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2008 POLARIS SPORTSMAN 500 EFI / X2 / TOURING / 500 H.O. * DIY SERVICE / REPAIR / MAINTENANCE MANUAL 08 - DOWNLOAD (52 mb)

2008 POLARIS SPORTSMAN 500 EFI / X2 / TOURING / 500 H.O. * DIY SERVICE / REPAIR / MAINTENANCE MANUAL 08 - (52 MB)DOWNLOAD NOW!

( VERY HIGH QUALITY FACTORY SERVICE MANUAL - 52 + MB !! )

File Format: PDF
Compatible: All Versions of Windows & Mac
Downloadable: YES
Language: English
Requirements: Adobe PDF Reader.
Pages: 406 +

SERVICE MANUAL COVERS:
==================

GENERAL 1
MAINTENANCE 2
ENGINE 3
FUEL SYSTEM 4
BODY / SUSPENSION 5
CLUTCH 6
TRANSMISSION 7
FINAL DRIVE 8
BRAKES 9
ELECTRICAL 10
INTERNATIONAL 11

INDEPTH CONTENTS WITH ACTUAL PAGE / SUBSECTION NUMBERS:
==========================================

A
A-Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
Active Descent Control (ADC) Coil . . . . . . . . . . . . . . 10.19
Active Descent Control Gearcase . . . . . . . . . . . . . . . . . . 7.22
ADC Gearcase Piston Service . . . . . . . . . . . . . . . . . . . . 7.27
ADC Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.23
ADC reservoir level inspection . . . . . . . . . . . . . . . . . . . 2.18
Air Filter, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
Alignment, Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
All Wheel Drive (AWD) Coil . . . . . . . . . . . . . . . . . . . 10.19
All Wheel Drive and Speedometer Troubleshooting Tests . .
10.14
Alternator / Ignition Components . . . . . . . . . . . . . . . . . 10.24
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
ATV Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . 2.36
B
Ball Joint Replacement, Front . . . . . . . . . . . . . . . . . . . . 5.21
Battery Activation, Conventional . . . . . . . . . . . . . . . . . 10.50
Battery Charging Procedure, Low Maintenance . . . . . 10.55
Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53
Battery Load Test, Low Maintenance . . . . . . . . . . . . . 10.55
Battery Off Season Storage . . . . . . . . . . . . . . . . . . . . . 10.52
Battery Off Season Storage, Low Maintenance . . . . . . 10.52
Battery Open Circuit Voltage (OCV), Low Maintenance . . .
10.55
Battery Removal / Inspection, Conventional . . . . . . . . 10.51
Battery Specific Gravity Tes, Conventional . . . . . . . . . 10.53
Battery Terminals/Bolts . . . . . . . . . . . . . . . . . . . . . . . . 10.51
Battery, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.51
Battery, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Body and Steering Torque Values . . . . . . . . . . . . . . . . . . 5.2
Body Assembly Exploded View . . . . . 5.12, 5.13, 5.14, 5.16
Body Rack Exploded View . . . . . . . . . . . . . . . . . . . . . . 5.15
Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Brake Burnishing Procedure . . . . . . . . . . . . . . . . . . . . . . 9.12
Brake Caliper Exploded View . . . . . . . . . . . . . . . . . . . . . 9.5
Brake Caliper Removal, Rear . . . . . . . . . . . . . . . . 9.21, 9.23
Brake Caliper, Assembly . . . . . . . . . . . . . . . . . . . . . . . . 9.24
Brake Caliper, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
Brake Disc, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
Brake Disc, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
Brake Light / Work Light Switch Replacement . . . . . . 10.38
Brake Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
Brake Noise Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 9.7
Brake Pad Install, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
Brake Pad Removal, Rear . . . . . . . . . . . . . . . . . . . . . . . . 9.19
Brake Pad, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
Brake Pad, Removal and Installation . . . . . . . . . . . . . . . 9.10
Brake System Components, Std, Sportsman . . . . . . . . . . 9.4
Brake System Components, X2 . . . . . . . . . . . . . . . . . . . . 9.3
Brake System Exploded View, International . . . . . . . . . 11.3
Brake System Exploded Views . . . . . . . . . . . . . . . . . . . . 9.3
Brake System Overview, International . . . . . . . . . . . . . . 11.2
Brake, Master Cylinder Removal . . . . . . . . . . . . . . . . . . . 9.9
