Polaris Sportsman 335 Manuals
Manuals and User Guides for Polaris Sport 335. We have 1 Polaris Sport 335 manual available for free PDF download: Service Extremity
Polesta Sportsman 335 Service Manual (666 pages)
Brand: Polaris | Family: Offroad Vehicle | Size: 15.13 MB
Put over of Contents
-
-
2
General Information / Specifications
-
2
Table of Table of contents
-
-
4
Chapter 1-
4
Engine Serial Identification number Emplacemen
-
4
Machine Model Number and VIN Number Positioning
-
4
Pose / VIN Identification
-
4
Transmission I.D. Numeral Position
-
5
Current Model Numbers
-
5
Vehicle Identification Number
-
5
Vehicle Identification Add up / Model Number Key
-
5
Year / Letter Identification
-
-
6
1999 Publication Part Numbers
-
6
General Information
-
6
Service Bulletin Index
-
6
Service Training Videos
-
7
1999 Paint Codes
-
-
8
Standard Torsion Specifications
-
10
Conversion Table
-
11
Metric Tap Drill Sizes
-
11
SAE Water tap Drill Sizes
-
-
11
Tap Drill Charts
-
12
Service Tips
-
13
Glossary of Terms
-
14
Gloss of Terms
-
16
Special Tools
-
17
1999 Model Specifications
-
17
Trail Blazer
-
19
Trail Boss 250
-
21
Xpress 300
-
23
Xplorer 300
-
25
Sportsman 335
-
28
Sportswoman 400
-
29
Scrambler 400
-
30
Scrambler 500
-
36
Magnum 500
-
-
36
1999 Manakin Specifications
-
41
Chase away Blazer
-
43
Xplorer 4X4
-
45
Trail Boss 325
-
51
Xpedition 325
-
53
Sportsman 335
-
55
Xplorer 400
-
57
Scrambler 400 2X4
-
59
Scrambler 400 4X4
-
61
Xpedition 425
-
63
Magnum 500
-
65
Scrambler 500
-
69
Sport 6X6
-
72
Maintenance
-
-
-
74
Chapter 2-
74
Periodic Maintenance Chart
-
75
Pre-Ride / Daily Review
-
76
Recommended Lubricants - Quick Reference
-
77
Polaris Premium Lubricant and Maintenance Product Part Numbers pool
-
79
Lubrication
-
81
Lubrication - Barb Force Models
-
82
Lubrication Chart - Shaft Drive Models
-
83
Gearcase Lubrication - Quickly Reference
-
84
Presence Gearcase Lubrication
-
86
Rear Gearcase Lubrication
-
87
Dipstick Models
-
87
Transmission Lubrication
-
88
Shaft / Chain Models Without Dipstick
-
89
Counter Libra Oil Changing Procedure
-
89
Counter Halter Lubrication (400Cc Engines)
-
89
Procedure for Adding Oil (400)
-
90
Torsion Stop Adjustment
-
90
Transmission Gearshift Gene linkage Adjustment, Preliminary Inspection
-
91
Shift Linkage Adjustment -High/Low/Reverse Transmissions
-
93
Shift Linkage Adjustment (High/Reverse Transmissions)
-
-
94
Carburettor Adjustments
-
94
Choke (Enricher) Adjustment
-
94
Throttle Operation - All Models
-
95
Airwave Screw Adjustment
-
96
Pilot light Screw Anti-Tamper Punch Remotion
-
97
Pilot film Screw (Wild Mixture) Readjustment Notes
-
97
Pilot program Gaoler Adjustment - 335 4- -Stroke Models
-
97
Pilot Screw Adjustment - 425 / 500 4- -Stroke Models
-
98
Idle Hurry Adjustment
-
99
Throttle Cable / Physics Throttle Control (ETC Switch) Adjustment
-
100
Oil Pump Adjustment Process
-
102
Oil Pump Bleeding Procedure
-
102
Oil Pump Troubleshooting Function
-
103
Oil Strain (2 Strokes)
-
104
Fuel Filter
-
104
Fuel Lines
-
-
104
Fire System
-
104
Vent Lines
-
105
Carburetor Exhausting
-
106
Compaction Test - 2 Stroke
-
106
Compression Examine - 4 Cam stroke
-
106
Engine Mounts
-
106
Fastener Torsion - Engine
-
-
107
Battery Upkeep
-
107
Physical phenomenon
-
108
Electrical
-
108
Engine-To-Frame Ground
-
108
Ignition Timing
-
108
Sparking plug
-
109
Coolant Strength / Type
-
109
Cooling System Hoses
-
109
Liquid Cooling System Overview
-
109
Radiator
-
110
Coolant Level Inspection
-
111
Cooling system
-
111
Radiator Coolant Level Review
-
112
Air cleaner Service of process (Trail Blazer Style)
-
113
Multiple Stage Air Cleaner - 300 Dash
-
113
Main Pre-Cleaner Sparkle Boot
-
114
Cleaning the Important Sink in
-
114
Secondary (Main) Filter
-
114
Secondary Trickle Removal and Installation
-
-
116
Air Filter Service, 2 CVA
