Polaris REPAIR GUIDE,SERVICE&MAINTENANCE AND DIAGNOSTIC,DIY Workshop Repair,Electronic part,wiring diagrams and System

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Archive for the ‘Polaris’ Category

Polaris Ranger 500 4×4 Engine TROUBLESHOOTING GUIDE

Engine Turns Over But Fails to Start
• No fuel
• Dirt in fuel line or filter
• Fuel will not pass through fuel valve
• Fuel pump inoperative/restricted
• Tank vent plugged
• Engine flooded
• Low compression (high cylinder leakage)
• No spark (Spark plug fouled)
Engine Does Not Turn Over
• Dead battery
• Starter motor does not turn
• Engine seized, rusted, or mechanical failure
Engine Runs But Will Not Idle
• Low compression
• Crankcase breather restricted
Engine Idles But Will Not Rev Up
• Spark plug fouled/weak spark
• Broken throttle cable
• Obstruction in air intake
• Air box removed (reinstall all intake components)
• Reverse speed limiter limiting speed
• Incorrect ignition timing
• Restricted exhaust system
Engine Has Low Power
• Spark plug fouled
• Cylinder, piston, ring, or valve wear or damage (check compression)
• PVT not operating properly
• Restricted exhaust muffler
Piston Failure – Scoring
• Lack of lubrication
• Dirt entering engine through cracks in air filter or ducts
• Engine oil dirty or contaminated
Excessive Smoke and Carbon Buildup
• Excessive piston-to-cylinder clearance
• Wet sumping
• Worn rings, piston, or cylinder
• Worn valves, guides or seals
• Restricted breather
• Air filter dirty or contaminated
Low Compression
• Decompressor stuck
• Cylinder head gasket leak
• No valve clearance or incorrectly adjusted
• Cylinder or piston worn
• Piston rings worn, leaking, broken, or sticking
• Bent valve or stuck valve
• Valve spring broken or weak
• Valve not seating properly (bent or carbon accumulated on sealing surface)
• Rocker arm sticking

Backfiring
• Fouled spark plug or incorrect plug or plug gap
• Exhaust system air leaks
• Ignition system faulty:
Spark plug cap cracked/broken
Ignition coil faulty
Ignition or kill switch circuit faulty
Ignition timing incorrect
Sheared flywheel key
• Poor connections in ignition system
• System wiring wet
• Valve sticking
• Air leaks in intake
• Lean condition
Spark Plug Fouling
• Spark plug cap loose or faulty
• Incorrect spark plug heat range or gap
• PVT system calibrated incorrectly or components worn or mis-adjusted
• Fuel quality poor (old) or octane too high
• Low compression
• Restricted exhaust
• Restricted air filter (main or pre-cleaner)
• Improperly assembled air intake system
• Restricted engine breather system
• Oil contaminated with fuel
• Restricted oil tank vent
Cooling Troubleshooting
Overheating
• Low coolant level
• Air in cooling system
• Wrong type of coolant
• Faulty pressure cap or system leaks
• Restricted system (mud or debris in radiator fins or restriction to air flow, passages blocked in radiator, lines, pump, or water jacket)
• Lean mixture (restricted jets, vents, or fuel pump)
• Fuel pump output weak
• Restricted radiator (internally or cooling fins)
• Water pump failure
• Cooling system restriction
• Cooling fan inoperative or turning too slowly
• Ignition timing misadjusted
• Low oil level
• Spark plug incorrect heat range
• Faulty hot light circuit
• Thermostat stuck closed or not opening completely
• Radiator is missing its internal diverter plate not  allowing coolant to flow through entire radiator Temperature Too Low
• Thermostat stuck open
Leak at Water Pump Weep Hole
• Faulty water pump mechanical seal (coolant leak)
• Faulty pump shaft oil seal (oil leak)

