Replace the spring if tabs are misaligned or the spring coils are distorted. Place main adapter Item 8 on puller. Remove output shaft assembly, large shim, and thrust button with its small shim. Use only genuine Polaris replacement parts. Rpm runs high and low inter changes. Using a valve spring compressor, compress the valve spring and remove the split keeper.
Start machine and slowly increase speed to 30 mph. Lubricate automatic compression release mechanism with clean engine oil. Be sure the shift linkage rod ends are firmly attached to the gear selector slides. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. Install outer thrust washer and bearing. The starter system must be in good condition and the battery fully charged.
Do not store or use a partial bottle of brake fluid. Do not substitute bolts or use old ones. Clean the master cylinder assembly with clean Dot 3 brake fluid, brake parts cleaner, or denatured alcohol. When the battery fluid nears the lower level, the battery should be removed and distilled water should be added to the upper level line. If the contact area is less than 75% of the cir- cumference of the seat, rotate the pilot 180°.
Smooth idle generally indicates good compression. Visually inspect each cam lobe for wear, chafing or damage. Shims must be added between bearing and circlip to reduce end play. Screw and Washer Assembly 4. Place a clean shop towel in the area below cam chain sprocket and remove sprocket retaining bolts. Insert the puller legs between the water pump drive shaft and the remaining portion of the mechanical seal. Place the transmission in neutral and start the engine.
McLevain died June 26 at Baptist-Memphis. Look for discoloration, shiny spots, or and area that looks different than the rest of the needle. Replace any parts found to be worn or damaged. Remove carburetor diaphragm chamber cover with a ratchet style screwdriver. Primary Winding Resistor Ignition Kill Meter Wire. Install moveable sheave with spacer washers.
Start new bushing evenly in moveable sheave. Remove left side shock absorber. Brake Fluid dicated level inside reservoir. Beginning at the oil tank, the oil flows through a screen fitting in the bottom of the tank and into the oil supply hose. Add Polaris Premium Synthetic Gearcase Lubricant to the proper level on dipstick. If you notice resistance, galling, or flat spots, replace rollers, pins and thrust washers in sets of three.
Access Plate Screws: 8 - 10 ft. Damping should be smooth throughout the range of travel. The caliper pistons are T-shaped, which allows both hand and foot brake to use the same caliper piston, but remain separated by seals. Inspect each rocker arm cam follower surface. Force U-joint cross to one side and lift out of inner yoke. Pull bushing removal tool and adapter from puller rod.
Loosen front wheel nuts slightly. Do not force fluid into hub. Screw and Washer Assembly 5. Install adapter reducer Item 9. Mark housing and casting for reference upon reassembly.