Brake, Rear Auxiliary Brake . . . . . . . . . . . . . . . . . . . . . 9.28
Brake, Rear Auxiliary Master Cylinder . . . . . . . . . . . . .9.26
Brake, Torque Specifications . . . . . . . . . . . . . . . . . . . . . .9.2
Brakes, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
Brakes, Operation Overview . . . . . . . . . . . . . . . . . . . . . . .9.6
Brakes, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .9.29
C
Cam Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14
Cam Chain Tensioner, Inspection . . . . . . . . . . . . . . . . . .3.14
Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
Camshaft Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.46
Carburetor (BST34) Exploded View . . . . . . . . . . . . . . . .4.33
Carburetor Jetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.32
Carburetor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.35
Carburetor Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.35
Carburetor, Air/Fuel Ratio . . . . . . . . . . . . . . . . . . . . . . .4.38
Carburetor, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .4.41
Carburetor, Choke System . . . . . . . . . . . . . . . . . . . . . . .4.36
Carburetor, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.40
Carburetor, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .4.39
Carburetor, Float Adjustment . . . . . . . . . . . . . . . . . . . . .4.42
Carburetor, Float System . . . . . . . . . . . . . . . . . . . . . . . . .4.37
Carburetor, Idle System . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
Carburetor, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .4.41
Carburetor, Jet Needle . . . . . . . . . . . . . . . . . . . . . . . . . . .4.39
Carburetor, Main System . . . . . . . . . . . . . . . . . . . . . . . .4.37
Carburetor, Needle Jet . . . . . . . . . . . . . . . . . . . . . . . . . . .4.39
Carburetor, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .4.35
Carburetor, Pilot Screw . . . . . . . . . . . . . . . . . . . . . . . . . .4.38
Carburetor, Throttle Opening vs. Fuel Flow . . . . . . . . . .4.39
Cargo Box, Removal and Installation . . . . . . . . . . . . . . .5.28
Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.53
Charging System - Break Even Test . . . . . . . . . . . . . . .10.27
Charging System Flow Chart . . . . . . . . . . . . . . 10.25, 10.29
Choke System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.32
Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
Clutch Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
Clutch, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .6.39
Clutching Chart . . . . . . . . . . . . . . . . . . . . .1.4, 1.6, 1.8, 1.10
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8
Component Locations, Sportsman . . . . . . . . . . . . . . . . . .2.7
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
Controls, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
Coolant Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . .10.21
Coolant, Level Inspection . . . . . . . . . . . . . . . . . . . . . . . .2.20
Coolant, Recommended Ratio . . . . . . . . . . . . . . . . . . . . . .3.8
Cooling System Pressure Test . . . . . . . . . . . . . . . . . . . . . .3.7
Cooling System Specifications . . . . . . . . . . . . . . . . . . . . .3.6
Cooling System, Maintenance . . . . . . . . . . . . . . . . . . . . .2.19
Counter Balancer Endplay Adjustment . . . . . . . . . . . . . .3.38
Counter Balancer, Removal and Inspection . . . . . . . . . .3.34
Crankcase Breather Filter, Service . . . . . . . . . . . . . . . . .2.22
Crankcase Separation . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
Crankshaft Endplay Adjustment . . . . . . . . . . . . . . . . . . .3.37
IX.2
Crankshaft Position Sensor (CPS) . . . . . . . . . . . . . . . . . .4.16
Crankshaft Position Sensor Gap . . . . . . . . . . . . . . . . . .10.26
Crankshaft Straightening . . . . . . . . . . . . . . . . . . . . . . . . .3.10
Crankshaft, Removal and Inspection . . . . . . . . . . . . . . . .3.35
Current Draw - Key Off Test . . . . . . . . . . . . . . . . . . . .10.27
CV Boot, Front Replacement . . . . . . . . . . . . . . . . . . . . . .7.5
CV Boot, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
