9921278_RZR_800 2008 Polaris RZR 800 Service Manual
User Manual: 2008 Polaris RZR 800 Service Manual
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2008 RANGER RZR
SERVICE MANUAL
FOREWORD
This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with
service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper
tools as specified.
Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc.
2100 Hwy 55 Medina Minnesota 55340.
2008 Service Manual PN 9921278
© Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:
WARNING
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or
person(s) inspecting or servicing the vehicle.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE:
NOTE provides key information by clarifying instructions.
IMPORTANT:
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or
by contacting the nearest Polaris dealer.
GENERAL INFORMATION
1
MAINTENANCE
2
ENGINE
3
FUEL INJECTION
4
BODY / STEERING / SUSPENSION
5
CLUTCHING
6
FINAL DRIVE
7
TRANSMISSION
8
BRAKES
9
ELECTRICAL
10
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL: 2008 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
1.1
GENERAL INFORMATION
MODEL INFORMATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
Model Year
Designation
}
}
}
}
Machine Model Number Identification
R 08 VH 76 AD
Emissions &
Model Option
Basic Chassis
Designation
Engine Designation
Engine Designation Number
EH076OLE021 ..................................................... Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start
VIN Identification
World
Mfg. ID
Vehicle Identifier
Vehicle Description
Body Style
Engine
}
}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A V H 7 6 A * 8 P 0 0 0 0 0 0
Model
Year
Emissions
Plant No.
Powertrain
Check Digit
Individual Serial No.
* This could be either
a number or a letter
Engine Serial Number Location
Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be
found on the sticker applied to the cylinder head on the side of engine.
1.2
GENERAL INFORMATION
Unit Serial Number (VIN) Location
The machine model number and serial number (VIN) are important for vehicle identification. The VIN number (A) is stamped on
a portion of the LH frame rail close to the front wheel. The model and VIN numbers are also located on a sticker under the hood
(B) or on the lower frame rail in front of the LH rear tire (C).
A
A
B
C
1.3
1
GENERAL INFORMATION
GENERAL SPECIFICATIONS
MODEL: 2008 RANGER RZR
MODEL NUMBER: R08VH76AD, AG
ENGINE MODEL: EH076OLE021
Category
Length
Width
Height
Wheel Base
Ground Clearance
Dry Weight
Gross Vehicle Weight
Front Storage Capacity
Cargo Box Dimension
Cargo Box Capacity
Maximum Weight
Capacity (Payload)
Hitch Towing Capacity
Hitch Tongue Capacity
FRONT
Dimension / Capacity
102 in. / 259 cm
50 in. / 127 cm
68.5 in. / 174 cm
77 in. / 196 cm
10 in. / 25.4 cm
945 lbs. / 429 kg
1727 lbs. / 783 kg
25 lbs. / 11.3 kg
42 in. x 22 in. / 107 cm x 56 cm
300 lbs. / 136 kg
740 lbs. / 336.4 kg
(Includes rider(s), cargo,
and accessories)
1500 lbs. / 680 kg
150 lbs. / 68 kg
TOP
REAR
SIDE
1.4
GENERAL INFORMATION
MODEL: 2008 RANGER RZR
Drivetrain
MODEL NUMBER: R08VH76AD, AG
ENGINE MODEL: EH076OLE021
Transmission Type
Polaris Automatic PVT
Platform
Polaris Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
Gear Ratio: Front / Rear
High
Low
Rev
3.14:1
8.71:1
5.94:1
Engine Model Number
EH076OLE021
Drive Ratio - Front
3.82:1
Engine Displacement
760cc
Drive Ratio - Final
3.70:1
Number of Cylinders
2
Shift Type
In Line Shift - H / L / N / R / P
Bore & Stroke (mm)
80 x 76.5 mm
Front Gearcase Oil Requirements
Polaris Demand Drive LT
Premium Fluid
6.75 oz. (200 ml)
Transmission Oil Requirements
Main Gearcase
Polaris High Performance AGL
24 oz. (710 ml)
Transmission Oil Requirements
Transfer Case
Polaris High Performance AGL
14 oz. (414 ml)
Rear Gearcase Oil Requirements
Polaris Premium ADF
18 oz. (532 ml)
Belt
3211113
Engine
Compression Ratio
10:1
Compression Pressure
150-200 psi
Engine Idle Speed
1150 ± 100 RPM
Engine Max Operating RPM
6500 ± 200 RPM
Lubrication
Pressurized Wet Sump
Oil Requirements
0W-40
Oil Capacity
2 qts. / 1.9 liters
Coolant Capacity
4.8 qts. / 4.5 liters
Overheat Warning
Instrument Cluster Indicator
Steering / Suspension
Single Pipe / Silencer
Front Suspension
Front Travel
9 in. / 23 cm
Fuel System Type
Bosch Electronic Fuel Injection
Rear Suspension
Independent Double A-arm
Fuel Delivery
Electronic Fuel Pump (in tank)
Rear Travel
9.5 in. / 24 cm
Fuel Pressure
39 psi
Cam Adjustment
Fuel Filters
See Chapter 4
Shock Preload Adjustment
Front / Rear
7 gal. (26.5 liters)
87 Octane (minimum)
Toe Out
1/8-1/4 in. / 3-6.35 mm
Fuel Capacity / Requirement
Exhaust System
Fuel System
Wheels / Brakes
Front Wheel Size
Front Tire Size
12 x 6 / 10 gauge
Maxxis / 25 x 8 R12
Rear Wheel Size
Rear Tire Size
12 x 8 / 10 gauge
Maxxis / 25 x 10 R12
Tire Air Pressure - Front / Rear
8 psi (55 kPa)
Electrical
Alternator Max Output
500 watts @ 3000 RPM
Lights: Main Headlights
2 - Dual Beam 55 watts / Halogen
Independent Double A-arm
Tail / Brake
2 - 27 watts
Worklights
2 - 13 watts
Starting System
Electric Start
Brake - Front / Rear
Foot Actuated - 4 Wheel
Hydraulic Disc
Ignition System
Bosch EFI (ECU Controlled)
Brake Fluid
DOT 4
Ignition Timing
13° BTDC @ 1200 RPM
Spark plug / Gap
Champion RC7YC3 /
.035 in. (0.9 mm)
Battery
Yuasa YTX20HL /
18 Amp Hr. / 310 CCA / 12 Volt
Instrument Type
Analog Speedometer
with Multifunction LCD
DC Outlet
Standard 12 V
Relays
EFI / Fan
Circuit Breaker
Fan Motor: 20 Amp
Fuses
Chassis: 20 Amp
EFI: 15 Amp
Lights: 15 Amp
Accessory: 15 Amp
Speedo/ECU: 5 Amp
CLUTCH CHART
Altitude
Meters
(Feet)
Shift Weight Drive Spring
Driven
Spring
0-1500
(0-5000)
20-62
(5631700)
Blue/Red
(7043199)
Red or Yellow
(3234452)
1500-3700
(5000 - 12000)
20-58
(5631216)
Blue/Red
(7043199)
Red or Yellow
(3234452)
1.5
1
GENERAL INFORMATION
VEHICLE INFORMATION
Publication Numbers
Model
Model No.
Owner’s Manual PN
Parts Manual PN
2008 RANGER RZR, Red
R08VH76AD
9921181
9921207
2008 RANGER RZR, Green
R08VH76AG
9921181
9921207
NOTE: When ordering service parts be sure to use the correct parts manual.
NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from
www.purepolaris.com.
Paint Codes
Painted Part
Color Description
Polaris Number
Frame / Bumpers / Racks
Gloss Black
P-067
Frame / Bumpers / Racks
Matte Black
P-458
Plastic - Hood / Dash / Fenders
Indy Red
P-293
Plastic - Hood / Dash / Fenders
Sage Brush Green Metallic
P-498
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.
KEY COVER
P/N 5533534
Key Series
Number
Series#
20
21
22
23
27
28
31
32
67
68
Part Number
4010278
4010278
4010321
4010321
4010321
4010321
4110141
4110148
4010278
4010278
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, by phone at 1-800-328-6657 or
on-line at http://polaris.spx.com/.
1.6
GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS
1
Conversion Table
°C to °F: 9/5(°C + 32) = °F
°F to °C: 5/9(°F - 32) = °C
1.7
GENERAL INFORMATION
Standard Torque Specifications
The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and
engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.
1.8
GENERAL INFORMATION
SAE Tap / Drill Sizes
Decimal Equivalents
1
Metric Tap / Drill Sizes
1.9
GENERAL INFORMATION
Glossary of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
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.
DCV: Direct current voltage
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.
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.
PVT: Polaris Variable Transmission (Drive Clutch system)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 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.
1.10
MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
50 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2
COMPONENT INSPECTION / SERVICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
FRONT AND REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
RH AND LH SIDE VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . 2.8
MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL PUMP / FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE OIL AND FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
ENGINE BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE AND TRANSMISSION MOUNT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
TRANSMISSION / GEARCASE SPECIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . 2.17
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
2.1
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
BATTERY CHARGING (SEALED BATTERY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
STEERING INSPECTION / TIE ROD ENDS AND HUBS . . . . . . . . . . . . . . . . . . . . . . . 2.28
TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
SUSPENSION SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
2.2
MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use
genuine Pure Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately
10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use
and determine the cause or see your dealer.
Break-In Period
The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. Careful treatment
of a new engine and drive components will result in more efficient performance and longer life for these components.
• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.
• Pull only light loads.
• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
• Change both the engine oil and filter after 25 hours or one month.
• See “Owner’s Manual” for additional break-in information.
Maintenance Chart Key
The following symbols denote potential items to be aware of during maintenance:
= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
= SEVERE USE ITEM: See information provided above.
E = Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING
Improperly performing the procedures marked could result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
2.3
2
MAINTENANCE
Pre-Ride - 25 Hour Maintenance Interval
Item
Steering
Front Suspension
Rear Suspension
Maintenance Interval
(whichever comes first)
Miles
Hours
Calendar
(KM)
Pre-Ride
-
Remarks
-
Pre-Ride
-
-
Pre-Ride
-
-
Pre-Ride
-
Brake Fluid Level
Brake Pedal Travel
-
Pre-Ride
-
-
Pre-Ride
-
Brake Systems
Wheels / Fasteners
Frame Fasteners
-
Pre-Ride
Pre-Ride
Pre-Ride
-
Engine Oil Level
-
Pre-Ride
-
Air Filter / Pre-Filter
-
Pre-Ride
-
Coolant Level
-
Daily
-
Head Lamp / Tail Lamp
-
Daily
-
-
Weekly
-
10 H
Monthly
100 (160)
Inspect periodically
25 H
Monthly
250 (400)
Check terminals; clean; test
25 H
Monthly
250 (400)
Inspect level; change yearly
25 H
Monthly
250 (400)
Inspect level; change yearly
25 H
Monthly
250 (400)
Inspect level; change yearly
25 H
Monthly
250 (400)
Inspect level; change yearly
25 H
Monthly
250 (400)
Inspect; replace if necessary
25 H
1M
250 (400)
Perform a break-in oil change at one month
Tires
E
E
Air Filter,
E
Main Element
Brake Pad Wear
E
E
Battery
Front Gearcase Oil
(Demand Drive Fluid LT)
Rear Gearcase Oil
(ATV Angle Drive Fluid)
Transmission - Main
(AGL Gearcase Lubricant)
Transmission - Transfer
(AGL Gearcase Lubricant)
Engine Breather
Filter (if equipped)
Engine Oil Change
(Break-In Period)
Make adjustments as needed.
See Pre-Ride Checklist on Page 2.9.
Inspect; clean often; replace as needed
Check level daily, change coolant every 2
years
Check operation; apply dielectric grease if
replacing
Inspect; replace as needed
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
2.4
MAINTENANCE
50 - 300 Hour Maintenance Interval
Item
Throttle Cable / Throttle
E Pedal
Throttle Body Air Intake
E
Ducts / Flange
General Lubrication
Shift Linkage
Maintenance Interval
(whichever comes first)
Miles
Hours
Calendar
(KM)
Remarks
2
50 H
6M
300 (500)
Inspect; adjust; lubricate; replace if
necessary
50 H
6M
300 (500)
Inspect ducts for proper sealing / air leaks
50 H
50 H
3M
6M
500 (800)
500 (800)
Lubricate all fittings, pivots, cables, etc.
Inspect, lubricate, adjust
Steering
50 H
6M
500 (800)
Lubricate
Front Suspension
Rear Suspension
50 H
6M
500 (800)
Lubricate
50 H
6M
500 (800)
50 H
6M
500 (800)
Fuel System
E
100 H
12 M
600 (1000)
Lubricate
Inspect coolant strength seasonally;
pressure test system yearly
Check for leaks at tank cap, fuel line, fuel
pump, and fuel rail.
Replace lines every two years.
Spark Plug
E
100 H
12 M
600 (1000)
Engine Oil & Filter Change
100 H
6M
1000 (1600)
100 H
100 H
12 M
12 M
1000 (1600)
1000 (1600)
Perform a break-in oil change at 25 hours or
one month / always replace oil filter when
changing engine oil
Inspect; replace as needed
Inspect; clean external surfaces
100 H
12 M
1000 (1600)
Inspect for leaks
100 H
100 H
12 M
12 M
1000 (1600)
1000 (1600)
Wiring
100 H
12 M
1000 (1600)
Clutches (Drive and Driven)
Front Wheel Bearings
Brake Fluid
Spark Arrestor
100 H
100 H
200 H
300 H
12 M
12 M
24 M
36 M
1000 (1600)
1000 (1600)
2000 (3200)
3000 (4800)
Inspect, torque to specification
Inspect
Inspect for wear, routing, security; apply
dielectric grease to connectors subjected to
water, mud, etc.
Inspect; clean; replace worn parts
Inspect; replace as needed
Change every two years (DOT 4)
Clean out
Inspect periodically; adjust when parts are
replaced
Adjust as needed
Cooling System
E
Drive Belt
Radiator
Cooling Hoses
Engine Assembly Mounts
Exhaust Muffler / Pipe
Toe Adjustment
Headlight Aim
-
Inspect; replace as needed
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
2.5
MAINTENANCE
COMPONENT INSPECTION / SERVICE LOCATIONS
Front and Rear View
2.6
MAINTENANCE
RH and LH Side Views
2
2.7
MAINTENANCE
LUBRICANTS / SERVICE PRODUCTS
Polaris Lubricants, Maintenance and Service
Products
NOTE: Each item can be purchased separately at
your local Polaris dealer.
Part No.
Description
Additives / Sealants / Thread Locking Agents / Misc.
Part No.
Description
Engine Lubricant
2870585
Loctite™ Primer N, Aerosol, 25 g
2871956
Loctite™ Thread Sealant 565
(50 ml.) (6 Count)
2870791
Fogging Oil (12 oz. Aerosol)
2871281
Premium 4-Cycle Synthetic 0W-40
Engine Oil (Quart) (12 Count)
2871949
Loctite™ Threadlock 242
(50 ml.) (10 Count)
2871844
Premium 4-Cycle Synthetic 0W-40
Engine Oil (Gallon) (4 Count)
2871950
Loctite™ Threadlock 242
(6 ml.) (12 Count)
2871567
Premium 4-Cycle Synthetic 0W-40
Engine Oil (16 Gallon) (4-Cycle)
2871951
Loctite™ Threadlock 262
(50 ml.) (10 Count)
2871952
Loctite™ Threadlock 262
(6 ml.) (12 Count)
2871953
Loctite™ Threadlock 271
(6 ml.) (12 Count)
2871954
AGL - Synthetic ATV Gearcase Lubricant
(2.5 Gal.) (2 Count)
Loctite™ Threadlock 271
(36 ml.) (6 Count)
2870584
ATV Angle Drive Fluid
(8 oz.) (12 Count)
Loctite™ 680-Retaining Compound
(10 ml.)
2870587
Loctite™ 518 Gasket Eliminator / Flange
Sealant (50 ml.) (10 Count)
2871326
Premium Carbon Clean
(12 oz.) (12 Count)
Gearcase / Transmission Lubricants
2873602
2873603
2873604
2871653
2872276
AGL - Synthetic ATV Gearcase Lubricant
(1 Qt.) (12 Count)
AGL - Synthetic ATV Gearcase Lubricant
(1 Gal.) (4 Count)
ATV Angle Drive Fluid
(2.5 Gal) (2 Count)
2871654
Premium Demand Drive Fluid LT
(1 Qt.) (12 Count)
2870652
Fuel Stabilizer (16 oz.) (12 Count)
2870465
Oil Pump for 1 Gallon Jug
2872189
DOT 4 Brake Fluid (12 Count)
Grease / Specialized Lubricants
2871557
Crankcase Sealant, 3-Bond 1215 (5oz.)
2872893
Engine Degreaser (12oz.) (12 Count)
2871312
Grease Gun Kit
2871322
Premium All Season Grease
(3 oz. cartridge) (24 Count)
2871423
Premium All Season Grease
(14 oz. cartridge) (10 Count)
2871460
Starter Drive Grease (12 Count)
2871515
Premium U-Joint Lube (3 oz.) (24 Count)
2871551
Premium U-Joint Lube (14 oz.) (10 Count)
2871329
Dielectric Grease (Nyogel™)
Coolant
2871323
60/40 Coolant (Gallon) (6 Count)
2871534
60/40 Coolant (Quart) (12 Count)
2.8
NOTE: The number count indicated by each part
number in the table above indicates the number of
units that are shipped with each order.
MAINTENANCE
MAINTENANCE REFERENCES
Item
Ref.
Rec. Lube / Fluid
Method
Frequency*
Change after 25 hrs, and then
6 months or 100 hours
thereafter; Change more
often in extremely dirty
conditions, or short trip cold
weather operation.
Engine Oil
Page 2.7
Premium 4-Cycle Synthetic
0W-40 (PN 2871281)
Add oil to proper level on
dipstick.
Engine Coolant
Page 2.6
Polaris Antifreeze 60/40
(PN 2871534)
Fill recovery bottle between Fill as required. Change
MAX and MIN lines.
coolant every 2 years.
Brake Fluid
Page 2.7
DOT 4 (PN 2872189)
Fill reservoir between MAX Fill as required. Change
and MIN lines.
brake fluid every 2 years.
Transmission
(Main Gearcase)
Page 2.7
AGL Synthetic Gearcase
Lubricant (PN 2873602)
Add lube to bottom of fill
Change annually***
plug threads. 24 oz. (710 ml)
Transmission
(Transfer Case)
Page 2.7
AGL Synthetic Gearcase
Lubricant (PN 2873602)
Add lube to bottom of level
check plug threads.
14 oz. (414 ml)
Change annually***
Front Gearcase
Page 2.7
Premium Demand Drive
Fluid LT (PN 2876251)
Drain completely and add
specified quantity of lube.
6.75 oz. (200 ml)
Change annually***
Rear Gearcase
Page 2.7
ATV Angle Drive Fluid
(PN 2871653)
Add lube to bottom of fill
Change annually***
plug threads. 18 oz. (532 ml)
Prop Shaft
Page 2.7
Polaris Premium U-Joint
Lube (PN 2871551)
Locate fitting and grease with
Semi-annually**
grease gun.
Page 2.6
Locate grease fittings on the
upper and lower A-arms of
Polaris Premium All Season the front and rear suspension
Semi-annually**
and grease with grease gun.
Grease (PN 2871423)
(4) Front A-arms
(6) Rear A-arms
Page 2.7
Locate grease fittings on the
front and rear stabilizer bars
Polaris Premium All Season
and grease with grease gun. Semi-annually**
Grease (PN 2871423)
(2) Front Stabilizer Bar
(2) Rear Stabilizer Bar
Control Arm Pivot
Bushings, FT / RR
Stabilizer Bar
Bushings, FT / RR
* More often under severe use, such as operated in water or under severe loads.
**Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
2.9
2
MAINTENANCE
GENERAL VEHICLE INSPECTION
AND MAINTENANCE
Shift Cable Inspection / Adjustment
Shift cable adjustment may be necessary if symptoms include:
• No AWD or gear position display on instrument cluster
Pre-Ride / Daily Inspection
• Ratcheting noise on deceleration
Perform the following pre-ride inspection daily, and when
servicing the vehicle at each scheduled maintenance.
• Inability to engage into a gear
• Excessive gear clash (noise)
• Tires - check condition and pressures
• Gear selector moving out of desired range
• Fuel tank - fill to proper level
1.
Locate the shift cable in the rear LH wheel well area.
• All brakes - check operation and adjustment
Clevis Pin
• Throttle - check for free operation and closing
Shift Cable
Mount
• Headlights/Taillights/Brakelights/Worklights - also
check operation of all indicator lights and switches
• Engine stop switch - check for proper function
• Wheels - check for tightness of wheel nuts and axle
nuts; check to be sure axle nuts are secured by cotter
pins
• Air cleaner element - check for dirt; clean or replace
Shift Cable
Dust Boot
• Steering - check for free operation noting any unusual
looseness in any area
2.
Inspect shift cable, clevis pin, pivot bushings, and dust
boot. Replace if worn or damaged.
3.
If adjustment is required, loosen the lower jam nut and pull
the cable out of the mount to move the upper jam nut.
• Loose parts - visually inspect vehicle for any damaged
or loose nuts, bolts or fasteners
• Engine coolant - check for proper level at the recovery
bottle
Upper
Jam Nut
• Check all front and rear suspension components for
wear or damage.
Frame, Nuts, Bolts, and Fasteners
Periodically inspect the torque of all fasteners in accordance
with the maintenance schedule. Check that all cotter pins are in
place. Refer to specific fastener torques listed in each chapter.
Lower
Jam Nut
4.
Adjust the shift cable so there is the same amount of cable
travel when shifting slightly past the detents of HIGH (H)
gear and PARK (P).
5.
Thread the upper or lower jam nut as required to obtain
proper cable adjustment.
NOTE: This procedure may require a few attempts to
obtain the proper adjustment.
