Used Items For parts or not working 2 Items 2. Not Specified 7 Items 7. Please provide a valid price range. Buying Format. All Listings. Accepts Offers. Buy It Now. Item Location. Canada Only. North America. Shipping Options. S Tighten shift linkage rod end jam nuts properly after adjustment. Page 40 - projex inbox. Place gear selector in neutral. Make sure the transmission bell cranks are engaged in the neutral position detents.
Be sure the shift linkage rod ends are firmly attached to the gear selector slides. Adjust the low range inside rod so the rod end is centered on the transmission bell crank. Page Throttle Operation - projex inbox. Throttle lever operation should be smooth and lever must return freely without binding.
Place the gear selector in neutral. Set parking brake. Page Pilot Screw Adjustment - projex inbox. Start engine and warm it up to operating temperature about 10 minutes. This is a very important step. Page 43 - projex inbox.
Slide boot off throttle cable adjuster and jam nut. Place shift selector in neutral and set parking brake. Start engine and set idle to specified RPM, then shut off engine. Page Fuel System - projex inbox. Always stop the engine and refuel outdoors or in a well ventilated area.
Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Page Carburetor Draining - projex inbox. NOTE: The bowl drain screw is located on the bottom left side of the float bowl. Page Compression Test - projex inbox. Compression readings will vary in pro- portion to cranking speed during the test. Average compression measured is about psi during a compres- sion test. Smooth idle generally indicates good compression.
Page Battery Maintenance - projex inbox. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Page Spark Plug - projex inbox.
Remove spark plug high tension lead. Clean plug area Recommended Spark Plug: so no dirt and debris can fall into engine when plug is removed. Refer to Specifications 2. Remove spark plug. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of Spark Plug Torque: 14 Ft. Page Cooling System Hoses S Overheating of engine could occur if air is not fully purged from system.
Do not dilute with water. Page Coolant Level Inspection 1. Remove reservoir cap. Inner splash cap vent hole must be clear and open. Page 51 - projex inbox. When riding in extremely dusty conditions re- placement will be required more often. Gasket The pre filter should be cleaned before each ride, using the following procedure. Drain whenever deposits are visible in the clear tube. NOTE: The sediment tube will require more frequent ser- vice if the vehicle is operated in wet conditions or at high throttle openings for extended periods.
Page Recoil Housing - projex inbox. This should also be done before storing the ATV. The drain screw is located at the bot- tom of the recoil housing. Run engine two to three minutes until warm. Stop engine. Clean area around drain plug B at bottom of oil tank.
Place a drain pan beneath oil tank and remove drain Ambient Temperature Range: plug. Page 55 Reinstall drain plug. Crankcase Drain Remove dipstick and fill tank with 2 quarts 1. Place gear selector in neutral and set parking brake. Prime oil pump using procedure below. Stop the engine and inspect for leaks. Page Valve Clearance - projex inbox. Remove the seat. Remove body panels and fuel tank as necessary to gain access to valve cover.
Page Intake Valve Clearance Adjustment - projex inbox. Insert a. Using a 10 mm wrench and a screwdriver, loosen adjuster lock nut and turn adjusting screw until there is a slight drag on the feeler gauge. Page 58 Polaris parts. WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component re- pair and adjustment be performed by an authorized Polaris Dealer. Only a qualified technician should replace worn or damaged steering parts.
Use only genuine Polaris replacement parts. Page 59 - projex inbox. See note below. NOTE: String should just touch side surface of rear tire on each side of machine. Measure from string to rim at front and rear of rim. Page 60 - projex inbox. Place machine on a smooth level surface. Set handlebars in a straight ahead position and secure handlebars in this position.
NOTE: The steering frog can be used as an indicator of whether the handlebars are straight. Page 61 2. NOTE: Do not force the fluid into the hub under pressure or seal damage may occur. Page Exhaust Pipe - projex inbox. Remove the clean out plugs located on the bottom of the muffler as shown at right. Place the transmission in neutral and start the engine.
Purge accumulated carbon from the system by momen- Clean Out Plug tarily revving the engine several times. Check brake system for fluid leaks. Check brake for excessive travel or spongy feel.