CV Boot, Rear Replacement . . . . . . . . . . . . . . . . . . . . . .7.37
CV Carburetor System Function . . . . . . . . . . . . . . . . . . .4.35
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . .3.19
Cylinder Head Torque Procedure . . . . . . . . . . . . . . . . . .3.45
Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9
Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27
D
Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.12
Diagnostic Mode, EFI System . . . . . . . . . . . . . . . . . . .10.12
Differential Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . .10.32
Drive Belt, Installation . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
Drive Belt, Removal/Inspection . . . . . . . . . . . . . . . . . . .6.12
Drive Clutch Service, EBS . . . . . . . . . . . . . . . . . . . . . . .6.15
Drive Clutch Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8
Drive Clutch Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9
Drive Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
Drive Clutch, Standard . . . . . . . . . . . . . . . . . . . . . . . . . .6.28
Drive Shaft Boot Inspection . . . . . . . . . . . . . . . . . . . . . . .7.5
Driven Clutch Service, EBS . . . . . . . . . . . . . . . . . . . . . .6.22
Driven Clutch, Assembly . . . . . . . . . . . . . . . . . . . . . . . .6.37
Driven Clutch, Bushing Service . . . . . . . . . . . . . . . . . . .6.35
Driven Clutch, Disassembly / Inspection . . . . . . . . . . . .6.34
Driven Clutch, Exploded View . . . . . . . . . . . . . . . . . . . .6.34
Driven Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . .6.6
Driven Clutch, Standard . . . . . . . . . . . . . . . . . . . . . . . . .6.34
E
EBS Drive Clutch Service . . . . . . . . . . . . . . . . . . . . . . . .6.15
EBS Driven Clutch Service . . . . . . . . . . . . . . . . . . . . . . .6.22
EBS Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . 6.4, 6.5
EBS, Driven Clutch Operation . . . . . . . . . . . . . . . . . . . . .6.7
EFI Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . .4.9
EFI Priming / Starting Procedure . . . . . . . . . . . . . . . . . .4.10
Electrical Service Notes . . . . . . . . . . . . . . . . . . . . . . . . .10.4
Electrical, Service Notes . . . . . . . . . . . . . . . . . . . . . . . . .10.4
Electrical, Special Tools . . . . . . . . . . . . . . . . . . . . . . . . .10.3
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . .4.11
Elelctrical, Troubleshooting Diagrams . . . . . . . . . . . . .10.56
Engine Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . .4.23
Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14
Engine Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . .3.13
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . .3.9
Engine Oil, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
Engine Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8
Engine Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4
Engine Temperature Sensor . . . . . . . . . . . . . . . . . . . . . .4.20
Engine Temperature Sensor Replacement . . . . . . . . . . . 4.21
Engine Temperature Sensor Test . . . . . . . . . . . . . . . . . . 4.21
Engine, Fastener Torque Patterns . . . . . . . . . . . . . . . . . . 3.3
Engine, Lubrication Requirements . . . . . . . . . . . . . . . . 3.11
Engine, Oil and Filter Change . . . . . . . . . . . . . . . . . . . . 2.23
Engine, Oil Pump Priming . . . . . . . . . . . . . . . . . . . . . . . 2.25
Engine, Torque Specifications . . . . . . . . . . . . . . . . . . . . . 3.3
Engine, Valve Clearance / Adjustment . . . . . . . . . . . . . 2.25
ETC Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
ETC Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
F
Fan Control Circuit Operation . . . . . . . . . . . . . . . . . . . 10.20
Fan Control Circuit Operation / Testing . . . . . . . . . . . 10.20
Fan Motor Current Draw . . . . . . . . . . . . . . . . . . . . . . . 10.20
Final Drive Torque Specifications . . . . . . . . . . . . . . . . . . 7.2
Flywheel / Stator Removal . . . . . . . . . . . . . . . . . . . . . . . 3.31
Foot Well Removal / Installation . . . . . . . . . . . . . . . . . . . 5.5
Front Cab Removal / Installation . . . . . . . . . . . . . . . . . . . 5.9
