Polaris Sawtooth Owner's Manual. Polaris Sportsman Spare Parts Catalog. Polaris Industries is an American engineering company manufacturing motorcycles, snowmobiles , ATVs and electric cars, headquartered in Midine, Minnesota.
The history of Polaris can be traced from its founding to its founders - Edgar Hettin, his younger brother Allan and his close friend David Johnson. Given the shortage of metal during World War II, their farm machinery repair skills quickly earned the respect of regular customers.
But they deserve a place in history, working on ways to quickly get to forest hunting lodges in deep snow. These developments led to the creation of the first prototype of a snowmobile in To prove that the new type of transport is not just a toy, Edgar and three friends took a journey of km through the wild places of Alaska, demonstrating the reliability of the device. The devices became so popular that Polaris began to produce exclusively snowmobiles, and this lasted for many years until the company expanded its product line that required new skills in the development, production, distribution, marketing, new power units and technologies.
Production Continues in Roseau, Minnesota the first Polaris liquid-cooled engine was installed in the TX-L, and shortly afterwards the first snowmobile with independent suspension was built W. Hall Wendell, Jr. The company is becoming a world leader in the production of motor vehicles.
Pilot El Anser Jr. Vine joins Polaris team Annual sales for the first time exceed 2 billion. Polaris acquires the legendary Indian Motorcycle and restarts Chieftain in Sturges in Page Cylinder Head Reassembly ENGINE Lubricate the valve guides with clean engine oil, and apply Valve seals should be installed after the valves are in the oil or water based lapping compound to the face of the head to avoid valve seal damage.
Install new valve seals valve. When all valves are installed, tap lightly with soft faced hammer on the end Remove the valve lifter's by reaching into the crankcase of the valves to seat the split keepers.
Do not scratch the ring lands. Remove circlip A. Mark the piston with a white pen to ensure proper orientation if reused during assembly. Repeat procedure for second ring. Remove all gasket material from the cylinder sealing surfaces. Inspect the top of the cylinder B for warp using a straight edge A and feeler gauge C. Refer to Ill.
Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin. Wipe cylinder bore with oil immediately in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-to-groove clearance to remove residue and prevent rust. Replace starter drive Install Flywheel Puller PN and remove if gear teeth are cracked, worn, or broken.
Remove the starter bendix G , wire holddown plate H , and the woodruff key I from the crankshaft. Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears.
If there is no tension, check the springs inside of the cam gear assembly. With a white marking pen, accent the timing mark on the Insert the pointed dowels from the Tapered Pins PU- gear that contains the springs. Inspect the gear teeth and the three tabs on the gears for wear. Line up the two gears using the timing marks and the three into one assembly hole counter clockwise gear tabs that were referenced earlier.
Push the gears back together, using both hands and hold securely. Remove the bolt and nut from the balance shaft gear. Try Install the Flywheel Puller PN and remove the to remove the balance shaft gear. If the gear does not come crankshaft gear, if needed. Use a feeler gauge to measure the clearance between the dowel in first. If the valve is installed incorrectly, two rotors. Measure the gap between the two rotor tips as shown below. Place the shaft in a press to remove the bearing.
Press gear onto shaft while supporting the housing. Bearing Press shaft into the new bearing.. Remove thrust plate U. New Bearing Remove and inspect crankshaft main journal bearings for damaged.
When removing the oil baffle bolts, use a abnormal wear. Follow Steps of this section to prime the engine and to help aid proper break-in. Apply Crankcase Sealant PN to the top gearcase halve. Apply assembly lube to cam journals and balance shaft bearing surfaces of the MAG case halve.
Install cam and Assemble the crankcase halves. Orientate the piston rings on the piston before installation order as removed in disassembly. Apply Lubriplate or into the cylinders. Position cylinder and piston assemblies onto the connecting Install camshaft thrust plate G with new bolts.
Torque rods and push the piston pins through the piston and bolts to specification. Lubricate Rotors Align the bolt holes and install oil pump assembly into crankcase. Before installing the crankshaft gear I , heat the crankshaft Install washer and bolt. Carefully install the tapered end of the Crankshaft Seal cover O. Apply Crankcase Sealant PN to the outside Torque bolts in proper sequence to crankcases mate.