-
116
Air Filtrate Servicing, 4 Stroke
-
116
Breather Filter
-
117
Air Box Deposit Tube
-
118
Breather Filter Inspection
-
118
Breather Hose
-
-
119
Recoil Lodging
-
120
Engine Oil Level (4 Fondle)
-
120
Oil and Filter Shift (4 Stroke)
-
122
Valve Clearance - 335, 425, 500Cc Engines
-
123
Exhaust Valve Headway Fitting
-
123
Intake Valve Clearance Adjustment
-
125
Steering & Toe Alinement Review
-
125
Attach Rod cell Finish / Steering Inspection
-
126
Straightedge or String
-
127
Chalk
-
127
Two-toed Alignment Accommodation
-
128
Front Hub Fluid Change (AWD Models)
-
128
Front Hub Fluid Level Inspection (AWD Models)
-
129
Exhaust Pipe
-
130
Brake Pad Inspection
-
130
The brakes Inspection
-
-
130
Brake System Service
-
130
Hose/Fitting Review
-
131
Secondary Bracken Adjustment (Hydraulic)
-
132
Aide Brake Adjustment - Mechanical
-
132
Auxiliary Pteridium aquilinu Testing
-
132
Auxiliary Mechanical The brakes
-
133
Drive Chain and Sprocket Inspection
-
133
Drive Range of mountains Inspection
-
133
Sprocket Inspection
-
134
Bum Drive Sir Ernst Boris Chain Tension Adjustment - Normal Swingarm
-
134
Rear Beat back Mountain range Tension Inspection - Standard Swingarm
-
135
Adjustment Procedure - Homocentric Swingarm Rear Axles (Tapered Roller Bearings)
-
135
Drive Chain Adjustment, Concentric Swingarm
-
138
Center/Front Drive Chain Inspection/Adjustment
-
138
Center/Front Drive Chain Slack Adjustment
-
139
6X6 Chain Inspection
-
139
6X6 Middle Axle Chain Adjustment
-
139
6X6 Rear Axle Drive Chain Adjustment
-
139
Tug Chain Inspection/Adjustment - 6X6
-
140
Controls
-
140
Foremost Intermission
-
140
Rear Suspension
-
140
Suspension Spring Preload Modification
-
141
Bod Maintenance
-
141
Wheel Removal Front or Rump
-
141
Wheel, Hub, and Spindle Torque Table
-
141
Wheels
-
142
Frame, Nuts, Bolts, Fasteners
-
-
142
Tire Review
-
142
Exhaust Pressure
-
142
Exhaust Trample Depth
-
144
Engine
-
146
Torsion Specifications
-
148
Engine Fastener Torque Patterns
-
149
Piston Clearance Specifications (2 Throw Engines)
-
149
Walter Piston Identification
-
150
ES33PFE01 / 02 Locomotive Table service Data
-
152
EH42PLE02 / EH50PLE04, 06, 08, 09 Engine Service Data
-
154
Bleed Hole Inspection
-
154
Radiator Pileus Pressure Test
-
154
System Pressure Test
-
-
-
155
Chapter 3-
155
Engine cooling system Specifications
-
155
Advisable Coolant
-
156
Accessible Components - Wholly Models
-
156
Engine Removal
-
157
Locomotive engine Remotion
-
158
Bleed Engine cooling system
-
-
158
Engine Installation Notes
-
158
General Items
-
158
PVT Arrangement
-
159
EC25PF / EC28PF Engine Dismantling
-
160
Connecting Rod Side Clearance
-
160
Crankshaft Main Charge Inspection
-
161
EC25PF/EC28PF Engine Assembly
-
161
Measure out Crankshaft Width - - Bearings Installed
-
166
Oil Pump End Play Registration
-
167
Oil Check Valve Examination (EC25PF)
-
167
Oil Check Valve Testing (EC28PF)
-
168
Recoil Disassembly
-
-
169
EC25PF Bounce Forum
-
171
EC38PL Engine Disassembly
-
172
EC38PL Engine Inspection
-
177
Connecting Radial Clearance
-
178
Reed Valve Review
-
178
Water Pump Impeller Clearance
-
179
Impeller Spacer Shim Part Numbers
-
180
Oil Check Valve Testing (EC38PL)
-
181
Cylinder Inspection/Measuring
-
181
Walter Piston Inspection/Measurement (2 Apoplexy)
-
182
Walter Piston Call Installed Gap
-
183
Cleaning the Cylinder afterward Honing
-
183
Cylinder Hone Selection/Honing Routine
-
183
Honing to Oversize
-
184
Connecting Rod Small End Comportment Inspection
-
-
185
Crankshaft Runout Inspection - 2 Throw
-
185
Crankshaft Straightening
-
186
4 Stroke Engine Service
-
188
Engine Lubrication - ES33PF / EH50PL
-
188
Oil Pressure Mental testing - ES33PF / EH50PL
-
189
Oil Flow -- ES33PF
-
190
335 (ES33PFE) Oil Flow Chart
-
-
191
ES50PL Lubrication/Oil Current
-
192
EH50PL Oil Flow Chart
-
193
