GENERAL INFORMATION
CHAPTER 1 GENERAL INFORMATION
1
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE AND MACHINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
2009 SPORTSMAN 800 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 MODEL NUMBER: A09MN76AX, AZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2009 SPORTSMAN X2 800 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL NUMBER: A09TN76AL, AX, AZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
2009 SPORTSMAN TOURING 800 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 MODEL NUMBER: A09DN76AB, AL / A09DN76FC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
1.1
GENERAL INFORMATION MODEL INFORMATION
Engine and Machine Serial Numbers
Model Number
Be sure to refer to the engine model number and serial number whenever corresponding about an engine.
The machine model number must be used with any correspondence regarding warranty or service. A 09 DN 76 AS
This information can be found on the sticker applied to the top side of the crankcase (A). An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow.
Engine Designation Numbers EH068OLE - Twin Cylinder, Liquid Cooled,4 Stroke, Electric Start EH076OLE - Twin Cylinder, Liquid Cooled,4 Stroke, Electric Start
VIN Identification 9 xxx
xx xxx
TRANSMISSION I.D. LOCATION Sportsman X2 and Touring The machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the lower left side of the frame tube (B).
Sportsman
1.2
GENERAL INFORMATION PUBLICATIONS
1
Table 1-1: Publications Year
Model
Model No.
Owner's Manual PN
Parts Manual PN
2009
Sportsman 800 EFI
A09MN76A
9921831
9921833
2009
Sportsman X2 800 EFI
A09TN76A
9921845
9921925
2009
Sportsman Touring 800 EFI International
A08DN76A A08DN76F
9921788 9921792
9921793 9922175
PAINT CODES Table 1-2: Paint Codes PAINTED PART Sportsman 800 Frame
COLOR DESCRIPTION
DITZLER NUMBER
POLARIS NUMBER
Black
9440
P-067
REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, ignition switch replacement is required.
Table 1-3: Key Numbers Series # 20 21 22 23 27 28 31 32 67 68
Part Number 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278
Key Boot PN 5433534
1.3
GENERAL INFORMATION 2009 SPORTSMAN 800 EFI MODEL NUMBER:
A09MN76AX, AZ
ENGINE MODEL:
EH076OLE
Table 1-4: Sportsman 800 EFI General Specifications Category Length Width Height
Seat Height Wheel Base Dry Weight Gross Vehicle Weight Front Rack Capacity Rear Rack Capacity Towing Capacity Body Style Hitch Tongue Capacity
Dimension / Capacity 83 in./205.74 cm 48 in./116.8 cm 48 in./119.4 cm 34 in./86.4 cm 50.75 in./128.9 cm 770 lbs./326.6 kg 1220 lbs. / 553 kg 100 lbs./45.4 kg 200 lbs./90.7 kg 1500 lbs./680 kg Spirit 150 lbs./68 kg Combination of rear rack weight and tongue weight not to exceed 200 lbs. (91kg)
1.4
GENERAL INFORMATION Table 1-5: 2009 800 EFI Specifications
Drivetrain
ENGINE Platform
Polaris Twin Cylinder
Engine Model Number Engine Displacement
EH076OLE 760cc
Number of Cylinders
2
Bore & Stroke (mm)
80 x 76.5 mm
Compression Ratio Compression Pressure Engine Idle Speed
Liquid - 3.6 qt/ 3.4 ltr.
Lubrication Oil Requirements / Capacity Exhaust System
HOT on Instrument Cluster Pressurized Wet Sump Polaris 2W-50 2 qt. / 1.9 liters Dual Pipe / Silencer
Fuel System Fuel System Fuel Pump
30 micron in Tank - (unserviceable)
Fuel Injector(s)
Bosch
EFI Controller
Bosch MSE 1.1B
Fuel Capacity / Requirement
4.13 gal US / 15.6 liters 87 Octane (minimum) or 89 Oxygenated
Electrical Alternator Output
500 w @ 6000 RPM
Pod
50 watts
Grill
Two x 37 watts
Brake
8.26 watts
Tail
26.9 watts
Worklights (If equipped)
Front Gearcase Capacity- CH
8.97 / 265 ml
Rear Gearcase Capacity
5 oz. / 150ml
Gear Ratio :
Low Rev High Front Drive Rear Drive
Clutch Type
PVT w/ EBS
Belt
3211113
Steering / Suspension Front Suspension / Shock
8.2 in. / 21 cm
Rear Suspension / Shock
Progressive Rate Independent Coil - over shock 9.5 in. / 24.13 cm
Ground Clearance
11.25 in. / 28.6 cm
Shock Preload Adjustment Front / Rear
Front -Non Adjustable. Rear - Ratchet Style- Std.