See photos below. This helps to prevent specification. Install water pump impeller P. Secure the impeller with Torque the nut to starter drive. Install the starter bendix. NOTE: There are thrust washers on both sides of starter drive. Page Remove primer plug from the engine. Push oz. Remove the adapter.
Apply sealant to the plug threads. This will ensure proper sealing when installing bolts. Install the head gasket A on the cylinder B. Lubricate rockers E with engine oil. Lightly Install thermostat J , new O-ring, and thermostat housing. The reed has a tab and will assemble one-way only. Torque the breather bolts to specification. Repeat this procedure as often as desired to maintain the The dual exhaust canisters on select Polaris EFIs are powder canister's finish.
To maintain the finish and prevent corrosion, periodic maintenance is required. Fuel Injectors 5. Fuel Filter if equipped - not shown 6. Refer to the steps below for fuel line removal. Place a shop towel around the fuel line to catch any dripping fuel. Squeeze the connector tabs together and push the locking slide back. Page Electronic Fuel Injection NOTE: Accurate testing of EFI components is The ignition and injection functions are electronically controlled, monitored and continually corrected during recommended utilizing Polaris Diagnostic operation to maintain peak performance.
Software dealer only. The central component of the system is the Bosch Engine Depending on the another Polaris ATV EFI of the same model may be used significance or severity of the fault, normal operation may without system or engine component damage.
Attach Polaris pressure tester PU Route the tester Internal 30 Micron clear hose into a portable gasoline container or the Strainer Bottom equipment fuel tank.
Plug the fuel line and tank inlet or use a shop towel during removal. The throttle position sensor TPS is a non-serviceable item. If it is faulty, it must be replaced. This indicates all other components are working properly. Refer to Chapter 10 for ETS testing. Press inside insert A until it snaps into place. Step 3 Side Panel Removal Side panel removal is quick and easy, use the following instructions for removal and installation.
Remove seat by releasing the latch if equipped and lifting up on the seat. Front Storage Remove Bolts Remove the two T25 screws that secure the storage box to the front fender well areas each side. Pull the tabs out of the notches and lift up on the cover piece.
Remove the two screws B that secure the front cab to the frame in the fuel tank mount area. Install rear rack onto rear frame and cab. The bottom handle bar block has a side with 3 holes, the side with 3 holes faces up and to the front of the ATV. Align the pin A in the top block with the middle hole B in the bottom block for proper installation. Ball Joint Stud Bushing 8 ft. Apply grease to extension cap and threads of puller bolt to NOTE: Refer to the illustration on the previous page ease removal.
Front Strut Cartridge Replacement Remove the handle bar pod. NOTE: Refer to illustration on following page. Remove the handle bar. Remove the fuel tank bracket assembly. Hold strut rod and remove top nut.
Remove the steering tie rod ends from the steering bracket. The passenger backrest should be face down in the cargo box and the driver seat backrest should be locked into position. Reverse the removal steps to reinstall the cargo box. Refer to the standard fastener torque values in Chapter 1 during Remove the four bolts attaching the rear of the cargo box assembly.
Passenger Backrest Unlatch the driver seat backrest by turning the engagement knobs on each side in the directions shown below. With the passenger Configure the seating for 2-UP riding. Lift up on the latch seat bottom in place, remove the two screws retaining the for the passenger backrest and lift the backrest to the full seat bottom.
Remove the two pivot pins holding the backrest to the frame. Lift up on the backrest latch and tilt the backrest in towards the cargo box and lift up to remove it. For installation, reverse the removal steps. Torx Screw 2. Cam Assembly 3. Retaining Ring 4. E-clip 5. Washer 6. Roller 7. Outer Spider 8. Spring 9. Shaft Moveable Sheave Thrust Washer Roller Pin Spring Pin Periodic inspection and maintenance is required to keep the system operating at peak performance.
Refer to the spring specification chart for specific free length measurements and tolerances. Also check to see that spring coils are parallel to one another. These shift weights have many different 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 the effects they have on belt to sheave clearance, clutch balance, engagement and shifting characteristics.
The ATV should be fasteners and fastener placement. Replace if proper clutch offset on reassembly. Align the alignment mark on the cover with the mark on the engine seal. Mark drive belt direction of rotation so that it can be installed in the same direction. The belt is normally positioned so part numbers are easily read.
NOTE: Be sure to position belt so part number is easily read. Verify new belt is seated properly in the clutches before operating the ATV. Adjust if necessary. Remove belt and install the Clutch Offset Alignment Tool as shown.