2.10
MAINTENANCE
6.
7.
Once the proper adjustment is obtained, place the shift
cable and upper jam nut into the mount. Tighten the lower
jam nut against the mount.
Start engine and shift through all gears to ensure the shift
cable is properly adjusted. If transmission still ratchets
after cable adjustment, the transmission will require
service.
2.
Be sure fuel line is routed properly.
IMPORTANT: Make sure line is not kinked or pinched.
3.
Replace fuel line every two years.
Fuel Pump / Fuel Filters
The 800 EFI RZR engine uses a non-serviceable, high-volume,
high-pressure, fuel pump that includes a preliminary filter and
an internal fine filter located before the pump regulator.
FUEL SYSTEM AND AIR INTAKE
Fuel Pump Asm
Fuel System
WARNING
Gasoline is extremely flammable and explosive
under certain conditions.
Always stop the engine and refuel outdoors or in
a well ventilated area.
Do not smoke or allow open flames or sparks in
or near the area where refueling is performed or
where gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately.
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water
and change clothing.
Never start the engine or let it run in an enclosed
area. Engine exhaust fumes are poisonous and
can result loss of consciousness or death
in a short time.
Never drain the fuel when the engine is hot.
Severe burns may result.
NOTE: Neither filter is servicable.
Fuel Pump Asm
Located in Fuel Tank
Fine Filter
Fuel Line
1.
Preliminary Filter
Check the quick-connect fuel line for signs of wear,
deterioration, damage or leakage. Replace if necessary.
Fuel Line
Injector Rail
Connector
NOTE: For all other information related to the EFI
System, refer to Chapter 4.
Vent Lines
Fuel Pump
Connector
1.
Check fuel tank, front gear case, rear gear case and
transmission vent lines for signs of wear, deterioration,
damage or leakage. Replace every two years.
2.
Be sure vent lines are routed properly and secured with
cable ties.
IMPORTANT: Ensure lines are not kinked or pinched.
2.11
2
MAINTENANCE
Throttle Pedal Inspection
3.
Squeeze the end of the rubber boot and slide it far enough
to expose the end of the inline cable adjuster.
If the throttle pedal has excessive play due to cable stretch or
cable misadjustment, it will cause a delay in throttle speed.
Also, the throttle may not open fully. If the throttle pedal has no
play, the throttle may be hard to control, and the idle speed may
be erratic.
Boot
Lock Nut
4.
5.
Throttle Pedal
Check the throttle pedal play periodically in accordance with the
Periodic Maintenance Chart and adjust the play if necessary.
Adjuster
Loosen the adjuster lock nut.
Rotate the boot to turn the adjuster until 1/16" to 1/8"
(1.5 - 3 mm) of freeplay is achieved at the throttle pedal.
NOTE: While adjusting, lightly flip the throttle pedal
up and down.
6.
7.
Tighten the lock nut.
Squeeze the end of the rubber boot and slide it over the
cable adjuster to its original position.
Throttle Freeplay Adjustment
Air Filter Service
Inspection
It is recommended that the air filter be inspected as part of
pre-ride inspection. When riding in extremely dusty conditions,
apply grease to the seal under the air box cap. In extremely dusty
conditions, air filter replacement will be required more often.
1.
2.
3.
Place the transmission in the P (Park) position.
Start the engine, and warm it up thoroughly.
Measure the distance the throttle pedal moves before the
engine begins to pick up speed. Free play should be 1/16”
- 1/8” (1.5 - 3 mm).
The filter should be inspected using the following procedure.
Removal
Adjustment
1.
1.
2.
2.
Remove the seat and rear service panel.
Locate the throttle cable adjuster just above the PVT cover.
Throttle Cable
Adjuster
2.12
The air box is located just above the rear LH wheel in the
wheel well area.
Unlatch the (2) clips and remove the air box cap. Inspect
the seal. It should adhere tightly to the cover and seal all
the way around.
Air Box Location
MAINTENANCE
3.
4.
Remove air filter assembly and remove the pre-filter sleeve.
Inspect the main air filter element and replace if necessary.
Do not clean the main filter, the filter should be replaced.
NOTE: If the filter has been soaked with fuel or oil it
must be replaced.
5. Wash pre-filter in warm soapy water and allow it to air dry.
NOTE: If unable to clean the pre-filter, replace it.
Seal
Installation
1.
2.
3.
Clean the air box thoroughly.
Install a new or clean pre-filter over the main air filter
element.
Reinstall the filter into the air box. Be sure the filter fits
tightly in the air box.
NOTE: Apply a small amount of general purpose
grease to the sealing edges of the filter and the air
box cap seal before installing.
4.
Install air box cap and secure with clips.
Secure Clips
Cap
Pre-Filter
Sleeve
Air Filter
NOTE: Service more frequently if vehicle is operated
in wet conditions or at high throttle openings for
extended periods.
Intake Box
Air Box
Foam Seal
Intake Duct
Foam Seal
Air Intake Duct
Breather
Filter
Breather
Hose
Seal
Fitting
Cap
Seal
T-MAP
Sensor
Air Filter
Boot
Clip (2)
Clamps
Pre-Filter
Sleeve
Air Box Can
2.13
2
MAINTENANCE
ENGINE
Lever Lock
Engine Oil Level
The twin cylinder engine is a wet-sump engine, meaning the oil
is contained in the bottom of the crankcase. To check the oil
level follow the procedure listed below.
Dipstick
SAFE
Dipstick
6.
ADD 8 OZ
Reinstall the dipstick completely, but do not lock it.
NOTE: Make certain the dipstick is inserted all the
way into the filler tube to keep the angle and depth of
dipstick consistent.
1.
Position vehicle on a level surface.
2.
Place the transmission in PARK (P).
3.
Be sure the machine has sat for awhile before removing the
dipstick.
7.
IMPORTANT: Do not run the machine and then check
the dipstick.
4.
Remove both seats and the rear service panel.
5.
Stop engine and lift the lever lock. Remove dipstick and
wipe dry with a clean cloth.
Remove the dipstick and check the oil level. Maintain the
oil level in the “SAFE” range. Add oil as indicated by the
level on the dipstick. Do not overfill (see NOTE below).
NOTE: Due to the dipstick entry angle into the
crankcase, the oil level will read higher on the
bottom side of the dipstick. Proper level indication
is determined on the upper surface of the dipstick as
it is being removed, regardless of the level marks
being on top or on bottom (see the next illustration).
Dipstick
Always read top side of dipstick to
properly check oil level in crankcase
Dipstick
Lever Lock
NOTE: A rising oil level between checks
weather driving can indicate contaminants
gas or moisture collecting in the crankcase.
level is over the full mark, change
immediately.
8.
2.14
Reinstall the dipstick and seat the lever lock.
in cool
such as
If the oil
the oil
MAINTENANCE
Engine Oil and Filter Service
Always change engine oil and filter at the intervals outlined in
the Periodic Maintenance Chart. Always change the oil filter
whenever changing the engine oil.
WARNING
NOTE: The sealing surface on the drain plug should
be clean and free of burrs, nicks or scratches.
8.
Reinstall drain plug and torque to 16 ft. lbs. (22 Nm).
9.
Remove both seats and rear service panel.
10. Place shop towels beneath oil filter. Using Oil Filter
Wrench (PV-43527) and a 3/8” extension, turn the oil filter
counter-clockwise to remove it.
Personal injury can occur when handling used
oil. Hot oil can cause burns or skin damage.
Oil Filter
Recommended Engine Oil:
Premium 4-Cycle Synthetic OW-40
(PN 2871281) (Quart)
Ambient Temperature Range
-40° F to 120° F
1.
Position vehicle on a level surface.
2.
Place the transmission in PARK (P).
3.
Start the engine. Allow it to idle for two to three minutes
until warm. Stop the engine.
4.
Clean area around oil drain plug at bottom of engine.
11. Using a clean dry cloth, clean filter sealing surface on the
crankcase.
12. Lubricate O-ring on new filter with a film of fresh engine
oil. Check to make sure the O-ring is in good condition.
13. Install new filter and turn by hand until filter gasket contacts
the sealing surface, then turn an additional 1/2 turn.
14. Remove dipstick and fill sump with 2 quarts (1.9 l) of
Polaris Premium 4-Cycle Synthetic Oil (PN 2871281).
NOTE: Drain plug is accessed
through the skid plate.
Crankcase Drain Plug Torque:
16 ft. lbs. (22 Nm)
Oil Filter Torque:
Turn by hand until filter gasket contacts
sealing surface, then turn an
additional 1/2 turn
Drain Plug
Oil Filter Wrench:
(PV-43527)
CAUTION
Oil may be hot. Do not allow hot oil to come into
contact with skin, as serious burns may result.
15. Verify the transmission is still positioned in PARK (P).
16. Start the engine and let it idle for one to two minutes.
17. Stop the engine and inspect for leaks.
5.
Place a drain pan beneath engine crankcase and remove the
drain plug.
6.
Allow oil to drain completely.
18. Re-check the oil level on the dipstick and add oil as
necessary to bring the level to the upper mark on the
dipstick.
7.
Replace the sealing washer on drain plug.
19. Dispose of used oil and oil filter properly.
2.15
2
MAINTENANCE
Engine Breather Hose Inspection
The engine is equipped with a breather hose. Inspect the
breather hose for possible kinks or wear. The hose is form fitted for a proper fit. Follow the breather hose from the side of
the airbox to the engine valve cover.
A smooth idle generally indicates good compression. Low
engine compression is rarely a factor in running condition
problems above idle speed.
A cylinder leakdown test is the best indication of engine
condition. Follow manufacturer's instructions to perform a
cylinder leakage test (never use high pressure leakage testers, as
crankshaft seals may dislodge and leak).
Breather
Hose
Cylinder Compression
Standard: 150-200 PSI
Cylinder Leakdown
Service Limit 15%
(Inspect for cause if test exceeds 15%)
Exhaust - Spark Arrestor
WARNING
Do not clean spark arrestor immediately after the
engine has been run, as the exhaust system
becomes very hot. Serious burns could result from
contact with the exhaust components. Allow
components to cool sufficiently before proceeding.
Wear eye protection and gloves.
Never run the engine in an enclosed area. Exhaust
contains poisonous carbon monoxide gas that can
cause loss of consciousness or death in a very
short time.
NOTE: Make sure line is not kinked or pinched.
Engine and Transmission Mount Locations
Periodically inspect engine and transmission mounts for cracks
or damage.
Rear Mount
Periodically clean the spark arrestor to remove accumulated
carbon.
1.
Remove the retaining screw and remove the arrestor from
the end of the muffler.
2.
Use a non-synthetic brush to clean the arrestor screen. A
synthetic brush may melt if components are warm.
3.
Inspect the screen for wear and damage. Replace if needed.
4.
Reinstall the arrestor and torque the screw to 5-7 ft. lbs.
(7-9 Nm).
Arrestor
LH Mount
Screen
RH Mount
Compression and Leakdown Test
NOTE: This engine does NOT have decompression
components. Compression readings will vary in
proportion to cranking speed during the test.
2.16
Muffler
Retaining
Screw
MAINTENANCE
TRANSMISSION AND GEARCASES
Transmission / Gearcase Specification Chart
DRAIN / LEVEL CHECK
PLUG TORQUE
GEARCASE
LUBRICANT
CAPACITY
Transmission
(Main Gearcase)
AGL - Synthetic ATV
Gearcase Lubricant
24 oz. (710 ml)
40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm)
Transmission
(Transfer Case)
AGL - Synthetic ATV
Gearcase Lubricant
14 oz. (414 ml)
40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm)
Front Gearcase
Premium Demand Drive
Fluid LT
6.75 oz. (200 ml)
8-10 ft. lbs. (11-14 Nm) 8-10 ft. lbs. (11-14 Nm)
Rear Gearcase
ATV Angle Drive Fluid
18 oz. (532 ml)
40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm)
FILL PLUG TORQUE
Transmission Lubrication
Transfer Case - Lubricant Level Check:
NOTE: It is important to follow the transmission and
gearcase maintenance intervals described in the
Periodic Maintenance Chart. Regular fluid level
inspections on these components should be
performed as well.
1.
Position vehicle on a level surface.
2.
Remove the fill plug.
3.
Remove the level check plug.
4.
Add the recommended fluid through the fill plug hole until
it begins to flow out the level check plug hole.
Transmission Specifications
Specified Lubricant:
AGL Synthetic Gearcase Lubricant
(PN 2873602)
Fill Plug
Approximate Capacity at Change:
Main Gearcase - 24 oz. (710 ml)
Transfer Case - 14 oz. (414 ml)
Level Check Plug
Drain / Level Plug Torque:
30-45 in. lbs. (3-5 Nm)
Fill Plug Torque:
40-50 ft. lbs. (54-68 Nm)
Drain Plug
The transmission lubricant levels should be checked and
changed in accordance with the maintenance schedule.
5.
Reinstall the level check plug and torque to 30-45 in. lbs.
(3-5 Nm).
• Be sure vehicle is positioned on a level surface when
checking or changing fluid.
6.
Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm).
• Check vent hose to be sure it is routed properly and
unobstructed.
2.17
2
MAINTENANCE
Main Gearcase - Lubricant Level Check:
The fill plug is located on the side of the gearcase just below the
shift lever bell crank. Maintain the fluid level even with the
bottom of the fill plug hole.
1.
Position vehicle on a level surface.
2.
Remove the fill plug.
3.
Check the fluid level.
Transfer Case
Drain Plug
Main Gearcase
Drain Plug
Transfer Case Lubricant Change:
1.
Remove the fill plug and the level check plug (refer to
“Transfer Case - Lubricant Level Check”).
2.
Place a drain pan under the transfer case drain plug.
3.
Remove the drain plug and allow to drain completely.
4.
Clean the drain plug.
5.
Reinstall the drain plug with a new o-ring and torque to
30-45 in. lbs. (3-5 Nm).
Add the recommended fluid through the fill plug hole until
it begins to flow out the check plug hole. Do not overfill.
6.
Fill Plug /
Level Check Plug
7.
Reinstall the level check plug and torque to 30-45 in. lbs.
(3-5 Nm).
8.
Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm).
Main Gearcase Lubricant Change:
4.
If fluid level is not at fill plug hole, add the recommended
fluid as needed.
9.
5.
Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm).
10. Place a drain pan under the main gearcase drain plug.
Transmission Lubricant Change:
The lubricant change procedure is relatively the same for the
main gearcase and the transfer case. To minimize confusion,
perform the lubricant change on only one gearcase at a time.
Access the drain plugs through the drain holes in the skid plate.
Remove the fill plug (refer to “Main Gearcase - Lubricant
Level Check”).
11. Remove the drain plug and allow to drain completely.
12. Clean the drain plug.
13. Reinstall the drain plug with a new o-ring and torque to
30-45 in. lbs. (3-5 Nm).
14. Add the recommended fluid through the fill plug hole.
Maintain the fluid level at the bottom of the fill plug hole
when filling the Main Gearcase. Do not overfill.
15. Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm).
16. Check for leaks. Discard the used lubricant properly.
2.18
MAINTENANCE
Front Gearcase Lubrication
1.
Position vehicle on a level surface.
The front gearcase lubricant level should be checked and
changed in accordance with the maintenance schedule.
2.
Remove the fill plug and check the fluid level.
3.
Add the recommended fluid as needed.
• Be sure vehicle is positioned on a level surface when
checking or changing fluid.
4.
Reinstall the fill plug and torque to 8-10 ft. lbs. (11-14 Nm).
• Check vent hose to be sure it is routed properly and
unobstructed.
Lubricant Change:
The drain plug is located on the bottom of the gearcase.
Front Gearcase Specifications
Fill Plug
8-10 ft. lbs.
(11-14 Nm)
Specified Lubricant:
Premium Demand Drive Fluid LT
(PN 2876251)
Capacity: 6.75 oz. (200 ml)
Fill Plug: 8-10 ft. lbs. (11-14 Nm)
Drain Plug: 8-10 ft. lbs. (11-14 Nm)
Drain Plug
8-10 ft. lbs.
(11-14 Nm)
Lubricant Level Check:
The fill plug is located on the bottom right side of the front
gearcase. Maintain the lubricant level even with the bottom
threads of the fill plug hole.
1.
Remove the fill plug.
2.
Place a drain pan under the drain plug.
3.
Remove the drain plug and allow fluid to drain completely.
4.
Clean the drain plug. Inspect the O-ring and replace if
damaged.
5.
Reinstall the drain plug; torque to 8-10 ft. lbs. (11-14 Nm).
6.
Add the recommended fluid. Maintain the lubricant level
even with the bottom threads of the fill plug hole.
7.
Reinstall the fill plug; torque to 8-10 ft. lbs. (11-14 Nm).
8.
Check for leaks. Discard the used lubricant properly.
Fill Plug
8-10 ft. lbs.
(11-14 Nm)
2.19
2
MAINTENANCE
Rear Gearcase Lubrication
Rear Gearcase Specifications
Lubricant Change:
The drain plug is located on the bottom right side of the rear
gearcase.
Specified Lubricant:
ATV Angle Drive Fluid (PN 2871653)
Capacity: 18 oz. (532 ml)
Fill Plug
Fill Plug Torque: 40-50 ft. lbs. (54-68 Nm)
Drain Plug Torque: 30-45 in. lbs. (3-5 Nm)
Lubricant Level Check:
The fill plug is located on the right side of the rear gearcase.
Maintain the fluid level even with the bottom of the threads of
the fill plug hole.
Drain Plug
Fill Plug
40-50 ft. lbs.
(54-68 Nm)
Maintain Level at
Bottom of Threads
1.
Position the vehicle on a level surface.
2.
Remove the fill plug and check the fluid level. The
lubricant level should be even with the bottom of the
threads of the fill plug hole.
3.
Add the recommended lubricant as needed.
4.
Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm)
1.
Remove the fill plug.
2.
Place a drain pan under the drain plug.
3.
Remove the drain plug and allow the lubricant to drain
completely.
4.
Clean the drain plug.
5.
Reinstall the drain plug with new O-ring and torque to
30-45 in. lbs. (3-5 Nm).
Fill Plug
40-50 ft. lbs.
(54-68 Nm)
Maintain Level at
Bottom of Threads
2.20
Drain Plug
30-45 in. lbs.
(3-5 Nm)
6.
Add the recommended lubricant. Maintain the fluid level
even with the bottom threads of the fill plug hole.
7.
Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm).
8.
Check for leaks. Discard used lubricant properly.
MAINTENANCE
COOLING SYSTEM
Cooling System Overview
The engine coolant level is controlled, or maintained, by the
recovery system. The recovery system components are the
recovery bottle, radiator filler neck, radiator pressure cap and
connecting hose.
4.
NOTE: If overheating is evident, allow system to
cool completely and check coolant level in the
radiator and inspect for signs of trapped air in
system.
WARNING
As coolant operating temperature increases, the expanding
(heated) excess coolant is forced out of the radiator past the
pressure cap and into the recovery bottle. As engine coolant
temperature decreases the contracting (cooled) coolant is drawn
back up from the tank past the pressure cap and into the radiator.
NOTE: Some coolant level drop on new machines is
normal as the system is purging itself of trapped air.
Observe coolant levels often during the break-in
period.
NOTE: Overheating of engine could occur if air is
not fully purged from system.
Polaris Premium 60/40 is already premixed and ready to use. Do
not dilute with water.
Never remove the pressure cap when the
engine is warm or hot. Escaping steam can
cause severe burns. The engine must be cool
before removing the pressure cap.
5.
Remove the pressure cap. Using a funnel, add coolant to
the top of the filler neck.
6.
Reinstall the pressure cap.
NOTE: Use of a non-standard pressure cap will not
allow the recovery system to function properly.
7.
Remove recovery bottle cap and add coolant using a funnel.
8.
Fill recovery bottle to MAX level with Polaris 60/40
premix Anti Freeze/Coolant or 50/50 or 60/40 mixture of
antifreeze and distilled water as required for freeze
protection in your area.
9.
Reinstall the recovery bottle cap.
Coolant Level Inspection
The pressure cap and recovery bottle are located under the front
hood of the vehicle. The coolant level must be maintained
between the minimum and maximum levels indicated on the
recovery bottle.
Recovery Bottle
If the coolant level is below the MIN line, inspect the
coolant level in the radiator.
10. If coolant was required, start engine and check for leaks.
Make sure radiator fins are clean to prevent overheating.
Coolant Strength / Type
Test the strength of the coolant using an antifreeze hydrometer.
Pressure Cap
Antifreeze Hydrometer
• A 50/50 or 60/40 mixture of antifreeze and distilled
water will provide the optimum cooling, corrosion
protection, and antifreeze protection.
With the engine at operating temperature, the coolant level
should be between the upper and lower marks on the coolant
recovery bottle. If not, perform the following procedure.
1.
Position the vehicle on a level surface.
2.
Remove the hood by lifting it straight up from the front cab
to allow the inserts to disengage from the grommets.
3.
• Do not use tap water, straight antifreeze, or straight
water in the system. Tap water contains minerals and
impurities which build up in the system.
• Straight water or antifreeze may cause the system to
freeze, corrode, or overheat.
Polaris 60/40 Anti-Freeze / Coolant
(PN 2871323)
View the coolant level in the recovery bottle.
2.21
2
MAINTENANCE
Cooling System Pressure Test
2.
Carefully straighten any bent radiator fins.
Refer to Chapter 3 for cooling system pressure test procedure.
3.
Remove any obstructions with compressed air or low
pressure water.
Cooling System Hoses
1.
Inspect all hoses for cracks, deterioration, abrasion or
leaks. Replace if necessary.
CAUTION
Washing the vehicle with a high-pressure
washer could damage the radiator fins and
impair the radiators effectiveness. Use of a
high-pressure washer is not recommended.
Recovery
Bottle
Coolant Drain / Radiator Removal
Filler Neck
Coolant Drain
1.
WARNING
T-Connector
2.
Remove the front hood.