Es33Pfengine Exploded View
-
194
EH50PL Engine Exploded View
-
195
Cam Chain Tensioner/Rocking chair Arm/Camshaft Removal
-
195
Engine Disassembly / Inspection
-
195
To Military position Crankshaft at Top Breathless Substance (TDC) on Compression Stroke
-
196
Cam River Chain Tensioner Inspection
-
-
196
ES33PF / EH50PL Engine Removal
-
197
Rocker Weapon system/Shaft Removal
-
198
Rocker Arm/Shaft Inspection
-
200
Camshaft Remotion
-
202
Machine-driven Compression Release Initiation
-
202
Automatic Compression Release Remotion/Inspection
-
202
If Camshaft Is Installed in the Engine
-
202
If Camshaft Is Removed from Engine
-
203
Camshaft Review
-
204
Cylinder Head Exploded View, ES33PF
-
205
Cylinder Head Exploded View, EH50PL
-
206
Cylinder Head Inspection
-
207
Piston chamber Head Disassembly
-
207
Cylinder Head Warpage
-
209
Valve Inspection
-
210
Combustion Chamber
-
211
Piston chamber Head Reconditioning
-
211
Valve Guide Removal/Installation
-
211
Valve Seat Inspection
-
212
Reaming the Valve Guide
-
212
Valve Seat Reconditioning
-
215
Cylinder Head Forum
-
216
Valve Sealing Examination
-
217
Piston chamber/Walter Piston Removal and Inspection
-
-
217
ES33PF / EH50PL Engine Butt End Disassembly
-
219
Piston Removal
-
220
Piston chamber Inspection
-
221
Piston-To-Cylinder Clearance
-
224
Crankcase Disassembly
-
224
Starter Push on Remotion/Inspection
-
225
Flywheel/Stator coil Removal/Review
-
226
Cam Chain/Tensioner Blade
-
227
One Style Valve
-
228
Crankcase Separation
-
229
Oil Pump Removal/Inspection
-
231
Oil Ticker Fabrication
-
232
Counter Halter Shaft Remotion/Inspection
-
233
Crankshaft Removal/Inspection
-
234
Crankcase Bearing Inspection
-
234
Pump Shaft Oil Cachet/ Water Pump Mechanic SEAL Removal (Railway locomotive Disassembled)
-
235
Bearing Installation
-
235
Crankcase Assembly
-
236
Crankshaft End Play Adjustment
-
236
End Play Inspection/Adjustment
-
238
Counter Balancer Shaft End Play Adjustment
-
239
Pump Shaft
-
239
Pump Shaft Oil Seal Instalmen
-
240
Crankshaft, Counter Balancer, and Oil Heart Installation
-
241
Body of water Pump Mechanical Seal Installation (EH50PL)
-
241
Water Heart Mechanical Cachet Removal - Engine Installed (EH50PL)
-
243
Cam Mountain range Drive Sprocket Installation
-
243
I Style Valve Initiation
-
243
Tensioner Blade Facility
-
244
Piston Ring Installation
-
245
Piston Installation
-
246
Cylinder Instalmen
-
248
Cylinder Fountainhead Installation
-
249
Cam Chain/Camshaft Installation
-
249
Camshaft Timing
-
-
251
ES33PF / EH50PL Engine Assembly/Inspection
-
252
Cam Chain Tensioner Induction
-
252
Stator, Flywheel and Starter Drive Installation
-
253
Flywheel
-
253
Starter Crusade
-
254
Oil Pipes
-
254
Rocker Shaft/Rocker Branch Assembly Installation
-
254
Thermostat Installation
-
255
Flinch Dismantlement/Inspection
-
257
To Complete Recoil Assembly
-
257
To Install a New Spring
-
257
To Reinstall an Old Spring
-
258
Plug Fouling - 2 Stroke Engines
-
258
Sparking plug Fouling - 4 Stroke Engines
-
-
258
Sparking plug Fouling Checklist
-
259
2 Stroke Locomotive engine Troubleshooting
-
261
Engine Does Not Upset
-
261
Locomotive engine Idles simply will Non Rev up
-
261
Engine Runs but volition Not Otiose
-
261
Engine Turns over but Fails to Start
-
262
Backfiring
-
262
Unrestrained Smoke and Carbon Buildup
-
262
Low Condensation
-
263
EH42PL/EH50PL Cooling System Troubleshooting
-
263
Leak at Water Pump Weep Hole
-
263
Overheating
-
263
Temperature too Low
-
264
Fuel System/Carburetion
-
266
Air Screw (2 Cycle) / Aviate Screw (4 Cycle) Adjustment
-
-
266
Primary Jet Selection
-
-
-
266
Chapter 4-
266
Jetting Guidelines
-
267
Fuel Tank Assembly / Oil Tank Assembly
-
269
Fuel Flow Diagrams
-
269
Fuel System Diagram - 2 Stroke Models
-
269
Fire Arrangement Diagram - 4 Stroke Models
-
272
Send/Fuel Mixture Ratio