Drive Clutch Disassembly Inspect Shaft Using a permanent marker, mark the cover, spider, and moveable and stationary sheaves for reference, as the cast- in X's may not have been in alignment before disassembly. Turn roller with your finger. If spider during assembly. Inspect BOTH sheaves for signs of wear, grooving or cracking. In order to remove bushings it will be Place main adapter Item 8 on puller. Rotate one-way clutch clockwise as viewed from the cover plate side. The clutch should rotate on the shaft Removal Tool 3 with only slight amount of drag.
Verify there is no binding Nut C or rough spots. Reinstall shift weights using new lock nuts on the bolts. Spider Nut Torque: 15 ft. Remove snap ring A and slowly Remove driven clutch from the transmission input shaft. Pull out the clutch roller pins L and rollers M.
Inspect the spider dampener E for wear and replaced if needed. Remove the E-clip F , washer G , and the clutch rollers H. Inspect the bearing for wear. To remove the bearing, simply press the bearing from the shaft. Turn puller barrel for further tension if Press a new bearing onto the output shaft using a press. Turn clutch sheave counterclockwise until bushing is removed and sheave comes free. Both Sides. Install the roller pin into the sheave assembly.
Both sides. The flat side of the roller pin faces downward when the shaft side is laying flat on the bench. Install the spider assembly onto the shaft with the retaining ring on top of the spider.
Install the cam assembly helix over the shaft. NOTE: If the cam assembly helix is difficult to install, be sure the sheaves are aligned. Page Pvt Troubleshooting During this procedure, the throttle should not be held at the full position for more than 10 seconds.
PVT seals should be inspected for damage if repeated leaking occurs. Engine RPM below specified operating range -Install correct shift weight kit to match engine -Drive clutch shift weight too heavy. Inspect brake Belt burnt, thin spots -Dragging brake system. Removal Set the ATV in park. Remove hub dust cap. Remove cotter pin. Loosen the hub retaining nut.
Loosen - but do not remove - the wheel nuts. Remove lower A-arm from ball joint. Install new compression ring on drive shaft. Apply an anti-seize compound to splines. Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer.
Check the front and rear driveshaft CV boots for any tears or leaking grease. If the driveshaft boot loses all of the grease CV joint failure will occur. Slide strut off end of drive shaft and tie it up out of the way of the shaft. Install the small clamp on the boot. Inspect the grease carefully for contamination, and clean the joint thoroughly if necessary. Slide prop shaft back and away from housing, then pull sharply forward to Always wear eye protection when working with remove from transmission shaft.
Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislodge needle bearings upon installation of cross joint. Repeat procedure for other side. Install snap ring to contain bearing cap just installed. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown.
Once enabled, the AWD Ring Gear remains engaged while the front gearcase is moving and will not disengage until the rear wheels regain traction. Description Ref. If only one band of wear is present or if there is wear between the two bands, inspect the coil area as Check the gearcase coil resistance. Also inspect the roll cage for cracks and ensure the rollers are Stop engine, place machine in Park and set parking brake. To install gearcase, reverse removal procedures.
Use new Remove bolts securing the bottom of housing to the skid roll pin in front prop shaft. Remove bolts arrows retaining the outer cover plate Locate bleeder valves found on either side of differential assembly.
Remove and Remove the armature plate. Inspect the armature plate for inspect the cover o-ring 1. Inspect thrust bearing 2 for wear, distortion or other damage. Replace component as wear. Replace items as required. Inspect roll cage sliding surface 2. This surface must be clean and free of nicks, burrs or scratches.
Remove and inspect the H-springs 4. Replace any components as required. Remove and inspect the bearing surfaces of the output hub. Inspect the magnetic coil 1 in the outer cover plate Inspect the magnetic coil 1 and bushing in the input cover assembly. Inspect the backlash pad 2 for excessive wear. Replace the input cover seal. Remove the snap ring retaining the input shaft assembly.
Safety glasses or a face shield are required. Using moderate hand pressure, hold the tool on top of the piston while using compressed air at the gearcase passage circled to force piston up and out of the case. Coat the edges of the verify alignment of the sight hole circled and piston mark piston cavities. Thoroughly clean the gearcase components before beginning reassembly. Install a new seal in the main gearcase halve. Install the input shaft assembly.