Polaris Sportsman 800 Engine TROUBLESHOOTING GUIDE

Spark Plug Fouling
• Spark plug cap loose or faulty
• Incorrect spark plug heat range or gap
• PVT system calibrated incorrectly/ components worn or mis-adjusted
• Fuel quality poor (old) or octane too high
• Low compression
• Restricted exhaust
• Weak ignition (loose coil ground, faulty coil, stator, or  ETC switch)
• ETC switch mis-adjusted
• Restricted air filter (main or pre-cleaner) or breather  system
• Improperly assembled air intake system
• Restricted engine breather system
• Oil contaminated with fuel
Engine Turns Over But Fails To Start
•No fuel
• Dirt in fuel line or filter
• Fuel will not pass through fuel valve
• Fuel pump inoperative/restricted
• Tank vent plugged or pinched
• Engine flooded
• Low compression (high cylinder leakage)
• No spark (Spark plug fouled) ignition component  failure
Engine Does Not Turn Over
• Dead battery
• Starter motor does not turn
• Engine seized, rusted, or mechanical failure
Engine Runs But Will Not Idle
• Restricted carburetor pilot system
• Low compression
• Crankcase breather restricted
Engine Idles But Will Not Accelerate
• Spark plug fouled/weak spark
• Broken throttle cable
• Obstruction in air intake
• Air box removed (reinstall all intake components)
• Incorrect or restricted carburetor jetting
• ETC switch limiting speed
• Reverse speed limiter limiting speed
• Incorrect ignition timing
• Restricted exhaust system
• Cam worn excessively
Engine Has Low Power
• Spark plug fouled
• Cylinder, piston, ring, or valve wear or damage (check  compression)
• PVT not operating properly
• Restricted exhaust muffler
• Cam worn excessively
Piston Failure – Scoring
• Lack of lubrication
• Dirt entering engine through cracks in air filter or ducts
• Engine oil dirty or contaminated
Excessive Smoke and Carbon Buildup
• Excessive piston-to-cylinder clearance
• Wet sumping (Oil Level Too Full)
• Worn rings, piston, or cylinder
• Worn valve guides or seals
• Restricted breather
• Air filter dirty or contaminated
Piston Failure – Scoring
• Lack of lubrication
• Dirt entering engine through cracks in air filter or ducts
• Engine oil dirty or contaminated

Excessive Smoke and Carbon Buildup
• Excessive piston-to-cylinder clearance
• Wet sumping due to over-full crankcase
• Worn rings, piston, or cylinder
• Worn valve guides or seals
• Restricted breather
• Air filter dirty or contaminated
Low Compression
• Cylinder head gasket leak
• No valve clearance ( cam wear )
• Cylinder or piston worn
• Piston rings worn, leaking, broken, or sticking
• Bent valve or stuck valve
• Valve spring broken or weak
• Valve not seating properly (bent or carbon accumulated  on sealing surface)
• Rocker arm sticking
Backfiring
• ETC or speed limiter system malfunction
• Fouled spark plug or incorrect plug or plug gap
• Exhaust system air leaks
• Exhaust system air leaks
• Ignition system faulty: Spark plug cap cracked/broken, Ignition coil faulty, Ignition or kill switch circuit faulty,  Ignition poor connections in ignition system
• n timing incorrect, Sheared flywheel key
• Valve sticking

Cooling System
Overheating
• Low coolant level
• Air in cooling system
• Wrong type/mix of coolant
• Faulty pressure cap or system leaks
• Restricted system (mud or debris in radiator fins causing restriction to air flow, passages blocked in radiator, lines, pump, or water jacket, accident damage)

• Lean mixture (restricted jets, vents, fuel pump or fuel valve)
• Fuel pump output weak
• Electrical malfunction
• Water pump failure/ Loose impeller
• Thermistor failure
• Cooling fan inoperative or turning too slowly (perform current draw test)
• Ignition timing mis-adjusted
• Low oil level
• Spark plug incorrect heat range
• Faulty hot light circuit
• Thermostat stuck closed or not opening completely
• Possible diverter plate loose or missing inside radiator
Temperature Too Low
• Thermostat stuck open
Leak at Water Pump Weep Hole
• Faulty water pump mechanical seal (coolant leak)
• Faulty pump shaft oil seal (oil leak)

polaris 2004 sportsman 600/700 troubleshooting guide

Spark Plug Fouling

  • Spark plug cap loose or faulty
  • Choke cable adjustment or plunger/cable sticking
  • Foreign material on choke plunger seat or plunger
  • Incorrect spark plug heat range or gap
  • Carburetor inlet needle and seat worn
  • Jet needle and/or needle jet worn or improperly adjusted
  • Excessive carburetor vibration (loose or missing needle jet locating clips)
  • Loose jets in carburetor or calibration incorrect for altitude/temperature
  • Incorrect float level setting
  • PVT system calibrated incorrectly/components worn or mis-adjusted
  • Fuel quality poor (old) or octane too high
  • Low compression
  • Restricted exhaust
  • Weak ignition (loose coil round, faulty coil, stator, or ETC switch)
  • ETC switch mis-adjusted
  • Restricted air filter (main or pre-cleaner) or breathersystem
  • Improperly assembled air intake system
  • Restricted en ine breather system
  • Oil contaminated with fuel

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2003-2006 Magnum 330 ATV Service Repair Manual pdf

This is the most complete service repair manual for the 2003-2006 Polaris Magnum 330 ATV. This manual contains service,repair procedures,assembling,disassembling, wiring diagrams and everything you need to know.

This PDF service manual will show you every nut and bolt on your vehicle. With hundreds of pages, it will show you how to distinguish any problem (from an oil change to a transmission swap) and how to fix it on your own. There are many illustrations to aid you during your job and easy to read text throughout the manual. You will be able to use the search function to browse the manual and print out your needed pages.