Never drain the coolant when the engine and
radiator are warm or hot. Hot coolant can cause
severe burns. Allow engine and radiator to cool.
Check tightness of all hose clamps.
CAUTION
Do not over-tighten hose clamps at radiator, or
radiator fitting may distort, causing a restriction
to coolant flow. Radiator hose clamp torque is
36 in. lbs. (4 Nm).
2.
Slowly remove the pressure cap to relieve any cooling
system pressure.
3.
Place a suitable drain pan underneath the T-fitting on the
front RH side of the vehicle.
4.
Drain the coolant from the radiator by removing the lower
engine inlet hose from the T-fitting. Properly dispose of the
coolant.
Radiator
1.
T-Fitting
Check radiator (A) air passages for restrictions or damage.
A
Drain Here
5.
Flush radiator fins
in this direction
2.22
Allow coolant to completely drain.
MAINTENANCE
FINAL DRIVE / WHEEL AND TIRE
Radiator Removal
1.
Remove the front bumper (see Chapter 5).
2.
Remove the upper engine outlet hose and recovery hose
from the top of the radiator.
3.
Wheel, Hub, and Spindle Torque Table
Item
Nut Type
Specification
Aluminum Wheels
(Cast)
Lug Nut
#1
90 ft. lbs. (122 Nm)
Steel Wheels
(Black / Camo)
Flange Nut
#2
27 ft. lbs. (37 Nm)
Hub Retaining Nuts
(Front & Rear)
-
80 ft. lbs. (108 Nm)
Remove the (2) upper radiator retaining bolts and the (4)
bolts retaining the lower radiator mount bracket. Remove
the bracket from the frame.
#2
#1
4.
Disconnect the fan motor and remove the radiator from the
vehicle. Take care not to damage the cooling fins.
5.
Reverse procedure for installation.
Steel Wheel
90 ft. lbs. (122 Nm)
27 ft. lbs. (37 Nm)
NOTE: Do not lubricate the stud or the lug nut.
Fan Motor Asm.
Recovery
Hose
Aluminum Wheel
Wheel Removal
1.
Position the vehicle on a level surface.
2.
Place the transmission in PARK (P) and stop the engine.
3.
Loosen the wheel nuts slightly. If wheel hub removal is
required, remove the cotter pin and loosen the hub nut
slightly.
4.
Elevate the appropriate side of the vehicle by placing a
suitable stand under the frame.
5.
Remove the wheel nuts and remove the wheel.
6.
If hub removal is required, remove the hub nut and washers.
Inserts
Radiator
T-Fitting
Engine
Outlet Hose
Screws
Grommets
Engine
Inlet Hose
Wheel Installation
1.
Verify the transmission is still in PARK (P).
2.
Install the wheel hub, washers, and hub nut, if previously
removed.
3.
Place the wheel in the correct position on the wheel hub.
Be sure the valve stem is toward the outside and rotation
arrows on the tire point toward forward rotation.
4.
Attach the wheel nuts and finger tighten them.
2.23
2
MAINTENANCE
5.
Carefully lower the vehicle to the ground.
6.
Torque the wheel nuts and/or hub nut to the proper torque
specification listed in the torque table at the beginning of
this section.
7.
If hub nut was removed, install a new cotter pin after the
hub nut has been tightened.
WARNING
Operating a RANGER with worn tires will
increase the possibility of the vehicle skidding
easily with possible loss of control.
Worn tires can cause an accident.
Use a new
cotter pin
Note
Tire Rotation
Always replace tires when the tread depth
measures 1/8", (.3 cm) or less.
Hub Nut
Tire Pressure
CAUTION
Wheel Nuts (4)
Valve stem
facing outward
Maintain proper tire pressure.
Refer to the warning tire pressure decal
applied to the vehicle.
Tire Pressure Inspection (Cold)
CAUTION
If wheels are improperly installed it could affect
vehicle handling and tire wear. On vehicles with
tapered rear wheel nuts, make sure tapered end
of nut goes into taper on wheel.
Tire Inspection
• Improper tire inflation may affect vehicle
maneuverability.
Front
Rear
8 psi (55 kPa)
8 (55 kPa)
Drive Shaft Boot Inspection
Inspect the front and rear drive shaft boots for damage, tears,
wear, or leaking grease. If the rubber boots exhibit any of these
symptoms, replace the boot(s). Refer to Chapter 7 for drive shaft
boot replacement.
Front Boots
• When replacing a tire always use original equipment
size and type.
• The use of non-standard size or type tires may affect
vehicle handling.
Tire Tread Depth
Always replace tires when tread depth is worn to 1/8" (3 mm) or
less.
Tread
Depth 1/8" (3 mm)
2.24
Rear Boots
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM
Battery Removal
Battery Maintenance
1.
Keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove the corrosion with a stiff wire
brush. Wash with a solution of one tablespoon baking soda and
one cup water. Rinse well with tap water and dry off with clean
shop towels. Coat the terminals with dielectric grease or
petroleum jelly.
Remove the driver’s seat to access the battery.
Battery
2
Be careful not to allow cleaning solution or tap water into the
battery
WARNING
Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
2.
Disconnect the black (negative) battery cable.
3.
Disconnect the red (positive) battery cable.
4.
Remove the rubber strap and lift the battery out of the
vehicle.
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
CAUTION
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed
space. Always shield eyes when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
NOTE: Batteries must be fully charged before use or
battery life will be reduced by 10-30% of full
potential. Charge battery for 3-5 hours at a current
equivalent of 1/10 of the battery’s rated amp/hour
capacity. Do not use the alternator to charge a new
battery.
To reduce the chance of sparks: Whenever
removing the battery, disconnect the black
(negative) cable first. When reinstalling the
battery, install the black (negative) cable last.
Battery Installation
IMPORTANT: Using a new battery that has not been
fully charged can damage the battery and result in a
shorter life. It can also hinder vehicle performance.
Follow the battery charging procedure before
installing the battery.
1.
Ensure the battery is fully charged.
2.
Place the battery in the battery holder and secure with
rubber strap.
3.
Coat the terminals with dielectric grease or petroleum jelly.
4.
Connect and tighten the red (positive) cable first.
5.
Connect and tighten the black (negative) cable last.
6.
Verify that cables are properly routed and reinstall the
driver’s seat.
2.25
MAINTENANCE
Battery Off Season Storage
Spark Plug Service
Whenever the vehicle is not used for a period of three months or
more, remove the battery from the vehicle, ensure that it's fully
charged, and store it out of the sun in a cool, dry place. Check
battery voltage each month during storage and recharge as
needed to maintain a full charge.
1.
Remove both driver and passenger seats.
2.
Remove the rear service panel.
NOTE: Battery charge can be maintained by using a
Polaris battery tender charger or by charging about
once a month to make up for normal self-discharge.
Battery tenders can be left connected during the
storage period, and will automatically charge the
battery if the voltage drops below a pre-determined
point.
Battery Charging (Sealed Battery)
WARNING
A hot exhaust system and engine can cause serious
burns. Allow engine to cool or wear protective
gloves when removing the spark plugs
3.
The PTO side spark plug can be accessed with the service
panel removed. The MAG side spark plug can be accessed
through the rear RH wheel well area.
4.
Remove both spark plug caps.
5.
Clean plug area so no dirt and debris can fall into engine
when plugs are removed.
6.
Remove spark plugs.
7.
Inspect electrodes for wear and carbon buildup. Look for
a sharp outer edge with no rounding or erosion of the
electrodes.
The sealed battery is already filled with electrolyte and has been
sealed at the factory. Never pry the sealing strip off or add any
type of fluid to this battery.
The single most important thing about maintaining a sealed
battery is to keep it fully charged. Since the battery is sealed and
the sealing strip cannot be removed, you must use a voltmeter or
multimeter to measure the DC voltage at the battery terminals.
1.
Check the battery voltage with a voltmeter or multimeter.
The battery voltage should read 12.8 VDC or higher.
2.
If the voltage is less than 12.8 volts, charge the battery at
1.2 amps or less until battery voltage is 12.8 VDC or
greater.
NOTE: When using an automatic charger, refer to
the charger manufacturer’s instructions for battery
charging directions. When using a constant current
charger, follow the guidelines in the following table:
STATE OF
CHARGE
VOLTAGE
ACTION
CHARGE
TIME
100%
12.8 - 13 VDC
None, check
again in 3
months
None
Required
May need slight
charge, check
75% - 100% 12.5 - 12.8 VDC
again in 3
months
3 - 6 hrs
50% - 75% 12.0 - 12.5 VDC Needs Charge
5 - 11 hrs
25% - 50% 11.5 - 12.0 VDC Needs Charge
At least 13
hrs, verify
state of
charge
0% - 25%
2.26
Needs Charge
At least 20
11.5 VDC or less with desulfating
hrs
charger
Inspect electrode for
wear and buildup
8.
Clean with electrical contact cleaner or a glass bead spark
plug cleaner only. CAUTION: A wire brush or coated
abrasive should not be used.
MAINTENANCE
9.
Measure gap with a wire gauge. Refer to specifications in
the following illustration for proper spark plug type and
gap. Adjust gap if necessary by carefully bending the side
electrode.
STEERING AND SUSPENSION
Steering Inspection
The steering components should be checked periodically for
loose fasteners, worn tie rod ends, ball joints, and damage. Also
check to make sure all cotter pins are in place. If cotter pins are
removed, they must not be re–used. Always use new cotter pins.
Spark Plug Gap
Gap - .035" (0.90 mm)
10. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if the
incorrect spark plug is used.
Replace any worn or damaged steering components. Steering
should move freely through the entire range of travel without
binding. Check routing of all cables, hoses, and wiring to be
sure the steering mechanism is not restricted or limited.
NOTE: Whenever
steering
components
replaced, check front end alignment.
11. Apply anti-seize compound to the spark plug threads.
are
WARNING
12. Install spark plug and torque to specification.
Due to the critical nature of the procedures outlined in
this chapter, Polaris recommends steering component
repair and adjustment be performed by an authorized
Polaris MSD certified technician when replacing
worn or damaged steering parts.
Use only genuine Polaris replacement parts.
Recommended Spark Plug:
Champion RC7YC3
Spark Plug Torque:
18 ft. lbs. (24 Nm)
Steering Wheel Freeplay
Engine To Frame Ground
Inspect engine ground cable connection. Be sure it is clean and
tight. The ground cable runs from the engine starter motor to the
ground terminal location under the driver’s seat near the battery.
Ground
Terminal Location
Check the steering wheel for specified freeplay and operation.
1.
Position the vehicle on level ground.
2.
Lightly turn the steering wheel left and right.
3.
There should be 0.8”-1.0” (20-25 mm) of freeplay.
4.
If there is excessive freeplay or the steering feels rough,
inspect the following components.
• Tie Rod Ends
• Steering Shaft U-Joints
• Steering Gearbox
Engine
Ground Strap
Tie Rod
U-Joints
Tie Rod
Gearbox
2.27
2
MAINTENANCE
Steering Inspection / Tie Rod Ends and Hubs
• To check for play in the tie rod end, grasp the steering
tie rod and pull in all directions feeling for movement.
Toe Alignment Inspection
1.
Place machine on a smooth level surface.
2.
Set steering wheel in a straight ahead position and secure
the steering wheel in this position.
3.
Place a chalk mark on the center line of the front tires
approximately 10” (25.4 cm) from the floor or as close to
the hub/axle center line as possible.
Measurement “B”
• Elevate front end of machine so front wheels are off the
ground. Check for any looseness in front hub and wheel
assembly by grasping the tire firmly at top and bottom
first, and then at front and rear. Try to move the wheel
and hub by pushing inward and pulling outward.
Check for Loose Wheel or Hub
• If abnormal movement is detected, inspect the hub and
wheel assembly to determine the cause (possible loose
wheel nuts or loose front hub components).
• Refer to Chapter 7 “Final Drive” for front hub service
procedures.
2.28
Chalk Mark
Measurement “A”
NOTE: It is important that the height of both marks
be equally positioned in order to get an accurate
measurement.
4.
Measure the distance between the marks and record the
measurement. Call this measurement “A”.
5.
Rotate the tires 180° by moving vehicle forward or
backward. Position chalk marks facing rearward, even with
the hub/axle center line.
6.
Again measure the distance between the marks and record.
Call this measurement “B”. Subtract measurement “B”
from measurement “A”. The difference between
measurements “A” and “B” is the vehicle toe alignment.
The recommended vehicle toe tolerance is 1/8” to 1/4”
(.3 to .6 cm) toe out. This means the measurement at the
front of the tire (A) is 1/8” to 1/4” (.3 to .6 cm) wider than
the measurement at the rear (B).
= In. / mm.
Wheel Toe-Out:
(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)
MAINTENANCE
Toe Adjustment
Suspension Spring Adjustment
If toe alignment is incorrect, measure the distance between
vehicle center and each wheel. This will tell you which tie rod
needs adjusting.
1.
Position the vehicle on a level surface.
2.
Stop the engine.
NOTE: Be sure steering wheel is straight ahead
before determining which tie rod(s) need
adjustment.
3.
Raise and safely support the front or rear of the vehicle off
the ground to allow the suspension to fully extend.
CAUTION
NOTE: The tires should not be touching the ground.
4.
To adjust the suspension, use the adjustment cam located
near the bottom of the shock.
During tie rod adjustment, it is very important that
the following precautions be taken when
tightening tie rod end jam nuts.
If the rod end is positioned incorrectly it will not
pivot, and may break.
Shock Spanner Wrench
(PN 2870872)
5.
Rotate the adjustment cam clockwise to increase spring
tension or counter-clockwise to decrease spring tension.
To adjust toe alignment:
• Hold tie rod end to keep it from rotating.
• Loosen jam nuts at both ends of the tie rod.
• Shorten or lengthen the tie rod until alignment is as
required to achieve the proper toe setting as specified in
Toe Alignment Inspection.
• IMPORTANT: When tightening the tie rod end jam
nuts, the rod ends must be held parallel to prevent rod
end damage and premature wear. Damage may not be
immediately apparent if done incorrectly.
Cam
Increase
Preload
• After alignment is complete, torque jam nuts to
specification.
=T
Tie Rod Jam Nut Torque:
12-14 ft. lbs. (16-19 Nm)
Decrease
Preload
Suspension Spring Preload Adjustment
The front and rear shock absorber springs are adjustable by
rotating the adjustment cam to change spring tension preload.
6.
Each notch of the adjustment will add 6% - 8% more
preload to the spring over the primary position.
WARNING
Uneven adjustment may cause poor handling of the
vehicle, which could result in an accident and
serious injury or death. Always adjust both the left
and right spring preloads equally.
2.29
2
MAINTENANCE
BRAKE SYSTEM
Brake Pad / Disc Inspection
Brake Fluid Inspection
1.
Check the brake pads for wear, damage, or looseness.
Always check the brake pedal travel and inspect the brake fluid
reservoir level before each operation. If the fluid level is low,
add DOT 4 brake fluid only.
2.
Inspect the brake pad wear surface for excessive wear.
3.
Pads should be changed when the friction material is worn
to .040” (1 mm).
Brake fluid should be changed every two years. The fluid
should also be changed anytime the fluid becomes
contaminated, the fluid level is below the minimum level, or if
the type and brand of the fluid in the reservoir is unknown.
The brake fluid master cylinder reservoir can be accessed
through the left front wheel well.
1.
Position the vehicle on a level surface.
2.
Place the transmission in PARK (P).
3.
View the brake fluid level in the reservoir. The level should
be between the MAX and MIN level lines.
4.
If the fluid level is lower than the MIN level line, add brake
fluid until it reaches the MAX level line.
5.
Install the reservoir cap and apply the brake pedal
forcefully for a few seconds and check for fluid leakage
around the master cylinder fittings and the brake caliper
fittings.
Measure Pad Material
Thickness
4.
Check surface condition of the brake discs.
5.
Measure the thickness of the front and rear brake discs.
6.
The disc(s) should be replaced if thickness is less than .170”
(4.32 mm).
Measure Brake Disc Thickness
Rear
Disc
Maximum
Service Limit:
.040" (1 mm)
Front
Disc
Minimum
Service Limit:
.170" (4.32 mm)
Master Cylinder
Brake Hose and Fitting Inspection
Check brake system hoses and fittings for cracks, deterioration,
abrasion, and leaks. Tighten any loose fittings and replace any
worn or damaged parts.
2.30
ENGINE
CHAPTER 3
ENGINE
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
CRANKCASE EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
ENGINE FASTENER TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
800 EFI ENGINE SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
COOLING SYSTEM SPECIFICATIONS / PRESSURE TEST / EXPLODED VIEW. . . . 3.12
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
ENGINE / TRANSMISSION SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
ENGINE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CYLINDER HEAD ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
ROCKER ARMS / PUSH RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
CYLINDER HEAD WARP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
VALVE SEAL / SPRING SERVICE (ON ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
VALVE LIFTER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CYLINDER HONE SELECTION AND HONING PROCEDURE . . . . . . . . . . . . . . . . . . . 3.35
HONING TO DEGLAZE / CLEANING THE CYLINDER AFTER HONING. . . . . . . . . . . 3.35
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
STARTER DRIVE BENDIX REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
FLYWHEEL / STATOR REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
ENGINE CRANKCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 3.38
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47
FLYWHEEL / STATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56
CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56
OIL PUMP PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
ENGINE ASSEMBLY AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.62
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.62
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.63
3.1
ENGINE
ENGINE SPECIFICATIONS
Crankcase Exploded Views
3.2
ENGINE
Oil Pump / Water Pump / Engine Cover Exploded View
3
3.3
ENGINE
Stator Cover / Starter / Water Pump Oil Filter / Pressure Relief / Exploded View
3.4
ENGINE
Cylinder / Cylinder Head / Piston Exploded View
3
3.5
ENGINE
Engine EFI Sensors / Valve Cover / General Component Exploded View
NOTE: See Chapter 4 for more information on the EFI System
3.6
ENGINE
Engine Fastener Torque Patterns
Crankcase Bolt Tighten Sequence
3
22 ± 2 ft. lbs. (30 ± 3 Nm)
Cylinder Head Bolt Tighten Sequence
Lubricate threads and between washer and underside of bolt with engine oil.
Torque in sequence to spec provided, allow the gasket to set for 1 minute, then
tighten in sequence 90° (1/4 turn).
35 ± 4 ft. lbs.
(47.5 ± 5.5 Nm) + 90° (1/4 turn)
3.7
ENGINE
Torque Specifications
Engine Torque Specifications
Fastener
Size
in. lbs. (Nm)
ft. lbs. (Nm)
Camshaft Gear
8 mm
22 ± 2 (30 ± 3)
Camshaft Thrust Plate
6 mm
115 ± 12 (13 ± 1.35)
9.5 ± 1 (13 ± 1.35)
Throttle Body Adaptor Bolts
8 mm
216 ± 24 (24.5-± 2.7)
18 ± 2 (24.5 ± 2.7)
Counterbalance Gear
8 mm
22 ± 2 (30 ± 3)
Crankcase Bolts
8 mm
* 22 ± 2 (30 ± 3)
Crankcase Breather
5 mm
Cylinder Head Bolts
11 mm
Exhaust Manifold
8 mm
Flywheel
14 mm
Injector Rail
8 mm
216 ± 24 (24.5 ± 2.70)
18 ± 2 (24.5 ± 2.7)
Magneto Cover
6 mm
* 96 ± 3 (10.85 ± 0.35)
-
Oil Baffle Weldment
5 mm
60 ± 6 (6.8 ± 0.68)
-
Oil Drain Bolt (Crankcase)
12 mm
192 ± 24 (21.7 ± 2.7)
16 ± (21.7)
Oil Fill Tube Bolt
5 mm
50 ± 5 (5.64 ± 0.56)
-
Oil Filter Pipe Fitting
20 mm
Oil Pick Up
5 mm
60 ± 6 (6.8 ± 0.68)
-
Oil Pressure Relief Plug
10 mm
22 ± 2 (30 ± 3)
-
Oil Pump Housing Screw
6 mm
* 84 ± 8 (9.50 ± 0.90)
-
Rocker Arm
8 mm
Rocker Cover
6 mm
* 84 ± 8 (9.5 ± 0.9)
-
Spark Plug
14 mm
216 ± 24 (24.5 ± 2.7)
18 ± 2 (24.5 ± 2.7)
Starter Motor
6 mm
* 84 ± 8 (9.5 ± 0.9)
-
Stator Assembly
6 mm
96 ± 3 (10.85 ± 0.35)
-
Stator Housing
6 mm
* 96 ± 3 (10.85 ± 0.35)
-
20 ± 5 (2.5 ± 0.55)
* 35 ± 4 (47.5 ± 5.5)
216 ± 24 (24.5 ± 2.70)
18 ± 2 (24.5 ± 2.7)
65 ± 7 (88 ± 9.50)
35 ± 4 (47.5 ± 5.4)
* 22 ± 2 (30 ± 3)
Temperature Switch
3/8 NPT
17 ± 2 (23 ± 3)
Thermostat Housing
6 mm
Timing Plug
3/4-16
Trigger Coil/Stator Wire Holddown
5 mm
* 96 ± 3 (10.85 ± 0.35)
-
Water Pump Housing Cover
6 mm
* 96 ± 3 (10.85 ± 0.35)
-
Water Pump Impeller Nut
8 mm
108 ± 3 (12 ± 0.35)
-
84 ± 8 (9.5 ± 0.9)
7 - 9 (10 - 12)
NOTE: * See exploded views for notes or torque sequences.
