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A09BG50AA
Polaris A09BG50AA User Manual
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ELECT
RICAL
10.2
COMPONE
NTS
OF
E
H500PLE
/
240
W
A
TT
AL
TERNA
T
OR
CDI
B
ox
Resi
stor
Cap
Stat
or
Plate
Ignit
ion
Coil
Meter
NOT
E:
CDI
boxes
m
ay
look
t
he
s
ame
but
hav
e
different
internal
c
ircuitr
y
.
Be
sure
to
always
use
the
c
orrect
CDI
box
par
t
number
.
Batt
ery
Charging
Coils
10.5k
Ω
Pulse
Coil
(T
r
igger)
Air
G
ap:
.
016-.030
″
(.4
-
.75
mm)
Fly
wheel
and
Ring
Gear
Casting.
Re
fe
r
T
o
Wiring
Dia
gra
ms
For
Sp
ecified
Stato
r
Coi
l
Resistan
ce
217
219
Table of Contents
Table of Contents
1
Model Identification
2
Engine Serial Number Location
2
General Information
2
Replacement Keys
3
Publication Numbers
3
Paint Codes
3
Standard Torque Specifications
6
Conversion Table
8
Glossary of Terms
9
Table of Contents
11
Periodic Maintenance Chart
12
Maintenance and Lubrication
13
Pre-Ride Inspection
17
Front Gearcase Lubrication
21
Lubrication Charts
21
Transmission Lubrication 4X4
22
Throttle Operation / Choke Adjustment
24
Pilot Screw Adjustment
25
Idle Speed Adjustment
25
Fuel System
27
Fuel Lines
27
Vent Lines
28
Fuel Filter
28
Carburetor Draining
28
Battery Maintenance
29
Engine Mounts
29
Spark Plug
31
Ignition Timing
32
Liquid Cooling System Overview
32
Cooling System Hoses
32
Cooling System Pressure Test
33
Radiator Coolant Level Inspection
33
Compression Test
29
Air Box Sediment Tube Service
35
Breather Filter
35
Breather Hose
36
Recoil Housing
36
Engine Oil Level
36
Oil Change/Filter
37
Valve Clearance
39
Exhaust Valve Clearance Adjustment
40
Camber and Caster
41
Exhaust Pipe
43
Brake Pad Inspection
44
Brake System Inspection
44
Rear Axle
47
Suspension Spring Preload Adjustment
48
Front Suspension
48
Rear Suspension
48
CV Shaft Boot Inspection
49
Wheel Removal Front or Rear
49
Tire Inspection
50
Piston Identification
55
Engine Fastener Torque Patterns
55
Cooling System
55
Cooling System Specifications
57
Honing to Oversize
59
Cleaning the Cylinder after Honing
59
Crankshaft Straightening
60
Eh50Pl Oil Flow Diagram
62
Engine Disassembly
64
Cam Chain Tensioner Inspection
65
Camshaft Removal
66
Camshaft Inspection
68
Automatic Compression Release Installation
68
Cylinder Head Removal
69
Cylinder Head Inspection
71
Cylinder Head Disassembly
71
Cylinder Head Warpage
71
Valve Inspection
72
Combustion Chamber
73
Valve Seat Reconditioning
73
Cylinder Head Assembly
76
Valve Sealing Test
76
Piston Removal
78
Cylinder Inspection
79
Piston Ring Installed Gap
81
Crankcase Disassembly
81
Crankcase Separation
83
Oil Pump Assembly
85
Bearing Installation
88
Crankshaft End Play Adjustment
88
Oil Pump Shaft End Play Adjustment
90
Pump Shaft Oil Seal Installation
91
Crankcase Assembly
91
Water Pump Mechanical Seal Installation
92
Piston Ring Installation
94
Piston Installation
94
Cylinder Installation
95
Cylinder Head Installation
96
Cam Chain Tensioner Installation
99
Thermostat Installation
100
Oil Pipes
101
Recoil Assembly
102
Wheel Removal / Installation
50
Tire Pressure
50
Table of Contents
105
Fuel Flow Diagram
107
Jetting Guidelines
108
Carburetor Jetting
109
Mikuni Jet Part Numbers
109
Assembly, CV Carburetor
110
Mikuni CV Carb Operation
110
Float System
112
Main System
