Polaris 1999 Sportsman 400 User manual

CONTENTS
QUICK REFERENCE DATA . . . . . . . . • . . . • . • . . . . . . . . . . . . . . • . IX
CHAPTER ONE .
GENERAL INFORMATION
Manual organization
Notes, cautions and warnings
Safety first
Cleaning parts
Handling gasoline s
af ely
Service hints
Torque sped fications
Fasteners
Lubricants
Threadlocking compound
RTV gasket sealant
CHAPTER TWO . . . . .
TROUBLESHOOTING
Operating requirement s
Troubleshooting instruments
Starting the engine
Starting difficulties
Engine is difficult to start
Engine starting system
Charging system
Ignition system
Electronic throttle control
.. .. .. . 1
Expendable supplies
Serial numbers
Warning and information labels
Basic hand tools
Precision measuring tools
Special tools
Fabricating tools
Mechanic's tips
Beari ng replacement
Seals
Storage
.. 36
Fuel system
Engine overheating
Engine
Engine noises
Cylinder leak down test
P
owe r train
Steering
Frame noise
Brakes

CHAPTER THREE . .. .... .. .. • . •.. .
LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride check list
Tires and whee ls
Battery
Battery electrical cabl e connectors
Periodic lubrication
CHAPTER FOUR .
ENGINE TOP END
Engine principles
Engine cooling
Engine lubrication
Servicing the engine in the frame
Exhaust system
Cylin
der head cover
Rocker
ann assembly
CHAPTER FIVE . . • .
ENGINE LOWER END
Engine
Flywheel and stator plate
Recoi l starter
Crankcase
Crankshaft inspec tion
Balancer shaft inspection
CHAPTER SIX • . . . .
FUEL SYSTEM
Carburetor operation
Carburetor
Carburetor cleaning and inspection
Carburetor tests and adj ustments
Throttle cable replacement
CHAPTER SEVEN. ........•
COOLING SYSTEMS
Polaris variable transmission ( PVT)
air cooling system
Engine
cooling system
Safety precautions
Hoses and hose clamps
Engine gaskets/seals
.... .. 53
Periodic main tenance
Unscheduled inspection
and maint
enan ce
Engine tune-up
.. .. .. ...... 94
Camshaft
Cylinde r head
Valves and valve components
Cylinder block
Piston and piston rings
Camshaft chain and sprockets
Break-in proc
edur e
. . . 137
Shan end float measurement
and shim selection
Oil pumr
Oil system one-way check valve
Break-in proc
edu re
175
St all ing enrichment (choke) cab le
Fuel tank
Fuel shutoff valve
Air filter air box
Fu ~ l pllm p
.... 198
Coo ling system inspection
Radiator
Coo ling fan
Coo lant pump
Thermostat
Temperature sensors

CHAPTER EIGHT .
CLUTCH/DRIVE BELT SYSTEM
Drive unit
Drive pulley
Special tools
Driven pulley
Drive belt
CHAPTER NINE .
TRANSMISSION
Tra nsmission
Tra nsmission inspection
Shift shafts
Front output shaft
CHAPTER TEN . . . . . . .
FRONT DRIVE SYSTEM
Front hub and Hillard clutch
Front drive axle, boots and CV
(constant velocity) joints
CHAPTER ELEVEN . .
ELECTRICAL SYSTEM
Ba sic information
Negative battery terminal
Charging system
Alte rna torstator
Voltage regulator/rectificr
Capacitordischarge ignition
Ignition coil
Ignition statorcoils
CHAPTER TWELVE .
FRONT SUSPENSION AND STEERING
Front wheel
Front hub
Front strut cartridge and spring
Front strut/spindle
Control a rm
CHAPTER THIRTEEN .
REAR SUSPENSION
Rear wheels
Tire changing and tirerepairs
Shock absorber
Rear hub and bearing carrier
Rearaxles
Upper control arm
. .. .. .. .... 213
Drive pulley
Driven pulley
Clutch outer and innercover
(all models)
. . 249
Transmission gearcase oil seal
inspection andreplacement
Shift selector linkage
..... .... 290
Front drive shaft
Front drive unit
.. .. . 303
Electric starting system
S tarter drive gears
Starter solenoid
Lighting system
Electrical components
Sw itches
Wi rin g dia gram s
. 337
Handlebar
Tie rods
Steering shaft
Tires and wheels
. 362
Lowercontrol arm
Upper and lowercontrol
arm inspection
Stabilizer linkage
Stabilizer support

CHAPTER FOURTEEN.
BRAKES
Disc brakes
Front brake padreplacement
Front caliper
Ou tput shaft brake pad replacement
(199 6-1997 models)
Output shall brake caliper
(]
996- 1997 models)
Outpu t shall brake pad replacement
( I998-on models)
Outp ut shaft brake caliper
(I 998-on models)
CHAPTER FIFTEEN
BODY
Seat
F ront rack and grille
Side p an els
Front fender
Front bumper (models so equipped)
SUPPLEMENT .
2001-2003 SERVICE INFORMATION
Startin g theengine
Ignition system
Periodic maintena nce
Engine tUIl C- Up
Cylinder block
Piston and piston rings
Engine
Fl ywhee l and stator plate
C
arbur etor (Sportsman 500 H.G. models)
Cleaning and inspection
Carburetortests and adjustments
Drive belt
Driven pulley (2003 models bui lt
after 07/08102)
INDEX .
WIRING DIAGRAMS .
.. . .. .. 382
Fron t mastercylinder
Rear mastercylinder
Brake hose replacement
Rear brake pedal
Rem brake lever
(1996-1997 Sweden models)
Foot brak e
(1998-on Sweden models)
Brake disc
Bleeding the system
... .. .. .. . 425
Radiator guard
Rear rack
Rear fender
Footv .. 'ells
Rear bumper (models so equipped)
... ... .... . 437
Tra nsmission
Lighting system
Electrical components
Steering shall (2002-on models)
Rear hub and bearing carrier (2003 models)
Rear
brake pad rep lace men t
(2003 m
ode ls)
Rear calipers (2003 models)
F ront master cylinder
Rear mast er cylinder (2003 models)
Rear brake disc (2003 models)
Brake hose replacemen t (2003 models)
.470
.4 76