3.8
-
ENGINE
800 EFI Engine Service Specifications
Cylinder Head - Engine Specifications
Main Component: Cylinder Head
Camshaft
Counter Balance
EH076OLE021
Cam Lobe Height - Intake / Exhaust
1.3334" (33.8674 mm)
Camshaft Journal Outer Diameter - Mag
1.654" ± 0.00039" (42 ± 0.010 mm)
Camshaft Journal Outer Diameter - Center
1.634"± 0.00039" (41.50 ± 0.010 mm)
Camshaft Journal Outer Diameter - PTO
1.614" ± 0.00039" (41 ± 0.010 mm)
Camshaft Journal Bore Inner Diameter - Mag
1.656" ± 0.00039" (42.07 ± 0.010 mm)
Camshaft Journal Bore Inner Diameter - Center
1.637" ± 0.00039" (41.58 ± 0.010 mm)
Camshaft Journal Bore Inner Diameter - PTO
1.617" ± 0.00039" (41.07 ± 0.010 mm)
Camshaft Oil Clearance
0.00276" ± 0.00079" (0.07 ± 0.02 mm)
Camshaft End Play
0.0167" ± 0.0098" (0.425 ± 0.25 mm)
Counter Balance End Play
0.005" (0.127 mm)
Cylinder Head - Surface warp limit
0.00394" (0.1 mm)
Cylinder Head - Standard height
3.478" (88.35 mm)
Valve Seat - Contacting Width - Intake
0.0472" ± 0.00787" - 0.0039"
(1.20 ± 0.20 - 0.10mm)
Valve Seat - Contacting Width - Exhaust
0.0591" ± 0.00787" - 0.0039"
(1.50 ± 0.20 - 0.10 mm)
Valve Seat Angle
45.5° ± 0.255°
Valve Guide Inner diameter
0.2367" ± 0.00029" (6.012 ± 0.007 mm)
Valve Guide Protrusion Above Head
0.807" ± 0.0039" (20.50 ± 0.01 mm)
Valve Margin Thickness - Intake
Standard: 0.79" (20.06 mm)
Max- 0.98" (24.89 mm) Min.- 0.59" (14.98 mm)
Valve Margin Thickness - Exhaust
Standard: 0.80" (20.32 mm)
Max- 1.0" (25.4 mm) Min.- 0.60" (15.24 mm)
Valve Stem Diameter - Intake
0.2356" ± 0.00039" (5.985 ± 0.01 mm)
Valve Stem Diameter - Exhaust
0.2351" ± 0.00039" (5.972 ± 0.01 mm)
Valve Stem Oil Clearance - Intake
0.00228" ± 0.00098" (0.058 ± 0.025 mm)
Valve Stem Oil Clearance - Exhaust
0.00275" ± 0.00098" (0.0870 ± 0.025mm)
Valve Stem Overall Length - Intake
4.51" ± 0.01476" (114.5550 ± 0.375 mm)
Valve Stem Overall Length - Exhaust
4.5453" ± .01496" (115.45 ± 0.38 mm)
Valve Spring Overall Length - Free Length
1.735" (46.069 mm)
Valve Spring Overall Length - Installed Height
Intake - 1.4638" (37.18 mm)
Exhaust - 1.4736" (37.43 mm)
3
Cylinder Head
Valve Seat
Valve Guide
Valve
Valve Spring
3.9
ENGINE
Cylinder / Piston - Engine Specifications
Main Components: Cylinder / Piston / Connecting Rod
Cylinder
Lifter
Piston
Piston Pin
EH076OLE021
Cylinder - Surface warp limit
(mating with cylinder head)
0.004" (0.10 mm)
Cylinder Bore - Standard
3.1495" (80 mm)
Cylinder Taper Limit
0.00031" (0.008 mm)
Cylinder Out of Round Limit
0.00030" (0.0075 mm)
Cylinder to Piston Clearance
.0015" ± .00059" (.040 ± .015mm)
Lifter Outer Diameter Standard
0.84245" ± 0.00025" (21.39 8 ± 0.00635 mm)
Lifter Block Bore
0.8438" ± 0.00062" (21.4322 ± 0.0157 mm)
Piston - Standard
3.14803" ± .00028" (79.960 ± .007mm)
Piston Standard Inner Diameter of
Piston Pin Bore
0.70902" ± .00012" (18.009 ± 0.003 mm)
Piston Pin Outer Diameter
0.70866" - 0.70846" (18 - 17.995 mm)
Piston Pin - Standard Clearance - Piston Pin to
Pin Bore
0.00047" ± 0.00024" (0.012 ± 0.006 mm)
Piston Pin - Degree of Fit
Piston pin must be push fit (by hand) at 68° F (20° C)
Piston / Connecting Rod / Crankshaft - Engine Specifications
Main Components: Piston / Connecting Rod
Installed
Gap
Piston Ring
Ring to
Groove
Clearance
Top Ring - Standard
0.0059± 0.138" (0.15 ± 0.35mm)
Top Ring - Limit
> 15% Leakdown
Second Ring - Standard
0.0098 ± 0.197" (0.25 ± 0.50mm)
Second Ring - Limit
> 15% Leakdown
Oil Ring - Standard
0.0196± 0.00984" (0.50 ± 0.25mm)
Oil Ring - Limit
> 15% Leakdown
Top Ring - Standard
0.0024" ± 0.0008" (0.060 ± 0.020 mm)
Top Ring - Limit
> 15% Leakdown
Second Ring - Standard
0.0028" ± 0.0008" (0.070 ± 0.020 mm)
Second Ring - Limit
> 15% Leakdown
Connecting Rod Small End I.D.
Connecting Rod
Crankshaft
3.10
EH076OLE021
Connecting Rod Small End
Radial Clearance
Connecting Rod Big End
Side Clearance
Connecting Rod Big End
Radial Clearance
Crankshaft Runout Limit
0.7096"−0.70846" (18 −17.995 mm)
0.0098"± 0.00039" (0.025 ± 0.010mm)
0.01181"± 0.00591" (0.030 ± 0.015mm)
0.0015"± 0.00006" (0.0038 ± 0.0015mm)
0.00236" (0.060mm)
ENGINE
Special Tools
Part Number
Tool Description
PV-43527
OIL FILTER WRENCH
2200634
VALVE SEAT RECONDITIONING KIT
PU-45257
VALVE SPRING COMPRESSOR
PU-45652
VALVE PRESSURE HOSE
2871043
FLYWHEEL PULLER
2870390
PISTON SUPPORT BLOCK
PU-45497-1
CAM GEAR SPRING INSTALLATION KIT
PU-45497-2
CAM GEAR TOOTH ALIGNMENT TOOL
PU-45498
CAM SPANNER WRENCH
PU-45838
GEAR HOLDER
3
PA-44995
WATER PUMP MECHANICAL SEAL INSTALLER
PU-45543
UNIVERSAL DRIVER HANDLE
PA-45483
MAIN SEAL INSTALLER
PU-45658
CRANKSHAFT MAIN SEAL SAVER
PA-45401
WATER PUMP SEAL SAVER
2870975
MITY VAC™ PRESSURE TEST TOOL
PU-45778
OIL SYSTEM PRIMING TOOL
3.11
ENGINE
ENGINE COOLING SYSTEM
3.
Cooling System Specifications
Condition
Thermostat Open
Thermostat Full Open Lift
Thermostat Closed
System Capacity
Specification
The system must maintain 10 psi for five minutes or longer.
If pressure loss is evident within five minutes, check the
radiator, hoses, clamps and water pump seals for leakage.
Pressure Cap Test
WARNING
180° F (82° C)
6 mm at 203° F (95° C)
Never remove pressure cap when engine is
warm or hot. The cooling system is under
pressure and serious burns may result.
Allow the engine and cooling system to cool
before servicing.
171° F (77° C)
4.8 Quarts (4.5 liters)
Pressure Cap Relief
13 PSI
Polaris Premium Antifreeze
2871534 - Quart
2871323 - Gallon
1.
Remove pressure cap and test cap using a commercially
available pressure cap tester.
2.
The pressure cap relief pressure is 13 psi. Replace cap if it
does not meet this specification.
Recommended Coolant
Use only high quality antifreeze/coolant mixed with distilled
water in a 50/50 or 60/40 ratio, depending on freeze protection
required in your area.
CAUTION: Using tap water in the cooling system will lead to
a buildup of deposits which may restrict coolant flow and reduce
heat dissipation, resulting in possible engine damage. Polaris
Premium 60/40 Antifreeze/Coolant is recommended for use in
all cooling systems and comes pre-mixed, ready to use.
Cooling System Pressure Test
1.
Remove the front hood.
2.
Remove pressure cap and pressure test the cooling system
using a commercially available pressure tester.
Remove
Cap
Test Here
3.12
Pressure Cap
ENGINE
Cooling System Exploded View
Engine Outlet Hose
(Thermostat Housing)
Radiator
Inlet Hose
3
Engine Inlet Hose
(Water Pump Cover)
Fan Motor
Pressure Cap
Shroud
To Bottle
Filler Neck
Recovery Bottle
Radiator
Outlet Hose
If Built After 4/16/2007
Radiator
To Filler Neck
Coolant Flow Diagram
Filler Neck
Engine
Water Pump
Engine
Thermostat Housing
Recovery Bottle
Radiator
3.13
ENGINE
Cooling System Bleeding Procedure
WARNING
3.
Remove pressure cap and top off coolant.
4.
Remove recovery bottle cap and fill bottle to the full line.
Recovery Bottle
Always wear safety glasses and proper shop
clothing when performing the procedures in this
manual. Failing to do so may lead to possible
injury or death.
Pressure Cap
CAUTION
Use caution when performing these procedures.
Coolant may be hot and may cause
severe injury or burns.
NOTE: If the coolant level is LOW in the radiator, or
if there are leaks in the system, the coolant system
will not draw coolant from the reservoir tank.
NOTE: Use this procedure when a unit overheats
and no apparent leaks in the cooling system are
found.
1.
2.
Drive the vehicle onto a slight incline and use properly
weight rated ramps. If an incline is not available, slightly
elevate the front of the vehicle.
5.
Leave the cap off of the radiator to allow any possible air
to escape.
6.
Start the engine and let it idle for 5-10 minutes or until the
thermostat opens and allows coolant to flow through the
system.
7.
Slightly loosen the bleed screw (C) on the thermostat cover
to let air escape. If no air is present, a steady stream of
coolant will stream out. If air is present, the screw will
bubble and sputter as the air escapes.
Place the vehicle in Park and block the rear wheels.
Top LH Side
of Engine
Pressure Cap
C
CAUTION
Be sure the engine has cooled and no pressure
is built up in the cooling system before removing
the pressure cap. The coolant may be hot and
could cause severe injury or burns.
3.14
8.
Tighten the bleed screw to 70 ± 10 in.lbs. (8 ± 1.13 Nm) on
the thermostat housing and properly install the pressure
cap.
9.
Squeeze the coolant lines by hand to help purge the system
of air.
NOTE: If there is air in the system you will see air
bubbles forming through the radiator filler neck.
ENGINE
10. Add Polaris Premium Antifreeze to the radiator filler neck
if the level goes down. If no bubbles are seen at the filler
neck, the system should be purged of air
GENERAL ENGINE SERVICE
Engine Lubrication Specifications
WARNING
=
Be sure to install the pressure cap before
shutting off the engine.
Coolant may spit out of the radiator.
11. Stop the engine and let cool, top off the radiator filler neck
with coolant. If you hear or see a “glug” at the filler neck,
or there is a dropping of the coolant level, indicating that
coolant has been pulled into the system; Fill the recovery
bottle only after you have completely filled the cooling
system at the radiator filler neck.
12. Repeat this procedure, if overheating still occurs.
Capacity - Approximately 2 U.S. Quarts (1.9 L)
Oil Type - Polaris Premium 0W-40 Synthetic
Filter Wrench - PV-43527 or equivalent
- Oil Pressure Specification 27-35 psi @ 6000 RPM, Polaris 0W-40
Synthetic, Engine at operating temperature.
Accessible Engine Components
The following components can be serviced or removed with the
engine installed:
•
•
•
•
•
•
Starter Motor / Drive
Cylinder Head
Cylinder
Piston / Rings
Rocker Arms
Water Pump
The following components require engine removal for service:
• Flywheel
• Alternator (Stator)
• Counterbalance Shaft or Bearings
• Gear Train Components
• Camshaft
• Oil Pump / Oil Pump Drive Gear
• Connecting Rod
• Crankshaft
• Crankshaft Main Bearings
• Crankcase
Oil Pressure Test
1.
Remove blind plug/sender from left side of crankcase.
2.
Insert a 1/8 NPT oil pressure gauge adaptor into the
crankcase and attach the gauge.
3.
Start engine and allow it to reach operating temperature,
monitoring gauge indicator.
Oil Pressure at Idle: 6 psi
Oil Pressure at 6000 RPM (Engine Hot):
Minimum: 27 psi
Standard: 31 psi
Maximum: 35 psi
3.15
3
ENGINE
Oil Flow Chart
This chart describes the flow of oil through the 800 EFI engine. Beginning in the crankcase sump, the oil is drawn through an oil
galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve
contained in the filter allows oil to bypass the filter element. At this point, the oil is supplied to the main oil galley through a crankcase
passage. Oil is then diverted three ways from the main oil galley, with the first path entering the camshaft bores, onto the rear balance
shaft journal and then draining back into the crankcase sump. The second oil path from the main oil galley feeds the lifter bores and
then drains back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side crankshaft journal and
also to the front balance shaft journal and onto the crankcase sump. The oil pressure switch is fed off the main oil galley.
3.16
ENGINE
Engine Removal
8.
Remove the (2) push rivets from the rear of the center
console.
Because of its design configuration, Polaris recommends
removing the engine, transmission, and rear gearcase as one
assembly. Use the following procedure when engine removal is
required.
IMPORTANT: Some engine repair procedures can be
performed without removing the RZR engine
assembly from the vehicle. Refer to “Accessible
Engine Components” on Page 3.15 for further
information.
3
NOTE: The use of an overhead or portable engine
hoist is the only recommended method for removing
and installing the engine / transmission / rear
gearcase assembly.
NOTE: Have an assistant help guide the engine in
and out of the vehicle while using an engine hoist to
prevent personal injury or damage to vehicle
components.
9.
Remove the (2) fasteners from the rear seat base and
remove the assembly from the vehicle.
WARNING
Always wear safety glasses and proper shop
clothing when performing the procedures in this
manual. Failing to do so may lead to possible
injury or death.
1.
If vehicle was recently operated, allow it to cool down
before attempting to perform any work.
2.
Clean work area.
3.
Thoroughly clean the engine and chassis.
4.
Drain appropriate lubricant(s):
• If servicing the engine, drain engine oil.
10. Remove the rear plastic bumper, rear cargo box and box
supports from the vehicle (see Chapter 5).
11. Remove the (2) push rivets and remove the intake box from
the vehicle.
• If servicing the transmission, drain the lubricant from
the main gearcase and transfer case.
• If servicing the rear gearcase, drain the gearcase
lubricant.
5.
Remove the driver and passenger seats (see Chapter 5).
6.
Disconnect (-) negative battery cable.
7.
Remove the rear service panel (see Chapter 5).
Remove
Push Rivets
3.17
ENGINE
12. Elevate the rear of the vehicle off the ground using a
suitable ATV lift and remove both rear wheels.
13. Remove all exhaust components from vehicle and engine.
14. Loosen the hose clamp attaching the outlet duct to the PVT
cover. Leave the duct attached to the upper frame support.
18. Remove the (6) fasteners retaining the upper bolt-in frame
brace and remove it from the vehicle with the ignition coil
and PVT duct attached.
Frame Brace
Ignition
Coil
PVT Duct
Outlet Duct
PVT Cover
19. Remove the upper nut and grommet from the stabilizer bar
linkage on both sides of the vehicle.
15. Remove the (8) screws that retain the PVT cover and
remove cover.
16. Remove the high tension leads from the spark plugs and
disconnect the ignition coil harness.
Harness
Connection
20. Remove the (4) fasteners retaining the stabilizer bar and
bracket and remove the assembly from the vehicle.
17. Remove the vent lines from the upper bolt-in frame brace
and plug vent lines to prevent fluid leakage during removal.
21. Remove the engine breather hose from the valve cover.
3.18
ENGINE
22. Loosen the hose clamp between the throttle body and intake
adaptor.
Loosen
Clamp
25. Remove the airbox and throttle body from the vehicle as an
assembly. Take care in not allowing the throttle cable to
bend excessively or kink. Carefully place the assembly on
the floor next to the vehicle. Insert a shop towel into the
engine intake adaptor to prevent dirt from entering the
engine.
NOTE: Ensure throttle cable is not being
excessively bent or kinked while removed from the
vehicle.
26. Mark the fuel injector harnesses to identify MAG and PTO
harness connections to aid during reassembly. Disconnect
the fuel injector harnesses.
23. Disconnect the T-MAP and TPS harnesses (see photo).
NOTE: The Bosch harness connector and locking
spring is bonded to the fuel injectors with an epoxy
mix. DO NOT attempt to disconnect the Bosch
connector from the fuel injectors. Damage will occur
to the injector and/or harness if attempting to
separate at that location. Separate the fuel injector
from the vehicle by disconnecting at the end of the
harness as shown.
Fuel
Injector
Disconnect Here
Harness
24. Remove the remaining bolt attaching the airbox to the
frame (see photo).
DO NOT
Disconnect Here
27. Disconnect the fuel line from the fuel injector rail.
28. Disconnect the shift cable from the transmission bell crank.
Remove
Clip
3.19
3
ENGINE
29. Mark the upper jam nut and loosen the lower jam nut. Pull
the shift cable out of the mount.
32. Disconnect the stator / alternator harness.
Stator
Connector
Mark Upper
Jam Nut
Lower
Jam Nut
33. Disconnect the transmission speed sensor harness.
NOTE: If the upper jam nut is moved, shift cable
adjustment will be required during engine
installation (see Chapter 2 “Shift Cable Inspection /
Adjustment”).
Speed Sensor
Connector
30. Disconnect the transmission gear indicator switch harness.
Gear Switch
Connector
34. Remove the castle nuts from both rear wheel hubs.
31. Disconnect the CPS harness.
CPS
Connector
Castle Nut
3.20
ENGINE
35. Remove the through-bolt that attaches the upper A-arm to
the rear hub on both sides of the vehicle.
38. Disconnect the engine coolant temperature (ECT) sensor
harness.
ECT
Connector
3
36. Pivot the A-arms upward and rear hub carriers downward
and remove the drive shafts from the hub carriers.
39. Loosen the hose clamp and remove the lower coolant hose
from the water pump cover inlet and drain coolant into a
suitable container.
Hub Carrier
37. Grasp the rear drive shafts and pull sharply outward on the
shafts to disengage them from the rear gearcase.
40. Remove the filler neck pressure cap to relieve the cooling
system vacuum.
NOTE: Use a portable wet-vac or syphon to prevent
any coolant from spilling.
41. Remove the upper coolant hose from the thermostat
housing outlet to relieve any coolant vacuum created in the
engine. Allow engine coolant to completely drain.
Properly dispose of the engine coolant / antifreeze.
42. Remove the (+) positive battery cable from the starter
motor terminal and (-) negative battery cable from the
starter motor engine mount.
43. Remove the outer PVT cover.
NOTE: Clean area around drive shaft orifices on
both sides of rear gearcase and cover orifices using
duct tape. This will prevent the lubricant from
leaking out during removal.
3.21
ENGINE
44. Remove RH engine mount fastener.
47. Using an engine hoist, hook a chain between the engine /
transmission mounting plate and the transmission / rear
gearcase mounting plate.
45. Remove the (2) lower bolts that retain the LH transmission
mount to the frame.
Engine/Transmission
Mount Plate
Transmission/Gearcase
Mount Plate
Remove
(2) Lower Bolts
46. Remove the (2) rear gearcase mount bracket fasteners and
mount bolt and remove bracket from vehicle.
NOTE: Have an assistant help guide the engine in
and out of the vehicle while using an engine hoist to
prevent personal injury or damage to vehicle
components.
48. Lift the front portion of the assembly out first to allow the
engine valve cover to clear the vehicle frame.
Allow valve cover
to clear frame
NOTE: The use of an overhead or portable engine
hoist is the only recommended method for removing
and installing the engine / transmission / rear
gearcase assembly.
3.22
ENGINE
49. Remove propshaft from the transmission output shaft.
3.
Remove only the (4) outer fasteners retaining the engine to
the transmission bracket.
50. Then move assembly towards the front of the vehicle while
lifting it out to allow the rear gearcase to clear the rear
portion of the frame.
51. Then lift assembly high enough to clear vehicle frame and
completely remove it from the vehicle to a work bench.
3
NOTE: Vehicles manufactured on or after 5/21/07,
will be assembled with an added support bracket
mounted between the engine and transmission.
Support Bracket
Engine / Transmission Separation
Once the engine / transmission / rear gearcase assembly has
been removed from the vehicle, the engine and transmission will
need to be separated to allow engine servicing. Use the
following procedure to separate the engine from the assembly.
1.
Remove the drive belt, drive clutch and driven clutch (see
Chapter 6).
2.
Remove the (6) fasteners retaining the inner clutch cover
to the engine and transmission.
4.
Tilt the assembly up and remove the remaining (2) nuts that
retain the transmission to the engine.
5.
Carefully separate the engine and perform the required
service (see “Engine Disassembly and Inspection”).
3.23
ENGINE
ENGINE DISASSEMBLY AND INSPECTION
Cylinder Head Assembly Exploded View
Rocker Arms
Retainer Locks (keepers)
Push Rods
Spring Retainers
Springs
Valve Seals
Valve Spring Seats
Cylinder Head
Hydraulic Lifters
Valves
3.24
ENGINE
Rocker Arms
5.
1.
Remove the valve cover.
2.
Mark or tag rocker arms in order of disassembly to keep
them in order for reassembly.
If the push rod (A) is visibly bent, it should be replaced.
A
3
Cylinder Head Removal
3.
Inspect the wear pad at the valve end of the rocker arm for
indications of scuffing or abnormal wear. If the pad is
grooved, replace the rocker arm.
NOTE: Do not attempt to true this surface by
grinding.
4.
