Polaris 2007 sportsman service manual

Loosen the hub retaining nut B. Loosen the wheel nuts C. Safely support the rear of the ATV. Remove both lower control arm bolts.

From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown or press out using a hydraulic press. Remove bearing carrier. Support bottom of bearing carrier housing. Start bearing in housing. Install snap ring into groove. Installation Insert bearing carrier on drive shaft. Tip hub outward and remove Lift bearing carrier until top aligns with upper control arm.

Tap CV housing off shaft with a soft faced Remove clamps from rubber boot s using the CV Boot hammer while holding snap ring open. Clamp Pliers PN A. Take care not to Remove CV joint from end of shaft. The joint is fully assembled when the snap ring is located in the groove on Remove boot from shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life.

ATV at the frame. Remove both rear wheels. Drain transmission lubricant if required. Transmission Case Bolts Remove seat, both side panels, both rear cab quarter panels and both footwells. Remove all fasteners X attaching the torsion mount, and Remove both upper control arms I. Refer to Chapter 7 for more details. Page Transmission Installation Install the upper control arms. Refer to Chapter 5 for procedures and torque specifications.

Page Troubleshooting Checklist Install the rear wheel nuts and torque to specification. See Chapter 2 for proper fill procedures and Torque Specifications. Place the transmission in the Neutral gear before disassembly. Drain and properly dispose of transmission oil. See Chapter Remove the bellcrank nut 1 and remove the bellcrank 2.

Remove the c-clip 3 that holds the gear selector switch 4 onto the shaft and remove the selector switch. Remove all cover bolts. Using suitable pry tools, remove Remove the cam chain tensioner spring Slide the cam the cover using the designated pry points. Tap cover with chain tensioner shoe 15 , pins 16 , and cam chain soft face hammer to remove.

Remove the T27 screws that secure the output gear 21 with a T27 hex socket or driver. Gear Cluster Disassembly Remove the shift drum 22 from the gearcase by moving the drum up and to the right to clear the shift shaft. Reverse Shaft Needle The reverse shaft should slide out of the silent chain 4 to To disassemble the shift fork rail remove the snap ring 10 separate the assembly. If needed, remove the seal from the front of the snorkel shaft snorkel tube Remove the snap ring Remove the second snap ring 13 and spacer 14 from the Front Drive Snorkel Assembly snorkel shaft.

To remove the remaining bearing on the snorkel shaft 15 , Inspect the output gear assembly 1 , replace bearings if remove the retaining ring and press the bearing off. Inspect the 91T gear for nics, chips, or abnormal worn teeth. If the output shaft lash appears to be too tight, rotate the the snorkel shaft bevel gear with the output bevel gear. This will allow the lock screw Input Shaft Assembly A. Inspect the NOTE: To ease assembly use a plastic tie strap to hold the shift forks D and the shift drum C together during splines of the shift drum.

Replace the O-rings on the end of the shift drum and lubricate them before assembly. Lift the leg of the spring up and over the rear pin. The Install the oil deflector shield into the gearcase.

Apply tensioner cam will lift the shoe and tension chain. Torque the screws to in. Apply a continuous bead of Crankcase Sealant 3-Bond Install the O-ring if not yet done and lockout disc H onto PN to the LH gearcase mating surface and install the shift drum shaft.

Be sure to install the lockout disc H the cover. Install the bellcrank onto the shift shaft. Note the key splined on the bellcrank and shaft. Install the nut. Torque the nut to ft. Install the transmission switch and secure the switch with the retaining ring. Socket Set Screw B. Bleeder Screw C.

Caliper Asm. Boot E. Square O-rings F. Piston G. Loose wheel hub or bearings replace bearings if worn Page in. Repeat procedure Steps for the remaining caliper s. Begin bleeding procedure with the caliper that is farthest Install a box end wrench on inside reservoir. Install diaphragm, sight glass, cap and screws.