-
272
E-Prune Position Vs. Fuel Flux
-
272
Pilot Aerial Screw
-
272
Aviate Jet
-
273
Jet Goad
-
273
Needle Jet
-
273
Throttle Opening Vs. Fuel Menstruate
-
-
274
Main Jet / Pilot Jet Part Numbers
-
274
Accelerator
-
275
Starter System - Unreceptive Throttle (2 Rhythm)
-
276
Pilot System (0-3/8 Throttle) (2 Cycle)
-
277
Slide Cutaway (1/8-3/8 Throttle) (2 Motorcycle)
-
278
Fountain Needle/Needle Jet (3/8-3/4 Throttle) (2 Cycle)
-
279
Main System (3/4 to Full Throttle) (2 Cycle)
-
-
280
Carburetor Component Function (2 Cycle)
-
280
Component Effect Vs. Throttle Opening (2 Cycle)
-
280
Mikuni Fuel Manner of speaking (2 Rhythm)
-
-
281
Assembly, 105 Carburetor
-
281
Float Height Adjustment (2 Cycle)
-
281
Needle and Seat Leakage Try out - 2 Bike
-
281
Vent Systems (2 Cycle)
-
282
Mikuni VM30SS / VM34SS Carburetor Unconnected Purview
-
283
4 Cycle CV Carburetor System of rules Function
-
283
Air Systems - 4 Cycle CV Carburettor
-
284
Mikuni CV Carb Operation
-
285
Pilot (Idle and Slow) System
-
285
Starter System (Choke operating theater Enrichment)
-
286
Swim Organization
-
286
Main System
-
287
Mikuni BST 34 Carburetor Exploded View
-
288
Mikuni BST 40 Carburetor Exploded Consider
-
289
Carburetor Disassembly Notes- Mikuni CV
-
291
Carburetor Cleaning - Mikuni CV
-
292
Carburettor Inspection - Mikuni CV
-
293
Carburettor Assembly - Mikuni CV
-
294
Carburetor Adjustment - Mikuni CV
-
294
Float Height Adjustment
-
295
Fuel Level
-
295
Acerate leaf and Seat Escape Test
-
-
296
Fuel Pump
-
296
Fuel Ticker Dismantlement
-
296
Fire Heart Review/Fabrication
-
-
297
Fuel Pump Exploded Regar
-
298
Fuel Famishment/Lean Mixture
-
298
Poor Idle
-
-
298
Troubleshooting
-
298
Colorful Mixture
-
299
Erratic Unsupported
-
299
Idle too Low
-
300
Body / Guidance / Suspension
-
302
Torsion Specifications, Special Tools
-
303
Body Assembly Exploded Though (Gen Ll - Typical)
-
303
Front Cab Assembly
-
303
Rear end Cab Fabrication
-
304
Cover/Panel Removal (Gen Ll - Typical)
-
305
Body Fabrication Exploded View (Gen Lll - Typical)
-
306
Covering fire/Control board Removal (Gen Lli - Characteristic)
-
307
Body Assembly Unconnected Though (Gen Lv - Typical)
-
308
Cover/Panel Removal (Gen Lv - Typical)
-
309
Headlamp Seedpod Exploded View (Gen Lv - Typical)
-
310
Side Empanel Removal (Gen Lv - Typical)
-
311
Typic Steering Assembly, Exploded View, '99 Trail Boss 250
-
312
Steerage Assembly, Exploded View, - 2X4 Models (Take out '99 Trail Knob 250)
-
313
Steerage Assembly, Unconnected View All 4X4 and 6X6 Models
-
314
A-Arm Replacement
-
315
Concentric Swing Arm Removal
-
317
Standard Lilt Weapon system and Rear Suspension Exploded View
-
318
Quill Ride Swingarm Unconnected Sentiment
-
319
Shaft Depend upon Swingarm
-
319
Swingarm Installation
-
320
Rear Suspension Assembly, - Chouse Driving Models
-
321
Rear Strut Stabiliser, 6X6 Models
-
322
Rear Swing Arm Weldment, 6X6 Models
-
323
Frontmost Swing Arm Weldment, 6X6 Models
-
324
Strut Assembly Exploded View - 2X4 Models
-
325
Sasha Assembly - AWD Models
-
326
Front Strut Cartridge Replacement
-
326
Front Strut Weldment Replacement
-
327
Ball Joint Replacement
-
327
Front Strut Ball Joint Replacement
-
330
Decalcomania Replacement
-
332
Clutches
-
334
Clutch Specifications
-
334
PVT System Fastener Torques
-
334
Special Service Tools and Supplies
-
335
Drive Clutch Operation
-
335
Driven Clutch Operation
-
335
PVT Operation
-
335
Standard PVT Organization Introduction
-
-
-
336
Chapter 6-
336
PVT Maintenance/Inspection
-
336
PVT Drying
-
336
PVT Overheating
-
336
PVT Sealing and Ducting Components
-
337
PVT Dismantlement
-
339
PVT Gathering
-
340
PVT Sealing and Ducting Components
-
343
Family relationship of Drive Clutch pedal Weights and Spring in Maintaining Operating RPM
-
344
Drive Clutch Spring Specifications
-
-
345
Shift Weights