Turning Radius
76 in. / 193 cm
Toe Out
0 - 1/16 in / .0 - .159 mm
Wheels / Brakes Wheel Size / Pattern - Front
26 x 8 - 12 / 4-156
Wheel Size / Pattern - Rear
26 x 11 - 12 / 4-156
Front Tire Size
26 x 8 - 12
Rear Tire Size
26 x 11 - 12
Recommended Air Pressure
Front - 5 psi & Rear - 5 psi
Brake - Front
Dual Hydraulic Disc
Brake - Rear
Dual Hydraulic Disc
2 x 13 watts
Table 1-7: A09MN76A Clutching
DC/CDI Ignition
Ignition Timing
13°BTDC @ 1200 RPM
Altitude
Spark plug / Gap
RC7YC/ .035 in. / 0.9 mm
Meters (Feet)
Battery / Amp Hr
Lead Acid / 30 Amp Hr
Circuit Breakers
Fan 20 amp / Harness 20 amp / ECU 15 amp / Inst. Cluster / Voltage Regulator 6 amp
Instrument Cluster
A-arm / MacPherson Strut
Front Travel
Ignition System
Starting
7.49:1 5.11:1 2.88:1 3.82:1 3.10:1
Rear Travel Electronic Fuel Injection 25L per hour at 39 PSI
Fuel Filter(s)
15 oz. / 450ml
1150 ± 100 RPM
Cooling System / Capacity
Drumshift - H/L/N/Rev/Park
Transmission Capacity
11:1
6600 Rpm ± 200 Rpm
Overheat Warning
Transmission Type
150-200 psi
Engine Max Operating Rpm
Lights :
Table 1-6: 2009 800 EFI Specifications
Electric
Shift Weight
Drive Clutch Spring
Driven Clutch Type (Non-Adjustable)
0-1800 (0-6000)
A08MN76
21-74 5632170 w/EBS
Red/Wht 7043349 w/EBS
EBS - 1322751
1800-3700 (6000-12000)
A08MN76
21-72 5632119 w/EBS
Red/Wht 7043349 w/EBS
EBS - 1322751
Analog Speedo w/ LCD
1.5
1
GENERAL INFORMATION 2009 SPORTSMAN X2 800 EFI MODEL NUMBER:
A09TN76AL, AX, AZ
ENGINE MODEL:
EH076OLE
Table 1-8: Sportsman X2 800 EFI General Specifications Category Length Width Height
Seat Height Wheel Base Dry Weight Gross Vehicle Weight Front Rack/ Box Capacity Rear Box Capacity Towing Capacity Body Style Hitch Tongue Capacity
Dimension / Capacity 93 in./236 cm 48 in./116.8 cm 48 in./119.4 cm 34 in./86.4 cm 57 in./144.7 cm 830 lbs./376.5 kg 1500 lbs./680.3 kg 90 lbs./40.8 kg 400 lbs./181.4 kg 1500 lbs./680 kg Spirit 150 lbs./68 kg Combination of rear rack weight and tongue weight not to exceed 400 lbs. (181.5 kg)
1.6
GENERAL INFORMATION Table 1-9: 2009 X2 800 EFI Specifications
Table 1-10: 2009 X2 800 EFI Specifications Drivetrain
ENGINE Platform
Polaris Twin Cylinder
Engine Model Number Engine Displacement
EH076OLE 760cc
Number of Cylinders
2
Bore & Stroke (mm)
80 x 76.5 mm
Compression Ratio Compression Pressure Engine Idle Speed
Transmission Type
1150 ± 100 RPM
32 oz. / 946.3ml
Front Gearcase Capacity- ADC Gear Ratio :
23.91:1 21.74:1 8.28:1 3.82:1
Clutch Type
PVT w/ EBS
Belt
3211113
Engine Max Operating Rpm
6500 Rpm ± 200 Rpm
Steering / Suspension
Cooling System / Capacity
Liquid - 3.4 qt/ 3.2 ltr.