QUICK REFERENCE DATA
ATV INFORMATION
MODEL: YEAR: _
VIN NUMBER:, _
ENGINE SERIAL NUMBER: _
CARBURETOR SERIAL NUMBER OR 1
.0. MARK : _
TIRE INFLATION PRESSURE (COLD)'
Model
kPa PSI
Front wheels
34.5 5
Rear
wheels
34.5 5
"Tlre
pressure for original equipment tires . Aftermarket tires may require different Inflation pressure .
RECOMMENDED LUBRICANTS, FLUIDS AND CAPACITIES
Item
Engine 011
Transmission all
Front gear case
Front hubs
Brake fluid
Coolant
Grease
Item
Engine all
Transmission all
Front gear case (all years)
Front hubs
Coolant
Lubricant or fluid type
Polaris Premium 4 Synthetic 10W/4Q
or 10W/40 motor all
Polaris synthetic gear case 011 (part No. 2871478)
Polaris front gearcase lube (part No. 2871653), or
API GL5 80·90
gear lube
Polaris demand drive hub fluid (part No. 2871654),
or ATF Type F.
DOT 3
brake fluid
50:50 mixture ethylene glycol·based
coolant compounded for aluminum radiators
and engines
Polaris all season grease , or equivalent
RECOMMENDED CAPACITIES
Quantity
1.89 L (2 U.S. qts.)
946.3 cc (32 U.S. oz.}
96 cc (3.25 U.S. oz.)
75 cc (2.5 U.S. oz.)
Appro x. 2.16 L (2.25 U.S. qts .)
IX

MAIN TENANC E AND TUN E·UP TORQUE SPECIFICATIONS
Item
N'm
in. .. lb.
Crankcase oil drain plug 19
Cylinder head cover screws 8.2 72
Front gear case drain plug 9.4 83
Handlebar upper hold er bolts 13·17 115-150
Oil
tank drain plug
19
0 11 tank screen and fitting 20
Valve adjuster locknuts 6-7 53-62
Whee/lug nuts
Front 21
Rear 21
MAINTENANC E A ND TUNE ·UP SPECIFICATIONS
ft .·lb.
14
14
15
15
15
Item
Disc brake pad thickness wear limit
2003 Sportsman 500 & 500 H.O.
Rear brake
All other models and years
Front and rear brakes
Valve clearance (cold)
Intake and exhaust
Spark plug
400 cc
Heat r ange
Gap
500 ee
Heat r ange
1996-1997
1998-2001
2002
·on
Gap
1996·1998
1999-2000
2001
·on
Idle speed
1996-1988, 2001-on
1997·2000
Carburetor pilot air screw (34 mm)
1996
1997
·1998
1999-2000
2001
-on (400 ee)
Carburetor pilot air screw (40 mm )
2001
2002-on
Item
Headlight s
Grill moun ted lights
1996
1997
1998 -on
Tai lli g ht
Brake light
Indicator lights
1996
1997-on
Spec ificat ion
4.6 mm (0.180 In.)
3.81 mm (0.150 In.)
0.15 mm (0.006 In.)
NGK BKR5E
0.9 mm (0.036 in.)
NGK BKR5ES
NGK
BKR5 E
NGK
BKR6 E
0.6-0.7 mm (0.024-0.028 in.
0.7 mm (0.028 In.)
0.9 mm (0.036 in.)
1100-1300 rpm
1000-1400
rpm
1 1/2turns out
2turns out
2 5/8 turns out
23/4 turns out
2 1/2 turns out
2turns out
REPLACE MENT B ULB S
Spe c ifica tion
12 volt, 6 0/60 watt Haloge n
12 volt, 37.5 watt (2)
12 volt, 35 watt (2)
12 volt, 27 watt
12 volt, 8.26 watt
12 volt, 6.9 watt
12 volt, 1.25 watt
12 volt ,l.0 watt
x

CHAPTER ONE
GENERAL INFORMATION
This detailed. comprehensive manu al covers the
Polaris Sportsman 400, 500 and Xplorer 500 4 x4
from I996-on.
Keep this book handy in the toolbox. Reading
and using it will help to better understand how the
vehi cle runs, lower repair costs and generally im-
prove personal satisfaction with the vehicle.
The following tables are included at the end of
this chapter:
Tah le 1 lists model year and number.
Tahle 2 lists general dimensions.
Table 3 lists vehicle weight (dry) .
Table 4 lists decimal and metric equivalents.
Tab le 5 lists general torque specifications.
Table 6 lists conversion tables.
Ta ble 7 lists technical abbreviations.
Table 8 lists metric tap and drill sizes.
Tables 1-8 are at the end of this chapter.
MANU AL OR GA NIZATlO :'ll
All dimensions and capacities are expressed in
English units familiar to U.S. mechanics. as well as
in metric units.
This chapter provides general informationand
discusses equipment and tools useful both for pre-
ventive maintenance and troubleshooting.
Chapter Two provides methods and suggestions
for the quick and accu rate diagnosis and repair of
problems.Troubles hoo tingproceduresdiscuss typ-