Install a new seal and o-ring the input shaft cover 2 prior to reassembly. Install the clutch pack 1 , spacer 2 and ring gear 3. Install a new o-ring on the backlash pad 2 stem. NOTE: Ring gear backlash 2 is set at the factory. Install new cover o-ring 1 on the cover plate assembly Place cover assembly on Install bolts arrows retaining the and a new passage o-ring 2 on the gear case.
NOTE: Ring gear backlash is set at the factory. No Set the gearcase upright. Rotate the input shaft at least 4 adjustment is required, unless the front cover is times. Remove rear hub cap. Remove hub. Remove cotter pin A. Loosen the hub retaining nut B. Loosen the wheel nuts C. Safely support the rear of the ATV. Remove both lower control arm bolts. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown or press out using a hydraulic press.
Remove bearing carrier. Support bottom of bearing carrier housing. Start bearing in housing. Install snap ring into groove. Installation Insert bearing carrier on drive shaft. Tip hub outward and remove Lift bearing carrier until top aligns with upper control arm.
The joint is fully inner and outer CV joints. Position clamp over boot end and make sure clamp tabs are located in slots. Refer to Chapter 9. Slide shaft assembly into bearing carrier hub. Install rear wheel and torque wheel nuts to specification. Refer to Page 7. Loosen both rear wheel nuts. Loosen both rear center hub nuts. Lift and safely support rear of ATV so that the rear wheels are off the ground. Spin the bearing to check the ball bearings for Inspect the pinion shaft bushing for wear.
Replace the bearing if needed. Remove the input shaft cover and the pinion shaft from the gearcase housing. Replace the drain plug washers to ensure proper sealing after filling. Input Cover Bolt Torque: 25 ft. Page 80 ft. Place the bellcrank in neutral position. Remove the front propshaft. Remove the the keyed spline.
Note the raised edge on the detent detent spring B. Remove the shift shaft and detent lever. Mark the detent gear C with a white pen. You may Remove the bearing from the reverse shaft using a puller. Remove the park lock engagement dog. Remove the wave spring and reverse engagement dog. Remove the snap ring and washer from the reverse shaft. Use a press to remove the gear from the shaft. Remove low gear 33T and the needle bearing.
Make note of the direction of the gear and hub location. Slide off the shift dogs and wave springs. Remove the pinion shaft retainer plate and the pinion shaft. Remove the front housing cover screws. Remove the snap ring, washer, gear, and split bearing. Remove the front housing cover, shim, thrust button, and Remove the shafts as an assembly. Reinstall the chain onto the front output shaft and rear output shaft.
Remove the silent chain from the assembly for shaft inspection. Install front and rear output shafts into the case. Note location of hubs Reinstall cover and torque bolts in a and torque screws to specification. NOTE: Verify case locating pins knock pipes are in place.
Slide the reverse shaft assembly through the silent chain. As the engagement dogs are installed onto the shaft, place the wave springs into the spring groove. Keep the spring in place while the fork is being installed on the shaft and while placing the shafts into the case. Position the shift forks up and so the pins point toward the Be sure the assembly. Place a small amount of grease PN into the Apply Crankcase Sealant PN onto the cover and pocket before installing the sector gear.
Install the shift gear case mating surfaces. Install the cover and hand tighten all 16T on the shift drum shaft. Refer to Maintenance Chapter 2 for more information. Refer to Chapter 2 for transmission lubricant service.
Brake caliper removal is Remove the middle transmission support bracket K required. Do not let calipers hang by the brake line. See completely from the ATV. Chapters 7 and 9 Remove both upper shock absorber mounting bolts and swing shocks away from the transmission. Page Transmission Installation Transmission Installation Reconnect the torsion bar to both lower control arms.
Page Troubleshooting Checklist Once the PVT system is installed. Tighten all remaining transmission mounting bolts to specification. See page 8. Lubricant to the proper level. See Chapter 2 for proper fill procedures and Torque Specifications. Place the transmission in the Neutral gear before disassembly. Drain and properly dispose of transmission oil. See Chapter Remove the bellcrank nut 1 and remove the bellcrank 2.
Remove the c-clip 3 that holds the gear selector switch 4 onto the shaft and remove the selector switch. Remove all cover bolts. Using suitable pry tools, remove Remove the cam chain tensioner spring Slide the cam the cover using the designated pry points.
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