Front Cover Removal / Installation . . . . . . . . . . . . . . . . . 5.4
Front Drive Axle Installation . . . . . . . . . . . . . . . . . . . . . . 7.4
Front Drive Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Front Gearcase - Back Lash Pad Adjustment . . . . . . . . 7.18
Front Gearcase Coil Resistance . . . . . . . . . . . . . . .7.14, 7.23
Front Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . 2.12
Front Gearcase, Active Descent Control Exploded View 7.21
Front Gearcase, Diagnoses . . . . . . . . . . . . . . . . . . . . . . . 7.19
Front Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.13
Front Gearcase, Exploded View . . . . . . . . . . . . . . . . . . 7.11
Front Gearcase, Installation . . . . . . . . . . . . . . . . . . . . . . 7.20
Front Gearcase, Operation . . . . . . . . . . . . . . . . . . . . . . . 7.11
Front Gearcase, Reassembly . . . . . . . . . . . . . . . . . . . . . 7.29
Front Gearcase, Reassembly / Inspection . . . . . . . . . . . 7.17
Front Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Front Hub, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Front Hub, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Front Storage Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Front Storage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Fuel Filter, Replacement . . . . . . . . . . . . . . . . . . . .2.17, 4.46
Fuel Gauge Sender, Installation . . . . . . . . . . . . . . . . . . . 4.47
Fuel Gauge Sender, Removal . . . . . . . . . . . . . . . . . . . . . 4.46
Fuel Injection, Component Locations . . . . . . . . . . . . . . . 4.8
Fuel Injection, Exploded View . . . . . . . . . . . . . . . . . . . . 4.7
Fuel Injection, Service Notes . . . . . . . . . . . . . . . . . . . . . . 4.6
Fuel Injection, Special Tools . . . . . . . . . . . . . . . . . . . . . . 4.4
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Fuel Level Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.43
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Fuel Pump / Tank Assembly . . . . . . . . . . . . . . . . . . . . . 4.12
Fuel Pump, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.45
Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
Fuel System Special Tools . . . . . . . . . . . . . . . . . . . . . . . 4.32
Fuel System, EFI Circuit Diagrams . . . . . . . . . . . . . . . . 4.24
Fuel System, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Fuel Tank/Fuel Delivery System . . . . . . . . . . . . . . . . . . 4.44
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
G
Gear Position Indicator Switch Test . . . . . . . . . . . . . . . 10.21
Gearcase, ADC Hydraulic Fluid Change . . . . . . . . . . . . 2.14
Gearcase, Front Capacity and Fluid Type . . . . . . . . . . . . 7.2
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
H
Handlebar Block Installation Procedure . . . . . . . . . . . . . 5.18
Headlamp Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
Headlight Housing Replacement . . . . . . . . . . . . . . . . . 10.34
Headlight Pod Exploded View . . . . . . . . . . . . . . . . . . . . 5.17
High Beam Bulb Replacement . . . . . . . . . . . . . . . . . . . 10.34
High Beam Headlight Adjustment . . . . . . . . . . . . . . . . 10.35
Hydraulic Brake System Operation Overview . . . . . . . . . 9.6
I
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
Ignition System Troubleshooting . . . . . . . . . . . . . . . . . 10.26
Instrument Cluster (Speedometer) Overview . . . . . . . . . 10.8
Instrument Cluster Diagnostic Mode . . . . . . . . . . . . . . . 10.9
Instrument Cluster Overview . . . . . . . . . . . . . . . . . . . . . 10.8
Instrument Cluster, Setting New Service Interval . . . . 10.11
K
Keys, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
L
Low Beam Headlight Adjustment . . . . . . . . . . . . . . . . 10.37
Low Maintenance Battery Charging . . . . . . . . . . . . . . . 10.54
Low Maintenance Battery Info . . . . . . . . . . . . . . . . . . . 10.54
Lower Headlamp Housing Removal . . . . . . . . . . . . . . 10.36
Lower Headlamp Removal . . . . . . . . . . . . . . . . . . . . . . 10.36
Lubricants/Fluids, Polaris Brand Part Numbers . . . . . . . . 2.9
Lubricants/Fluids, Polaris Brand Symbol Identification Chart