2
ica l sy mpto ms and logical method s to pinpoint the
t
roub le.
Chap
ter Th ree explains all periodic lubrication
and routine maintenance necessary to
keep the veh i-
cle funn ing well. Cha pter Three also includes rec-
ommended tUIl C
-Up proce du res, el i mina ting the
nee d to constantly consult chapters on the various
assemblies.
S
ubsequen t c hapters describe specific systems
such as the engi ne, clutch / drive belt system, trans-
mission, exhaust, cooling, suspension and brakes.
Eac h c hapter provides disass emb ly, repair and as-
sembly procedures in a simple step-
by- step f orm .
Ifa repair is impract ical for a home me chan ic. it is
so indicated.It is usually faster ami less expensive
to take such repairs to a dealer or competent repair
shop. Specifications concerning a particular system
arc i ncluded at the end of the appropriate chapter.
So
me of the proc edures in this manual spec ify
s
pec ial too ls. In most case s, the too l is illustrated ei-
ther in actual use or alone. Well-equi
pped mec han-
ics may find they can substitute similar tools
alre ady on hand or can fabricate thei r own .
NOTES , CAUTIONS AND WARNI NGS
The term s NOT E, CAUTION and WAR NING
have specific
mean ings in this manual. A NOTE
provides add itio nal inform ation to
mak e a step or
procedure easier or clearer . Di sre gardi ng aNOTE
cou ld cau se in con venience, but wou ld not cause
equ
ipment damage or personal injur y.
A
CAUTION emp hasize, areas where eq uipment
da
mag e co uld result. Di sreg arding a CA UTION
could cause permane nt mechanical dama ge; hO\\I-
eve r, personal inju ry is unlikely.
A WARNING emphasizes areas where pe
rsona l
injury or eve n death could result from negligence.
Mechanical da mage may also
occ ur. W ARNI NGS
are fa be taken seriously. In some cases, serious in-
jut)' or death has resulted from dis reg ar ding similar
warnings .
SA rETY FIRST
Professional mechan ics can work for years and
never sustain a serious injury. Ifa few rules of com-
mon sense and safety arc ob served. man y safe hours
can be enjo yed servicing the ATY. Ignoring these
CHAPTER ONE
rules can injure so meo ne working on the vehicle. or
damage the AT V.
I. Never lise gaso line or any t ype of low flash po int
solvent to clean parts, Sec Cleaning Parts and Han-
dling Gasoline Safety in this chapter for add itional
i
nfor mat ion on parts cleaning, gasoline usc and
safety.
NOT E
The flash point is the lowest tempera-
lur e at which the vapo rsfrom a com-
bustible li quid will ignite when in
o
pe n ail: A lowjl ash point solvent will
ignite at a lower temperature than a
higlzj lash poi nt solvent.
2. Never smo ke or usc a torch in the vicinity of
flammable liquids in ope n co ntain
ers , such as gas o-
line or cleaning so lvent.
3. lf wc lding or brazing is req uired on the vehicle .
remove the fuel rank, c
arbur etor, and fron t and rear
shocks to a safe dist
ance at least 50 feet (15 m)
away.
4. Use the pro per sized wre nches to
avo id damage
to fasteners.
5. When loosening a tight or stuck nut, be guided
by what would h
app en if the wrench slips.
6. When rep lacing afastener, make sure to usc one
with the same measurem
ent s and strength as the old
one. Incorrect or mismatched fasteners can result in
da
mage to the vehi cle and possibl e personal injury.
Beware
of fastener kits that are filled with cheap
and p
oor ly made nuts. bolts, was hers and cotter
pins. R ef er to Fasteners in this chapter for addi-
tional inform ation.
7. K eep all hand and power tool s in good condition.
Wipe greasy
and oily too ls after using them. Dirty
tools arc difficult to hold
and can cause injury. Re-
place or repair worn or dama ged tools.
8. Kee p the work area clean and uncl uttered.
9.
Wear safety g og glcs during all operation s in-
volving drillin g, grinding. the use of a cold chis el,
u sin g che micals, cleaning parts, when u sing com-
pressed air or an ytim ethe safety of eyes is in-
vo lved.
10.
Mak e sure to wear the correct typ e of clothes
for the
jo b. L on g h air should be tied up or covered
with a cap so thai it cannot be caught by a piece of
moving equipme nt or tool.

G ENE RAL INFO RMATION
11. Keep an approved fire extinguisher nearby. Be
sure it is rated fur gasoline (Class B) and electrical
(Class C) fires.
12. When drying bearings or other rotating paris
with compressed air, never allow the airjet to rotate
the bearing or pari. The air je t is capable of rotating
them at speeds tar in excess of those for which they
were designed . The bearing or rotating part is very
likely to disintegrate and cause serious injury and
damage. To prevent bearing damage when using
com pressed air, hold the inner bearing race by hand.
WARNING
The improper use
of compressed air is
velJ' dangerous. Using compressed
air to tlUSI
off clothes, the ATV or
workbench can cause jl ying particles
to be blown into eyes or skill. Never
direct or blow compress
ed air in/a
skin or through any bod y opening (in-
cluding cuts) as this can cause severe
injury or death. Compressed air must
be used care /id ly; never allow chil-
dren to lise or play with a ll)' com-
pressedair equipment or hoses.
13. Never work on the upper part of the vehicle
while someone is worki ng underneath it.
14. When putting the vehicle on a stand, make sure
the vehicle is secure before walking away from it.
15. Never carry sharp tools in clothing pockets.
16. There is always a right and wrong way to use
tools. Learn to use them the right way.
17. Do not start and run the ATV in an enclosed
area, The exhaust gases contain carbon monoxide, a
colorless, odorless, poisonous gas. Carbon monox-
ide levels build quickly in a small closed area and
can cause unconsciousness and death in a short
time. When it is necessary to start and run the vehi-
cle during a service procedure, alwaysdo so out-
side, or in aservice area equipped with aventilating
system.
CLEANING PARTS
Cleaning parts is one
of the more tedious and dif-
ficu lt service jobs
per formed in the home garage.
While there are a nnmber
of chemical cleaners and
solvents available for home and shop lise, most arc
poisonous and extremely flammable. To prevent
chemical overexposure, vapor buildup, tire and sc-
3
rious injury. observe all manufacturer 's directions
and warn ings while noting the following,
I. Read the entire product label before using the
chem ical. Observe the precautions and warnings on
the label. Always know what type
of chemical is be-
ing used.
2. If the chemical product must be mixed, measure
the proper amount according to the direction s.
3. Always provide sufficient ventilation when
working with solvents or other chemicals. If a
chemical can be smelled, there is some vapor in the
air. The stronger the smell, the stronger the vapor
concentration.
4. If a product is listed as combustible, flammable
or an extremely flammable Iiquid, the danger
offi re
increases as the vapor collects and builds up in the
shop.
5. lf a product is listed as a poison, the vapor is poi-
sonous as well as the liquid.
o. To prevent skin exposure, wear protective
gloves when cleaning parts. Select a pair of chemi-
cal-resistant gloves suitable for the type of cherni-
cals that will be used. Replace the gloves whcn they
become thin, damaged, change COIOf, or swell.
7. Wear safety goggles when using chemicals and
cleaning parts.
8. Do not lise more than one type of cleaning sol-
vent at alime.
9. If a pan must be heated to remove abearing,
clean it thoroughly to remove all oil, grease and
cleaner residue. Then wash with soapy water and
rinse with clear water,
10. Wear a respirator if the instruction label says to
do so.
II . Keep chemical products out
of reach of chil-
dren and pets.
12. To prevent sparks, usc a nylon bristle brush
when cleaning paris.
13. When using a commerc ial paris washer, read
and follow the manufacturer's instructions lor se-
lecting the type of solvent to usc. Parts washers
must be equ ipped with a fusible link designed to
melt and drop the cover in the event
of fire.
14. Wash both hands and arms thoroughly after
cleaning parts,
HANDLING GASOLINE SAFE LY
Gasoline, a volatile flammable liquid, is one of
the most dangerous items in the shop, However, be-
a