Front Suspension / Shock
Overheat Warning Lubrication Oil Requirements / Capacity Exhaust System
HOT on Instrument Cluster Pressurized Wet Sump
Front Travel
8.2 in. / 21 cm
Rear Suspension / Shock
8.75 in. / 22.22 cm
Ground Clearance
Fuel System
Shock Preload Adjustment Front / Rear
Electronic Fuel Injection 25L per hour at 39 PSI
Fuel Filter(s)
30 micron in Tank - (unserviceable)
Fuel Injector(s)
Bosch
EFI Controller
Bosch
Fuel Capacity / Requirement
6.0 gal US / 22.7 liters 87 Octane (minimum) or 89 Oxygenated
Lights :
11.25 in. / 28.6 cm Front -Non Adjustable. Rear - Ratchet Style- Std.
Turning Radius
82 in. / 208.2 cm
Toe Out
0 - 1/16 in / .0 - .159 mm
Wheels / Brakes Wheel Size / Pattern - Front
25 x 8 - 12 / 4-156
Wheel Size / Pattern - Rear
25 x 11 - 12 / 4-156
Front Tire Size
Electrical Alternator Output
Progressive Rate Independent Coil - over shock
Rear Travel
Fuel System Fuel Pump
A-arm / MacPherson Strut
Polaris 2W-50 2 qt. / 1.9 liters Single Pipe / Silencer
9.3 / 275 ml
Low Rev High Front Drive
11:1 150-200 psi
Drumshift - H/L/N/Rev/Park
Transmission Capacity
500 w @ 6000 RPM
25 x 8 - 12
Rear Tire Size
25 x 11 - 12
Recommended Air Pressure
Front - 5 psi & Rear - 5 psi
Pod
50 watts
Grill
Two x 37 watts
Brake - Front
Dual Hydraulic Disc
Tail
2 x 26.9 watts
Brake - Rear
Dual Hydraulic Disc
Brake
2 x 8.26 watts
Worklights (Deluxe Only)
2 x 13 watts
Indicator Panel
1 watt
Altitude
Ignition System
DC/CDI Ignition
Ignition Timing
Variable - ECU controlled
Spark plug / Gap
RC7YC/ .035 in. / 0.9 mm
Battery / Amp Hr
Lead Acid / 30 Amp Hr
Fuses
Starting Instrument Cluster
Table 1-11: A09TN76A EFI Clutching
Fan 20 amp / Harness 20 amp / ECU 15 amp / Inst. Cluster / Voltage Regulator 5 amp
Shift Weight
Drive Clutch Spring
Driven Clutch Type (Non-Adjustable)
A09TN76A
21-74 5632170 w/EBS
Red/Wht 7043427 w/EBS
EBS - 1322751
1800-3700 A09TN76A (6000-12000)
21-72 5632119 w/EBS
Red/Wht 7043427 w/EBS
EBS - 1322751
Meters (Feet) 0-1800 (0-6000)
Electric Analog Speedo w/ LCD
1.7
1
GENERAL INFORMATION 2009 SPORTSMAN TOURING 800 EFI MODEL NUMBER:
A09DN76AB, AL / A09DN76FC (Domestic)
ENGINE MODEL:
EH076OLE
Table 1-12: 2009 Sportsman Touring 800 EFI General Specifications Category Length Width Height
Seat Height Wheel Base Dry Weight Gross Vehicle Weight Front Rack/ Box Capacity Rear Rack Capacity Towing Capacity Unbraked Trailer Towing Capacity (EU)* Body Style Hitch Tongue Capacity
Dimension / Capacity 86 in./218.44 cm 48 in./116.8 cm 48 in./119.4 cm 34 in./86.4 cm 57 in./144.7 cm 795 lbs./361 kg 1500 lbs./680.3 kg 90 lbs./40.8 kg 180 lbs./82 kg 1500 lbs./680 kg 1995.1 lbs./905 kg Spirit 150 lbs./68 kg Combination of rear rack weight and tongue weight not to exceed 180 lbs. (82kg)
* Data Based On EU Directive 76/432/EEC
1.8
(International)
GENERAL INFORMATION Table 1-13: 2009 Touring 800 EFI Specifications
Table 1-14: 2009 Touring 800 EFI Specifications Drivetrain
ENGINE Platform
Polaris Twin Cylinder
Engine Model Number
EH076OLE
Engine Displacement
760cc
Number of Cylinders
2
Bore & Stroke (mm)
80 x 76.5 mm
Compression Ratio Compression Pressure Engine Idle Speed Engine Max Operating Rpm Cooling System / Capacity Overheat Warning Lubrication Oil Requirements / Capacity Exhaust System
Fuel System Fuel Pump
150-200 psi 1150 ± 100 RPM
Transmission Capacity
32 oz. / 946.3ml
Front Gearcase Capacity- ADC Gear Ratio :
23.91:1 21.74:1 8.28:1 3.82:1
Clutch Type
PVT w/ EBS (Standard and Deluxe)
Belt
3211113
Liquid - 3.4 qt/ 3.2 ltr.