Field test machine at low speed before putting into service. Check for proper braking action and lever reserve. Pad Removal Torque to 15 ft. Page Assembly Assembly edge. Remove inner pad. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. Severe injury may occur. Loosen and remove brake line to caliper. Place a container under caliper to catch fluid draining from brake line.

Install piston D with a twisting motion while pushing inward. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.

Remove the rear wheel Loosen pad adjuster screw turns. NOTE: Brake fluid will Support caliper so as not to kink Support the machine. Remove the rear tire. Remove the slide pin clips from the slide bolt. Push caliper pistons into caliper bore slowly with pads installed. Torque the slide pin to specification. Install new brake pads in caliper body. Install Pads ft. Clean caliper area before removal. Place a container below the caliper to catch brake fluid that will drain from the brake line.

Service Limit: 1. Clean the disc bracket pad C , and the brake pads D. The caliper body is a 2-step piston. The rear step is measured as well Install new O-rings in the slide bolt bushing holes. Be sure as the outside step.

O-ring and seal grooves are thoroughly cleaned of all residue, or piston may bind in bore. Inspection Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. Use a micrometer and measure disc thickness at 8 different points around perimeter of disc. Master Cylinder Bolts B. Rear Brake Line C. Rear Master Cylinder D. Bushing s E. Washer s F. Cotter Pin G. Foot Pedal H. Spring I. Front Brake Line J. Banjo Fitting 9. Page Overview If required, remove the rear brake line from the master cylinder.

Use a suitable container to catch the brake fluid. Polaris disc brake systems are light weight, low maintenance Dispose of brake fluid properly. Remove the RH footwell to gain access to the rear master cylinder. Remove the rear brake lines from the master cylinder. Use Banjo Bolt Torque: a suitable container to catch the brake fluid.

There are no service parts in the PDM. If the PDM fails, it must be replaced. Once tripped, switch. This is charged. When it begins to flash, release the button. The setting will increase by one hour each time the button is pressed. This will help the instrument instrument cluster. The gap should be Re-connect all wires. Disconnect spark plug wire from the spark 0. Using an inductive amperage metering device, set to DC amps connect to the negative battery cable.

Each should measure 0. Using a digital ohmmeter, test the solenoid at the connector leads and compare to the specification. Replacement of solenoid is required as it is not serviceable. Both Carefully remove head lamp bulb from housing. Sides Remove the head lamp and replace with a new head lamp. NOTE: Do not touch the lamp with bare fingers. The low beam can be adjusted slightly upward or downward. Loosen Screw Remove the lamp and replace with a new head lamp. NOTE: Do not touch the new lamp with bare fingers.

Hold the plastic part 1 of the lamp. The The brake light A and the work light B are both located in the switch A snaps out by pushing in on the tabs on both sides of rear tail lamp housing. Remove the front cover. Brake Lamp Switch X2 and Sportsman - Once the red tab is pulled out, press in on the black tab and pull out to disconnect harness.

Remove sensor and inspect the o-ring Set the fuel tank on a flat surface. This enables quick installation. Refer to Chapter 2 for more information on winch installation and operation. Some solvents may leave a residue or damage internal parts and insulation. Remove the starter from the engine. Remove the two bolts, washers, and sealing O-Rings. Remove armature from starter casing. NOTE: Note order of shims on drive end for reassembly. Brush Inspection Measure length of each carbon brush.

Replace brush Inspect surface of commutator. Do not drop or strike the housing as magnet damage is possible. If magnets are damaged, starter must be replaced. Inspect permanent magnets in starter housing. Make sure they are not cracked or separated from housing. Use either of the following methods to remove and install a new garter spring: A. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test.

This flow chart assumes that the starter lockout system is functional. With the tester on the VDC position, place the tester's black lead on the battery negative and the Remove battery and properly service. Different types of Battery electrolyte is poisonous. It contains sulfuric batteries require different service procedures. Serious burns can result from contact with Proper servicing and upkeep of your battery is very skin, eyes or clothing. Page Terminal Preparation 1.