NOTE: The cargo box assembly and the upper frame
bolt-in brace must be removed to allow enough
clearance to remove all the cylinder head bolts.
Refer to Chapter 5 for removal procedures.
1.
Loosen the six cylinder head bolts evenly 1/8 turn each in
a criss-cross pattern until loose.
2.
Remove bolts (A) and tap cylinder head (B) lightly with a
soft face hammer until loose. CAUTION: Tap only in
reinforced areas or on thick parts of cylinder head casting
to avoid damaging the head or cylinder.
3.
Remove cylinder head (B) and head gasket (C) from the
cylinder (D).
Check the rocker arm pad and fulcrum seat for excessive
wear, cracks, nicks or burrs.
Push Rods
1.
Clean push rods (A) in a suitable solvent. Blow dry push
rods with compressed air.
2.
Use compressed air to confirm the oil passage is clear in the
center of the push rod.
WARNING
Always wear safety glasses when working with
compressed air to prevent personal injury.
3.
Check the ends of the push rods (A) for nicks, grooves,
roughness or excessive wear.
4.
The push rods (A) can be visually checked for straightness
while they are installed in the engine by rotating them with
the valve closed. Push rods can also be checked with a dial
indicator or rolled across a flat surface to check for
straightness.
A
B
C
D
3.25
ENGINE
Cylinder Head Inspection
Valve Seal / Spring Service (On Engine)
Thoroughly clean cylinder head surface to remove all traces of
gasket material and carbon.
NOTE: The following procedure is only for servicing
the top end of the valve train when replacing valve
springs or replacing valve seals.
CAUTION
Use care not to damage sealing surface.
In some cases the valve train can be serviced while the cylinder
head is still on the engine. Keep all parts in order with respect
to their location in the cylinder head.
WARNING
Cylinder Head Warp
1.
Lay a straight edge (A) across the surface of the cylinder
head (B) at several different points and measure warp by
inserting a feeler gauge between the straight edge and the
cylinder head surface. If warp exceeds the service limit,
replace the cylinder head.
Wear eye protection or a face shield during
cylinder head disassembly and reassembly.
1.
Having already removed the valve cover, rocker arms and
pushrods, align the cylinder to be worked on at top dead
center (TDC). Install the Valve Pressure Hose (PU45652) into the spark plug hole. Hook the hose to an air
compressor and supply 50 to 100 psi to the hose. This will
seat the valves during valve spring removal. Do not
remove air from the hose at anytime until reassembly is
completed.
2.
Using the Valve Spring Compressor (PU-45257),
compress the valve spring and remove the valve keepers.
A
B
NOTE: A small parts magnet (A) can aid in the
removal of the retainers (B).
Measure at different
points on the surface.
B
= In. / mm.
Cylinder Head Warp Limit:
.004" (.1016 mm) max
A
PU-45257
NOTE: To prevent damage to the valve seals, do not
compress the valve spring more than is needed to
remove the valve keepers.
3.26
3.
Remove spring retainer and spring.
4.
The valve seals are now serviceable.
ENGINE
Cylinder Head Disassembly
4.
1.
IMPORTANT: It is recommended to replace seals
whenever the cylinder head is disassembled.
Hardened, cracked or worn valve seals will cause
excessive oil consumption and carbon buildup.
Carefully remove the cylinder components.
5.
Remove valve guide seals.
Mark the valves with a white pen. Remove the valves from
the cylinder head. This will ensure that the valves are
properly placed during engine reassembly.
3
Mark the Valves
2.
Place the hydraulic lifters (C), pushrods (D), and rocker
arms (E) in a safe, clean area.
C
D
E
3.
Measure free length of spring with a Vernier caliper.
Compare to specifications. Replace spring if measurement
is out of specification.
Valve Spring
Free Length
= In. / mm.
Valve Spring Free Length:
Std: 1.735" (44.069 mm)
3.27
ENGINE
Valve Inspection
1.
2.
Remove all carbon from valves with a soft wire wheel or
brush.
Check valve face for runout, pitting, and burnt spots. To
check for bent valve stems, mount valve in a drill or use “V”
blocks and a dial indicator.
= In. / mm.
Valve Stem Diameter:
Intake: 0.2356" + 0.00039"
(5.985 + 0.01 mm)
Exhaust: 0.2351" + 0.00039"
(5.972 + 0.01 mm)
6.
Measure valve guide (C) inside diameter at the top middle
and end of the guide using a small hole gauge and a
micrometer. Measure in two directions.
C
3.
Check end of valve stem for flaring, pitting, wear or damage
(A).
A
B
Inspect split keeper groove for wear or flaring of the keeper
seat area (B).
NOTE: The valves can be re-faced or end ground, if
necessary. They must be replaced if extensively
worn, burnt, bent, or damaged.
= In. / mm.
4.
5.
Measure diameter of valve stem with a micrometer in three
places, then rotate 90 degrees and measure again (six
measurements total). Compare to specifications.
Measure valve stem in several places.
Rotate the valve 90 degrees and measure
for wear.
3.28
Valve Guide I.D.:
0.23672" + 0.000295"
(6.0617 + 0.0075 mm)
7.
Subtract valve stem measurement from the valve guide
measurement to obtain stem to guide clearance. NOTE:
The valve guides cannot be replaced. Be sure to measure
each guide and valve combination individually.
ENGINE
Combustion Chamber
1.
Clean all accumulated carbon deposits from combustion
chamber and valve seat area with carbon cleaner and a soft
plastic scraper.
IMPORTANT: Do not use a wire brush, metal scraper,
or abrasive cleaners to clean the bottom of the
cylinder head. Extensive damage to the cylinder head
may result. Wear safety glasses during cleaning.
Combustion Area
NOTE: Valve seat width and point of contact on the
valve face is very important for proper sealing. The
valve must contact the valve seat over the entire
circumference of the seat, and the seat must be the
proper width all the way around. If the seat is
uneven, compression leakage will result. If the seat
is too wide, seat pressure is reduced, causing
carbon accumulation and possible compression
loss. If the seat is too narrow, heat transfer from
valve to seat is reduced. The valve may overheat
and warp, resulting in burnt valves.
1.
Install pilot into valve guide.
2.
Apply cutting oil to valve seat and cutter.
3.
Place 46° cutter on the pilot and make a light cut.
Valve Seat Reconditioning
NOTE: Polaris recommends that the work be done
by a local machine shop that specializes in this area.
NOTE: The cylinder head valve guides cannot be
replaced.
WARNING
Wear eye protection or a face shield during
cylinder head disassembly and reassembly.
Valve Seat Inspection
Inspect valve seat in cylinder head for pitting, burnt spots,
roughness, and uneven surface. If any of the above conditions
exist, the valve seat must be reconditioned. If the valve seat is
cracked the cylinder head must be replaced.
Follow the manufacturers instructions provided with the valve
seat cutters in the Cylinder Head Reconditioning Kit (PN
2200634). Abrasive stone seat reconditioning equipment can
also be used. Keep all valves in order with their respective seat.
3.29
3
ENGINE
4.
Inspect the cut area of the seat:
* If the contact area is less than 75% of the circumference of the
seat, rotate the pilot 180° and make another light cut.
NOTE: When using an interference angle, the seat
contact point on the valve will be very narrow, and is
a normal condition.
Look for an even and
continuous contact point all the way around the
valve face (A).
* If the cutter now contacts the uncut portion of the seat, check
the pilot. Look for burrs, nicks, or runout. If the pilot is bent it
must be replaced.
B
* If the contact area of the cutter is in the same place, the valve
guide is distorted from improper installation
* If the contact area of the initial cut is greater than 75%,
continue to cut the seat until all pits are removed and a new seat
surface is evident. NOTE: Remove only the amount of material
necessary to repair the seat surface.
5.
To check the contact area of the seat on the valve face, apply
a thin coating of Prussian Blue™ paste to the valve seat. If
using an interference angle (46° ) apply black permanent
marker to the entire valve face (A).
A
Proper Seat Contact
on Valve Face
Bottom 60° Seat 45°
Top 30°
A
6.
7.
Insert valve into guide and tap valve lightly into place a few
times.
Remove valve and check where the Prussian Blue™
indicates seat contact on the valve face. The valve seat
should contact the middle of the valve face or slightly
above, and must be the proper width.
Seat
Width
* If the indicated seat contact is at the top edge of the valve face
and contacts the margin area (B) it is too high on the valve face.
Use the 30° cutter to lower the valve seat.
* If too low, use the 60° cutter to raise the seat. When contact
area is centered on the valve face, measure seat width.
* If the seat is too wide or uneven, use both top and bottom
cutters to narrow the seat.
= In. / mm.
* If the seat is too narrow, widen using the 45° cutter and recheck contact point on the valve face and seat width after each
cut.
Valve Seat Width:
Intake Std: .028" (.7 mm)
Limit: .055" (1.4 mm)
Exhaust Std: .039I (1.0 mm)
Limit: .071" (1.8 mm)
3.30
ENGINE
8.
Clean all filings from the area with hot soapy water. Rinse
and dry with compressed air.
9.
Lubricate the valve guides with clean engine oil, and apply
oil or water based lapping compound to the face of the
valve.
Cylinder Head Reassembly
NOTE: Assemble the valves one at a time to
maintain proper order.
1.
Apply engine oil to valve guides and seats.
NOTE: Lapping is not required with an interference
angle valve job.
2.
Coat valve stem with molybdenum disulfide grease or
0W-40 Synthetic oil.
10. Insert the valve into its respective guide and lap using a
lapping tool or a section of fuel line connected to the valve
stem.
3.
Install valve carefully with a rotating motion to avoid
damaging valve seal.
4.
Valve seals should be installed after the valves are in the
head to avoid valve seal damage. Install new valve seals
on valve guides.
5.
Dip valve spring and retainer in clean engine oil and install.
6.
Place retainer on spring and install Valve Spring
Compressor (PU-45257). Install split keepers with the gap
even on both sides.
NOTE: A small magnet can be used to aid in the
installation of the keepers.
PU-45257
11. Rotate the valve rapidly back and forth until the cut sounds
smooth. Lift the valve slightly off of the seat, rotate 1/4
turn, and repeat the lapping process. Do this four to five
times until the valve is fully seated, and repeat process for
the other valve(s).
12. Thoroughly clean cylinder head and valves.
7.
Repeat procedure for remaining valves. When all valves
are installed, tap lightly with soft faced hammer on the end
of the valves to seat the split keepers.
NOTE: To prevent damage to the valve seals, do not
compress the valve spring more than necessary to
install the keepers.
3.31
3
ENGINE
Valve Sealing Test
Valve Lifter Removal / Inspection
1.
1.
Remove the valve lifters by reaching into the crankcase
and pushing the lifter up through the lifter bore by hand.
2.
Thoroughly clean the lifters in cleaning solvent and wipe
them with a clean, lint-free cloth.
3.
Mark the lifters with a white pen if using the lifters for
reassembly. This will ensure that the lifters are properly
placed during engine reassembly.
Clean and dry the combustion chamber area (A).
A
Mark Hydraulic Lifter
2.
Pour a small amount of clean solvent onto the intake port
and check for leakage around each intake valve. The valve
seats should hold fluid with no seepage.
3.
Repeat for exhaust valves by pouring fluid into exhaust
port.
Cylinder Removal
1.
2.
3.
4.
Check the lifters for wear or scores.
Follow engine disassembly procedures to remove rocker
cover and cylinder head.
5.
Check the bottom end of lifter to make sure that it has a
slight convex.
Tap cylinder (A) lightly with a rubber mallet in the
reinforced areas only until loose.
6.
If the bottom surface has worn flat, it may be used with the
original camshaft only.
Rock cylinder forward and backward while lifting it from
the crankcase, supporting pistons and connecting rods.
Support pistons with Piston Support Block (PN 2870390).
A
Inspect Hydraulic Lifter
NOTE: Lifters that are scored, worn, or if the bottom
is not smooth should be replaced with new lifters
and cam as an assembly. If replacing the lifters, the
camshaft should also be replaced.
3.32
ENGINE
Piston Removal
1.
Remove circlip (A). Mark the piston with a white pen to
ensure proper orientation (if reused) during assembly.
The oil control ring is a three piece design consisting of a top and
bottom steel rail and a center expander section. The top rail has
a locating tab on the end which fits into a notch (B) in the upper
oil ring land of the piston.
To Remove:
A) Remove the top rail first followed by the bottom rail.
B) Remove the expander.
Compression
Rings
B
3
Oil Ring
NOTE: If the pistons are to be reused, reassemble
the pistons in the same cylinder and direction from
which they were removed.
NOTE: New pistons are non-directional and can be
placed in either cylinder.
2.
3.
Remove piston circlip and push piston pin out of piston. If
necessary, heat the crown of the piston slightly with a
propane torch. CAUTION: Do not apply heat to the piston
rings. The ring may lose radial tension.
Remove top compression ring:
*Using a piston ring pliers: Carefully expand ring and lift it off
the piston. CAUTION: Do not expand the ring more than the
amount necessary to remove it from the piston, or the ring may
break.
*By hand: Placing both thumbs as shown, spread the ring open
and push up on the opposite side. Do not scratch the ring lands.
4.
Repeat procedure for second ring.
5.
Remove the oil control ring.
3.33
ENGINE
Cylinder Inspection
1.
Remove all gasket material from the cylinder sealing
surfaces.
2.
Inspect the top of the cylinder (B) for warp using a straight
edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2.
3.
Inspect cylinder for wear, scratches, or damage.
4.
Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in two
different directions, front to back and side to side, on three
different levels (1/2, down from top, in the middle, and 1/
2, up from bottom). Record measurements. If cylinder is
tapered or out of round beyond .002", the cylinder must be
replaced.
A
B
Measure at different
points on surface.
B
1/2” Down From Top of Cylinder
A
C
= In. / mm.
Cylinder Warp: .004" (0.1 mm) Max.
1/2” Up From Bottom
= In. / mm.
Cylinder Taper Limit:
.002" (9.05mm) Max.
Cylinder Out of Round:
Limit: .002" (.0 mm) Max.
3.34
ENGINE
Standard Bore Size
(Both Cylinders): 3.1496" (80 mm)
If cylinder wear or damage is excessive, it will be necessary to
replace the cylinder. The cylinders are lined with a nicasil
coating and are not repairable. Hone only enough to de-glaze
the outer layer of the cylinder bore.
Cylinder Hone Selection and Honing
Procedure
Cylinders may be wet or dry honed depending upon the hone
manufacturer’s recommendations. Wet honing removes more
material faster and leaves a more distinct pattern in the bore.
3
CAUTION
A hone which will straighten as well as remove
material from the cylinder is very important.
Using a common spring loaded glaze breaker
for honing is not advised for nicasil cylinders.
Polaris recommends using a rigid hone or arbor
honing machine. Cylinders may be wet or dry
honed depending upon the hone manufacturer's
recommendations.
Wet honing removes more material faster and
leaves a more distinct pattern in the bore.
Example of Cross Hatch Pattern
IMPORTANT: Clean the cylinder after honing
If cylinder wear or damage is excessive, it will be necessary to
replace the cylinder. The cylinders are lined with a nicasil
coating and are not repairable. Hone only enough to de-glaze
the outer layer of the cylinder bore.
Cleaning the Cylinder After Honing
Honing To Deglaze
A finished cylinder should have a cross-hatch pattern to ensure
piston ring seating and to aid in the retention of the fuel/oil
mixture during initial break in. Hone cylinder according to hone
manufacturer's instructions, or these guidelines:
It is very important that the cylinder be thoroughly cleaned after
honing to remove all grit material. Wash the cylinder in a
solvent, then in hot, soapy water. Pay close attention to areas
where the cylinder sleeve meets the aluminum casting (transfer
port area). Use electrical contact cleaner if necessary to clean
these areas. Rinse thoroughly, dry with compressed air, and oil
the bore immediately with Polaris Lubricant.
• Honing should be done with a diamond hone. Cylinder
could be damaged if the hone is not hard enough to
scratch the nicasil lining.
• Use a motor speed of approximately 300-500 RPM, run
the hone in and out of the cylinder rapidly until cutting
tension decreases. Remember to keep the hone drive
shaft centered (or cylinder centered on arbor) and to
bring the stones approximately 1/2” (1.3 cm) above and
below the bore at the end of each stroke.
• Release the hone at regular intervals and inspect the
bore to determine if it has been sufficiently de-glazed,
and to check for correct cross-hatch.
NOTE: Do not allow cylinder to heat up during honing.
• After honing has been completed, inspect cylinder for
thinning or peeling.
3.35
ENGINE
Piston-to-Cylinder Clearance
2.
Measure piston pin O.D. Replace piston and/or piston pin
if out of tolerance.
Measure piston outside diameter at a point 5 mm up from the
bottom of the piston at a right angle to the direction of the piston
pin.
Subtract this measurement from the maximum cylinder
measurement obtained in Step 5.
5 mm
Piston Pin Measurement Locations
Piston
Piston Pin
Piston to Cylinder Clearance:
See “800 EFI Engine Service
Specifications” on page 3.9
Piston Pin O.D.:
See “800 EFI Engine Service
Specifications” on page 3.9
3.
Measure connecting rod small end ID.
Piston O.D.:
See “800 EFI Engine Service
Specifications” on page 3.9
Piston / Rod Inspection
1.
Measure piston pin bore.
Connecting Rod Small End I.D.:
See “800 EFI Engine Service
Specifications” on page 3.9
Piston Pin Bore:
See “800 EFI Engine Service
Specifications” on page 3.9
3.36
ENGINE
4.
Measure piston ring to groove clearance by placing the ring
in the ring land and measuring with a thickness gauge.
Replace piston and rings if ring-to-groove clearance
exceeds service limits.
3.
If the bottom installed gap measurement exceeds the
service limit, replace the rings. If ring gap is smaller than
the specified limit, file ring ends until gap is within
specified range.
NOTE: Always check piston ring installed gap after
re-boring a cylinder or when installing new rings. A
re-bored cylinder should always be scrubbed
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with oil immediately
to remove residue and prevent rust.
Piston
Ring
Starter Drive Bendix Removal / Inspection
Feeler Gauge
See “800 EFI Engine Service
Specifications” on page 3.9
Remove stator housing bolts and remove housing.
2.
Remove the flywheel nut and washer. Install Flywheel
Puller (PN 2871043) and remove flywheel.
NOTE: Do not thread the puller bolts into the
flywheel more than 1/4, or stator coils may be
damaged.
3.
Piston Ring Installed Gap
1.
1.
Remove starter bendix assembly (A). Note the thrust
washers located on both sides of the bendix.
Place each piston ring (A) inside cylinder (B) using piston
to push ring squarely into place as shown.
A
C
B
25-50 mm
A
Piston Ring Installed Gap
See “800 EFI Engine Service
Specifications” on page 3.9
NOTE: Ring should be installed with the mark facing
upward.
2.
4.
Inspect the thrust washer for wear or damage and replace
if necessary.
5.
After the bendix is removed, remove the two bolts retaining
the starter. Tap on the starter assembly (B) with a soft faced
mallet to loosen the starter from the crankcase.
B
Measure installed gap with a feeler gauge (C) at both the
top and bottom of the cylinder.
IMPORTANT: A difference in end gap indicates
cylinder taper. The cylinder should be measured for
excessive taper and out of round.
3.37
3
ENGINE
6.
Inspect gear teeth on starter drive (A). Replace starter drive
if gear teeth are cracked, worn, or broken.
7.
Inspect the bendix bushing (C) in the mag cover for wear.
Replace as needed.
C
2871043
4.
A
Use caution when removing the wire holddown (B) and the
stator assembly (D). Do not tap or bump the gear /stator
housing cover or the stator. This could cause the seal
around the gear/stator housing cover and the crankcase to
break, causing a leak.
Flywheel / Stator Removal / Inspection
1.
Remove stator housing bolts and remove housing.
D
E
B
Remove Stator
Cover
5.
Remove the bendix (E) if necessary.
Engine Crankcase Disassembly / Inspection
2.
Remove flywheel nut and washer.
3.
Install Flywheel Puller (PN 2871043) and remove flywheel
(A).
1.
Remove the stator cover (A) and water pump cover (B).
CAUTION
B
Do not thread the puller bolts into the flywheel
more than 1/4, or stator coils may be damaged.
A
3.38
ENGINE
2.
Remove the nylok nut (C), washer (D), and water pump
impeller (E). Remove part of the water pump seal behind
the impeller.
5.
Remove the starter bendix (G), wire holddown plate (H),
and the woodruff key (I) from the crankshaft. The stator
does not have to be removed at this point.
I
E
3
G
D
C
H
6.
3.
Remove flywheel nut and washer.
4.
Install Flywheel Puller (PN 2871043) and remove flywheel
(F).
Remove the gear/stator housing bolts and remove the gear/
stator housing cover (J) and gasket from the crankcase. Be
sure to catch the excess oil from the crankcase.
CAUTION
Do not thread the puller bolts into the flywheel
more than 1/4, or stator coils may be damaged.
J
7.
2871043
Note the positions of the gears in the photo.
Camshaft Gear
F
Crank Gear
Counterbalance Gear
3.39
ENGINE
8.
Use a white pen to accent the timing marks on the following
gears: camshaft gear (K), crankshaft gear (M), or
counterbalance gear (N) This will ensure proper gear
alignment and timing during reassembly of the gears.
K
Water Pump Gear
Timing Marks
CAUTION
Wear safety glasses at all times. Use caution
when working with the top gear.
The springs could cause injury or become lost
should they pop out.
12. Remove all three springs using one of the tapered pins from
the Tapered Pins (PU-45497-1).
M
N
NOTE: If replacing one of the gears, it is
recommended that all of the gears be replaced. A
gear kit is available.
9.
Use the Cam Gear Tooth Alignment Tool (PU-45497-2)
(O) to align the cam split gear assembly. With the split gear
aligned, remove the bolt and cam gear assembly.