Front Suspension / Shock
HOT on Instrument Cluster Pressurized Wet Sump
A-arm / MacPherson Strut
Front Travel
8.2 in. / 21 cm
Rear Suspension / Shock
Progressive Rate Independent Coil - over shock
Polaris 2W-50 2 qt. / 1.9 liters Single Pipe / Silencer
Electronic Fuel Injection
30 micron in Tank - (unserviceable) Bosch
EFI Controller
Bosch 6.0 gal US / 22.7 liters 87 Octane (minimum) or 89 Oxygenated
9.3 / 275 ml
Low Rev High Front Drive
Steering / Suspension
Fuel Injector(s)
Fuel Capacity / Requirement
Drumshift - H/L/N/Rev/Park
6600 Rpm ± 200 Rpm
25L per hour at 39 PSI
Fuel Filter(s)
Transmission Type
11:1
Fuel System
Rear Travel
8.75 in. / 22.22 cm
Ground Clearance
11.25 in. / 28.6 cm
Shock Preload Adjustment Front / Rear
Front -Non Adjustable. Rear - Ratchet Style- Std.
Turning Radius
82 in. / 208.2 cm
Toe Out
0 - 1/16 in / .0 - .159 mm
Wheels / Brakes Wheel Size / Pattern - Front
25 x 8 - 12 / 4-156
Wheel Size / Pattern - Rear
25 x 11 - 12 / 4-156
Electrical
Front Tire Size
25 x 8 - 12
Alternator Output
Rear Tire Size
25 x 11 - 12
Lights :
1
Pod
500 w @ 6000 RPM 50 watts
Recommended Air Pressure
Grill
Two x 37 watts
Brake - Front
Tail
2 x 26.9 watts
Brake - Rear
Brake
2 x 8.26 watts
Worklights (Deluxe Only)
2 x 13 watts
Indicator Panel
1 watt DC/CDI Ignition
Ignition Timing
Variable - ECU controlled
Spark plug / Gap
RC7YC/ .035 in. / 0.9 mm
Battery / Amp Hr
Lead Acid / 30 Amp Hr
Fuses
Starting Instrument Cluster
Fan 20 amp / Harness 20 amp / ECU 15 amp / Inst. Cluster / Voltage Regulator 5 amp
Dual Hydraulic Disc Dual Hydraulic Disc
Table 1-15: A09DN76A Clutching Altitude
Ignition System
Front - 5 psi & Rear - 5 psi
Meters (Feet)
Shift Weight
Drive Clutch Spring
Driven Clutch Type (Non-Adjustable)
0-1800 (0-6000)
A09DN76
21-74 5632170 w/EBS
Red/Wht 7043427 w/EBS
EBS - 1322751
1800-3700 (6000-12000)
A09DN76
21-72 5632119 w/EBS
Red/Wht 7043427 w/EBS
EBS - 1322751
Electric Analog Speedo w/ LCD
1.9
Thank you very much for your reading. Please Click Here Then Get More Information. NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
GENERAL INFORMATION MISC. NUMBERS/CHARTS Standard Torque Specifications The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.