2.10
M
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 2.41, 2.42
Maintenance, General Information . . . . . . . . . . . . . . . . . . 2.3
MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
Mikuni Jet Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . 4.32
Misc. Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Model Number Information . . . . . . . . . . . . . . . . . . . . . . . 1.2
N
Needle and Seat, Leakage Test . . . . . . . . . . . . . . . . . . . . 4.42
O
Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Oil Flow, Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Oil Pressure Test, Engine . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Oil Pump Priming Procedure . . . . . . . . . . . . . . . . . . . . . 3.11
Oil Pump Shaft Endplay Adjustment . . . . . . . . . . . . . . . 3.39
Oil Pump, Removal and Inspection . . . . . . . . . . . . . . . . 3.33
P
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
Passenger Seat, Operation . . . . . . . . . . . . . . . . . . . . . . . .5.31
PDM, 450 Connector Pin Table . . . . . . . . . . . . . . . . . . .10.6
PDM, 500 Carbureted Overview . . . . . . . . . . . . . . . . . . .10.5
Pilot System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6
Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . 3.30, 3.43
Plastic Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3
Pre-ride Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
Propshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7
Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
PVT Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.11
PVT Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
PVT Drive Clutch Operation . . . . . . . . . . . . . . . . . . . . . . .6.6
PVT Drive Clutch Shift Weights . . . . . . . . . . . . . . . . . . .6.9
PVT Drive Clutch Specifications . . . . . . . . . . . . . . . . . . .6.8
PVT Driven Clutch Operation . . . . . . . . . . . . . . . . . . . . . .6.6
PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
PVT Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3
PVT Maintenance / Inspection . . . . . . . . . . . . . . . . . . . . .6.7
PVT Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
PVT Overheating Chart . . . . . . . . . . . . . . . . . . . . . . . . . .6.39
PVT Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
PVT Torque Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
PVT Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . .6.40
PVT, Button to Tower Clearance . . . . . . . . . . . . . 6.17, 6.30
PVT, Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
PVT, Clutch Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
PVT, Drive Belt Installation . . . . . . . . . . . . . . . . . . . . . .6.13
PVT, Drive Belt Removal/Inspection . . . . . . . . . . . . . . .6.12
PVT, Drive Clutch Disassembly . . . . . . . . . . . . . . 6.15, 6.28
PVT, Drive Clutch Exploded View . . . . . . . . . . . . . . . . . .6.3
PVT, Drive Clutch Reassembly . . . . . . . . . . . . . . 6.20, 6.32
PVT, Drive Clutch Spider Removal . . . . . . . . . . . 6.15, 6.29
PVT, Driven Clutch Bushing Service . . . . . . . . . . . . . . .6.24
PVT, Driven Clutch Disassembly . . . . . . . . . . . . . . . . . .6.22
PVT, Driven Clutch Reassembly . . . . . . . . . . . . . . . . . .6.25
PVT, EBS Clutch Operation . . . . . . . . . . . . . . . . . . . . . . .6.7
PVT, EBS Drive Clutch Bushing Service . . . . . . . 6.18, 6.31
PVT, EBS Drive Clutch Cover Bushing Remove/Install 6.19,
6.32
PVT, Moveable Sheave Inspection . . . . . . . . . . . . 6.18, 6.31
R
Radiator Cap Pressure Test . . . . . . . . . . . . . . . . . . . . . . . .3.7
Radiator Screen Removal . . . . . . . . . . . . . . . . . . . . . . . .5.11
Rear Cab Removal / Installation . . . . . . . . . . . . . . . . . . .5.10
Rear Master Cylinder, Exploded View . . . . . . . . . . . . . .9.26
Rear Rack Removal / Installation . . . . . . . . . . . . . . . . . . .5.8
Rear Storage Removal / Installation . . . . . . . . . . . . . . . .5.11
Rear Suspension Assembly . . . . . . . . . . . . . . . . . . 5.24, 5.25
Recoil Housing, Draining / Inspection . . . . . . . . . . . . . .2.22
Recoil, Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
