Replace the disc if runout exceeds specifications. Forward Fuel tank-mounted valve Oil Level Sensor Vent Hose Oil Tank Oil Filter Forward Polaris Sales Inc. Install pinion shaft with bearing. If the light is not on when neutral is selected, check the bulb. Do not use the cast mark to determine flywheel application. Check all cam timing marks to verify proper cam timing, and install the cam chain tensioner body with a new gasket.
Do not substitute bolts or use old ones. Be sure sealing surfaces cover transmission case are clean. Ratchet Friction Ring and Pawl Guide 10. Lubricate and install inner thrust washer, low gear, and needle bearing. The sprockets and outer rollers require periodic lubrication. Remove the remaining gears and shafts as an assembly.
Remove pinion shaft retainer plate and pinion shaft. Minimum Check brake for excessive travel or spongy feel. Lubricate front housing O-ring thoroughly with Polaris All Season grease. Remove outer bearing and spacer. In order to avoid serious burns, wear some type of insulated gloves for the rest of the removal process. Remove camshaft end cap and O-Ring. Repeat for exhaust valves by pouring fluid into exhaust port.
Remove ratchet pawl with spring and inspect. Slide axle assembly out left side. Note hole location of spring in helix and sheave 4. The venturi cross-sectional area in the carbure- tor bore is increased or decreased automatically by the vacuum slide, which moves according to the amount of negative pressure less than atmospheric present in the venturi. Polaris Xplorer 400 4x4 Manual Pdf can be very useful guide, and Polaris Xplorer 400 4x4 Manual Pdf play an important role in your products. Step 5 and 6 6. Bend rear of side panel and insert the two tabs into the rear cab.
Tensioner cam will lift shoe and tension chain. Reinstall cover and torque bolts in a criss-cross pattern in 3 steps to 18 ft. Piston Pin Measurement Locations Polaris Sales Inc. Set up a dial indicator to measure shaft end play. Tighten mounting fasteners in order A-F as shown. Turn clutch sheave counterclockwise until bushing is removed. Tighten the jam nut securely while holding the adjuster bolt.
Std ±15% Polaris Sales Inc. Oil Pump Attaching Bolt Torque: 6 ft. Place vehicle on a level surface. Compare to specifications on page 3. Cutaway Angle Throttle Valve Jet Needle Air Jet By-pass Pilot Outlet Engine Side Air Box Side Pilot Jet Needle Jet Main Jet Larger Smaller Leaner Richer Polaris Sales Inc. Install the crankcase flange bolts and tighten in 3 steps in a criss-cross pattern to specified torque.
Check recoil and ratchet operation. Reinstall battery, attaching positive + red cable first and then the negative - black cable. Remove front hub and bearings. Lubricate eccentric housing grease fitting with Polaris Premium All Season Grease. Big End Radial Clearance: Refer to page 3. I don't think the previous owners knew there was engine oil in the 2 stroke. Reinstall the left and right body panels.
Follow procedure install hilliard clutch components and hub as outlined on page 7. Install the tensioner blade and tighten the mounting bolt to specified torque. The needle and seat should hold pressure indefinitely. Remove nut from puller rod and take installation tool and clutch cover off rod. Replace pads if worn beyond the service limit. Outer Dust Seal Polaris Sales Inc.
Remove bottom transmission bolts as shown in illustration. Measure diameter of valve stem with a micrometer in three places and in two different directions six measurements total. Do not hang caliper by brake line. Make sure to verify no continuity as well as continuity. Remove needle bearing, low gear, and inner thrust washer.