cause gasoline is used so often,manypeople forget
that it is a dangerous prod uct. Gasoline should be
used only as fuel for internal-combustion engines.
Never usc gas oline to clean pa
rt s, tools or to wash
hand s. When working on an ATV. motorcycle or
any othertype
of gasoline engine. gasoline will al-
ways be present in tbe fuel tank, fuel line and carbu-
retor. To avoida disa strou s accidentwhen w orkin g
around gasoline oron thefuel system, carefully ob-
serve the following
precauti ons:
I. Never usc gasoline to clean part s. See Cleaning
Parts in this chapterforadditional information on
pans cleaning and safety.
2. When workingon the fuel sys tem, work outside
or in a well-ventilatedarea.
3. Do not add fuel to the fuel t ank or service the fuel
system while the ATV is in the vicinity of open
flames, spark sor where some oneissmoking. Gaso-
line vapors arc actually more dangerous than liquid
gasoline. Because these vapors are heavier than air.
they collect in low areas and are easily ignited.
4. Allow the engine to
coo lcompletely bef ore
working on any fuel system component.
5. When draining the carburetor, catch the gasoline
in a plastic container and then pour it into a
safety-approved gas can.
6. Do not store gasoline in any type of glass con-
tainer. If the glass shoold break . a serious explosion
orfirecouldoccu r.
7. Wipe up spilled gasoline immediately with dry
rags. Store the rags in ametal container with alid
ontil they can be properly disposed of . or put them
outside in a safe place to dry.
8. Do not pour water onto a gasoline tire. Water
spreads the lire and makes it more difficult to put
oot. Use a Class B. BC. or AIlC fire extinguisher to
smother the
name s and put the fire out.
9. Always tum the engine
off before refueling. Usc
awide-mouth funnel to prevent spilling gasoline
onto the engine. exhaust pipe or
muffl er. Do not
overfillthefuel
tank . Leaveanairspace at the topof
the fuel tank to prevent fuel from spilling out when
installing the cap.
10. Always refuel the ATV while it is parked out-
side andaway fro m all open flames andsparks.
II . When transporting the ATV in another vehicle.
keep it upright with the fuel valve turned oiT.
12. Do not perform aspark test (as described in
ChapterTwo) if there is any gasoline leaking from
the fuel
tank , fuel line or carburetor .
CIIAI'TER O~E
FR ONT
REAR
SERVICE HINTS
~ .. Iost of the service p rocedur es covered are
straightfor wa rd and can be performed by any one
reasonably handy with tools. It is suggested. how-
ever. that the personal capabilities be carefully eon-
sidercd before
attemp ting any o peratio n involving
majordisassembly of the engine.
Take time and do the jo b right. Do not forget that
anewly rebuilt engine must be broken in the same
wayas anewone. RefertotheEngineBr eak-In pro-
c cdur e listed in Chapter Four and Chapter Five .
J. Fron t, as used in this manual, refersto the fro nt
of the vehicle; the front of any component is the end
closest to the front of the vehicle. The left and right
sides refertothe positionafthe p art sas viewed bya
rider sitting 011 the seat rac ing forward. For exam-
ple, the t hrottle control is on the right side. The se
rules aresimple. butconfusioncancause a major in-
convenience during service. Sec Figure 1.
2. When ever servicing an engine or suspe ns ion
component, securethe vehicle in a safe mann er.
3. Tag all similar internal part s for location and
mark all matin g part s for position. Record number

GE NER AL INFORMA nON
and thickness of any shims as they are removed.
Small parts such as bolts can be identified by plac-
ing them in plastic sandwich bags (Figu re 2). Seal
and label them with masking tape.
4. Tag disconnected wires and connectors with
masking tape and a marking pen.
Ag ain, do not rely
on memory alone.
5. Protect finished surfaces from physical damage
or corrosion. Keep gasoline and other chemicals off
painted surfaces.
6. Use penetrating oil on frozen or tight bolts, then
strike the bolt head a few times with a hammer and
punch (use a screwdriver on screws). Avoid using
heat where possible, as it can war p, melt or affect
the temper of parts. Heat also ruins finishes, espe-
cially paint and plastics.
7. When a part is a press fit or requires a special
tool to remove it, the necessary informat ion or type
of too l is called out in the text. Otherwise, if a part is
difficult to remove or install, lind out why before
proceeding.
S. To prevent small objects and abrasive dust from
falling into the engine, cover all openings after ex-
posing them.
9. Read each procedure completely while looking
at the actual parts before starting a job. Make sure
the procedural steps are fully understood, then fol-
low the procedure step by step.
10. Recommendations are occasionally made to re-
fer service or maintenance to a Polaris dealership or
a specialist in a particular field. In these cases, the
work will be done more quickly and economically
than by the home mechanic.
11. In procedural steps, the term replace means to
discard a defective part and replace itwith a new or
rebui lt unit. Overhaul means to remove, disassem-
5
ble, inspect, measure, repair and/or replace parts as
required.
12. Some operations require the usc of a hydraulic
press. If a press is not available, it is wiser to have
these operations pe rf ormed by a shop equipped for
such work, rather than to try to do the job yourself
with makeshift equipment that may damage the ma-
chine.
13. Repairs go much faster and easier if the vehi-
cle is clean before starting on the job. There are
many special cleaners on the market, like Bel-Ray
Degrcascr, for wash ing the engine and related
parts. Follow the manufact
urer' s directions on the
contai ner for the best results. Clean all oily or
greasy parts with cleaning solvent as they are re-
moved.
WARNING
Never use gasoline to clean parts or
tools. 11 presents all extremefire haz-
an i. Be sure 10 work in a
well-ventilated area when using
cleaning solvent. Keep afire extin-
guisher rated for gasoline
fir es near
by in any case.
C AU TI ON
If a car wash is used to clean tile A rv,
do 1I0t direct tire high-pressure water
hose at steering hearings. carburetor
hoses, suspension components, wheel
bearings, or electrical components.
The water wtllflusb grease out of the
bearings or damage the seals.
14. Muc h of the labor charges for repairs made by
dealerships are for the time involved during the re-
moval, disass emb ly, assembly, and reinstallation of
other parts in order to reach the defective part.
When poss ible, perform the preliminary operations
and take the defective unit to the dealer for repair at
considerable savings.
15. When special tools are required, make ar-
rangcmcnts to get them before starting on the job.
It is frustrating and time-consuming to get partly
into a jo b and then be unable to com plete it. When
special tools are requ ired, they will be described
(including part number) at the beginning of a pro-
cedure.
16. Make diagrams wherever similar-appearing
parts arc found. For instance, crankcase bolts arc
of -
ten not the same length. Do not rely on memory