112
Carburetor Cleaning
113
Carburetor Inspection
114
Carburetor Assembly
114
CV Carburetor System Function (4 Cycle)
110
Fuel Level
116
Needle and Seat Leakage Test
116
Pilot Screw
116
Fuel Pump Service
117
Fuel Pump Disassembly
117
Troubleshooting
119
Fuel System/Carburetion Notes
121
Body Assembly Exploded View
123
Steering Assembly, Exploded View
124
A-Arm Replacement
125
Concentric Swing Arm Removal
126
Concentric Swing Arm Assembly/Installation
127
Decal Replacement
132
Steering Post Assembly
132
Table of Contents
133
Drive Clutch Operation
134
Driven Clutch Operation
134
Pvt System Fastener Torques
134
Special Tools and Supplies
134
PVT Maintenance/Inspection
135
Pvt Drying
135
PVT Disassembly
137
PVT Assembly
138
Drive Clutch Exploded View
139
PVT Sealing and Ducting Components
139
Drive Clutch Spring Specifications
140
Shift Weights
141
Shift Weight Inspection
142
Button to Tower Clearance Inspection
142
Drive Clutch Disassembly/Inspection
143
Spider Removal
143
Drive Clutch Assembly
144
Drive Belt Tension
145
Drive Belt Removal/Inspection
146
Clutch Alignment /Offset
147
Clutch Offset
148
Drive Belt Installation
147
Drive Clutch Bushing Service
148
Driven Clutch Disassembly/Inspection
151
Driven Clutch Assembly
153
Troubleshooting
157
Table of Contents
159
AWD Front Hub Exploded View
160
Final Drive
160
AWD Operation Overview
161
AWD Front Hub Bearing Adjustment
163
AWD Hub Seal Replacement
164
AWD Armature Plate Inspection
166
AWD Front Drive Axle Removal
167
AWD Front Drive Axle Installation
168
AWD Front Drive Axle Exploded View
171
AWD Front Prop Shaft Removal
173
U-Joint Assembly
174
U-Joint Disassembly
174
AWD Front Housing Removal
175
AWD Front Housing Assembly
176
AWD Front Housing Exploded View
178
Rear Axle Removal
179
Table of Contents
185
Torque Specifications
186
Transmission Removal / Installation
186
Transmission Disassembly
187
Transmission Reassembly
190
Troubleshooting
192
Troubleshooting Checklist
192
Table of Contents
193
Hydraulic Brake System Operation
195
Brake Noise Troubleshooting
196
Brake System Main Components
196
Brake System Service Notes
196
Brake Bleeding / Fluid Change
197
Hydraulic Caliper Bleeding
197
Master Cylinder Installation
200
Master Cylinder Removal
200
Front Pad Removal
201
Front Pad Installation
202
Brake Burnishing
203
Front Disc Inspection
203
Front Caliper Disassembly
204
Front Caliper Removal
204
Front Caliper Inspection
205
Front Caliper Reassembly
205
Front Caliper Installation
206
Rear Caliper Removal/Inspection
210
Rear Caliper Assembly
211
Rear Caliper Exploded View
213
Troubleshooting
215
Electrical Service Notes
219
Fan Motor Current Draw
226
Etc Operation Test
227
Alternator Output Test
238
Battery Testing
241
Conventional Battery Installation
243
Conventional Battery Testing
244
Conventional Battery Specific Gravity Test
244
Headlight Adjustment
246
Brake Light Switch
247
Indicator Lamp Replacement
247
Headlamp Switch
247
Starter System
248
Voltage Drop Test
249
Starter Motor Disassembly
250
Armature Testing
252
Starter Drive
253
5
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Polaris A09BG50AA Specifications
General
Brand
Polaris
Model
A09BG50AA
Category
Offroad Vehicle
Language
English
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