NOTE: Install the Cam Gear Tooth Alignment Tool
(PU-45497-2) into the assembly hole counter
clockwise from the timing mark as shown.
10. Inspect the cam gear teeth and check to make sure there is
spring tension offsetting the teeth between the two gears.
If there is no tension, check the springs inside of the cam
gear assembly.
PU-45497-1
13. With a white marking pen, accent the timing mark on the
gear that contains the springs.
3 Loaded Springs
Accent Timing Marks
11. The cam gear assembly contains three loaded springs. To
open the cam gear assembly:
• Place the cam gear on a flat surface with the timing
mark side facing up.
• While holding both gears together, lightly work a small
flathead screwdriver between the two gears.
• Remove the top gear. The springs should stay in place.
3.40
ENGINE
14. Inspect the gear teeth and the three tabs on the gears for
wear.
Inspect Teeth & Tabs
To Assemble:
• Hold the spring with one finger.
• Start the pointed end of the tapered pin into the cam
gear hole. Slowly push the dowel through the hole until
the end of the dowel is almost flush with the spring.
• Perform this procedure with all three tapered pins.
• Do not push the pins too far through or the springs will
pop out.
NOTE: Do not remove the tapered pins at this time.
17. Note in photograph that the Tapered Pins (PU-45497-1)
are below flush with end of the springs. This helps to align
the three gear tabs during the next step.
Replace 3 Springs
15. Install the new springs into the grooves of the cam gear.
Install Springs
PU-45497-1
16. Insert the pointed dowels from the Tapered Pins (PU45497-1) into the cam gear.
Cam Gear Spring Installation Tool Kit:
(PU-45497)
Tapered Pins:
(PU-45497-1)
Cam Gear Tooth Align Tool:
(PU-45497-2)
18. Line up the two gears using the timing marks and the three
gear tabs that were referenced earlier. Push the gears back
together, using both hands and hold securely.
Align Timing Marks
PU-45497-1
3.41
3
ENGINE
19. Once the gears are pressed together, firmly hold the gears
together with one hand. Carefully remove the Tapered Pins
(PU-45497-1) by pulling them out one at a time with the
other hand.
21. To remove the balance shaft gear, the flat side of the
camshaft (P) must face the balance shaft gear. To rotate the
camshaft, use the Cam Spanner Wrench (PU-45498) to
rotate the camshaft so the flat side of the camshaft faces the
balance shaft gear.
PU-45498
P
20. After the tapered pins are removed, be sure the cam gear
assembly is held together tightly. Place the cam gear
assembly on a flat surface. Use the Cam Gear Tooth
Alignment Tool (PU-45497-2) to align the teeth of the cam
gears, as shown in the picture.
NOTE: Install the Cam Gear Alignment Tool (PU45497-2) into one assembly hole counter clockwise
from the timing mark.
NOTE: This Cam Spanner Wrench (PU-45498) is
only needed to rotate the camshaft when the entire
valve train is assembled. If the rocker arms are
removed, the cam-shaft can be turned by hand.
22. Remove the bolt and nut from the balance shaft gear. Try
to remove the balance shaft gear. If the gear does not come
off manually, use the Flywheel Puller (PN 2871043) to
remove the balance shaft gear.
2871043
PU-45497-2
NOTE: For ease of installing the Cam Gear
Alignment Tool (PU-45497-2), use a twisting motion
when pushing down on the tool.
3.42
ENGINE
23. Inspect the crankshaft gear (Q) for broken or worn teeth. If
the crankshaft gear does not need to be replaced, it does not
need to be removed. If the crankshaft gear is damaged,
remove the crankshaft gear with the Flywheel Puller
(PN 2871043).
26. Rotate the water/oil pump gear (S), so that all four bolts are
visible though the gear. Remove the four bolts with a hex
wrench. Pull out the pump.
S
Q
24. Install the two puller bolts (R). Tighten the puller bolts up
so that the bolts are at equal length.
3
27. Inspect the oil pump rotors for wear. Mark the rotors with
a white pen to ensure upon reassembly that the correct sides
of the rotors are installed and mesh with the same edges as
previously installed.
Mark Rotors
R
25. Install the Flywheel Puller (PN 2871043) and remove the
crankshaft gear, if needed.
2871043
NOTE: If replacing the old rotors, new replacement
rotors will fit into the original oil/water pump
housing.
28. Use a feeler gauge to measure the clearance between the
two rotors. Measure the gap between the two rotor tips as
shown below. The clearance should not exceed 0.006"
(0.15 mm).
Max Tip Clearance
0.006” (0.15 mm)
3.43
ENGINE
29. Remove the oil pressure relief. The oil pressure relief
consists of a bolt, washer, spring, and valve (dowel).
Inspect the valve (dowel) for signs of possible obstructions.
Use compressed air to blow out any debris.
31. Carefully press the gear off the assembly while supporting
the housing assembly.
Press Off Gear
CAUTION
30. Reinstall the valve (dowel chamfered end first). Install the
spring, washer, and bolt. Torque to specification .
22 ± 2 ft. lbs.
(30 ± 3 Nm).
Wear appropriate safety gear during this
procedure. Protective gloves, clothing and eye
wear are required.
32. Remove the snap ring from the assembly. Place the housing
in a support and press out the bearing/shaft assembly.
Press out shaft
and bearing
assembly.
Chamfer
End First
Bearing
=T
22 ± 2 ft. lbs. (30 ± 3 Nm)
NOTE: Be sure to place the tapered end of the valve
(dowel) in first. If the valve is installed incorrectly,
oil pressure and oil priming problems will occur.
Retaining Ring
33. Place the shaft in a press to remove the bearing.
Press Off Bearing
3.44
ENGINE
34. Press shaft into the new bearing..
37. Remove thrust plate (U).
U
Press On Bearing
3
35. Press the bearing/shaft assembly using the bearing's outer
race. Do not use the shaft to press the assembly into the
housing, as bearing damage may result. Install retaining
ring.
Press Bearing / Shaft
Assembly using
outer race only
36. Press gear onto shaft while supporting the housing.
38. Remove PTO end engine mount. Remove crankcase bolts.
Tap on the reinforced areas on the cases using soft hammer.
Carefully separate the two crankcase halves.
Separate
Crankcase Halves
NOTE: Only remove the oil baffle if the baffle is
damaged. When removing the oil baffle bolts, use a
heat gun to heat the bolts and loosen the Loctite™.
This will prevent any possible damage to the bolts or
to the crankcase casting.
3.45
ENGINE
39. Remove and clean oil pick up (V) and oil baffle weldment
(W).
Camshaft Inspection
1.
2.
3.
W
Thoroughly clean the cam shaft.
Visually inspect each cam lobe for wear, chafing or
damage.
Measure height of each cam lobe using a micrometer.
Compare to specification.
V
40. Remove balance shaft and crankshaft.
Cam Lobe Height
= In. / mm.
Cam Lobe Height
(Intake & Exhaust):
Std: 1.3334" (33.8674 mm)
4.
Measure camshaft journal outside diameters (O.D.).
41. Remove and inspect crankshaft main journal bearings for
abnormal wear. It is recommended to replace the
bearings anytime the engine is disassembled.
C
B
A
= In. / mm.
Camshaft Journal O.D. :
A. (Mag): 1.654" ± .00039" (42 ± .010 mm)
B. (Ctr.): 1.634" ± .00039" (41.50 ± .010 mm)
C. (PTO): 1.614" ± .00039" (41 ± .010 mm)
3.46
ENGINE
5.
Measure ID of camshaft journal bores.
= In. / mm.
ENGINE REASSEMBLY
Crankcase Reassembly
CAUTION
Camshaft Journal Bore I.D.:
(Mag): 1.656" ± 0.00039" (42.07± 0.010 mm)
(Ctr.) 1.637" ± 0.00039" (41.58 ± 0.010 mm)
(PTO) 1.617" ± 0.00039" (41.07 ± 0.010 mm)
6.
Calculate oil clearance by subtracting journal O.D.s from
journal bore I.D.s. Compare to specification.
= In. / mm.
Calculated Camshaft Oil Clearance:
Std: 0.0027" (.070mm)
Limit: .0039" (.10 mm)
After any reassembly or rebuild, the engine
must be primed using the Oil Priming Adapter
(PU-45778) and a 3/4-full oil filter before initial
start-up (see “Oil Pump Priming”).
NOTE: Before assembly, clean the bolts and bolt
holes with Primer N (PN 2870585) to remove any
debris.
This will ensure proper sealing when
installing bolts.
1.
Install oil pick up (A), if removed. Torque to specification.
NOTE: Replace camshaft if damaged or if any part is
worn past the service limit.
B
NOTE: Replace engine block if camshaft journal
bores are damaged or worn excessively.
A
2.
Install oil baffle weldment (B).
specification.
Torque bolts to
=T
Oil Baffle Weldment & Oil Pick Up Bolt Torque:
60 ± 6 in. lbs. (6.8 ± 0.68 Nm)
3.
Install the balance shaft. Inspect balance shaft clearance
(C) in both gearcase halves. Rotate balance shaft to ensure
there is clearance between it and the oil baffle weldment.
C
3.47
3
ENGINE
NOTE: Always install new balance shaft bearings.
4.
7.
Apply assembly lube to cam journals and balance shaft
bearing surfaces of the MAG case halve. Install camshaft
and balance shaft.
Assemble the crankcase halves. Apply LocTite™ 242 (PN
2871949) to the threads and pipe sealant to the bolt flanges.
Torque bolts to specification following torque pattern at
beginning of this chapter.
=T
Crankcase Bolt Torque:
22 + 2 ft. lbs. (30 + 3 Nm)
Torque in sequence
8.
Lubricate cam lobes and valve lifters with Moly Lube
Grease.
Apply Moly Lube
5.
Cam Lobes
Install crankshaft assembly and apply engine oil to crank
pins and rods (D). Apply assembly lube to the main
journals and bearings.
Lifters
9.
Lubricate lifters with engine oil and install in the original
order as removed in disassembly. Apply Lubricant or Moly
Lube to the ends of the lifters.
NOTE: Always replace the camshaft and lifters as a
set.
D
6.
Apply Crankcase Sealant (PN 2871557) to the top gearcase
halve.
NOTE: Do not apply sealant to cam relief hole (E).
E
3.48
ENGINE
10. Lubricate connecting rods with 0W-40 engine oil.
13. Install piston assemblies into cylinder aligning the piston
pin holes, to ensure proper alignment of the pistons to the
connecting rods upon assembly. Partially install the piston
pins into the pistons.
3
11. Install new cylinder gasket on crankcase. Align gasket on
the dowel pins for proper gasket alignment.
NOTE: To help align the pistons, slide a rod that is
close to the same diameter as the wrist pin holes to
properly align them in the cylinder.
14. Position cylinder and piston assemblies onto the connecting
rods and push the piston pins through the piston and
connecting rods.
12. Orientate the piston rings on the piston before installation
into the cylinders. Set the gaps of the rings every 120°
(See Illustration Below).
1
Piston Ring
Orientation
2
3
1. Top Ring
2. Second Ring
Push in Piston Pins
15. Install the piston pin circlips. The circlip ends should be
installed at the 12 O'clock position.
3. Oil Ring
Piston Pin Cirlcip in
12 O’clock position
3.49
ENGINE
NOTE: While installing in piston circlips, cover all
engine passages. The clip could fall into the engine
during installation.
17. Assemble rotors as marked when disassembled. Use a
cleaner to remove the marks previously made on the rotors.
Line Up Marks
18. Apply assembly lube or oil to the rotors on the oil pump
shaft.
16. Install camshaft thrust plate (G) with new bolts. Torque
bolts to specification.
NOTE: New bolts have patch lock on the threads
and do not require Loctite™.
NOTE: The application of lubrication aids in priming
the oil pump during initial engine start up.
Lubricate Rotors
G
19. Align the bolt holes and install oil pump assembly into
crankcase. Rotate the rotors in the housing during
installation, as this checks for binding if new rotors are
used.
=T
NOTE: For assembly of the gears, the cam gear and
the crankshaft gear are stamped with “This Side
Out." This indicates the side of the gear that faces
outward or away from the case.
Thrust Plate Screw Torque:
115 ± 12 in.lbs. (13 ± 1.35 Nm)
NOTE: Before assembly, clean the bolts and bolt
holes with Primer N (PN 2870585) to remove any
debris.
This will ensure proper sealing when
installing bolts and new Loctite™.
3.50
ENGINE
20. Install oil pump housing bolts (H). The new bolts contain
patch lock, so Loctite™ is not needed on the new bolts.
Torque bolts to specification and follow the torque
sequence at beginning of the chapter.
22. Before installing the crankshaft gear (I), heat the crankshaft
gear to 250° F (121° C) on a hot plate (J).
J
I
H
3
NOTE: Occasionally spin the oil pump when
installing bolts to check for binding of the rotors.
=T
Oil Pump Bolt Torque:
84 ± 8 in.lbs. (9.50 ± 0.90 Nm)
* Torque in Sequence
21. Apply Loctite™ 242 (PN 2871949) to the crankshaft.
CAUTION
The crankshaft gear is extremely hot! Severe
burns or injury can occur if the gear is not
handled with extreme care and caution. Follow
the procedure below to help ensure safety.
23. Use extreme caution when removing the crankshaft gear
from the hot plate. Use a pair of pliers and leather gloves
when handling the crankshaft gear.
24. Install the crankshaft gear (I) onto the crankshaft.
NOTE: For assembly of the gears, the cam gear and
the crankshaft gear are stamped with This Side Out."
This indicates the side of the gear that faces outward
or away from the case.
I
3.51
ENGINE
25. Install counter balance shaft gear (J) with new key, aligning
timing marks with crankshaft gear (I). Install washer and
bolt. Use the Gear Holder (PU-45838). Torque to
specification.
NOTE: Cam Spanner Wrench (PU-45498) is only
needed to rotate the camshaft when the entire valve
train is assembled.
J
PU-45498
I
PU-45838
=T
Balance Shaft Gear Bolt Torque:
22 ± 2 ft. lbs. (30 ± 3 Nm)
27. Reinstall the camshaft gear; so the timing marks are
properly aligned. Install the washer and bolt. Torque to
specification.
NOTE: Be sure all of the timing marks are properly
aligned.
26. Use the Cam Gear Alignment Tool (PU-45497-2) to align
the teeth of the cam gear (M). Install the cam gear (M) (with
the Cam Gear Alignment Tool still in place) onto the
camshaft. The timing marks on the camshaft gear should
align with the keyway on the balance shaft gear.
K
Water Pump Gear
Timing Marks
PU-45497-2
M
N
M
Timing Marks
NOTE: If the timing mark on the camshaft gear does
not align properly, remove the camshaft gear and
tool. Use the Cam Spanner Wrench (PU-45498) to
rotate the cam to the proper position.
=T
Counterbalance Gear and Camshaft
Gear Bolt Torque:
22 ± 2 ft. lbs. (30 ± 3 Nm)
3.52
ENGINE
28. Before installing the gear / stator housing, replace the seals
in the cover. Install a new water pump seal (N) into the gear
/ stator housing. Use the Water Pump Mechanical Seal
Installer (PA-44995) to properly install the seal to the
correct depth in the cover.
NOTE: Install the crankshaft seal (P) with the seal lip
facing out (towards the crankcase).
P
PA-44995
O
PA
99
-4 4
3
5
N
Seal lip goes towards the crankcase.
30. Once the crankshaft seal is installed into the gear / stator
housing cover, set the direction of the paper lip by sliding
the Main Crankshaft Seal Saver (PA-45658) into the
crankshaft seal from the rubber lipped side to the paper lip
side (Back to Front). Remove the tool.
IMPORTANT: Due to seal design and construction,
seals MUST be installed DRY (no lubricant) during
assembly. Use of lubricants (oil, soapy water, etc.)
will not allow the seal to wear-in and seal properly. Do
not touch seal surface or allow seal surface to come
in contact with contaminates during installation.
Thoroughly clean parts, tools and hands before
installation.
Important: Set the direction
of the paper lip seal
PU-45658
NOTE: To remove the water pump seal, the gear/
stator housing must be removed. The water pump
seal cannot be removed or installed with the gear/
stator housing attached to the engine. Shaft damage
will occur.
NOTE: Install the water pump seal (N) with the seal
lip facing out (towards the crankcase). Use of a
hydraulic press is recommended for this procedure.
29. Install a new crankshaft seal (P) into the gear/stator housing
cover. Use the Universal Driver Handle (PU-45543) and
the Main Seal Installer (PA-45483) to seat the crankshaft
seal into place.
31. Carefully install the tapered end of the Crankshaft Seal
Protection Tool (PA-45658) through the paper side of the
crankshaft seal (Back to Front). Leave the seal protector
installed in the crankshaft seal. Check the crankshaft seal
lips to verify they have not been rolled or damaged.
PU-45543
PU-45658
P
PA-45483
3.53
ENGINE
32. Before installing the gear/stator housing cover, install the
Water Pump Seal Saver (PA-45401) onto the water pump
shaft.
PA-45401
35. Install the gear/stator housing gasket onto he crankcase.
Gear / Stator
Housing Gasket
33. Install a NEW gasket to the gear/stator housing cover and
crankcase. With the tools installed, carefully place the
gear/stator housing cover over the protection tools.
36. Secure the gear / stator housing cover to the crankcase with
the cover bolts. Torque bolts in proper sequence to
specification. Remove seal protectors from the shaft ends
once the cover is secure.
34. Apply Crankcase Sealant (PN 2871557) to the outside
edges of the crankcase halves (see arrows), where the
crankcases mate (see the following photos). This helps to
prevent coolant leakage.
PA-45401
PA-45658
=T
Gear/Stator Housing Bolt Torque:
96 ± 3 in. lbs. (10.85 ± 0.35 Nm)
*Torque in proper sequence
3.54
ENGINE
NOTE: Before assembly, clean the bolts and bolt
holes with Primer N (PN 2870585) to remove any
debris.
This will ensure proper sealing when
installing bolts.
39. Install water pump cover (R) with new O-ring seal. Torque
bolts to specification in proper sequence (see Page 3.4).
Install the O-ring dry, no lubricants
37. Install shaft seal with ceramic surface facing inward.
R
3
96 ± 3 in. lbs.
(10.85 ± 1.35 Nm)
=T
38. Install water pump impeller (P). Secure the impeller with
the washer and a new nylok nut (Q). Torque the nut to
specification.
P
Water Pump Housing Bolt Torque:
96 ± 3 in. lbs. (10.85 ± 0.35 Nm)
*Torque in proper sequence
40. Sparingly apply Starter Drive Grease (PN 2871423) to the
starter drive. Install the starter bendix.
NOTE: There are thrust washers on both sides of
starter drive.
Q
=T
Water Pump Impeller Nut Torque:
108 ± 6 in. lbs. (6.8 ± 0.68 Nm)
3.55
ENGINE
Flywheel / Stator Installation
=T
NOTE: Before assembly, clean the bolts and bolt
holes with Primer N (PN 2870585) to remove any
debris.
This will ensure proper sealing when
installing bolts.
1.
Install stator assembly (S) and bolts. Torque bolts to
specification.
2.
Install the wire hold down bracket (T). Install two new wire
hold down bolts. New bolts contain patch-lock. Torque
bolts to specification, following the proper bolt torque
sequence. Coat the stator wire grommet (U) with Nyogel™
Grease (PN 2871329).
Flywheel Nut Torque
65 ± 7 ft.lbs. (88 ± 9.50 Nm)
4.
Install stator housing with new o-rings. Torque the bolts to
specification and follow proper bolt torque sequence at the
beginning of this chapter.
96 ± 3 in.lbs.
(10.85 ± 0.35 Nm)
NOTE: Verify stator wires are routed properly under
the wire hold down bracket.
Replace 2 bolts with new bolts
=T
T
Stator Housing Bolt Torque:
96 ± 3 in. lbs. (10.85 ± 0.35 Nm)
S
U
Cylinder Head Reassembly
=T
Stator Assembly Bolt Torque:
96 ± 3 in.lbs. (10.85 ± 0.35 Nm)
3.
Install the flywheel, washer, nut, and key. Torque flywheel
nut to specification.
NOTE: Before reassembly, clean the bolts and bolt
holes with Primer N (PN 2870585) to remove any
debris. This will ensure proper sealing when
installing bolts.
1.
Install the head gasket (A) on the cylinder (B).
65 ± 7 ft. lbs.
(88 ± 9.50 Nm)
A
B
2.
3.56
Install cylinder head on cylinder.
ENGINE
3.
Lubricate threads and top of washers underside of bolt head
with engine oil. Install head bolts (C) and torque to
specification.
5.
Lubricate rockers (E) with engine oil.
E
C
3
6.
Verify pushrods are engaged in lifters.
7.
Install rockers. Be sure that tab of fulcrum (F) is seated in
head stand-off. Torque bolts to specification.
=T
F
Cylinder Head Bolt Torque:
Initial setting: 35± 4 ft. lbs. (47.5 ± 5.5 Nm)
Allow to set for 1 minute, then turn
additional 90° (1/4 turn)
*Torque Bolts In Sequence
4.
Lubricate push rods (D) and install into lifters.
D
=T
Rocker Arm Bolt Torque
22 + 2 ft. lbs. (30 ± 3 Nm)
3.57
ENGINE
8.
Install breather reed (G) into rocker cover (H). Lightly
apply black RTV sealant to the outer edges of the breather
reed. The reed has a tab and will assemble one-way only.
Torque the breather bolts to specification.
11. Install thermostat (J), new O-ring, and thermostat housing.
Torque to specification.
K
20 ± 5 in.lbs.
(2.5 ± .55 Nm)
17 ± 2 ft. lbs.
(23 ± 3 Nm)
H
J
I
G
84 ± 8 in. lbs.
(9.5 ± 0.9 Nm)
=T
=T
Breather Bolt Toque:
20 ± 5 in. lbs. (2.5± 0.55 Nm)
Thermostat Housing Bolt Torque:
84 ± 8 in. lbs. (9.5± 0.9 Nm)
12. Install temperature sender (K) and torque to specification.
NOTE: When applying RTV, do not get any RTV
inside the reed assembly.
