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

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Polaris Outlaw 525 450 TROUBLESHOOTING repair guide

1. Polaris Outlaw 525 450 Brake Noise Troubleshooting

Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning does not reduce the occurrence of brake noise, check the backing of each pad for worn spots allowing metal to metal contact. See table below:

Brake Noise Troubleshooting
Possible Cause Remedy
Dirt, dust, or imbedded material on pads or disc Spray disc and pads with a non–flammable aerosol brake

cleaner only! Remove pads and/or disc hub to clean imbedded

material from disc or pads.

Pad(s) dragging on disc (noise or premature pad wear)

Improper adjustment

Insufficient lever or pedal clearance

Master cylinder reservoir overfilled

Master cylinder compensating port restricted

Master cylinder piston not returning completely

Caliper piston(s) not returning

Operator error (riding the brake / park brake applied)

Adjust pad stop (front calipers)

Check position of controls & switches

Set to proper level

Clean compensating port

Inspect. Repair as necessary

Clean piston(s) seal

Educate operator

Loose wheel hub or bearings Check wheel and hub for abnormal movement
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
Noise is from other source (chain, axle, hub, disc or wheel) If noise does not change when brake is applied check other

sources. Inspect and repair as necessary

Wrong pad for conditions Change to a softer or harder pad

Brakes Squeal
• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn disc splines
• Glazed brake pads
Poor Brake Performance
• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted lever
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Improper clearance between lever and switch
Lever Vibration
• Disc damaged
• Disc worn (runout or thickness variance exceeds
service limit)
• Caliper overheats (Brakes Drag)
• Compensating port plugged
• Pad clearance set incorrectly
• Auxiliary brake pedal incorrectly adjusted
• Brake lever or pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes
Brakes Lock
• Alignment of caliper to disc
• Fluid overfill of the reservoir
• Stuck caliper piston

2. Polaris Outlaw 525 450  Ignition System Troubleshooting

No Spark, Weak or Intermittent Spark
• No 12 volt power or ground to CDI
• Spark plug gap incorrect
• Fouled spark plug
• Faulty spark plug cap or poor connection to high
tension lead
• Related wiring loose, disconnected, shorted, or
corroded
• Faulty engine stop switch, ignition switch, or tether
switch
• ETC switch misadjusted or faulty
• Poor ignition coil ground (e.g. coil mount loose or
corroded)
• Faulty pulse coil (measure resistance of value of pulse
coil)
• Incorrect wiring (inspect color coding in connectors
etc)
• Faulty ignition coil winding (measure resistance of
primary and secondary)
• Sheared flywheel key
• Flywheel loose or damaged
• Excessive crankshaft runout on magneto (RH)
end – should not exceed .005”
• Faulty CDI module
• Faulty 5 Amp or 10 Amp circuit breaker

3.  Polaris Outlaw 525 450  Starter System Troubleshooting

Starter Motor Does Not Turn
• Battery discharged. Low specific gravity
• Loose or faulty battery cables or corroded connections
(see Voltage Drop Tests)
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter motor
or starter solenoid (see Voltage Drop Tests)
• Faulty key switch
• Faulty kill switch
• Faulty neutral diode
• Faulty clutch switch
• Faulty starter solenoid or starter motor
• Engine problem – seized or binding (can engine be
rotated easily)?
Starter Motor Turns Over Slowly
• Battery discharged
• Excessive circuit resistance – poor connections (see
Voltage Drop Test)
• Engine problem – seized or binding (can engine be
rotated easily)?
• Faulty or worn brushes in starter motor
• Automatic compression release inoperative
Starter Motor Turns – Engine Does Not Rotate
• Faulty starter drive/one way clutch
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel
• Possible engine damage

2009 Polaris Scrambler SPORTSMAN XP 550 / XP 550 EPS TROUBLESHOOTING repair guide

Situation 1 : Engine RPM below specified operating range, although engine is properly tuned.

Probable Cause Remedy
-Wrong or broken drive clutch spring.

-Drive clutch shift weight too heavy.

-Driven clutch spring broken or installed in wrong

helix location.

-Replace with recommended spring.

-Install correct shift weight kit to match engine

application.

-Replace spring; refer to proper installation location.

Situation 2 :  Erratic engine operating RPM during acceleration or load variations.

-Drive clutch binding.

-Belt worn unevenly - thin / burnt spots.

-Driven clutch malfunction.

-Sheave face grooved.

A. Disassemble drive clutch; inspect shift weights for

wear and free operation.

B. Clean and polish stationary shaft hub; reassemble

clutch without spring to determine problem area.

Replace belt.

Inspect movable sheave for excessive bushing

clearance.

-Replace the clutch.

Situation 3:  Engine RPM above specified operating range.

-Incorrect drive clutch spring (too high spring rate).

-Drive clutch shift weights incorrect for application

(too light).

-Drive clutch binding.

-Driven clutch binding.

-Clutch sheaves greasy; belt slipage.

-Install correct recommended spring.

-Install correct recommended shift weights.

-Disassemble and clean clutch, inspecting shift weights

and rollers. Reassemble without the spring and move

sheaves through entire range to further determine

probable cause.

-Disassemble, clean, and inspect driven clutch.

-Clean sheaves with denatured alcohol or brake cleaner,

install new belt.

Situation 4:    Harsh drive clutch engagement.

 
-Drive belt worn too narrow.

-Excessive belt / sheave clearance with new belt.

-Replace belt.

-Perform belt / sheave clearance adjustment with shim

washers beneath spider.

Situation 5 : Drive belt turns over

-Wrong belt for application. -Replace with correct belt.
 

Situation 6 : Belt burnt, thin spots

-Abuse (continued throttle application when

vehicle is stationary, excess load)

-Dragging brake

-Slow, easy clutch engagement

-Caution operator to operate machine within guidelines.

-Vehicle operated with parking brake on.  Inspect brake

system.

-Fast, effective use of throttle for efficient engagement.

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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