6
alone to replace parts in their proper location. There
is also the possibility of being sidetracked and not
able to return to work for days or eve n wee ks, dur-
ing which time the carefully laid out parts may be-
come disturbed.
17. When assembling parts, make sure all shims
and washers are reinstalled exactly as they came
out.
18. When eve r a rotating part contacts a stationary
part, look for a shim or washer. Usc new gaskets if
there is any doubt abou t the condition of the old
ones. Athin coating of oil on n on-p ressure type gas-
kets may help them scal morc effe ctive ly.
19. Som e components are held in pl ace with
self-locking nuts. The locking ability of these nuts
is lessened every time they are installed or r emo ved.
It is recommended that they be replaced eve ry time
they are removed.
20. Use cold heavy grease to hold sma ll parts in
place ifth cy tend to fall out during assembly. How-
ever, keep grease and oil away from electrical and
brake components.
TORQ UE S PEC IFICAT IONS
The materials used in the manufacture of the Po-
laris may be subjected to un even stresses if the fas-
teners that hold the sub-a ssemblies are not installed
and tightened correctly. Loose or missing fasteners
can cause the cylinder head to warp . crankcase
leaks, and prematur e bearing and seal failure and
suspension failure from loose or missing fasteners.
Therefore, usc an accurate torque wrench (de-
scribed in this chapter) tog ethe r with the torqu e
specifica tions listed at the end of most chapters.
Torque specifications throu gho ut this manual nrc
given in Newton-meters (Nsm). foot-pounds
(f't.-lb.) and, w her e applicable, in inch-pounds
(in.-Ib.).
Existing torque wre nches calibrated in meter ki-
lograms can be used. Move the decimal point one
place to the right; for example, 3.5 mkg =35 Nsm.
The exact mathematical conversion is 3.5 mkg =
34.3 Nsm.
To mathemati cally convert foot-pounds to New-
ton meters multiply the foot pound s spec ification by
1.3558 to achieve a Nsrn equivalent. For example
150 ft.-lb. x 1.3558 =203 Nsrn.
Ref er to Table 5 for general torque specifications
for various size screws, bolts and nuts not listed in
CHAPTER ONE
the respective chapter tables. To usc the table, first
det ermin e the size of the bolt or nut. Use a vernier
caliper and meas ure the inside di men sion of the
threads of the nul (Figure 3) and across the threads
for a bolt (Fig ur e 4).
FASTENERS
The materials and designs ofth evarious fasteners
used on the Polaris are each designed fer a specific
purpose. Fastener des ign de tennine s: the type o ft ool
requ ired to work with the fastener. Fastener mate-
rial is carefu lly selected to d ecr ease the possibility
of physical failure.
Nuts, bolts and sc rews are manu fa ctur ed in a
wide range of thread pattern s. To jo in anut and
bolt, the diameter of the bolt and the diameter of
the hole in the nut must be the same. It isjustas im-
por tant that the thr ead s on both be properly
matched.

GENERAL INFO RMATION
Grade marking
The best way to tell if two fasteners' threads
match is to turn the nut on the bolt (or the bolt into
the threaded hole in a piece
of equipment) with fin-
gers only. Be sure both pieces are clean. If excessive
force is required, check the thread condition on each
fastener. If the thread condi tion is good but the fas-
teners jam, the threads are not compatible. A thread
pitch gauge can be used to determine pitch. Polaris
vehicles arc manufactured with ISO (International
Organization for Standardization) metric as well as
American fasteners. The threads are cut differently
than those
of American fasteners. All engi ne fasten-
ers are metric threads while the frame components
are secured with American threads
Most threads are cut so that the fastener must be
turned clockwise to tighten
it These arc called
right-hand threads.Some fasteners have left-hand
threads; they must be turned counterclockwise to be
tightened. Left-hand threads are used in locations
where normal rotation
of the equipment would tend
to loosen a right-hand threaded fastener.
ISO
Metr ic Scr ew Thre ads
(Bolls, Nuts and Screws)
ISO (InternationalOrganization for Standardiza-
tion) metric threads
come in three standard thread
sizes: coarse, fine and constant pitch. The ISO
coarse pitch is used for almost all common fastener
applications. The fine pitch thread is used on certain
precision tools and instrum ents. The constant pitch
thread is used mainly on machine parts and not for
fasteners. The constant pitch thread, however, is
used on all metric thread spark plugs.
Metric screws and bolts are
cla ssified by length
(L,
Figure 5), nominal di ameter (D) and distance
b
etween thread crests ( T) . The numbers 8 x
7
1.25 -1 30 identifi es a typical bolt. which would in-
dicate that the bolt has a nominal diameter o
f8 mm,
the distance between thread crests is 1.25
111m and
bolt length is 130 mm.
1I;·IRNING
Do not inst all screu-'s or bolts with a
lower strength grade classification
than installed originally by the manu-
factur er. Doing so may calise engine
or equipment failure and possible in-
j ury.
The measurement across two flats on the head of
the bolt indicates the proper wrench size to use. Flg-
nrc 4Sh O\ \o '5 how to determine bolt diameter. When
buying a boll from a dealer or parts store, it is im-
portant to know how to specify bolt length. The cor-
rect way 10 measure bolt length is by measuring the
length starting from underneath the bolt head to the
end
of the bolt. Alwaysmeasure bolt length in this
manner to avoid buying bolts that are
of the wrong
length.
Machine Screws
Ther e are many diff erent types of machine
screws. The screw heads arc also designed to pro-
trude above the metal (round) or slightly recessed in
the metal (flat) . See F
igure 6.
Nuts
Nuts are manufactured in a variety of types and
sizes. Most are hexagonal (6-sided) and fit on bolts,
screws and studs with the same diameter and pitch,
The co mmo n nut is generally used with a
lockwa
sher . Self-locking nuts have anylon insert
that prevents the nut from loosenin g; no lockwasher
is requi red. Wing nuts are designed for fast removal
by hand. Wing nuts are used for convenience in
non-critica l locations.
Toindicate the size of ametric nut. manufacturers
specify the diameter of the opening and the thread
pitch. This is similar to bolt specifications. but with-
out the length dimension. The measurement across
two flats on the nut indicates the proper wrench size
to be used.