-
346
Clit to Tower Clearance Review
-
346
Drive Clutch Review
-
346
Shift Burthen Inspection
-
347
Drive Clutch &A; East by south Exploded Eyeshot
-
348
Drive Clutch Disassembly/Inspection
-
349
Moveable Sheave Bushing Inspection
-
349
Spider Remotion
-
350
Rolling wave, Pin and Hurl Washer Inspection
-
-
351
Drive Clutch Assembly
-
353
Modular P-90 (Non-EBS) Clutch
-
355
Drive Belt out Tension
-
356
Drive Belt Removal/Review
-
357
Clutch Alignment/Offset
-
359
Drive in Clutch Bushing Service
-
359
Drive Clutch Moveable Sheave - Bushing Removal
-
359
Polaris Kit PN 2871226
-
360
Drive Hold Moveable Sheave - Bushing Installation
-
361
Drive Clutch Shroud - Bushing Remotion
-
362
Drive Hold close Cover - Cylindrical lining Installation
-
-
363
Driven Clutch Disassembly/Inspection
-
366
Goaded Clutch Gathering
-
367
Driven Clutch Bushing Service
-
369
Driven Clutch Moveable Sheave - Bushing Installment
-
372
Locomotive Braking System (EBS) Clutch
-
373
EBS Theory of Operation
-
374
Operation Guidelines for Ebs Clutches
-
-
375
EBS Exploded Opinion
-
376
One-Way Clutch Inspection (Drive Clutch)
-
379
Driven Clutch Disassembly/Inspection - EBS
-
379
Unidirectional Clutch Overture Review (Driven)
-
383
Ebs Clutch Cylindrical lining Removal and Installment
-
383
Ebs Drive Clutch Moveable Sheave - Bushing Removal
-
383
Removal and Installation Operating instructions
-
384
EBS Clutch Continue - Cylindrical lining Induction
-
384
EBS Clutch Cover - Bushing Removal
-
384
East by south Drive Moveable - Cylindrical lining Installation
-
385
EBS Determined - Bushing Installation
-
385
EBS Driven - Bushing Removal
-
386
EBS Driven - Backside (Outer) Bushing Installation
-
386
EBS Involuntary - Rear end (Outer) Bushing Removal
-
387
Clutch Troubleshooting
-
390
Inalterable Drive
-
392
Final Drive
-
393
2X4 Hub Bearing / Seal Replacement
-
-
-
393
Chapter 7-
393
2X4 Front Hub Disassembly/Inspection
-
396
2X4 Front Hub Installation
-
397
2X4 Front Hub Meeting place
-
397
2X4 Face Hub Exploded View
-
399
AWD Operation Overview
-
399
Electric Hub Engagement (AWD)
-
400
AWD Front Hub Disassembly
-
400
Front Hub Removal (AWD)
-
401
Hub/Wheel Bearing Initiation
-
-
402
AWD Front Hub Bearing Adjustment
-
403
AWD Frontal Hub Unconnected Perspective
-
405
AWD Hub Seal Alternate
-
406
AWD Magnetic Coil Service
-
406
Magnetic Coil Installation
-
406
Magnetic Coil Removal
-
-
407
AWD Hilliard Clutch Disassembly/Inspection
-
408
AWD Armature Plate Inspection
-
409
AWD Front Drive Axle Remotion
-
410
AWD Front Force Axle Installation
-
411
Driveshaft and CV Joint Handling Tips
-
411
Front Drive Shaft One hundred five Joint Charge Successor
-
-
413
AWD Breast Drive Axle Exploded View
-
413
Front Drive Axle Components
-
413
Front Prop Shaft Components
-
414
AWD Swagger Cast Front Drive Axle Seal Replacement
-
414
Bearing Replacement Note for Advanced Drive Axle and Front Hub
-
415
Seal Sleeve Replacement
-
415
Seal Arm Tool
-
-
416
AWD Strawma Prop Shaft Remotion
-
417
U-Conjoined Dismantling (Typical)
-
417
U-Joint Service
-
-
418
U-Joint Assembly
-
420
AWD Look Housing Remotion
-
420
Front Housing Disassembly
-
421
AWD Front Housing Identification
-
-
422
AWD Front line Housing Disassembly
-
422
AWD Front Housing Identification
-
424
AWD Front Housing Assembly
-
424
AWD Figurehead Housing Installation
-
427
Front Housing Installation
-
428
AWD Front Housing Unconnected View
-
429
Prat Drive
-
430
Raise Axle Bend
-
430
Rear Drive Axle Service - Xpress / Xplorer 300
-
431
Rear Axle Installation
-
431
Rear Axle Removal
-
432
Concentric Swingarm Rear Axle Removal
-
434
Concentric Swingarm Rear Axle Installation
-
435
Concentric Swingarm Rear Axle Assembly, Exploded View
-
436
Concentrical Swingarm Rear Axle Dismantling
-
437
Concentric Swingarm Buns Axle Meeting place
-
438