Recoil, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51
IX.4
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.31
S
Shift Linkage Inspection . . . . . . . . . . . . . . . . . . . . . . . . .2.14
Side Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4
Solenoid, Differential . . . . . . . . . . . . . . . . . . . . . . . . . .10.32
Spark Plug, Inspection / Replacement . . . . . . . . . . . . . . .2.18
Special Tools, Body & Steering . . . . . . . . . . . . . . . . . . . .5.2
Special Tools, EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4
Special Tools, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
Special Tools, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .7.2
Special Tools, Speed Sensor . . . . . . . . . . . . . . . . . . . . .10.39
Specificaiton, Stator Plate Bolt Torque . . . . . . . . . . . . . .3.49
Specification, Brake Disc Service Limit . . . . . . . . . . . . .9.25
Specification, Brake Disc Thickness . . . . . . . . . . . . . . . .9.25
Specification, Brake Pad Thickness . . . . . . . . . . . . . . . .9.19
Specification, Cam Chain Stretch . . . . . . . . . . . . . . . . . .3.32
Specification, Cam Chain Tensioner Spring . . . . . . . . . .3.15
Specification, Camshaft Lobe Height . . . . . . . . . . . . . . .3.18
Specification, Crankcase Bolt Torque . . . . . . . . . . . . . . .3.41
Specification, Crankshaft Slotted Nut Torque . . . . . . . .3.43
Specification, Cylinder Compression . . . . . . . . . . . . . . .2.17
Specification, Cylinder Head Torque Procedure . . . . . . .3.45
Specification, Cylinder Head Warp . . . . . . . . . . . . . . . . .3.21
Specification, Cylinder Taper . . . . . . . . . . . . . . . . . . . . .3.29
Specification, Cylinder Warp . . . . . . . . . . . . . . . . . . . . .3.28
Specification, Differential Solenoid Resistance 10.32, 10.39
Specification, Differential Solenoid Torque . . . 10.33, 10.39
Specification, Drill and Tap Sizes . . . . . . . . . . . . . . . . . .1.13
Specification, Flywheel Nut Torque . . . . . . . . . . . . . . . .3.49
Specification, Fuel Pump Pressure . . . . . . . . . . . . . . . . .4.12
Specification, Oil and Filter . . . . . . . . . . . . . . . . . . . . . .2.23
Specification, Oil Pip Bolt Torque . . . . . . . . . . . . . . . . .3.50
Specification, Oil Pump Bolt Torque . . . . . . . . . . . . . . .3.34
Specification, Oil Pump Shaft Endplay . . . . . . . . . . . . . .3.39
Specification, One Way Valve Spring Length . . . . . . . .3.32
Specification, Piston to Cylinder Clearance . . . . . . . . . .3.29
Specification, PVT Center-to-Center Distance . . . . . . . .6.13
Specification, PVT Component Torque Table . . . . . . . . .6.2
Specification, PVT Drive Belt Width . . . . . . . . . . . . . . .6.13
Specification, Rocker Arm and Shaft . . . . . . . . . . . . . . .3.15
Specification, Rocker Shaft Bolt Torque . . . . . . . . . . . .3.50
Specification, Spark Plug Gap . . . . . . . . . . . . . . . . . . . .2.18
Specification, Speed Sensor Bolt Torque . . . . . . . . . . .10.39
Specification, Tensioner Blade Bolt Torque . . . . . . . . . .3.43
Specification, Transmission Silent Chain Length . . . . . .8.19
Specification, Valve Clearance . . . . . . . . . . . . . . . 2.26, 3.26
Specification, Valve Guide Height . . . . . . . . . . . . . . . . .3.23
Specification, Valve Stem and Guide . . . . . . . . . . . . . . .3.22
Specifications, Body and Steering Torque Values . . . . . .5.2
Specifications, Brake Component Service Limits . . . . . . .9.2
Specifications, Brake Component Torque Values . . . . . .9.2
Specifications, Engine Fastener Torque . . . . . . . . . . . . . .3.3
Specifications, Engine Service Data . . . . . . . . . . . . . . . . .3.4
Specifications, Final Drive Torque Values . . . . . . . . . . . .7.2
Specifications, Front Gearcase Lubrication Type/Capacity 7.2
Specifications, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
Specifications, Power Distribution Module . . . . . . . . . . 10.5
Specifications, Standard Torque Values . . . . . . . . . . . . 1.12
Specifications, Vehicle . . . . . . . . . . . . . . . 1.4, 1.6, 1.8, 1.10
Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
Speedometer Installation . . . . . . . . . . . . . . . . . . . . . . . 10.13
Speedometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
Speedometer Troubleshooting Tests . . . . . . . . . . . . . . 10.14
Starter Armature Testing . . . . . . . . . . . . . . . . . . . . . . . 10.45
Starter Assembly Exploded View . . . . . . . . . . . . . . . . 10.46
Starter Brush Inspection / Replacement . . . . . . . . . . . . 10.44
Starter Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
Starter Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
Starter Lockout, Troubleshooting . . . . . . . . . . . . . . . . 10.42
Starter Motor Dissassembly / Replacement . . . . . . . . . 10.44
Starter Reassembly / Installation . . . . . . . . . . . . . . . . . 10.46
Starter System Flow Chart . . . . . . . . . . . . . . . . . . . . . . 10.48
Steering A-Arm Exploded View . . . . . . . . . . . . . . . . . . 5.19
Steering Lock, Exploded View . . . . . . . . . . . . . . . . . . . 11.4
Steering Post Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
Steering Post Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
Steering Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Steering, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Storage Compartment, Latch Operation . . . . . . . . . . . . 2.34
Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
Strut Cartridge Replacement, Front . . . . . . . . . . . . . . . . 5.22
Suspension, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
T
Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Throttle Position Sensor Initialization . . . . . . . . . . . . . . 4.20
Throttle Position Sensor Replacement . . . . . . . . . . . . . . 4.19
Throttle, Linkage Inspection . . . . . . . . . . . . . . . . . . . . . 2.15
Tie Rod, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Trail Boss Emissions System . . . . . . . . . . . . . . . . . . . . . 11.5
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Transmission I.D. Information . . . . . . . . . . . . . . . . . . . . . 1.2
Transmission Mounts, Exploded View . . . . . . . . . . . . . . 8.2
Transmission, 500 Carbureted Exploded View . . . . . . . . 8.9
Transmission, Disassembly . . . . . . . . . . . . . . . . . . . . . . 8.11
Transmission, Exploded View . . . . . . . . . . . . . . . . . . . . . 8.7
Transmission, Fluid Check / Change . . . . . . . . . . . . . . . 2.13
Transmission, Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Transmission, Output Shaft Backlash Procedure . . . . . . 8.17
Transmission, Reassembly . . . . . . . . . . . . . . . . . . . . . . . 8.16
Transmission, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Transmission, Special Tools . . . . . . . . . . . . . . . . . . . . . . 8.3
Troubleshooting Diagrams, Elelctrical . . . . . . . . . . . . 10.56
Troubleshooting, EFI Circuit Diagrams . . . . . . . . . . . . . 4.24
Troubleshooting, Engine . . . . . . . . . . . . . . . . . . . . . . . . 3.53
U
U-joint, Disassembly and Assembly . . . . . . . . . . . . . . . . 7.7
V
Valve Clearance Adjustment . . . . . . . . . . . . . . . . 2.26, 3.26
Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . . . . 3.23
Vehicle Identification Number (VIN) . . . . . . . . . . . . . . . 1.2
Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
W
Warn Winch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
Water Pump Seal, Installation . . . . . . . . . . . . . . . . . . . . 3.41
Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Wheels, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Wheels, Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
Wheels, Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Wire Diagram, Winch Basic . . . . . . . . . . . . . . . . . . . . . 10.49
Wire Diagrams, Electrical . . . . . . . . . . . . . . . . . . . . . . 10.56
Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
X
X2, Seat Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32

ALL INFORMATION ARE FULLY SEARCHABLE AND COMPLETELY INDEXED FOR EASY NAVIGATION AND ATMOST EASE... :)

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DESCRIPTION:
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INFORMATION YOU CAN COUNT ON !!

RELATED KEYWORDS:
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