8
MACHINE SCREWS
CHAPTER ONE
Hex Flat Oval Fillister Round
Self -Locking Fastene rs
Severa l types of bolts, scr
ews and nuts incorpo-
rate asystemthatdevelops interference betweenthe
bolt, screw, and nut or lapped hole threads. Interfer-
ence is achieved in various ways: by dis tort ing
threads ,coatingt hread s with dry adhesive ornylon,
disto
rt ingthe top of anall-metal nut, using a nylon
inse
rt inthe ce nter orat th e top of a nut.
Self-locking fasteners offer greater holding
strength and better vibration resistance. The
self-locking fasteners used on the Polaris ATV can-
not be reused.Others, likethenyloninsertnut, form
an initial lock ing condition when Lite nut is first in-
stalled; the nylon forms close ly 10 the bolt thread
pattern, thus reducing any tendency for the nut to
loosen. Always discard
and replace selfClocking
fasteners afterremoval.
Was hers
There arc two basic types of wash er s: Ilat wash-
ers and lockwashers. Flat washers are simple discs
with ahole to fit a screw or bolt. Lockwashers are
designed to prevent a fastener fro m working loose
due to vibration. expansion and contraction.
\Vashers can be used in the following functions:
I. As spacers.
2. To prevent galling or damage of the equipment
by the fastener.
3. Tohelpdistribute fastenerloadduring tightening.
4. As seals.
Note that flat washers arc often used between a
lockwasherand a fastenerto provide a smoothbear-
ing surface. This allows the fastener to be
turn ed
easily with a tool.
NOTE
As much care should be given to the
selection and purchase
of wash er s as
that given to bolts, nuts and othe r/as -
teners. Beware of washers that are
made 0/ thin and weak materials.
These will def orm and crush tilefirst
lime they are used in a high-torque
application.
Cotter Pins
Incertain applications. a fastenermust be secured
so it cannot possibly loosen. The rear hub on an
A TV is one of' these applications. Forthis purpose,a
cotterpinandslotted orcastellatednul isoften used.
To use a cotter pin. first make sure the pin fits
snugly, but not too light. Then align the slot in the
fastener with thc hole in the b
ah or axlc.
Insert the cotter pin through the nul and bolt or
axle and bend the ends overto secure the cotterpin
tightly. If the holes do not align. tighten the nut just
enough to obtain the prop eralignment. Unless spe-
cifically instructed to do so. never loosen the fas-
tcner 10 align thc slot and the hole. Because the
cotter pin is weakened after installation and re-
moval, never reuse a cotter pin. Cotter pins are
available in several styles. lengths and diameters.
Measure the cotter pin length from the bottom of its
head to the lip
of thc shortest prong.
Circlips
Circlips can be internal or exte
rn al in design.
They are used to retain items on shafts (exte
rn al
type) or within lubes (internal type). In some appli-
cations. circlips of varying thicknesses are used to
control the endplay
of assemblies. These are often

GENE RAL II\'FO RMATION
CD
Full
'~~=;1;'7 T support
I" areas
j_
.... Rounded edges
1..tf111h Sharp edges
If: ~'\ I
. ~ m . ," ru"
callcd selective circlips. Circlips should bc rep laced
during in stallation. as rem oval weak ens and de-
f orm s them .
Two basic styles
of circlips are available: machined
and stamped circlips. Machined circlips (Figure 7)
can be insta lled in either dire ction (shaft or housing)
because both faces are ma chined. thus creating two
sharp edges. Stamped eirclips (Figure 8) are manu-
fact u re d withonesha rp edge and one rou nd ed edge.
When installing sta mped c ircli ps in a thru st si tuatio n
as on tran smission shafts. the sharp edge must face
away from the part producing the thrust. When install-
ing circlips, observe the following:
I. Compress or expand circlips only enough to in-
stall them.
2. Afterthe circlipis installed, make sure itis com-
pletely seated within its groove.
3.
Transmi ssioncirclips become WO nt withlise anti
increasesideplay.For thi sreason.alwaysin stall new
circlips whenever a tra nsmission is reassembled.
9
L UBRICANTS
Periodic lubrication assures long Iifc for any t yp e
of equipme nt. The type of lubricant used is jus t as
i mportant as the lubrication service itself, although
in an emergency the wrong type of lubricant is
beller than none at all. The following para graphs
describe the types
of lubricants most often used for
ATVs. Be sure to follow the manufacturer's recom-
mendations for l ubr icanttypes.
Generally all liquid lubricants are called oil. They
may be mineral-based (including petroleum bases),
natural-based (vege table and animal bases). syn-
thetic-based or emu lsions (mixtures). Grease is oil
to which a thickening base has been added so that
the end prod uct is semi-solid. Grease is often classi-
fied by the type
ofthiekcner added; lithium soap is
commonly used,
Engine Oil
Engine oil is classified by two standards: the
American Petroleum Institute (API) service classi-
fication and the Society of Automotive Engineers
(SA E) viscosity rating. This information is on the
oil contain
er label. Two leiters indicate the API ser-
vice classification.The number or sequence of
number s and leit er ( IOW-40 for exa mple} is the oi l's
viscosity ratin g. The API service classification and
the SAE viscosity index are not indications
of oil
quality.
The service classification indicates that the oil
meets specific lubrication standards. The first leiter
in the classification S indicates that the oil is for gas-
oline engines.
Th e second leiter indicates the stan -
dard the oil satisfies. The classification started with
the leiter Aand is currently at the letter1.
Always lise an oil with a classification recom-
mended by the manufacturer . Using an oil with a
classification different than that recommended can
cause engine damage.
Viscosity is an indication
of the oil's thickness.
Thin oils have a low er numb er while thick oils have
a higher number . Engine oils fall into the 5- to
50-weight range for single-grade oils.
Most manufacturers recommend mu ltigra de oil.
These oils
perform efficiently across a wide rang e
of operating conditions. Multigrade oils are identi-
fied by a IVafter the first number, which indicates
the low-temperature viscosity.