Concentric Swingarm Rear Living accommodations Remotion
-
440
Concentric Swingarm Rear Housing Installation
-
440
Concentric Swingarm Rear Housing Service
-
440
Rear Housing Assembly/Bearing Service
-
440
Rear Caparison Disassembly/Bearing Service
-
441
Rear Hub Review
-
445
Rear Axle Presence Remotion
-
446
Rise up Axle Bearing Installation
-
447
Rear Hub/Bearing Carrier Remotion
-
-
449
Parent Hub Installation - Independent
-
450
As Hub Disassembly - Independent
-
451
Rear Hub Assembly - Independent
-
452
Rear Drive Shaft Removal - Independent
-
454
Rear Drive Shaft Installing
-
455
Rear Drive Shaft Disassembly (U-Joint Style)
-
455
U-Joint Inspection - Rear Drive Shafts
-
456
Rear Drive Shaft Disassembly (Dual CV Joint Elan)
-
457
CV Joint Assembly Procedure
-
458
Iron boot Installation
-
458
The boot Replacing
-
458
CV Joint Cleaning / Replacement
-
459
Strong-minded Posterior Suspension Exploded View
-
-
460
Center Eccentric Caparison Service
-
460
Tapered Armorial bearing Center Freaky Assembly Process
-
461
Front Eccentric Disassembly / Assembly Procedure
-
-
461
Front Outlandish Housing Avail
-
461
Front Freaky Remotion / Installation Process
-
462
Center / Front Chain Tightener Exploded View
-
464
Contagion Serve
-
-
466
Transmission Type Identification
-
-
-
466
Chapter 8-
466
Torsion Specifications
-
467
Gear Shift Selector Removal
-
467
Gear Shift Selector Disassembly
-
469
Gear Shift Selector Assembly
-
470
Boot Replacement
-
470
Gearing Shift Selector Installation
-
471
Type III, EZ Shift Transmitting Assembly
-
471
Case III, EZ Shift Transmittal Disassembly
-
472
Eccentric Triplet, EZ Tilt Transmission Installation
-
477
Typewrite III, EZ-Shift Transmission Installation (Typical)
-
478
Speedometer Service
-
-
479
Type III, EZ Shift Transmission, Exploded View
-
480
Type IV, Shaft Drive Infection Assembly
-
480
Case IV, Barb Drive Transmission Disassembly
-
480
Eccentric IV, Shaft Drive Transmission Installation
-
480
Type IV, Jibe Push back Transmission Removal
-
484
Transmission Initiation
-
486
U Joint Style Shafts
-
487
Premium Synthetic substance Gearbox Lubricant
-
487
Rear Rack Retaining Bolt Torque
-
488
Transmission Disassembly
-
496
Bushing Drive Tool
-
497
Bushing Installation, Transmission Center Shaft
-
497
Head-on Output Housing (Schnorchel) Assembly
-
499
Final Installed Shaft Remnant Play
-
499
Front Output Housing (Snorkel) Initiation
-
500
Front End product Living accommodations (Snorkel) Rebound Adjustment
-
501
Transmission Output Gear Backlash Inspection/Adjustment
-
505
Oil color Deflector Screws
-
506
Tensioner Assembly - Top Regar
-
506
Tensioner Installation
-
506
View from Left Lateral of Transmission
-
508
Seal of approval Installation Tool
-
509
Transmitting Unconnected View
-
510
Transmission Removal/Installation
-
-
510
Type V, Shaft/Chain Transmission Assembly
-
510
Eccentric V, Shaft/Chain Transmission Disassembly
-
511
Slay Gear Indicator Switch(Es)
-
514
Transmittal Assembly
-
-
518
Type United States Virgin Islands, Barb Devolve on Transmittal Assembly
-
518
Typewrite VI, Dig Taunt Transmission Disassembly
-
518
Type VI, Scape Ride Transmission Installation
-
518
Case Cardinal, Cheat Ride Transmission Removal
-
526
Infection Exploded View
-
527
Transmission system Troubleshooting Checklist
-
528
Brakes
-
530
Brakes Specifications
-
531
Brakes Torque Specifications
-
532
Pteridium aquilinu Pad Basics
-
-
532
Brake Pad Kits
-
532
Brake System Service Notes
-
533
Brake Noise Troubleshooting
-
534
Binary compound Brake System Operation
-
534
Typical Hydraulic Brake System
-
535
Dual Hydraulic Brake Caliper (DH Calliper)
-
-
535
Treble Hydraulic Caliper Bleeding
-
537
Brake Bleeding - Fluid Change
-
537
Fluid Replacement/Hemorrhage Procedure
-
538
Get over Cylinder Fluent Level
-
538
Reservoir Cover Torsion
-
-
539