Terminal Preparation Use Polaris corrosion resistant Nyogel grease PN on battery bolts and terminals when installing a battery. This will help to prevent corrosion and maintain good electrical connection. Readings of Readings of 1. Differences of more than. To prevent shock or component damage, remove spark plug high tension leads and connect securely to engine ground before proceeding.

Low Maintenance batteries are permanently sealed at the time of manufacture. Remove thrust plate U. New Bearing Remove and inspect crankshaft main journal bearings for damaged. When removing the oil baffle bolts, use a abnormal wear.

Follow Steps of this section to prime the engine and to help aid proper break-in. Apply Crankcase Sealant PN to the top gearcase halve. Apply assembly lube to cam journals and balance shaft bearing surfaces of the MAG case halve. Install cam and Assemble the crankcase halves. Orientate the piston rings on the piston before installation order as removed in disassembly. Apply Lubriplate or into the cylinders. Position cylinder and piston assemblies onto the connecting Install camshaft thrust plate G with new bolts.

Torque rods and push the piston pins through the piston and bolts to specification. Lubricate Rotors Align the bolt holes and install oil pump assembly into crankcase. Before installing the crankshaft gear I , heat the crankshaft Install washer and bolt.

Carefully install the tapered end of the Crankshaft Seal cover O. Apply Crankcase Sealant PN to the outside Torque bolts in proper sequence to crankcases mate.

See photos below. This helps to prevent specification. Install water pump impeller P. Secure the impeller with Torque the nut to starter drive. Install the starter bendix. NOTE: There are thrust washers on both sides of starter drive. Page Remove primer plug from the engine. Push oz. Remove the adapter. Apply sealant to the plug threads. This will ensure proper sealing when installing bolts. Install the head gasket A on the cylinder B. Lubricate rockers E with engine oil. Lightly Install thermostat J , new O-ring, and thermostat housing.

The reed has a tab and will assemble one-way only. Torque the breather bolts to specification. To maintain a beautiful finish and prevent corrosion, periodic maintenance is required. DO NOT use Repeat this procedure as often as desired to maintain the caustic chemicals to clean, as they may damage the finish. This dealer-only software installs on laptop computers equipped Fuel Injectors 5.

Fuel Filter 6. Refer to the steps below for fuel line removal. Place a shop towel around the fuel line to catch any dripping fuel. Squeeze the connector tabs together and push the locking slide back. The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions. The ECU requires a minimum of 7. The memory in the ECU is operational the moment the without system or engine component damage. Connect the pressure hose of the Polaris pressure tester PN PU to the test valve on the fuel rail.

Route the clear hose into a portable Internal 30 Micron gasoline container or the equipment fuel tank. Remove the air box cover and remove the two gas tank mounting bolts at the rear of the gas tank. Loosen the fuel tank hose and pull the fuel line from Carefully pull the fuel tank out of the frame. A rubber-fiber diaphragm divides the regulator into two separate sections-, the fuel EFI Engines use a non-serviceable, high-volume, high- chamber and the pressure regulating chamber.

Excessive voltage will burn out the injector s. Do not ground the injector s with the Operation Overview ignition on. The throttle position sensor TPS is a non-serviceable item. If it is faulty, it must be replaced. The throttle plate should seal off throttle bore completely. Establishing correct flow: Now that the zero offset voltage has been set, you can now set the throttle body to the correct air flow Back Air Flow Screw Out Until No value.

This indicates all other components are working properly. Refer to Chapter 10 for ETS testing. Press inside insert A until it snaps into place. Step 3 Side Panel Removal Side panel removal is quick and easy, use the following instructions for removal and installation. Remove seat by releasing the latch and lifting up on the seat. Front Storage Remove Bolts Remove the two T25 screws that secure the storage box to the front fender well areas each side.

Pull the tabs out of the notches and lift up on the cover piece. Remove the two screws B that secure the front cab to the frame in the fuel tank mount area. Install rear rack onto rear frame and cab. Lift the rear cab from the frame.