10
Engine oils an: 111 0 St commonly mine ral (petro-
leum) based; howeversynthetic andsemi-synthetic
types are used more
fre quently. When selectingen-
gine oil, follow th e manu f actur er's recommenda-
tion
for type, classi fica tion and viscosity.
Grease
The National Lubricating Grease
In st itut e
(NLG I) grades greases . Grea ses arc grad ed by num-
beraccording tothe consistency of the grease;these
range from No. 000 to No. 6, with No. 6 being the
most solid. Typica l multipurpose grease is NLGI
No
.2 . For specific applications, equipment manu-
fac tu rersmay re qui re grease with an additive such
as molybdenum disulfide.
T HREAIl L OC KI :'oI G CO M P OU:'oI Il
A threadlocking compound should be used to
help securemany of the fasteners used 0 11 the vehi-
cle. A threadlock compound will lock fasteners
against vibration loosening and seal against leaks.
The following thread locking c omp ounds are rec-
ommended for many threadlock requirements de-
scribed in this m anual.
\. Thrcelsond TB134 2 (blue): low-strength, fre-
quent repai r.
2. Loctite No. 242 (blue): low-strength, frequent
repair.
3. Thr eeBond TB1360 (green): medium-strength,
high temperat ure.
4.
Thr eelsond No. 1333 B (red): medium-strength,
bearing
and stud lock.
5. Three Bond TB1303 (orange) : high-strength, in-
frequent repai r.
6. Loctite No. 27 1 (red): high-strength, infrequent
repair.
There areother quality thrcadlock brands on the
market.
RTV GASKET SE ALA NT
Room temperature vulcanizing (RTV) sealant is
used on some pr ef ormed gaskets and to seal some
components. RTVis asiliconegel supplied intubes
and is available at motorcycle and automotive sup-
plies stores and majorhardware stores.
Moisture in the air causes the
RT V to cure. Al-
ways place the cap on the tube as soon as possible
CHA PTE R ON E
whe n using RTV . RTV has a shelf life of approxi-
mately oneyearand will not curep rop erly whenthe
shelf life has expired. Check the expiration date on
the RTV tube prior topurchasing a new tube andon
using the sealant. Keep
parti ally used tubes tightly
scaled and discard
th emafter th eexpiration date.
A(lIJlying RTV Sealant
Clcan all old gasket residue from all mating sur-
faces. Remove all RTV gas ket material from blind
threaded holes; itcancause ahydraulic lock andaf-
fect bolt torque. leading to the boll not being ti ght -
ened to the co rrec t torqu especification. Finally,
spray the mating surfaces with an aerosol parts
cleanerand wipe with alint-free cloth.
Apply RTVsealant inacontinuous bead 2-3 ITIm
(0.08-0.12 in.) thick. Circle all mounting holes un-
less otherwi se spec ified. Do not allow any sealant to
enter th ese holes. Assemble and tighten the fa sten-
ers to the specified t orqu ewithin 10 m inut es after
application.
EXPEN IlAB LE SU PP LIE S
C erta in expendable supplies are required during
maintenanceandrepairwork.These include grease,
oil. and gasket cement, wiping rags and cleaning
solvent. Ask the dealership for the special locking
compounds. silicone lubricants and otherp rodu cts,
which make vehicle maintenance simpler and eas-
ier. Cleaning solvent or kerosene is available at
some service s
tat ions, paint orha rdwar e stores.
Be sureto followthe manuf
actur er's instructions
andw
arn ings listedonthe labelof the p roduct being
used, Some cleaning supplies arc very caustic and
aredangerous ifn ot used properly.

GENERAL INFORMATIOI'O
II
WARNING
Haring a sta ck ofcl ean shop rags Oil
hand is important when pe l/a rming
engine and suspension
se rvice work.
However. a pil e of solvent-soaked
rags
prese nts a fire hazard. Store
them in a
se aled metal container /lI 1-
til they can be washed or pro per ly
discarded.
NO TE
70 prevent solvent and other chemi-
cals fro m being absorbedinto the
skin. Il'ear a
pair of pe tro-
leum-resistant gloves when cleaning
parts. These can be purchased
through industrial supply houses 01'
well-equipped hardwarestores.
SERIAL N
UMIlERS
Polaris makes freq uent c ha nges during a model
year- some minor, some relatively major. When
ordering parts from the dealership or other parts dis-
t ribut or, always order by VIN and engine serial
numbers. The serial number locations arc as fol-
lows:
I. Model and YIN number (Figure 9) is stamped
on the left lower frame rail near the rear portion
of
the fro nt A-a rm mou nt. On some models. a decal
with the YIN number is located on the front fender
cover (Figure 10).
2. Engine serial number (Figure
II) is stamped on
a pad on the centertopof thecrankcase beneaththe
cylinder coolant elbow,
3. The tra nsmissionse ria lnumberis locatedontop
of the tra nsmission case below the shin bell c ra nk
and on a label on the right side (Figure 12).
4. The carburetor serial number (Figure 13) is lo-
cated on the left side of the carburetor body.
Enter these numbers on the ch art in the Quick
R ef erence Data table at the front of this book and
keep them for reference. Compare new parts to the
old ones before huying them. If they are not alike,
have the parts manager explain the difference. Ta-
ble 1 lists the model numbers for the models cov-
ered in this manual.

12
WAR;;ING AND INFORMATION LABELS
Anumber of warning labels (Fig
ure 14) arc at-
tachcd to the Polaris. The se labels conta in informa-
tion that is impo rt ant to personal safety when
operating. tran sp ortin gandstoring the vehicle. Also
refer to the informative labels fastened to the vari-
ous components on the vehicle. as this information
is veryuseful. Referto the owner's manual fora de-
scription and location of each label. If a label is
missing, order a replacement label from a Polaris
dea lership.
BASIC
llANO TOOLS
Manyof the procedures inthismanualcanbecar-
riedout with simple handtools and test equipment
familiarto thehome mechanic. Keep all tools clean
and in a toolbox. Keep them organized with the
sockets and related drives together, the open-end
combination w renche s together, etc. After using a
tool, wip e off dirt andgrease with a cleanclothand
returnthe tool to itscorrect place.
Top quality tools are essential; they are also more
e conomical inthe long run. If just startingto build a
tool collection, stay away from the adverti sed spe-
cials fea
ture dat some p art shouses, discountstores
and chain drug stores. These are usually poor grade
tools that arc mad e of infer ior material. and arc
thick, heavy and clumsy to use. Their rough finish
makes them difficult to clean and they usually do
not last very long. The wrenches do not fit the heads
of bolts and nuts correctly and may damage the fas-
tener.
Quality tools arc made of alloy steel and arc
heat-treated for greater strength. They are lighter
and better balanced than inferior ones. Their surface
is smooth.making themapleasure to workwithand
easy to clean. The initial cost of good quality tools
may be more, butthey are moreeconomical in the
long run. Do not try to buy everything in all sizes in
the beginning: buy a few at a time until all the nec-
essary tools arcon hand .
Screwd rivers
The screwdriver is a very basic tool, but if used
improp erly itwill do moredamage th an good. The
slot on a screw has adefinite dimension and shape.
Ascrewdriver must be selected to conform to t hat
CIIAPTER O;;E
shape. Use asmall screwdriverforsmall screws and
a large one for large screws, orthescrew headwill
be damaged.
Two basic types of screwdrivers are r equired :
common (flatblade) screwdrivers and Phillips
screwdrivers.
Screwdrivers arc available in sets that often in-
clude an assortment of common and Phillips blades.
If purchased individually, buy at least the follow-
ing:
I. Common screwdriver- 5!16 x 6 in. blade.
2. Common screwdrive r- 3/8 x 12 in. blade .
3. Phillips screwdriver
-s ize 2 tip, 6 in. blade.
4. Phillips screwdrive r-s ize 3 tip, 6 and 10 in.
blade.
Use screwdrivers only fordriving screws. Never
usc a screwdriver for p
ryin gorchiseling metal. Do
not try to remove a Phillips or Allen head screw
witha common screwdriver (unless the screw has a
combination head that will accept either type); if the
head is damaged, the proper tool will be unable to
remove it. Keep screwdrivers in the proper condi-
tion and they will last longer and p
erf orm better. Al-
ways keep the tip ofa commonscrewdriveringood
condition.
Pliers
Pliers come in a wide
range of types and sizes.
Pliers are useful for cutting, bend ing and crimping.
Do not usc them to cut h ardened objects or to tum
bolts or nuts. Each type of pliers has a specialized
function. Slip-jointpliers are gene ra lpurpose pliers
and are used mainly for holding thin gs and for
bending.

