Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly for both 300 and 400 H.O. models.
Fuel System:
Carburetor (for 300) and Electronic Fuel Injection (EFI) system (for 400 H.O.), fuel pump, fuel filter, fuel lines, and tank.
Ignition System:
Ignition timing, spark plugs, ignition coil, CDI unit, stator, and wiring diagrams.
Cooling System:
Radiator, fan, water pump, thermostat, coolant hoses, and coolant specifications.
Exhaust System:
Exhaust pipe, muffler, heat shields, and gasket replacement.
Drivetrain Transmission:
Automatic transmission (PVT - Polaris Variable Transmission), clutch system (primary and secondary), drive belt inspection and replacement, gear case, and differential.
Drivetrain Axles:
Front and rear drive shafts, CV joints, axle boots, and hub assembly.
Suspension Front:
A-arm design, shocks, springs, bushings, wheel bearings, and steering components.
Suspension Rear:
Independent Rear Suspension (IRS) details, shocks, springs, bushings, and trailing arm components.
Brakes Front:
Hydraulic disc brakes, brake calipers, master cylinder, brake lines, pads, and rotors.
Brakes Rear:
Hydraulic disc brake system, parking brake mechanism.
Steering System:
Handlebars, steering column, tie rods, steering rack, and adjustment procedures.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlights, taillights, brake lights), indicators, and electrical switches.
Wiring Diagrams:
Detailed, color-coded wiring diagrams for all electrical circuits.
Bodywork Chassis:
Frame inspection, plastic body panels, fenders, racks, seat, and mounting hardware.
Routine Maintenance:
Oil change, filter replacement, spark plug replacement, air filter cleaning/replacement, chain adjustment (if applicable), and general inspection checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable for EFI).
Engine Repair:
Top-end rebuild (cylinder, piston, rings), valve adjustment, camshaft service, crankshaft inspection.
Transmission Repair:
PVT belt replacement, clutch service and adjustment, gear case seal replacement.
Brake Service:
Brake pad replacement, brake fluid flush and bleed, caliper rebuild.
Suspension Service:
Shock absorber replacement, bushing replacement, wheel bearing replacement.
Steering Adjustment:
Tie rod adjustment, steering wheel alignment.
Electrical Diagnostics:
Testing charging system output, starter motor operation, lighting circuits, and switch functionality.
Efi Troubleshooting:
Diagnosing fuel pump issues, injector problems, sensor faults, and ECM related problems for the 400 H.O.
Depth Of Coverage:
Comprehensive from basic maintenance to complete engine and transmission rebuilds, including in-depth diagnostics and component specifications.
Diagnostic Codes:
Includes information on reading and interpreting diagnostic trouble codes (DTCs) for EFI models.
Torque Specifications:
Detailed torque values for all critical fasteners and bolts.
Clearances Tolerances:
Specifications for critical component clearances and wear tolerances (e.g., piston-to-cylinder, valve clearances).
Engine Oil Change:
Every 100 hours or 12 months, whichever comes first. Use Polaris AGL Synthetic Gearcase Lubricant or equivalent.
Service Intervals Filters
Oil Filter Replacement:
Replace with each oil change. Part Number: 2540086 (example).
Air Filter Maintenance:
Inspect and clean/replace every 50 hours or as needed based on operating conditions. Part Number: 3083501 (example).
Pvt Drive Belt Inspection:
Inspect for wear and damage every 50 hours. Replace as needed. Recommended Replacement Belt: 3211047 (example).
Engine Oil Type:
Polaris PS-4 5W-50 Full Synthetic 4-Cycle Engine Oil (or SAE 5W-50, API SG or higher).
Gearcase Oil:
Polaris AGL Synthetic Gearcase Lubricant (or SAE 75W-90 Synthetic Gear Oil).
Coolant:
Ethylene glycol-based antifreeze mixed 50/50 with distilled water. (e.g., Polaris Premium Coolant).
Brake Fluid:
DOT 4 Hydraulic Brake Fluid.
Common Wear Items:
PVT belt wear, wheel bearings, tie rod ends, and suspension bushings are common wear items requiring periodic inspection and replacement.
Efi Issues 400:
EFI models may experience issues related to fuel injectors, TPS sensors, or idle air control valves if not properly maintained.