Check friction pads for wear, damage and looseness. Check surface condition of the disc. Page Auxiliary Brake Testing - projex inbox. Free Play 1. Page Front Suspension - projex inbox. Adjust as necessary. Damping should be smooth throughout the range of travel. Check all front suspension components for wear or dam- age. Page Controls - projex inbox. Spacer Tab Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch body.
Align throttle control assembly clamp with knurl on handle- Throttle assembly clamp Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts.
Rear Wheel Nuts 20 Ft. Page Tire Pressure - projex inbox. Refer to the warning tire pressure decal applied to the vehicle. Page Engine - projex inbox. Torque Patterns Piston Identification. Page Torque Specifications - projex inbox. Nm Ft. Page Torque Patterns - projex inbox. Page Piston Identification - projex inbox. The other numbers are used for identification as to diameter, length and design.
Page Engine Service Data - projex inbox. Page 74 - projex inbox. Page Cooling System - projex inbox. The cooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing. Page Cooling System Specifications Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage.
Page Accessible Components - projex inbox. Clean work area. Thoroughly clean the ATV engine and chassis. Disconnect battery negative - cable.
Remove the following parts as required. Never substitute or mix oil brands. Page Honing To Oversize Selecting a hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded finger type glaze breaker for honing is never advised. Polaris recommends using a rigid hone or arbor honing machine which also has the capability of oversizing. Page Crankshaft Straightening - projex inbox.
Refer to the illustrations below. Page 82 Oil Type Page 83 - projex inbox. Beginning at the oil tank, the oil flows through a screen fitting in the bottom of the tank and into the oil supply hose. The feed side of the oil pump draws oil through the hose and into the crankcase oil gallery, and then pumps the oil through another passage to the one way valve.
Page 86 - projex inbox. Remove ignition timing inspection plug from recoil housing. Page Cam Chain Tensioner Inspection - projex inbox. Pull cam chain tensioner plunger outward to the end of its travel. Inspect teeth on ratchet pawl A and plunger teeth B for wear or damage. Push ratchet pawl and hold it.
The plunger should move smoothly in and out of the tensioner body. Mark or tag rocker arms to keep them in order for assembly. Inspect each rocker arm cam follower surface.
If there is any damage or uneven wear, replace the rocker arm. NOTE: Always inspect camshaft lobe if rocker arms are worn or damaged. Page 89 - projex inbox.
Measure I. Compare to specifications. Page Camshaft Removal - projex inbox. Remove thermostat housing. Remove camshaft sprocket inspection cover. Loosen three camshaft sprocket bolts.
Remove camshaft end cap and O-Ring. Inspect camshaft end cap thrust face for wear. Replace if worn or damaged. Page 91 - projex inbox.
Place a clean shop towel in the area below cam chain sprocket and remove sprocket retaining bolts. Slide camshaft inward to allow removal of cam sprocket and remove sprocket from camshaft and chain. Page Automatic Compression Release Installation - projex inbox.
The actuator ball in the camshaft is not replaceable. Replace the cam- shaft as an assembly if the actuator ball is worn or dam- aged. Page Camshaft Inspection - projex inbox. Visually inspect each cam lobe for wear, chafing or damage. Thoroughly clean the cam shaft, making sure the oil feed holes are not obstructed. Measure height of each cam lobe using a micrometer. Page Cylinder Head Exploded View - projex inbox.
Remove the two 6mm flange bolts A from cylinder head. Page Cylinder Head Inspection - projex inbox. Remove bolts A and tap cylinder head lightly with a plastic hammer until loose. Page Cylinder Head Disassembly - projex inbox. NOTE: Keep all parts in order with respect to their location in the cylinder head. Using a valve spring compressor, compress the valve spring and remove the split keeper. Page 97 - projex inbox. Measure free length of spring with a Vernier caliper. Check spring for squareness.
Replace spring if either measurement is out of specification. Page Valve Inspection - projex inbox. Remove all carbon from valve with a soft wire wheel. Check valve face for runout, pitting, and burnt spots. Page Combustion Chamber - projex inbox. Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions, front to back and side to side. Page Valve Seat Reconditioning - projex inbox.