The bottom handle bar block has a side with 3 holes, the side with 3 holes faces up and to the front of the ATV. Align the pin A in the top block with the middle hole B in the bottom block for proper installation. Ball Joint Stud Bushing 8 ft. Apply grease to extension cap and threads of puller bolt to NOTE: Refer to the illustration on the previous page ease removal.

Front Strut Cartridge Replacement Remove the handle bar pod. NOTE: Refer to illustration on following page. Remove the handle bar. Remove the fuel tank bracket assembly. Hold strut rod and remove top nut. Remove the steering tie rod ends from the steering bracket.

The passenger backrest should be face down in the cargo box and the driver seat backrest should be locked into position. Reverse the removal steps to reinstall the cargo box. Refer to the standard fastener torque values in Chapter 1 during Remove the four bolts attaching the rear of the cargo box assembly. Passenger Backrest Unlatch the driver seat backrest by turning the engagement knobs on each side in the directions shown below. Configure the seating for 2-UP riding. With the passenger seat bottom in place, remove the two screws retaining the seat bottom.

Torx Screw Moveable Sheave 2. Cam Assembly Roller Pin 3. Retaining Ring Spring Pin 4. E-clip Stationary Sheave 5. Washer Periodic inspection and maintenance is required to keep the system operating at peak performance. Refer to the spring specification chart for specific free length measurements and tolerances.

Also check to see that spring coils are parallel to one another. These shift weights have many different factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding the effects they have on belt to sheave clearance, clutch balance, engagement and shifting characteristics.

The ATV should be fasteners and fastener placement. Replace if proper clutch offset on reassembly. Align the alignment mark on the cover with the mark on the engine seal. Mark drive belt direction of rotation so that it can be installed in the same direction. The belt is normally positioned so part numbers are easily read. NOTE: Be sure to position belt so part number is easily read. Verify new belt is seated properly in the clutches before operating the ATV.

Adjust if necessary. Drive Clutch Disassembly Inspect Shaft Using a permanent marker, mark the cover, spider, and moveable and stationary sheaves for reference, as the cast- in X's may not have been in alignment before disassembly. Turn roller with your finger. If spider during assembly. Inspect BOTH sheaves for signs of wear, grooving or cracking. In order to remove bushings it will be Place main adapter Item 8 on puller.

Rotate one-way clutch clockwise as viewed from the cover plate side. The clutch should rotate on the shaft Removal Tool 3 with only slight amount of drag.

Verify there is no binding Nut C or rough spots. Reinstall shift weights using new lock nuts on the bolts. Spider Nut Torque: 15 ft. Remove snap ring A and slowly Remove driven clutch from the transmission input shaft. Pull out the clutch roller pins L and rollers M. Inspect the spider dampener E for wear and replaced if needed. Remove the E-clip F , washer G , and the clutch rollers H.

Inspect the bearing for wear. Spin the bearing, if the bearing does not spin smoothly replace as needed. To remove the bearing, simply press the bearing from the shaft.

Spin the bearing, if the Bushing Replacement Kit bearing does not spin smoothly replace as needed. Press a new bearing onto the output shaft using a press. Install adapter Item 9 onto puller. Both Sides. Install the roller pin into the sheave assembly. Both sides.

The flat side of the roller pin faces downward when the shaft side is laying flat on the bench. Install the spider assembly onto the shaft with the retaining ring on top of the spider. Install the cam assembly helix over the shaft. Replace the entire clutch as an Dealer MSD technician who has received the assembly if worn, damaged or cracked.

Torque cover bolts evenly to specification. Spacer Washers Spider Torque: ft. Any misalignment will alter clutch balance. Disassembly Using special tool PN , apply and hold downward pressure on the outer spring retainer and remove the snap ring A. Inspection Inspect both the inner and outer sheave surfaces. Install inner spring retainer if removed. Install the inner sheave onto the outer sheave. NOTE: Rollers and helix are non-serviceable items.

Page Pvt Troubleshooting During this procedure, the throttle should not be held at the full position for more than 10 seconds. PVT seals should be inspected for damage if repeated leaking occurs. Engine RPM below specified operating range -Install correct shift weight kit to match engine -Drive clutch shift weight too heavy.