GENE R AL INF ORM A TI ON 13
Cir clip Pli ers
Locking P lier s
Circlip pliers (Figure 15) are made for removing
and installing circlips. External pliers (spreading)
are used to remove circlips that fit on the outside of
a shaft. Internal pliers (squeezing) are used to re-
move circlips which fit inside a gear or housing.
II
Box, O pen-End and Com bination Wren ches
An adjustab le wrench (sometimes called crescent
wrench) can be adjusted to fit nearly any nut or bolt
head that has clear access around its entire perime-
ter. Adjustable wrenches are best used as a backup
wrench to keep a large nut or bolt from turning
while the other end is being loosencd or tightened
with a box-end or socket wrench,
Ad
jus table wrenches have only two gripping sur-
faces which make them more subject to slipping ofT
the fastener and damaging the part and possibly
A
djust ab le Wrenches
WAR NING
Because circlips call sometimes slip
ami fly of] when removing and install-
ing them. always wear safety glasses
when using them.
Open-end, box-end and combination wrenches
are available in sets or separately in a variety of
sizes. On open and box end wrenches, the number
stamped near the end refers to the distance between
two parallel flats on the hex head bolt or nut. On
combination wrenches, the number is stamped near
the center.
Open-end wrenches (A,
Fig ure 16) are speedy
and work best in areas with limited overhead ac-
cess. Their wide, flat jaws make them unstable for
situations where the bolt or nut is located in abore
or close to the edge of a casting. These wrenches
grip only two flats of a fastener; if eitherthe fastener
head or the wrench jaw s are worn, the wrench may
slip ofT.
Box-end wrenches (B, Figure 16) require clear
overhead access to the fastener but can work well in
situations where the fastener head is close to an-
other part. They grip on all six edges
of a fastener
for a very secure grip. They are available in either
6-point or 12-point. The 6-po int gives superior
holding flower and durability but requires a greater
swinging radius. The 12-point works better in situa-
tions where the swinging radius is limited.
Combination wrenches (C. Figure J6) have
open-end on one side and box-end on the other with
both ends being the same size. Professional me-
chanics favor these wrenches because of their ver-
satility.
o
:
s K
~ ... ~~~
A
®o
Q!
Locking pliers are used to hold objec ts very
tightly like a vise. But avoid using them unless nec-
essary since their sharp jaws will permanently scar
any objects that are held. Locking pliers are avail-
able in many types for more specific tasks.
Needlcnosc pliers are used to hold or bend small
objects. Water pump pliers can be ad
ju sted to hold
various sizes of objects; the jaws remain parallel to
griparound objects such as pipe or tubing. There arc
many more types of pliers. The ones described here
are most suitable for vehicle repairs.

14
causing injury. The fact that one jaw is adjustable
only aggravates this shortcoming.
These wrenches are directional: the solid jaw
must be the one transmitting the force. If the adjust-
able jaw is used (0 transmit the force. it will loosen
and possibly slip otT.
Socket
Wre nches
®
CHAPTER ONE
This type of wrench is undoubtedly the fastest,
safest and most convenient to use. Sockets. which
attach to a ratchet handle. are avai lable with 6-point
(A,
Figur e 17) or 12-point (B, Figu re 17) openings (;;;\
and 1/4, 3/8. 1/2 and 3/4 in. drives. The drive size ~
indicates the size of the square hole which mates
with the ratchet handle.
Allen
Wrenc hes
AB
Allen wrenches are available in sets or separately
in a variety
of sizes. These sets come in SAE and
metric sizes. Allen bolts arc sometimes called
socket bolts. Sometimes the bolts are difficult to
reach and it is suggested that a variety orAllen
wrenches be purchased, such as the socke t driven.
T-handle and extension type.
Torq ue Wrench
Atorque \ ... Tench is used with a socket to measure
how tightly a nut or bolt is installed. They come
with either 1/4
.3 18 or 1/2 in. square drive (Fig ure
18). The drive size indicates the size of the square
drive that mates with the socket.
I mpact Driver
This tool might have been designed with the ATV
mechanic in mind. This tool makes removal of fas-
teners easy and eliminates damage to bolts and
screw slots. Impact drivers (Figure 19) and inter-
changeable bits are available at most large hard-
ware, vehicle or auto parts stores. Sockets can also
be used with ahand impact driver; however, make
sure that the socket is designed for use with an im-
pact driver or air tool. Do not use regular hand sock-
ets, as they
111 3y shatter during use.
Hamm ers
The correct hammer is necessary for certain re-
pairs. A hammer with a face (or head)
of rubber or
plastic or a soft-faced type tilled with buckshot is
sometimes necessary in engine disassembly. Never
usc a metal-faced hammer on engine or suspension
parts. as severedamage will result in most cases.
The same amount of force can be produced with a
soft-faced hammer. The shock
of a metal-faced
hammer, however, is required for using ahand im-
pact driver or cold chisel.
Su
ppo rt Jacks
The correct type of support jack is necessary for
many routine service or major component replace-
ment procedures on the vehicle. The centerstand
scissor jack is suitable for most service procedures
on this series of vehicles. It is adjustable and is very
stable for usc with the frame configuration
of this
vehicle.
Also, the standard floor jack may be used for
some applications, To protect all engine and frame