Bolt Size
Threads/In
Grade 8 60 (6.9) 68 (7.8)
#10 #10
-
24 32
1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2
-
20 28 18 24 16 24 14 20 13 20
Grade 2 Grade 5 Torque in. lbs. (Nm) . . . . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . 43 (5.0) . . . . . . . . . . . . . . . . . . . . . . . . . 31 (3.6) . . . . . . . . . 49 (5.6) . . . . . . . . Torque ft. lbs. (Nm)* . . . . . . . . . . . . . . . . . 5 (7) . . . . . . . . . . . . 8 (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 (8) . . . . . . . . . . . . 10 (14) . . . . . . . . . . . . . . . . . . . . . . . . . . 11(15). . . . . . . . . . . 17 (23) . . . . . . . . . . . . . . . . . . . . . . . . . . 12(16) . . . . . . . . . . 19 (26) . . . . . . . . . . . . . . . . . . . . . . . . . . 20(27) . . . . . . . . . . 30 (40) . . . . . . . . . . . . . . . . . . . . . . . . . . 23(32) . . . . . . . . . . 35 (48) . . . . . . . . . . . . . . . . . . . . . . . . . . 30(40) . . . . . . . . . . 50 (69) . . . . . . . . . . . . . . . . . . . . . . . . . . 35(48) . . . . . . . . . . 55 (76) . . . . . . . . . . . . . . . . . . . . . . . . . . 50(69) . . . . . . . . . . 75 (104) . . . . . . . . . . . . . . . . . . . . . . . . . 55(76) . . . . . . . . . . 90 (124) . . . . . . . .
12 (16) 14 (19) 25 (35) 29 (40) 45 (62) 50 (69) 70 (97) 80 (110) 110 (152) 120 (166)
Metric / Torque 6 x 1.0. . . . . . . . . . 72-78 In.lbs. . . . . . . . . . 8 x 1.25
14-18 ft.lbs . . . . 10 x 1.25
26-30 ft.lbs.
SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, 1-800-328-6657.
1.10
GENERAL INFORMATION Decimal Equivalents
SAE Tap Drill Sizes Thread Size/ Drill Size #0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/16-20 25/64
Thread Size / Drill Size 1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 11/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 1 1/8-7 63/64 1 1/8-12 1 3/64 1 1/4-7 1 7/64 1 1/4-12 1 11/64 1 1/2-6 1 11/32 1 1/2-12 1 27/64 1 3/4-5 1 9/16 1 3/4-12 1 43/64 2-4 1/2 1 25/32 2-12 1 59/64 2 1/4-4 1/2 2 1/32 2 1/2-4 2 1/4 2 3/4-4 2 1/2 3-4 2 3/4
1/64 3/64 5/64 7/64 9/64 11/64 13/64 15/64 17/64 19/64 21/64 23/64 25/64 27/64 29/64 31/64 33/64 35/64 37/64 39/64
Metric Tap Drill Sizes Tap Size
Drill Size
3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6x1.00 7x1.00 8x1.00 8x1.25 9x1.00 9x1.25 10x1.25 10x1.50 11x1.50 12x1.50 12x1.75
#39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32
Decimal Equivalent 0.0995 0.0937 0.1285 0.125 0.166 0.161 0.196 0.234 0.277 0.265 0.3125 0.3125 0.3437 0.339 0.375 0.406 0.406
41/64 Nearest Fraction 3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32
43/64 45/64 47/64 49/64 51/64 53/64 55/64 57/64 59/64 61/64 63/64
................. 1/32 . . . . . . . . . . . . . ................. 1/16 . . . . . . . . . . . . . ................. 3/32 . . . . . . . . . . . . . ................. 1/8 . . . . . . . . .1250 ................. 5/32 . . . . . . . . . . . . . ................. 3/16 . . . . . . . . . . . . . ................. 7/32 . . . . . . . . . . . . . ................. 1/4 . . . . . . . . .25 ................. 9/32 . . . . . . . . . . . . . ................. 5/16 . . . . . . . . . . . . . ................. 11/32 . . . . . . . . . . . . ................. 3/8 . . . . . . . . .375 ................. 13/32 . . . . . . . . . . . . ................. 7/16 . . . . . . . . . . . . . ................. 15/32 . . . . . . . . . . . . ................. 1/2 . . . . . . . . .5. . . . ................. 17/32 . . . . . . . . . . . . ................. 9/16 . . . . . . . . . . . . . ................. 19/32 . . . . . . . . . . . . ................. 5/8 . . . . . . . . .625. . ................. 21/32 . . . . . . . . . . . . ................. 11/16 . . . . . . . . . . . . ................. 23/32 . . . . . . . . . . . . ................. 3/4 . . . . . . . . .75 ................. 25/32 . . . . . . . . . . . . ................. 13/16 . . . . . . . . . . . . ................. 27/32 . . . . . . . . . . . . ................. 7/8 . . . . . . . . .875 ................. 29/32 . . . . . . . . . . . . ................. 15/16 . . . . . . . . . . . . ................. 31/32 . . . . . . . . . . . . ................. 1. . . . . . . . . . 1.0
.0156 .0312 . . 1 mm= .0394" .0469 .0625 .0781 . . 2 mm = .0787" .0938 .1094 . . 3 mm =.1181" .1406 .1563 . . 4 mm = .1575" .1719 .1875 . . 5mm= .1969" .2031 .2188 .2344 . . 6 mm = .2362" .2656 . . 7 mm = .2756" .2813 .2969 .3125 . . 8mm= .3150" .3281 .3438 . . 9 mm = .3543" .3594 .3906 . . .4063 .4219 . . .4375 .4531 .4688 . . .4844 ....... .5156 .5313 .5469 . . .5625 .5781 . . .5938 .6094 ....... .6406 .6563 . . .6719 .6875 .7031 . . .7188 .7344 . .