If any of the above conditions exist, the valve seat must be reconditioned. See Valve Seat Reconditioning, page 3. If the valve seat is cracked the cylinder head must be replaced. Page - projex inbox. Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Recondi- tioning Kit PN Abrasive stone seat re- conditioning equipment can also be used.
Keep all valves in order with their respective seat. NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. Install pilot into valve guide. Apply cutting oil to valve seat and cutter. Inspect the cut area of the seat. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width.
If the indicated seat contact is at the top edge of the valve face and contacts the margin area B it is too high on the valve face. Page Cylinder Head Assembly - projex inbox. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem.
Rotate the valve rapidly back and forth until the cut sounds smooth. Page Valve Sealing Test - projex inbox. Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head.
Closely spaced coils toward cylinder head 6. Place retainer on spring and install valve spring compressor. Remove cam chain guide at front of cylinder. Loosen all four oil pipe banjo bolts and then remove the bolts and eight sealing washers.
Remove the two 6 mm cylinder base bolts. Page Piston Removal - projex inbox. Remove circlip. Note piston directional arrow pointing toward the right Mag side of engine. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch.
Page Cylinder Inspection - projex inbox. Remove all gasket material from the cylinder sealing surfaces. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge.
Cylinder Warpage:. Inspect cylinder for wear, scratches, or damage. Record measurements. If cylinder is tapered or out of round beyond. Cylinder Taper Limit:. Cylinder Out of Round Limit:. Standard Bore Size: 3. Measure piston pin bore. Piston Pin Bore:. Measure piston pin O. Piston Pin O. Page Piston Ring Installed Gap - projex inbox. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with Piston a thickness gauge.
Replace piston and rings if ring-to-groove clearance exceeds service limits. Remove recoil housing bolts and remove housing. Remove flywheel nut and washer. Install flywheel puller PN and remove flywheel. Remove bolt securing tensioner blade to crankcase A. Remove blade and inspect for cracks, wear, or damage. Remove cam chain. Inspect chain for worn or missing rollers or damage. Stretch chain tight on a flat surface and apply a 10 lb.
Page One Way Valve - projex inbox. Using the special socket, remove the crankshaft slotted nut A. NOTE: The slotted nut is a left hand thread.
Remove cam chain drive sprocket B and Woodruff key from crankshaft. Page Crankcase Separation - projex inbox.
Remove flange bolts 10 from magneto side crankcase evenly in a cross pattern. Separate crankcase by tapping with a soft faced hammer in reinforced areas. Tap lightly on balancer gear with a brass drift through the hole in the crankcase if necessary, to ensure the balancer shaft stays in the PTO side crankcase. Remove pump shaft bearing A and thrust washer B from pump shaft. Remove 2 bolts holding pump drive gear C.
Remove the three screws and strainer screen from pump. Clean screen thoroughly. Remove pump body screw and feed chamber cover. Measure pump end clearance using a feeler gauge and straight edge. Complete service manuals ordered after the release of new model year manual updates will contain the latest update.
However, all materials p. Comments or suggestions about this manual may be directed to: Polaris Sales Inc. Nye Co. This information can be found on the sticker applied to the manual starter recoil housing. Transmission 1. Number Location Transmission model and serial numbers are located on top of the transmission case below the shifting bell- cranks.
Carburetor 1. Number Location The carburetor I. I think its interesting what people do to get their Toys out to the play ground Do you wear your ring? Hi Ladies, I am new to the forum and to riding. I just bought a Honda ex and I love it. I went out riding for the first time last Sunday and I can't wait to get back out there on Saturday.
I just recently got engaged and I never take my ring off. It fits fine under my glove and I am wondering if anyone else has lost theirs or had a bad experience wearing it while riding. I believe I have a 85 lt e? I think. New to Atv any help will be appreciated to identify as i need to order some parts such as starter clutch as starter is not engaging pull start works fine.
I believe it's a 85 model. Bike only has front suspension no rear suspension on this model. Just 2wd , no high or low ,reverse lever postion on rightside case. Has full rack front and back. Have been trying to locate a workshop manual but no luck any help will be appreciated. Regards Paul Tasmania. Factory service manual for yamaha big bear? Anybody know where I can get a service manual for a yamaha big bear 4wd? Are Haynes or Chilton manuals any good for more than routine maintenance?
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