Captain Cylinder Disassembly
-
539
Brake cylinder Inspection
-
541
Hydraulic brake cylinder Forum
-
542
Master Cylinder Installation
-
544
Front Pad Removal
-
545
Front end Pad Brake Service
-
546
Front Disc Inspection
-
547
Front Bracken Disc Remotion / Replacement
-
548
Caliper Disassembly
-
-
548
Front Caliper Remotion
-
549
Front Caliper Dismantling
-
550
Front Caliper Assembly
-
550
Front Caliper Review
-
551
Front Calliper Installation
-
552
Front Pteridium aquilinu Caliper Unconnected Sentiment
-
553
Brake Dramatize Removal
-
553
Dual Hydraulic Pasture brake Caliper
-
554
Aide Brake Master Cylinder Fluid Level
-
554
Brake Pad Installation
-
554
DH Pasture brake Caliper
-
555
Multiple Binary compound Brake Caliper Remotion/Inspection
-
556
Double Hydraulic brakes Calliper Assembly
-
557
Calliper Mounting Bolt Torque
-
558
Dual Hydraulic Brake Disc Inspection
-
559
DH (Trans. Mounted) Caliper/Master Cylinder
-
560
DH (Rear Axle Mounted) Caliper/Master Piston chamber
-
561
DH (Beam of light Taunt) Caliper/Master Cylinder
-
562
Auxiliary Pteridium aquilinu Caliper Service (Mechanical) Disassembly
-
563
Ancillary Brake Caliper Service (Mechanical) Assembly
-
564
Auxiliary Pasture brake Calliper Robert William Service (Mechanical) Instalmen
-
564
Calliper Climb down Bolt Torque
-
564
Polaris DOT 3 Pteridium aquilinu Fluid
-
565
Auxiliary Brake Calliper (Mechanical)
-
566
Auxiliary Brake Caliper Mounting (Mechanical)
-
567
Brakes Squeal
-
567
Brakes Troubleshooting
-
567
Calliper Overheats (Brakes Pull)
-
567
Poor Bracken Carrying out
-
570
Electrical Special Tools
-
-
571
Headlamp Service, Gen II
-
571
Headlamp Service, Gen III
-
571
Headlamp Service, Gen Quartet
-
571
Headlight Adjustment (Gen II)
-
571
Headlamp Lamp Replacement (Gen II)
-
573
Adjustment - Trail Blazer and Sport
-
573
Headlight Adjustment (Gen Leash -Scrambler, Trail Blazer and Sport)
-
573
Headlamp Lamp Transposition (Gen Threesome)
-
573
Trail Sports coat and Sport
-
574
Trail bike
-
575
Headlamp Service - Gen Lv
-
575
Headlight Housing Replacement (Gen Quaternity)
-
575
Headlight Lamp Replacement (Gen Intravenous feeding)
-
575
Highschool Beam Headlight Adjustment (Gen IV)
-
576
Pilot light Replacement (Gen II)
-
576
Indicant Lamp Replacement (Gen Lll and Gen IV)
-
-
576
Indicator Lamp Servicing
-
576
Taillight/Brakelight Lamp Replacement
-
577
Timing Check Procedures
-
578
Typical 2-Stroke
-
578
Typical 4-Shot
-
-
578
Typical Ignition system Timing Curves
-
579
Crankshaft Arcdegree to Walter Piston Position Conversion
-
580
Flywheel Identification
-
580
Flywheel Identification Seal Location
-
581
Components of EC25/28PL 150 Watt Alternator (Exploded View)
-
582
Components of EC38PL 150 James Watt Alternator (Unconnected Prospect)
-
583
Components of EC38PL 200 Watt Alternator (Exploded View)
-
584
Components of ES33PF/EH50PL 200 / 250 Watt Alternator (Exploded View)
-
-
585
Ignition Testing
-
586
CDI Outturn Test Using Peak Reading Adaptor
-
586
Cranking Output Test with Peak Reading Voltmeter
-
-
587
Ignition System Troubleshooting
-
587
No Spark, Weak operating theatre Intermittent Activate
-
588
Assault and battery Terminals/Terminal Bolts
-
588
Initial Battery Service
-
589
Assault and battery Inspection/Removal
-
589
Stamp battery Installing
-
589
Battery Examination
-
589
OCV - Bald Circuit Potential dro Test
-
590
Lading Test
-
590
Specific Gravity Test
-
591
Charging Procedure
-
591
Electrolyte Freezing Points
-
591
Bump off Season Storage
-
591
Polaris Insulator Grease
-
-
592
Charging Organisation Testing
-
593
Charging System
-
593
Charging System "Break of serve Even" Test
-
593
Current Draw - Key off
-
594
Alternator Output Test (AC Amp)
-
595
Starter Does Not Wrick
-
595
Starting motor Turns over Slowly
-
-
595
Starter System Troubleshooting
-
596
Voltage Drop Testing
-
597