Inspect brake Belt burnt, thin spots -Dragging brake system. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly. Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint. Apply an anti-seize Inspection compound to splines. Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft Check the front and rear driveshaft CV boots for any tears or leaking grease.

Remove small clamp and boot from driveshaft. Inspect the grease carefully for contamination, and clean the joint thoroughly if necessary. Install the small clamp on the boot. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. Slide prop shaft back and away from housing, then pull sharply forward to Always wear eye protection when working with remove from transmission shaft.

Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislodge needle bearings upon installation of cross joint. Repeat procedure for other side. Install snap ring to contain bearing cap just installed. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown. Description Ref.

Gearcase Sub Asm. Once enabled, the AWD Ring Gear remains engaged while the front gearcase is moving and will not disengage until the rear wheels regain traction. Bolts and fluid drain plug are accessible through the skid plate. Pull the hub and strut assembly out and pull the drive-shaft out of the hub. Remove the armature plate and RH output hub assembly from the outer cover plate. Inspect the bearing and contact surfaces of the output hub for signs of wear or damage.

Inspect the bearing and Inspect roll cage B sliding surface. This surface must be contact surfaces of the output hub for signs of wear or clean and free of nicks, burrs or scratches. Inspect the H- damage. Inspect the magnetic coil A in the outer cover plate Remove the snap ring retaining the input shaft assembly. Inspect the backlash pad B for excessive wear. Remove the input shaft assembly. Inspect the pinion gear C for chipped, broken, or missing teeth. The output hub should spin freely.

Replace all O-rings, seals, and worn components. Install the RH output hub B into the output cover. The Press the pinion shaft seal into the pinion cover, until the output hub should spin freely.

Torque the cover plate bolts to specification. Be sure that the armature plate tabs are fully engaged into the roll cage assembly. The gearcase coil should measure turns. Re-apply Loctite onto the bottom screw threads. The top of the coil To install gearcase, reverse removal procedures. Use new should be seated below the U-shaped insert.

The U-shaped roll pin in front prop shaft. Operation is controlled by the ECU grounding and ungrounding the coil. Remove and Remove the armature plate. Inspect the armature plate for inspect the cover o-ring 1. Inspect thrust bearing 2 for wear, distortion or other damage. Replace component as wear. Replace items as required. Inspect roll cage sliding surface 2. This surface must be clean and free of nicks, burrs or scratches. Remove and inspect the H-springs 4.

Replace any components as required. Remove and inspect the bearing surfaces of the output hub. Inspect the magnetic coil 1 in the outer cover plate Inspect the magnetic coil 1 and bushing in the input cover assembly.

Inspect the backlash pad 2 for excessive wear. Replace the input cover seal. Safety glasses or a face shield are required. Using moderate hand pressure, hold the tool on top of the piston while using compressed air at the gearcase passage circled to force piston up and out of the case.

Coat the edges of the verify alignment of the sight hole circled and piston mark piston cavities. Thoroughly clean the gearcase components before beginning reassembly. Install a new seal in the main gearcase halve. Install the input shaft assembly. Install a new seal and o-ring the input shaft cover 2 prior to reassembly.

Install the clutch pack 1 , spacer 2 and ring gear 3. Install a new o-ring on the backlash pad 2 stem. NOTE: Ring gear backlash 2 is set at the factory. Install new cover o-ring 1 on the cover plate assembly Place cover assembly on Install bolts arrows retaining the and a new passage o-ring 2 on the gear case. Remove rear hub cap.

Remove hub. Remove cotter pin A. Loosen the hub retaining nut B. Add Vehicle. Your VIN provides important and specific information about your vehicle to make finding the right products fast and easy. Search Reset. Discount applied at checkout. Stock on Vehicle. Top Seller. ProductPriceFontFamily, pageSettings. ProductPriceFontSize, pageSettings. DiscountPrice : selectedProduct. Price : pageSettings. We're sorry. This item is no longer available.