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polaris sportsman troubleshooting – steering repair directions

The troubleshooting procedures described in this chapter provide typical symptoms and logical methods for isolating the cause(s).There may be several ways to solve a problem,but only a systematic approach will be successful in avoiding wasted time and possibly unnecessarily replacing parts.

Description of handling problems are subjective,but the following items will provide a starting point from which to troubleshoot handling and steering problems,some possible causes for each malfunction are listed in a logical sequence.

Disc brake troubleshooting

disc brake fluid leakage

check

  • loose or damaged line fittings
  • worn cliper piston seals
  • scored caliper piston and /or bore
  • loose banjo bolts
  • damaged washers
  • leaking master cylinder diaphragm
  • leaking master cylinder secondary seal
  • cracked master cylinder housing
  • brake fluid level too high
  • loose or damaged master cylinder cover

Brake overheating

check

  • warped brake disc
  • caliper piston and /or brake pads sticking
  • riding brakes

Brake chatter

check:

  • warped brake disc
  • loose brake disc
  • incorrect cliper alignment
  • loose front axle nut and/or clamps
  • worn wheel bearings
  • damaged hub
  • restricted brake hydraulic line
  • contaminated brake pads

Brake locking

check

  • incorrect brake fluid
  • plugged passages in master cyllinder
  • incorrect from brake adjustment
  • caliper piston and / or brake adjustment
  • warped brake disc

Insufficient brakes

check

  • air in brake lines
  • worn brake pads
  • low brake fluid
  • incorrect brake fluid
  • worn brake disc
  • worn caliper piston seals
  • glazed brake pads
  • leaking primary cup seal in master cylinder
  • contaminated brake pads and / or disc

Brake squeal

check

  • contaminated brake pads and/or disc
  • dust or dirt collected behind brake pads
  • loose parts

Generally Poor or Unpredictable Handling

  • 1. Improper tire inflation pressure .
  • 2. Improperly adjusted wheel alignment.
  • 3. Worn or damaged steering components.
  • 4. Worn or damaged suspension components.
  • 5. Bent or broken frame.

Loose Steering

  • 1. Loosesteering shaft. bushings or steering shaft fasteners.
  • 2. Loosetie rod ends.
  • 3. Worn spindle bushings.

Unequal Steering

  • 1. Improperly adjusted tie rods.
  • 2. Improperly adjusted steering stops.
  • 3. Damaged steering components.
  • 4. Uneven front tire pressure.

Steering \ wanders

  • 1. Looseor or worn steering components.
  • 2. Improperly adjusted wheel alignment (toe ant).
  • 3. Worn or damaged tires.
  • 4. Damaged shock absorber(s).
  • 5. Bent or broken frame.

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Polaris Ranger 400 4×4 EFI ATV 2013 Workshop Service Repair Manual

Here is the Most Realistic Assistance Restoration Handbook with the 2013 Polaris Ranger 400 4×4 EFI ATV Class Assistance Restoration Handbook Get. Assistance Restoration Handbook provides you with a complete and also practical details. This kind of DOWNLOAD consists of connected with high quality diagrams and also guidance about how in order to support and also restore your Polaris. This kind of remarkably detailed digital camera restore information consists of everything you could will certainly ever before have to restore, retain, reconstruct, refurbish or even regain your 2013 Polaris Ranger 400 4×4 EFI ATV.

Here is the similar details the dealer professionals and also technicians work with in order to detect and also restore your bike. With this particular specialist excellent remarkably detailed support restore information, you’ll be able to be effective on your own bike while using greatest resources accessible, that doesn’t just save you lots of money with restore bills however may also provide help to maintain your Polaris Ranger  ATV.

Models And Year Covers: 2013

2013 RANGER 400 MIDSIZE
2013 RANGER 500 EFI MIDSIZE
2013 RANGER 500 EFI CREW MIDSIZE

Workshop Service Repair Manual Covers:

General Information
Maintenance
Engine
Fuel Systems
Body Steering Suspension
Clutching
Final Drive
Transmission
Brakes
Electrical
Wire Diagmrams

repair-guidebook

. File Format: PDF
. Compatible: All Versions of Windows & Mac & Linux
. Printable: Yes
. Downloadable: Instant High Speed Download
. Requirements: WinZip & Adobe PDF Reader
. Size: 20MB

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Tags: Polaris Ranger 400 4×4 EFI ATV 2013, Alternator, Cooling System, Battery, Troubleshooting, Coolant, Shop Manual, Timing Belt, 6-Cylinder, Starter, Air Bags, Spark plugs, Change oil, Engine, Suspension, Steering, Repair Manual, 4-Cylinder, Radiator, Service Manual, Brakes, Air Filter, Air Conditioner

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