9.
Place a new seal (I) into the bottom of the cover. Be sure
the seal is seated into the cover properly.
K
IMPORTANT: Before assembly, clean the bolts and
bolt holes with Primer N (PN 2870585) to remove any
debris.
This will ensure proper sealing when
installing bolts.
10. Install rocker cover.
specification.
Torque bolts in sequence to
=T
Temperature Sender Torque:
17 ± 2 ft.lbs. (23 ± 3 Nm)
Oil Pump Priming
CAUTION
=T
Rocker Cover Bolt Torque:
84 ± 8 in.lbs. (9.5 ± 0.9 Nm)
3.58
After any reassembly or rebuild, the engine
must be primed using the Oil Priming Adapter
(PU-45778) and a 3/4-full oil filter before initial
start-up. Follow the steps in this section to
properly prime the engine and aid proper engine
break in. Failure to perform this procedure may
cause internal engine damage on initial start-up.
ENGINE
1.
After the engine is completely assembled and ready for
installation, the engine must be properly primed with
Polaris 0W-40 Synthetic Oil (PN 2871281). Fill the oil
filter three-quarters full with Polaris 0W-40 Synthetic Oil
(PN 2871281). Let the oil soak into the filter for 8-10
minutes. Install the filter onto the engine.
ENGINE INSTALLATION
Engine Assembly and Installation
Use the following procedure to reinstall the engine assembly.
Assemble the engine to the transmission on a work bench prior
to installation.
1.
Fill 3/4 full
with 0W-40
2.
Support the transmission / rear gearcase assembly while
setting the engine in place.
NOTE: A small number of vehicles were
manufactured with shims placed between the rear
transmission casting ear and the engine crankcase.
Be sure to use the same amount of shims upon
reassembly.
If shims were present upon disassembly but have
since been misplaced, look near the rear
transmission casting ear for the shim thickness
specification that is scribed into the casting.
Remove primer plug from the engine. Install Oil System
Priming Adapter (PU-45778) into the oil plug hole. Push
3-5 oz. (approx.) of Polaris 0W-40 into the adapter or until
resistance is felt. Remove the adapter. Apply sealant to the
plug threads. Install the plug and torque to specification.
PU-45778
Shim Size
Location
NOTE: Vehicles manufactured on or after 5/21/07,
will be assembled with an added support bracket
mounted between the engine and transmission.
Refer to the following image for torque
specifications. Snug the rear gearcase fasteners
first, followed by the engine fasteners.
Support Bracket
=T
28 ft. lbs.
(38 Nm)
Primer Plug Torque
18 ± 2 ft.lbs. (24.4 ± 2.71 Nm)
23-27 ft. lbs.
(31-37 Nm)
3.59
3
ENGINE
2.
3.
Lightly tighten all fasteners evenly to eliminate any gaps
that may be present in the mounting areas.
Torque fasteners to specification using a 2 part sequence.
• Install engine / transmission / rear gearcase mounting
hardware and torque to specification.
• Torque fasteners to half of the specified torque value
• Then torque fasteners to the full specified torque value
30 ft. lbs.
(41 Nm)
40 ft. lbs.
(54 Nm)
17 ft. lbs.
(23 Nm)
28 ft. lbs.
(38 Nm)
17 ft. lbs.
(23 Nm)
NOTE: If isolator mounts were removed or replaced,
use the following illustration to ensure proper
orientation during installation.
=T
Engine / Transmission Mounting Fasteners
(2) Lower 3/8” Nuts: 40 ft. lbs. (54 Nm)
(4) Outer M8 Bolts: 28 ft. lbs. (38 Nm)
Install drive clutch, driven clutch, and belt.
specification (see Chapter 6).
Mount Protrusion
Torque to
• Clean clutch sheaves thoroughly and inspect inlet and
outlet ducts for proper routing and sealing.
To install engine assembly, reverse the “Engine Removal”
procedure detailed earlier in this Chapter.
• Properly route all electrical harnesses for engine
assembly installation. Check for any possible rubbing
points of electrical wires.
• Carefully set the engine assembly into the vehicle while
installing the propshaft.
Front Isolator Mounts
The protrusion of the mount
must face inward towards
the engine.
Rear Isolator Mounts
The protrusion of the mount
must face the RH side of
the vehicle.
• Replace exhaust gaskets. Seal connections with high
temp silicone sealant. Check to be sure all exhaust
springs are in good condition.
• Inspect transmission operation and adjust linkage if
necessary (see Chapter 2 “Shift Linkage Adjustment”).
• Checks fluid levels: engine oil, transmission lubricant,
and rear gearcase lubricant.
• Bleed cooling system as described in this Chapter under
“Cooling System Bleeding Procedure.”
3.60
ENGINE
Engine Break-In Period
The break-in period consists of the first 25 hours of operation,
or the time it takes to use 14 gallons (53 liters) of fuel. Careful
treatment of a new engine and drive components will result in
more efficient performance and longer life for these
components.
CAUTION
3
Use only Polaris Premium 0-40W All Season
synthetic oil or equivalent.
Never substitute or mix oil brands.
Serious engine damage and voiding of
warranty can result.
Do not operate at full throttle or high speeds for
extended periods during the first three hours of
use. Excessive heat can build up and cause
damage to close fitted engine parts.
1.
Fill fuel tank with unleaded or leaded fuel which has a
minimum pump octane number of 87= (R+ M)/2.
2.
Check oil level indicated on dipstick. Add oil if necessary
(Refer to Chapter 2, “Engine Oil Level” ).
3.
Drive slowly at first to gradually bring engine up to
operating temperature.
4.
Vary throttle positions. Do not operate at sustained idle or
sustained high speed.
5.
Perform regular checks on fluid levels, controls and all
important bolt torques.
6.
Pull only light loads during initial break-in.
7.
Change oil and oil filter after break-in period at 25 hours.
=
Capacity - Approximately 2 U.S. Quarts (1.9 l)
Oil Type - Polaris Premium 0W-40 Synthetic
Filter Wrench - PV-43527 or equivalent
- Oil Pressure Specification 27-35 psi @ 6000 RPM, Polaris 0W-40
Synthetic, Engine at operating temperature.
3.61
ENGINE
TROUBLESHOOTING
Engine
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
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 ignition timing
• Restricted exhaust system
• Cam worn excessively
• Fuel quality poor (old) or octane too high
• Low compression
Engine Has Low Power
• Restricted exhaust
• Spark plug fouled
• Weak ignition (loose coil ground, faulty coil, or stator)
• Cylinder, piston, ring, or valve wear or damage (check
compression)
• Restricted air filter (main or pre-cleaner) or breather
system
• PVT not operating properly
• 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
• 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
• Fuel pump inoperative/restricted
• Excessive piston-to-cylinder clearance
• Tank vent plugged or pinched
• Wet sumping
• Engine flooded
• Worn rings, piston, or cylinder
• Low compression (high cylinder leakage)
• Worn valve guides or seals
• No spark (Spark plug fouled) ignition component
failure
• Restricted breather
Engine Does Not Turn Over
• Air filter dirty or contaminated
Piston Failure - Scoring
• Dead battery
• Lack of lubrication
• Starter motor does not turn
• Dirt entering engine through cracks in air filter or ducts
• Engine seized, rusted, or mechanical failure
• Engine oil dirty or contaminated
Engine Runs But Will Not Idle
• Restricted fuel supply
• Low compression
• Crankcase breather restricted
3.62
ENGINE
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
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)
• Cylinder head gasket leak
• No valve clearance ( cam wear )
• Lean mixture (vents, fuel pump or fuel valve)
• Cylinder or piston worn
• Fuel pump output weak
• Piston rings worn, leaking, broken, or sticking
• Electrical malfunction
• Bent valve or stuck valve
• Water pump failure/ Loose impeller
• Valve spring broken or weak
• Thermistor failure
• Valve not seating properly (bent or carbon accumulated
on sealing surface)
• Cooling fan inoperative or turning too slowly (perform
current draw test)
• Rocker arm sticking
• Low oil level
Backfiring
• Fouled spark plug or incorrect plug or plug gap
• Exhaust system air leaks
• Exhaust system air leaks
• Valve sticking
• Ignition system faulty:
• Spark plug incorrect heat range
• Faulty hot light circuit
• Thermostat stuck closed or not opening completely
Temperature Too Low
• Thermostat stuck open
Leak at Water Pump Weep Hole
Spark plug cap cracked / broken
• Faulty water pump mechanical seal (coolant leak)
Ignition coil faulty
• Faulty pump shaft oil seal (oil leak)
Ignition or kill switch circuit faulty
Poor connections in ignition system
Ignition timing incorrect
Sheared flywheel key
3.63
3
ELECTRONIC FUEL INJECTION
CHAPTER 4
ELECTRONIC FUEL INJECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
EFI SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
EFI SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FUEL LINES - QUICK CONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
PRINCIPAL COMPONENTS / EFI OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . 4.10
INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
ECU SERVICE / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
4
TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP) . . . . . . . . . 4.12
T-BAP TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
CPS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
CPS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
FUEL INJECTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
FUEL INJECTOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
FUEL SENDER TEST / FUEL PUMP TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
FUEL TANK / FUEL PUMP REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
FUEL PRESSURE REGULATOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 4.25
THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26
TPS TEST PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26
TPS INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28
TPS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29
ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . 4.30
ECT SENSOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
IGNITION COIL / HT LEAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
GENERAL TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
DIAGNOSTIC “BLINK CODES” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
EFI TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.33
EFI SYSTEM BREAKOUT DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
DIAGNOSTIC CONNECTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
MALFUNCTION INDICATOR LAMP (MIL) CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
FUEL INJECTOR (PTO) CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
FUEL INJECTOR (MAG) CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
ENGINE COOLANT TEMPERATURE SENSOR (ECT) CIRCUIT . . . . . . . . . . . . . . . . . 4.36
ENGINE OVERHEAT LAMP DRIVER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
CRANKSHAFT POSITION SENSOR (CPS) CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . 4.37
TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP) CIRCUIT . 4.37
THROTTLE POSITION SENSOR (TPS) CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38
FUEL PUMP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38
4.1
ELECTRONIC FUEL INJECTION
GENERAL INFORMATION
WARNING
* Gasoline is extremely flammable and explosive
under certain conditions.
* EFI components are under high pressure. Verify
system pressure has been relieved before
disassembly.
* Never drain the fuel system when the engine is hot.
Severe burns may result .
* Do not overfill the tank. The tank is at full capacity
when the fuel reaches the bottom of the filler neck.
Leave room for expansion of fuel.
* Never start the engine or let it run in an enclosed
area. Gasoline powered engine exhaust fumes are
poisonous and can cause loss of consciousness and
death in a short time.
* Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or where
gasoline is stored.
* If you get gasoline in your eyes or if you should
swallowgasoline,seekmedicalattentionimmediately.
* If you spill gasoline on your skin or clothing,
immediately wash with soap and water and change
clothing.
* Always stop the engine and refuel outdoors or in a
well ventilated area.
Special Tools
PART
NUMBER
TOOL DESCRIPTION
PU-47082
Throttle Position Sensor Tester
4010264
TPS Tester Regulator
PU-47315
Throttle Body Adjustment Screwdriver
(small “D” shape)
PU-43506-A
Fuel Pressure Gauge Kit
PU-47063
Digital Wrench™ Diagnostic Software
(Includes most recent version of software
and a serial number)
PU-47471
Digital Wrench™ SmartLink Module Kit
(PU-47470, PU-47469, PU-47468)
PU-47470
Digital Wrench™
PC Interface Cable
PU-47469
Digital Wrench™
Vehicle Interface Cable
PU-47468
Digital Wrench™
SmartLink Module
IMPORTANT: For the most recent information on
Digital Wrench™ software and fileset downloads
please visit the website: www.polaris.diagsys.com
Throttle Position Sensor Tester - PU-47082
This tester allows the use of a digital multi-meter to test TPS
function as well perform the TPS Initialization procedure.
NOTE: Voltage Regulator 4010264 is required if
using TPS harness PU-47082. If your dealership
sells Polaris snowmobiles, you may already have
this regulator from TPS tool PN 2201519. If you do
not have this regulator, you must order one from
SPX at 1-800-328-6657.
4.2
ELECTRONIC FUEL INJECTION
TPS Tester Regulator - 4010264
Fuel Pressure Gauge Kit - PU-43506-A
This tester regulator regulates the 9 volt battery voltage to a 5
volt input, required when using the TPS harness PU-47082.
IMPORTANT: The EFI fuel system remains under high
pressure, even when the engine is not running.
Before attempting to service any part of the fuel
system, the pressure must be relieved. The pressure
adapter has an integrated relief valve. Connect to the
test valve and release the pressure.
4
NOTE: If your dealership sells Polaris snowmobiles,
you may already have this regulator from TPS tool
PN 2201519. If you do not have this regulator, you
must order one from SPX at 1-800-328-6657.
Fuel Pressure Gauge Kit
PU-43506-A
Throttle Body Adjustment Screwdriver - PU-47315
This tool has a special ‘D’ shaped end for adjusting the throttle
stop screw during a TPS initialization procedure.
Test Valve
4.3
ELECTRONIC FUEL INJECTION
Digital Wrench™ Diagnostic Software - PU-47063
Digital Wrench™ - Download Website
This dealer-only software installs on laptop computers equipped
with a CD drive and serial port connection, and is designed to
replace multiple shop tools often used to test EFI components.
It also includes step-by-step diagnostic procedures to aid
technician repair and troubleshooting.
Located at: www.polaris.diagsys.com
IMPORTANT: If the PC you are using is not equipped
with a 9-pin serial port, a USB to serial port adaptor
will be necessary. A USB to serial port adaptor can be
purchased through DSA at: www.diagsys.com
Digital Wrench™ SmartLink Module Kit - PU-47471
This module kit contains the necessary cables and hardware to
communicate between the vehicle ECU and the Digital
Wrench™ diagnostic software. Polaris dealers can also order
the following kit components separately: SmartLink Module
PU-47468, Vehicle Interface Cable PU-47469 and PC
Interface Cable PU-47470. This module kit is used on all 8 pin
connector-based Polaris EFI systems. This kit is available to
Polaris dealers through our tool supplier SPX at (1-800-3286657) or http://polaris.spx.com
PU-47469
PU-47468
PU-47470
Digital Wrench™ - Diagnostic Connector
Located under the dash and accessible from the passenger side.
4.4
ELECTRONIC FUEL INJECTION
Service Notes
• For more convenient and accurate testing of EFI components, it is recommended dealers utilize the
Digital Wrench™ Diagnostic Software (dealer only), or testing may be done manually using the
procedures provided.
• 80% of all EFI problems are caused by wiring harness connections.
• For the purpose of troubleshooting difficult running issues, a known-good ECU from another Polaris
RANGER RZR EFI of the same model may be used without damaging system or engine components.
• Never attempt to service any fuel system component while engine is running or ignition switch is "on."
• Cleanliness is essential and must be maintained at all times when servicing or working on the EFI
system. Dirt, even in small quantities, can cause significant problems.
• Do not use compressed air if the system is open. Cover any parts removed and wrap any open joints
with plastic if they will remain open for any length of time. New parts should be removed from their
protective packaging just prior to installation.
• Clean any connector before opening to prevent dirt from entering the system.
• Although every precaution has been taken to prevent water intrusion failure, avoid direct water or
spray contact with system components.
• Do not disconnect or reconnect the wiring harness connector to the control unit or any individual
components with the ignition "on." This can send a damaging voltage spike through the ECU.
• Do not allow the battery cables to touch opposing terminals. When connecting battery cables attach the
positive (red) cable to positive (+) battery terminal first, followed by negative (black) cable to negative
(-) battery terminal.
• Never start the engine when the cables are loose or poorly connected to the battery terminals.
• Never disconnect battery while engine is running.
• Never use a battery boost-pack to start the engine.
• Do not charge battery with key switch "on."
• Always disconnect negative (-) battery cable lead before charging battery.
• Always unplug ECU from the wire harness before performing any welding on the unit.
4.5
4
ELECTRONIC FUEL INJECTION
EFI System Exploded View
1. Electronic Control Unit (ECU)
2. Intake Air Temperature / Manifold Air Pressure Sensor (T-BAP)
3. Crankshaft Position Sensor (CPS)
4. Fuel Injectors
5. Fuel Filter
6. Fuel Pump / Regulator / Gauge Sender Asm. (Located in tank as an assembly)
7. Fuel Rail
8. Engine Coolant Sensor (ECT)
9. Throttle Position Sensor (TPS)
10. Throttle Body
11. Ignition Coil
12. Spark Plugs
1
11
6
5
8
7
4
10
12
9
2
3
4.6
ELECTRONIC FUEL INJECTION
EFI System Component Locations
1.
4.
Electronic Control Unit (ECU)
- Located behind the driver’s seat next to the seat belt
assembly and just above the voltage regulator.
Fuel Injectors / Fuel Rail
- Attached to the fuel rail located in the intake track of the
cylinder head.
Fuel Injectors
ECU
4
Fuel Rail
5.
2.
Temperature and Barometric Air Pressure Sensor
(T-BAP)
- Located in the rubber intake boot between the air box and
throttle body.
Fuel Pump / Regulator / Fuel Gauge Sender Assembly
- Located under the passenger seat and in the fuel tank as a
complete assembly.
Fuel Pump Assembly
T-BAP
Located in Fuel Tank
3.
Crankshaft Position Sensor (CPS)
- Located in the magneto cover between the engine and
transmission.
Vent Line
Connection
Fuel Line
Connection
CPS
Fine Filter
Pump / Sending Unit
Connection
Fuel Pump
Preliminary Filter
Regulator
4.7
ELECTRONIC FUEL INJECTION
6.
Throttle Body
- Located between the rubber air box boot and the rubber
cylinder head adaptor.
9.
Ignition Coil
- Located behind the driver’s seat and rear service panel just
above the PVT cover.
Ignition Coil
Throttle Body
7.
Throttle Position Sensor (TPS)
- Located on the right-hand side of the throttle body.
TPS
8.
Engine Coolant Temperature Sensor (ECT)
- Located in the cylinder head next to the thermostat
housing. The sensor can be accessed with the driver and
passenger seats and rear service panel removed.
ECT
4.8
ELECTRONIC FUEL INJECTION
FUEL TANK
Exploded View
Screw
Screw
Rear
Tank Bracket
Front
Tank Bracket
Hi-Temp
Flex Conduit
Quick Connect
Fuel Line
4
Fuel Pump Asm
Pad
Pad
Cap
Gasket
Fuel Tank
Fuel Flow
Fuel Rail
Fuel Injectors
Fuel Tank
Pressure Regulator
Fuel Filters
Fuel Pump Assembly
Quick Connect Fuel Line
4.9
ELECTRONIC FUEL INJECTION
Fuel Lines - Quick Connect
ELECTRONIC FUEL INJECTION
RANGER EFI models use quick connect fuel lines. Refer to the
steps below for fuel line removal.
Principal Components
1.
The Electronic Fuel Injection (EFI) system is a complete engine
fuel and ignition management design. This system includes the
following principal components:
Place a shop towel around the fuel line to catch any
dripping fuel. Squeeze the connector tabs together and
push the locking slide back.
Squeeze Connector Tabs
2.
Pull on the fuel line for removal.
3.
To install the line, verify the connector and fuel tank nipple
are clean and free of debris.
4.
Snap the fuel line back over the nipple and slide the locking
mechanism back into place. Verify the connector tabs snap
back into place.
•
•
•
•
•
•
•
•
•
•
•
•
•
Fuel Pump
Fuel Rail
Fuel Line
Fuel Filter(s)
Fuel Injectors
Pressure Regulator
Throttle Body / lntake Manifold
Engine Control Unit (ECU)
Ignition Coils
Engine Coolant Temperature Sensor (ECT)
Throttle Position Sensor (TPS)
Crankshaft Position Sensor (CPS)
Intake Air Temperature and Barometric Air
Pressure Sensor (T-BAP)
• Wire Harness Assembly
• Check Engine Light
EFI Operation Overview
The EFI system is designed to provide peak engine performance
with optimum fuel efficiency and lowest possible emissions.
The ignition and injection functions are electronically
controlled, monitored and continually corrected during
operation to maintain peak performance.
The central component of the system is the Bosch Engine
Control Unit (ECU) which manages system operation,
determining the best combination of fuel mixture and ignition
timing for the current operating conditions.
An in-tank electric fuel pump is used to move fuel from the tank
through the fuel line and in-line fuel filter. The in-tank fuel
pressure regulator maintains a system operating pressure of 39
psi and returns any excess fuel to the tank. At the engine, fuel is
fed through the fuel rail and into the injectors, which inject into
the intake ports. The ECU controls the amount of fuel by varying
the length of time that the injectors are "on." This can range from
1.5-8.0 milliseconds depending on fuel requirements. The
controlled injection of the fuel occurs each crankshaft
revolution, or twice for each 4-stroke cycle. One-half the total
amount of fuel needed for one firing of a cylinder is injected
during each injection. When the intake valve opens, the fuel/air
mixture is drawn into the combustion chamber, ignited and
burned.
4.10
ELECTRONIC FUEL INJECTION
The ECU controls the amount of fuel being injected and the
ignition timing by monitoring the primary sensor signals for air
temperature, barometric air pressure, engine temperature, speed
(RPM), and throttle position (load). These primary signals are
compared to the programming in the ECU computer chip, and
the ECU adjusts the fuel delivery and ignition timing to match
the values.
During operation the ECU has the ability to re-adjust
temporarily, providing compensation for changes in overall
engine condition and operating environment, so it will be able
to maintain the ideal air/fuel ratio.
During certain operating periods such as cold starts, warm up,
acceleration, etc., a richer air / fuel ratio is automatically
calculated by the ECU.
