring, and relief valve from MAG side crankcase. Measure rotor tip clearance with a feeler gauge. Separate crankcase by tapping with a soft faced hammer in reinforced areas. Rotor Tip Clearance: 3. Watch the gap along the crankcase mating Std:. Use a feeler gauge to measure the connecting rod 2. Measure the width of the connecting rod at the big big end side clearance. Connecting Rod Width: Std:. Visually inspect bearing journal for scoring, damage or excessive wear.
Inspect the crankshaft main bearings. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. Look for signs of discoloration, scoring or galling. Turn the outer race of each bearing. The bearings should turn smoothly and quietly. Trademarks Polaris acknowledges the following products mentioned in this manual: Also be sure that colors match when wires are connected. Do not allow hot oil to contact skin. Synthetic Gearcase Lube O-ring chain lube Linkage rod will rotate 2.
Never sedvice down a hill. Remove the air box cover. Check for correct slack adjustment. Always follow the procedures outlined in this manual for operating over obstacles. Install moveable sheave with spacer washers. Become familiar with their meanings before reading the manual. Would you like to tell us about a lower price?
Insert the steering lock key and turn it clockwise. Add screws to 5 in. All information contained within this publication is based on the latest product information at the time of publication. Install diaphragm, cover, and screws. Check for damaged or missing o-rings or damaged rollers.
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