Slide mid drive shaft A onto the mid gearcase output shaft B. Remove the bearings from the axle tube with a bearing puller. Description : View and download polaris sportsman 6x6 owners manual online polaris 2002 atv owners manual sportsman 6x6 offroad vehicle pdf manual download also for 2002 sportsman 6x6 controls and features controls sportsman 6x6 vehicle nomenclature 1 service brake lever 2 middle axle auxiliary brake 3 throttle lever 4. Torque the bolts to specification and follow proper bolt torque sequence at the beginning of this chapter. These marks must align housing. Inspect the crankshaft gear Q for broken or worn teeth.
I am a new member from today friday the 21st of november i am a mecanic on my fritime and repair cars and trctors and so on just now i am helping a friend with his polaris sportsman 6x6 500 2009 and hope to find a service and repair manual for this. If damaged, replace the roll cage assembly. Remove balance shaft and crankshaft. The filter should be inspected periodically before each ride, using the following procedure. Install spindle through the backside of the hubstrut. Remove castle nut B and separate A-arm C from ball Refer to Front Strut Exploded View.
Remove the gear selector handle 2. E Emission Control System Service California Have an authorized Polaris dealer perform these services. Remove the input cover Inspect the pinion gear K and 26T output gear L for nics H and pinion gear assembly from the gearcase. Exhaust system temperatures can reach 1000° F. Install head bolts C and torque to specification. If oil or water deposits are found, drain them If the foam insert is dirty, clean the foam with a high flash into a suitable container. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.
Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Proceed at a steady rate of speed and throttle opening. Remove the bearing from the input shaft with a puller. Remove the large bearing from the differential assembly. Remove the shims from the armature shaft and their guides and remove brush plate. See page 99 for the part numbers of Polaris products.
Install oil pump housing bolts H. Reinstall the shock mounting bolts. Battery voltage should be checked with a digital multitester. The resistance of the component is equal to tested value minus the lead Part Number Tool Description resistance. Hydraulic Lifter Apply Polaris 0W-40 Oil Apply Moly Lube Grease.
Slide brush end frame inspect the O-rings located on the armature housing. Flywheel Nut Torque 65 ± 7 ft. Damping should be smooth throughout the range of travel. Replace the disc if any deep scratches are evident. Click on the instant download button to pay with your PayPal or credit card and you will receive the download link instantly. A gritty feeling indicates contamination. Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip.
Thoroughly clean the cam shaft. Once the gears are pressed together, firmly hold the gears 21. Loosen each U-bolt nut a few turns at a time, this will reduce stress on all of the U-bolts during Place the rear axle assembly on a clean surface. Some fasteners and procedures will vary. The pressure Gasoline is extremely flammable and explosive adapter has an integrated relief valve. Always refuel outdoors or in a well ventilated area. Field test machine at low speed before putting into service.
Use a press to remove the gear from the shaft. Never turn at excessive speeds. Rotate each bearing by hand and check for smooth rotation. If performing this service is difficult due to conditions or location, open the hood and temporarily disconnect the parking brake connector. Located in tank as an assembly 7. Wear Ring on Armature Plate Check the gearcase coil resistance.
Periodic inspection and maintenance is required according to the forces applied to it from the drive belt and the to keep the system operating at peak performance. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. They are specifically written for the do-it-yourself as well as the experienced mechanic. If this occurs, inspect and adjust parking brake cable tension. Inspect the foam insert in the engine intake air baffle box. This will tell you which tie rod should be smooth throughout the range of travel. Measure the thickness of the pad material.