Starter Motor Disassembly (Typical)
-
598
Brush Inspection/Replacement
-
600
Armature Testing
-
601
Starter Assembly
-
601
Entran Motor Installation (EC38PL)
-
602
Pinion Gear - Anti Kick-Kayoed Shoe, Garter Spring Replacement
-
-
602
Fledgeling Push back
-
602
Starter Solenoid Judiciary Test
-
603
Limiter Specifications
-
603
Speed Limiter Arrangement
-
604
Electronic Throttle Moderate (ETC) - Theory of Operation (Sportsman 335, Xplorer/Xpress 300, Trail Boss)(LR44)
-
604
Travel rapidly Limiter System - Theory of Operation (Sportsman 335, Xplorer/Xpress 300, Trail Honcho)
-
606
Module Wire Colour in Function
-
606
Belt along Limiter System Examination
-
607
Reverse Limit System
-
608
No Reverse Speed Limit
-
608
Reverse Speed Circumscribe System
-
610
All Wheel Drive (AWD) Testing
-
610
No Altogether Roll Drive (AWD) along Spear Drive Models Equipped with Hub Safety Module
-
610
No AWD in Reverse
-
611
All Wheel Drive Scheme
-
611
Front Hub Engagement Limiter (Front Spear Force Models)
-
611
Hub Engagement Clipper RPM Test
-
613
Electronic Speedometer Troubleshooting Overview of Operation
-
613
Engine Run Time Hour Meter
-
613
Reverse Fastness Limit (PVT Models Only)
-
613
Vehicle Swiftness and Odometer
-
615
Electronic Speedometer (Pvt Models)
-
616
Zero Entirely Wheel Drive
-
616
No Speedometer And/Or Hodometer Display
-
617
No High schoo Speed Engagement Limit
-
617
No Reverse Speed Limit (Vehicle bequeath Exceed 7-9Mph in Reverse)
-
618
Rescind Speed Limiter Activated in Forward Geartrain(S)
-
618
Wheel Speed up Sensor
-
619
Reset Speed indicator
-
621
Key Switch/Auxiliary Shut remove (Kill) Switch
-
621
Override Clitoris
-
621
Starter Switch
-
621
Switch Examination (Sportsman 335, Xplorer/Xpress 300, Lead Boss)
-
622
Gear Chooser Switch/Neutral Light
-
623
Coolant Temperature Detector Examine (Hot Light)
-
623
Torrid Light Circuit Test
-
623
Oil Level Sensor Testing (2 Stroke Models)
-
623
Oil colour Level Monition Unhorse Examination (2 Stroke Models)
-
-
623
Switch Testing
-
624
Embrocate Cooler Fan Circuit
-
624
Oil Cooler Devotee Notes
-
624
Thermistor / LR60 Rooter Control Examine
-
625
Stoplight Switch
-
-
625
Fan Motor Current Draw Test
-
625
Electrical switch Examination
-
626
Gear Position Indicator Switch Test
-
626
Switch Continuity Table
-
626
Change Schematic
-
-
627
Electronic Throttle Control Scheme Operation
-
627
ETC Operation Test
-
629
Wiring Diagrams
-
630
Wiring Diagram 1999 Trail Sport jacket
-
631
Wiring Diagram 1999 Give chase Boss
-
632
Wiring Diagram 1999 Xplorer 300 / Xpress 300
-
633
Wiring Diagram 1999 Sportsman 335
-
634
Wiring Diagram 1999 Sport 400
-
635
Wiring Diagram 1999 Dirt bike 400 (Early)
-
636
Wiring Plot 1999 Scrambler 400 (Late)
-
637
Wiring Plot 1999 Xplorer 400
-
638
Wiring Diagram 1999 Scrambler 500
-
639
Wiring Diagram 1999 Magnum 500
-
640
Wiring Diagram 1999 Sportsman 500 / Sportswoman 500 RSE
-
641
Wiring Plot 1999 Worker 500 (International)
-
642
Wiring Diagram 1999 Big Boss 500 6X6
-
643
Wiring Diagram 2000 Trail Blazer
-
644
Wiring Plot 2000 Xplorer 4X4
-
645
Wiring Diagram 2000 Trail Boss 325
-
646
Wiring Plot 2000 Magnum 325 2X4
-
647
Wiring Diagram 2000 Magnum 325 4X4
-
648
Wiring Diagram 2000 Xpedition 325
-
649
Wiring Diagram 2000 Sportsman 335 (Early)
-
650
Wiring Diagram 2000 Sportsman 335 (Late)
-
651
Wiring Diagram 2000 Xplorer 400
-
652
Wiring Diagram 2000 Scrambler 400 2X4
-
653
Wiring Diagram 2000 Scrambler 400 4X4
-
654
Wiring Diagram 2000 Xpedition 425
-
655
Wiring Diagram 2000 Magnum 500 (Early)
-
656
Wiring Diagram 2000 Magnum 500 (Late)
-
657
Wiring Diagram 2000 Scrambler 500 (Early)
-
658
Wiring Plot 2000 Scrambler 500 (Latterly)
-
659
Wiring Plot 2000 Sportsman 500 (Young)
-
660
Wiring Diagram 2000 Sport 500 (Late)
-
662
Index
-
-
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