Remove the mounting bolts from the transmission mounting on both sides of the transmission. Turn sheave and barrel together counterclockwise until Turn clutch cover counterclockwise on puller rod until bushing is seated. Remove cotter pin and castle nut from A-arm ball joint. Remove bolts and output shaft cover. Tighten bolts to specified torque. Generally, belt should be replaced if clutches can no longer be adjusted to provide proper belt deflection.
Remove the front housing cover, shim, thrust button, and thrust button shim. I'm not a pro but have some experience with these trucks go … od luck: Access the emergency fuel shut-off switch aka inertia switch located behind the passenger side kick panel and press the red button on it to de-activate the fuel pump. Torque the bolts to 18 ft. Install piston B with a twisting motion Rear Caliper Piston Bore I. To check the oil level follow the procedure listed below. Assemble rotors as marked when disassembled.
Install the lockout disc with the raised edge facing outward. Torque screws to 8 ft. Remove the shafts as an assembly. Turn puller apply additional tension if needed. Remove the rear wheel to gain access to the stabilizer bar, each side. Install the plug and torque to specification.
Support swing arm, remove rear axle shocks. Polaris Lubricants, Maintenance and Service Part No. Screws 20 ± 5 in. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip. Slide off the shift dogs and wave springs. Partially install the piston pins into the pistons.
If you didn't do this yet, you must go to the previous step and do it. Polaris measures chain length in number of pitches. Piston should slide in and out of bore smoothly, with light resistance. As you lift the latch off of the black plastic switch, push down on the gray connector. Be sure that tab of fulcrum F is seated in head stand-off.
The new bolts contain 22. Replace all O-ring, seals, and worn components. Disconnect the fuel line from the fuel pump. The throttle does not function correctly, replace it. Transmission Fill Plug 14-19 Nm 10-14 ft.
Remove screws D and ball joint retaining plate E. 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. Remove jackstand and torque mid hub nut to 110 ft. Install a new cotter pin with open ends toward rear of machine. Remove the rest of the bearings from the shafts.
Remove driven clutch offset spacers from the transmission input shaft. Check valve face for runout, pitting, and burnt spots. Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft. Torque banjo bolt to 15 ft. Compress the outer retainer and install the snap ring. Jack up and remove tires.
Sourcing a fuel pump is relatively easy. O-ring Seal 18 ± 2 ft. The last thing you want is more dirt in the tank. This fuel pump needed to be replaced. Adjust Polaris battery tender charger or by charging about gap if necessary by bending the side electrode carefully.