10 mm = .3937" 11 mm =.4331" 12 mm = .4724" 13mm = .5118" 14 mm = .5512" 15 mm = .5906" 16mm=. 6299" 17 mm =.6693" 18 mm = .7087" 19 mm = .7480"
.7656 .7813 . . 20 mm = .7874" .7969 .8125 . . 21 mm =.8268" .8281 .8438 .8594 . . 22 mm = .8661" .8906 . . 23 mm = .9055" .9063 .9219 .9375 . . 24 mm = .9449" .9531 .9688 . . 25 mm = .9843" .9844
1.11
1
GENERAL INFORMATION Conversion Table Unit of Measure
Multiplied by
Converts to
ft. lbs.
x 12
= in. lbs.
in. lbs.
x .0833
= ft. lbs.
ft. lbs.
x 1.356
= Nm
in. lbs.
x .0115
= kg-m
Nm
x .7376
= ft. lbs.
kg-m
x 7.233
= ft. lbs.
kg-m
x 86.796
= in. lbs.
kg-m
x 10
= Nm
in.
x 25.4
=mm
mm
x .03937
= in.
in.
x 2.54
= cm
mile (mi.)
x 1.6
= km
km
x .6214
= mile (mi.)
Ounces (oz.)
x 28.35
= Grams (g)
Fluid Ounces (fl. oz.)
x 29.57
= Cubic Centimeters (cc)
Cubic Centimeters (cc)
x .03381
= Fluid Ounces (fl. oz.)
Grams (g)
x 0.035
= Ounces (oz.)
lb.
x .454
= kg
kg
x 2.2046
= lb.
Cubic inches (cu. in)
x 16.387
= Cubic centimeters (cc)
Cubic centimeters (cc)
x 0.061
= Cubic inches (cu. in)
Imperial pints (Imp pt.)
x 0.568
= Liters (l)
Liters (l)
x 1.76
= Imperial pints (Imp pt.)
Imperial quarts (Imp qt.)
x 1.137
= Liters (l)
Liters (l)
x 0.88
= Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.)
x 1.201
= US quarts (US qt.)
US quarts (US qt.)
x 0.833
= Imperial quarts (Imp qt.)
US quarts (US qt.)
x 0.946
= Liters (l)
Liters (l)
x 1.057
= US quarts (US qt.)
US gallons (US gal)
x 3.785
=Liters (l)
Liters (l)
x 0.264
= US gallons (US gal)
Pounds - force per square inch (psi)
x 6.895
= Kilopascals (kPa)
Kilopascals (kPa)
x 0.145
= Pounds - force per square inch (psi)
Kilopascals (kPa)
x 0.01
= Kilograms - force per square cm
Kilograms - force per square cm
x 98.1
= Kilopascals (kPa)
π(3.14)xR x H (height) 2
°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: 5 (°F + 40) ÷ 9 - 40 = °C
1.12
= Cylinder Volume
GENERAL INFORMATION Glossary Of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. ADC: Active Descent Control. Engages front wheels for 4-wheel EBS. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO. CVT: Centrifugal Variable Transmission (Drive Clutch System) DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore. EBS: Engine Braking System. Uses engine compression to slow the ATV without the use of hydraulic brakes. Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching the chassis). End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm2: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. lbs/in2: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy is converted to electrical energy in the stator. mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approximately 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.
1.13
1