Initial Priming / Starting Procedure
ELECTRONIC CONTROL UNIT (ECU)
Operation Overview
The ECU is the brain or central processing computer of the
entire EFI fuel/ignition management system. During operation,
sensors continuously gather data which is relayed through the
wiring harness to input circuits within the ECU. Signals to the
ECU include: ignition (on/off), crankshaft position and speed
(RPM), throttle position, engine coolant temperature, air
temperature, intake manifold air pressure and battery voltage.
The ECU compares the input signals to the programmed maps
in its memory and determines the appropriate fuel and spark
requirements for the immediate operating conditions. The ECU
then sends output signals to set the injector duration and ignition
timing.
ECU
NOTE: The injection system must be purged of all
air prior to the initial start up, and / or any time the
system has been disassembled.
If the EFI system is completely empty of fuel or has been
disassembled and repaired:
1.
Cycle the key switch from “OFF” to “ON” 6 times,
waiting for approximately 3 seconds at each “ON” cycle to
allow the fuel pump to cycle and shut down.
2.
Once step 1 is completed, turn the key switch to “START”
until the engine starts or 5 seconds has passed.
3.
If the engine failed to start, repeat step 1 for 2 more cycles
and attempt to start the engine.
If the engine fails to start, a problem may still exist, and should
be diagnosed.
NOTE: Accurate testing of EFI components is
recommended utilizing the Digital Wrench™
Diagnostic Software (dealer only).
During operation, the ECU continually performs a diagnostic
check of itself, each of the sensors, and system performance. If
a fault is detected, the ECU turns on the “Check Engine” light
in the speedometer and stores the fault code in its fault memory.
Depending on the significance or severity of the fault, normal
operation may continue, or "Fail-Safe" operation (slowed speed,
richer running) may be initiated. A technician can determine the
cause of the “Check Engine” light by initiating the “Blink Code”
sequence or by using Digital Wrench™. The ECU requires a
minimum of 7.0 volts to operate. The memory in the ECU is
operational the moment the battery cables are connected.
To prevent engine over-speed and possible failure, a revlimiting feature is programmed into the ECU. If the maximum
RPM limit (6500) is exceeded, the ECU suppresses the injection
signals, cutting off the fuel flow. This process repeats it self in
rapid succession, limiting operation to the preset maximum.
4.11
4
ELECTRONIC FUEL INJECTION
RANGER RZR 800 EFI RPM Limit:
Hard Limit - Injector suppression occurs
• High: 6500
TEMPERATURE AND BAROMETRIC
AIR PRESSURE SENSOR (T-BAP)
Operation Overview
• Low: 6500
Mounted in the throttle body intake boot, the T-BAP sensor
performs two functions in one unit.
• Neutral: 6500
• Reverse: 6500
• Park: 6500
Soft Limit - Timing suppression occurs
• High: 6375
• Low: 6375
• Neutral: 6375
• Reverse: 6375
• Park: 6375
ECU Service
Never attempt to disassemble the ECU. It is sealed to prevent
damage to internal components. Warranty is void if the case is
opened or tampered with in any way.
All operating and control functions within the ECU are pre-set.
No internal servicing or readjustment may be performed. If a
problem is encountered, and you determine the ECU to be
faulty, contact the Polaris Service Department for specific
handling instructions. Do not replace the ECU without factory
authorization.
The relationship between the ECU and the throttle position
sensor (TPS) is very critical to proper system operation. If the
TPS is faulty, or the mounting position of the TPS to the throttle
body is altered, the TPS must be re-initialized (see TPS
Initialization for procedure if required).
For the purpose of troubleshooting, a known-good ECU from
another Polaris RANGER RZR EFI of the same model may be
used without system or engine component damage.
T-BAP
Air passing through the intake is measured by the T-BAP and
relayed to the ECU. These signals, comprised of separate air
temperature and barometric air pressure readings, are processed
by the ECU and compared to its programming for determining
the fuel and ignition requirements during operation.
T-BAP Test
The T-BAP sensor is a non-serviceable item. If it is faulty, it
must be replaced.
IMPORTANT: The T-BAP sensor requires a 5 VDC
input to operate, therefore the T-BAP sensor should
only be tested using the Digital Wrench™ Diagnostic
Software (dealer only). Refer to the EFI Diagnostic
Software Manual for more information.
T-BAP Replacement
ECU Replacement
1.
Disconnect sensor from engine harness.
1.
Remove the (2) retaining screws holding the ECU.
2.
Using a 3/8” wrench, remove the retaining bolt and remove
the sensor from the intake boot.
2.
With the Ignition turned off, disconnect the wire harness
from the ECU.
3.
To install, reverse the procedures and tighten screws to
specification.
=T
ECU Retaining Screws
10 in. lbs. (1.1 Nm)
4.12
ELECTRONIC FUEL INJECTION
3.
Install new sensor using a light coating of oil on the o-ring
to aid installation.
Bolt
T-BAP
Intake Boot
The two-tooth gap creates an “interrupt” input signal,
corresponding to specific crankshaft position for PTO cylinder.
This signal serves as a reference for the control of ignition
timing by the ECU. Synchronization of the CPS and crankshaft
position takes place during the first two revolutions each time
the engine is started. This sensor must be properly connected at
all times. If the sensor fails or becomes disconnected for any
reason, the engine will quit running.
CPS Test
The CPS is a sealed, non-serviceable assembly. If fault code
diagnosis indicates a problem within this sensor, test as follows:
1.
4.
Disconnect CPS (3-wire) harness connector on the lefthand side of the vehicle located below the transmission.
Torque the T-BAP retaining bolt to specification.
CPS
Connector
=T
T-BAP Retaining Bolt Torque:
29 in. lbs. (3.3 Nm)
CRANKSHAFT POSITION SENSOR
(CPS)
Operation Overview
The crankshaft position sensor is essential to engine operation,
constantly monitoring the rotational speed (RPM) and position
of the crankshaft.
2.
Connect an ohmmeter between the pin terminals leading
from the Yellow and White wires. A resistance value of
560Ω ± 10% at room temperature (20° C / 68° F) should
be obtained.
CPS Harness
CPS
A ferromagnetic 60-tooth ring gear with two consecutive teeth
missing is mounted on the flywheel. The inductive speed sensor
is mounted 1.0 ± 0.26 mm (0.059 ± 0.010 in.) away from the ring
gear. During rotation, an AC pulse is created within the sensor
for each passing tooth. The ECU calculates engine speed from
the time interval between the consecutive pulses.
White
Yellow
Black
CPS Resistance Specification:
560Ω ± 10% (20° C, 68° F)
4.13
4
ELECTRONIC FUEL INJECTION
3.
4.
If the resistance is correct.
- Test the main harness circuit between the sensor
connector terminals and the corresponding pin terminals at
the ECU (see wiring diagram).
- Check the sensor mounting, air gap, flywheel ring gear for
damage or runout, and flywheel key. Follow the “CPS
Replacement” procedure to inspect CPS and flywheel ring
gear for damage.
4.
Remove the (3) bolts retaining the front portion of the
mounting bracket to the transmission. Retain the bolts,
washers, and spacers for installation.
5.
Remove the bottom bolt that attaches the bracket to the rear
gearcase through the hole in the frame support as shown.
Transmission
Mounting Bolts
If the resistance is incorrect, follow the “CPS Replacement”
procedure.
CPS Replacement
Removal
1.
Safely support the rear of the vehicle off the ground and
remove the left-hand rear tire.
Rear Gearcase
Mounting Bolt
WARNING
Serious injury may result if machine tips or falls.
Be sure the vehicle is secure before beginning
this service procedure.
2.
6.
Remove the (2) remaining fasteners that attach the bracket
to the side of the rear gearcase.
7.
Remove the bolt from the bracket at the front of the rear
gearcase.
If not done already; disconnect the CPS harness connector
(see illustration under “CPS Test”).
IMPORTANT: In order to remove the CPS, the rear
portion of the exhaust system and the mounting
bracket between the transmission and rear gearcase
will need to be removed.
3.
Remove the exhaust pipe between the elbow pipe and the
exhaust silencer. Remove the exhaust silencer.
Silencer
Remove
Remove
Elbow
Pipe
4.14
Header
Pipe
ELECTRONIC FUEL INJECTION
8.
Lift the mounting bracket straight up and out from the
vehicle.
Remove
Bracket
Installation
IMPORTANT: When reinstalling the transmission to
rear gearcase mount bracket, it is extremely important
to torque all (7) fasteners to specification. Refer to the
following procedure.
NOTE: Special tool (PA-48873) will be required to
torque the mounting bracket fasteners when the
transmission and rear gearcase are installed in the
vehicle.
Special Tool
PA-48873
4
9.
Using a 5 mm hex wrench, remove the CPS retaining bolt
and remove the sensor from the magneto housing.
This tool is specifically designed to access
the critical transmission to rear gearcase
mounting bracket bolts on the RANGER
RZR when the transmission and rear
gearcase are installed in the vehicle. This
tool allows for proper torque to be applied to
½” SAE hex head cap screws with limited
wrench access. When used at a 90° angle
with a torque wrench, no torque multiplier
is necessary.
10. Install new sensor using a light coating of oil on the o-ring
to aid installation.
11. Torque the CPS retaining bolt to specification.
=T
CPS Retaining Bolt Torque:
25 in. lbs. (2.8 Nm)
1.
Clean bolt threads with solvent and allow them to dry.
Coat the circumference of the first 4 threads of the bolts
with Loctite before installing the bolts.
2.
Reinstall mounting bracket and hand tighten the (7) bolts.
3.
Torque ALL mounting bracket bolts to specification.
=T
Mount Bracket Bolt Torque:
23-27 ft. lbs. (31-37 Nm)
4.15
ELECTRONIC FUEL INJECTION
4.
Using special tool (PA-48873), torque the (3) bolts that
retain the front portion of the mounting bracket to the
transmission.
5.
Remove the special tool and attach an extension to the
torque wrench. Torque the bottom bolt that attaches the
bracket to the rear gearcase through the hole in the frame
support.
Upper Transmission Bolt
Bottom Rear Gearcase Bolt
NOTE: Special Tool is not required for this torque.
Torque with
an extension
Middle Transmission Bolt
6.
Using special tool (PA-48873), torque the upper (2) bolts
retaining the mounting bracket to the rear gearcase. Place
the torque wrench through the rear exhaust silencer opening
to gain access to the bolts.
Middle Rear Gearcase Bolt
Bottom Transmission Bolt
4.16
ELECTRONIC FUEL INJECTION
Upper Rear Gearcase Bolt
7.
4
Torque the remaining bolt that attaches the bracket to the
front side of the rear gearcase.
Front Rear Gearcase Bolt
NOTE: A multi-directional torque wrench is required
in this application because of the limited access to
this bolt. Check with the manufacturer of your
torque wrench to see if it can be used to tighten lefthand threaded bolts.
4.17
ELECTRONIC FUEL INJECTION
FUEL INJECTORS
Operation Overview
NOTE: All EFI units utilize quick connect fuel lines.
The fuel injectors mount into the cylinder head, and the fuel rail
attaches to them at the top end. Replaceable O-rings on both
ends of the injector prevent external fuel leaks and also insulate
it from heat and vibration.
Fuel Injectors
• When temperatures prohibit touching, listen for a
buzzing or clicking sound with a screwdriver or
mechanic's stethoscope.
• Disconnect the electrical connector from an injector and
listen for a change in idle performance (only running on
one cylinder) or a change in injector noise or vibration.
NOTE: Do not apply voltage directly to the fuel
injector(s). Excessive voltage will burn out the
injector(s). Do not ground the injector(s) with the
ignition on. lnjector(s) will open/turn on if relay is
energized.
If an injector is not operating, it can indicate either a bad injector,
or a wiring/electrical connection problem. Check as follows:
Injector leakage is very unlikely, but in rare instances it can be
internal (past the tip of the valve needle), or external (weeping
around the injector body). The loss of system pressure from the
leakage can cause hot restart problems and longer cranking
times.
Fuel Rail
When the key switch is on, the fuel rail is pressurized, and
voltage is present at the injector. At the proper instant, the ECU
completes the ground circuit, energizing the injector. The valve
needle in the injector is opened electromagnetically, and the
pressure in the fuel rail forces fuel down through the inside. The
“director plate” at the tip of the injector (see inset) contains a
series of calibrated openings which directs the fuel into the
intake port in a cone-shaped spray pattern.
The injector is opened and closed once for each crankshaft
revolution, however only one-half the total amount of fuel
needed for one firing is injected during each opening. The
amount of fuel injected is controlled by the ECU and determined
by the length of time the valve needle is held open, also referred
to as the “injection duration” or “pulse width”. It may vary in
length from 1.5-8 milliseconds depending on the speed and load
requirements of the engine.
Fuel Injector Service
Injector problems typically fall into three general categorieselectrical, dirty / clogged, or leakage. An electrical problem
usually causes one or both of the injectors to stop functioning.
Several methods may be used to check if the injectors are
operating.
• With the engine running at idle, feel for operational
vibration, indicating that they are opening and closing.
4.18
Injector problems due to dirt or clogging are unlikely due to the
design of the injectors, the high fuel pressure, the use of filters
and the detergent additives in the gasoline. Symptoms that could
be caused by dirty/clogged injectors include rough idle,
hesitation/stumble during acceleration, or triggering of fault
codes related to fuel delivery. Injector clogging is usually caused
by a buildup of deposits on the director plate, restricting the flow
of fuel, resulting in a poor spray pattern. Some contributing
factors to injector clogging include; dirty air filters, higher than
normal operating temperatures, short operating intervals and
dirty, incorrect, or poor quality fuel. Cleaning of clogged
injectors is not recommended; they should be replaced.
Additives and higher grades of fuel can be used as a preventative
measure if clogging has been a problem.
ELECTRONIC FUEL INJECTION
Fuel Injector Test
Fuel Injector Replacement
NOTE: The Bosch harness connector and locking
spring is bonded to the fuel injectors with an epoxy
mix. DO NOT attempt to disconnect the Bosch
connector from the fuel injectors. Damage will occur
to the injector and/or harness if attempting to
separate at that location. Separate the fuel injector
from the vehicle by disconnecting at the end of the
harness as shown in this procedure.
1.
Be sure the engine has cooled enough to work on.
2.
Depressurize the fuel system by connecting the Fuel
Pressure Gauge Kit PU-43506-A to the test valve at the end
of the fuel rail and properly drain the fuel into a suitable
container.
Fuel
Injector
Disconnect Here
Harness
4
Test Valve
DO NOT
Disconnect Here
The fuel injectors are non-serviceable. If fault code diagnosis
indicates a problem with either injector, test the resistance of the
fuel injector(s) by measuring between the two harness pin
terminals:
3.
Remove the exhaust pipe between the exhaust silencer and
the elbow pipe to allow better access to the fuel injector rail.
Silencer
Disconnect
and test here
Remove
Elbow
Pipe
Fuel Injector Resistance Specification:
13.8Ω - 15.2Ω
Header
Pipe
4.
Remove the engine breather hose from the valve cover.
5.
Remove both driver and passenger seats and remove the
rear service panel.
4.19
ELECTRONIC FUEL INJECTION
6.
Disconnect the harness for the fuel injector(s) located next
to the ignition coil. Cut the plastic tie strap and push the
harness for the fuel injector(s) up over the air box to allow
fuel injector removal.
8.
Fuel Injector
Harnesses
Using a 6mm hex wrench, loosen the fuel rail mounting
screw from the cylinder head. Carefully pull the rail away
from the injectors and remove the injector(s) from the
cylinder head along with the harness.
Fuel Rail
Mounting
Screw
Fuel Injectors
NOTE: The Bosch harness connector and locking
spring is bonded to the fuel injectors with an epoxy
mix. DO NOT attempt to disconnect the Bosch
connector from the fuel injectors. Damage will occur
to the injector and/or harness if attempting to
separate at that location. Separate the fuel injector
from the vehicle by disconnecting at the end of the
harness as shown previous in this procedure.
Fuel
Injector
Disconnect Here
Harness
9.
Reverse the previous procedures to install the new
injector(s) and reassemble.
IMPORTANT: The PTO Fuel Injector Harness wires
are Red/Black and White. The MAG Fuel Injector
Harness wires are Red/Black and White/Black.
10. Lubricate O-rings lightly with oil to aid installation. Torque
the fuel rail mounting screw to specification.
=T
DO NOT
Disconnect Here
7.
Thoroughly clean the area around the fuel injectors
including the throttle body manifold.
4.20
Fuel Rail Mounting Screw
16-20 ft. lbs. (22.6-27 Nm)
ELECTRONIC FUEL INJECTION
FUEL PUMP
• If the engine is stopped with the key switch "on" (as in
the case of an accident).
Operation Overview
NOTE: All EFI units utilize quick connect lines.
An electric fuel pump assembly is used to transfer fuel to the EFI
system from inside the fuel tank. This assembly includes the fuel
pump, fuel filters, regulator and fuel gauge sender. The pump is
rated for a minimum output of 25 liters per hour at 39 psi and has
two non-serviceable fuel filters.
Fuel Pump Assembly
In these situations, the “check engine” light will go on, but will
turn off after 4 cranking revolutions if system function is OK.
Once the engine is running, the fuel pump remains on.
Fuel Sender Test
If the fuel gauge reading on the instrument cluster is not
working, or if the display reading differs in large comparison to
the fuel in the tank, perform a resistance test on the fuel sender.
Disconnect the fuel pump / sending unit connection and measure
the resistance between the Purple and Brown wires (see chapter
10 for further details). If out of specification, replace the fuel
pump assembly.
NOTE: See the “Electronic Parts Catalog” for fuel
pump availability. It may be possible that the fuel
tank assembly must be replaced.
Fuel Sender Resistance Specifications:
Full: 90Ω
Empty: 5Ω
Fuel Pump Test
Located in Fuel Tank
Vent Line
Connection
Fuel Line
Connection
The fuel pump assembly may be a serviceable item on some
vehicles.
NOTE: See the “Electronic Parts Catalog” for fuel
pump availability. It may be possible that the fuel
tank assembly must be replaced.
Fine Filter
Pump / Sending Unit
Connection
Fuel Pump
Preliminary Filter
Regulator
If a fuel delivery problem is suspected, make certain the fuel
pump filters are not plugged, that the pump is being activated
through the ECU, all electrical connections are properly
secured, the fuses are good, and a minimum of 7.0 volts is being
supplied. If during starting the battery voltage drops below 7.0
volts, the ECU will fail to operate the system.
WARNING
When the key switch is turned to "ON", the ECU activates the
fuel pump, which pressurizes the system for start-up.
The ECU switches off the pump preventing the continued
delivery of fuel in these instances:
• If the key switch is not promptly turned to the "start"
position.
Check the fuel test valve for any possible fuel
seepage after performing any tests or
procedures. Fuel is extremely flammable and
may cause severe burns, injury, or death.
Do not use any device that produces a flame or
electrical devices that may spark around
fuel or fuel vapors.
• If the engine fails to start
4.21
4
ELECTRONIC FUEL INJECTION
1.
Remove the cap from the fuel test valve.
4.
If the pump did not activate (Step 3), disconnect the harness
connector from the fuel pump. Connect a DC voltmeter
across terminals “A” and “C” in the plug on the vehicle
harness side. Turn on the key switch and observe voltage
to ensure a minimum of 7 volts is present.
Disconnect and Test Here
Test Valve
2.
Pin “C”
Brown
Connect the pressure hose of the Polaris pressure tester
(PU-43506-A) to the test valve on the fuel rail. Route the
clear hose into a portable gasoline container or the
equipment fuel tank.
Pin “A”
Red
NOTE: If the voltage was below 7 VDC, test the
battery, ignition switch, relay(s), wiring harness and
ECU.
5.
Fuel Pressure Gauge Kit
PU-43506-A
3.
Turn on the key switch to activate the pump and check the
system pressure on the gauge. If system pressure of 39 psi
± 3 is observed, the ignition switch, ECU, fuel pump, and
pressure regulator are working properly. Turn the key
switch off and depress the valve button on the tester to
relieve the system pressure.
Normal Fuel Pressure: 39 psi. ± 3
NOTE: If the fuel pressure is out of specification,
replace the fuel pump assembly. See the “Electronic
Parts Catalog” for fuel pump availability. It may be
possible that the fuel tank assembly must be
replaced.
4.22
If the reading is between 7 and 14 volts, turn key switch off
and connect an ohmmeter between the terminals “A” and
“C”' in the plug on the pump harness side to check for
continuity within the fuel pump.
NOTE: If there was no continuity between the pump
terminals, replace the fuel pump assembly. See the
“Electronic Parts Catalog” for fuel pump availability.
It may be possible that the fuel tank assembly must
be replaced.
6.
If voltage at the plug was within the specified range, and
there was continuity across the pump terminals, reconnect
the plug to the pump, making sure you have clean
connections. Turn on the key switch and listen for the pump
to activate.
NOTE: If the pump starts, repeat steps 1, 2 and 3 to
verify correct pressure.
7.
If the pump still does not operate, check for correct ECU
operation by plugging in a known-good ECU of the same
model.
NOTE: If the pump still does not operate, replace the
fuel pump assembly. See the “Electronic Parts
Catalog” for fuel pump availability. It may be
possible that the fuel tank assembly must be
replaced.
ELECTRONIC FUEL INJECTION
Fuel Tank / Fuel Pump Replacement
5.
IMPORTANT: Syphon as much fuel from the tank as
possible before attempting to remove it from the
vehicle.
Disconnect the fuel pump electrical harness.
Disconnect Here
WARNING
Always wear safety goggles when working with
high pressure or flammable fluids. Failure to do so
could result in serious injury or complications.
NOTE: The fuel pump assembly may be a
serviceable item on some vehicles. See the
“Electronic Parts Catalog” for fuel pump availability.
It may be possible that the fuel tank assembly must
be replaced.
4
6.
Remove the fuel tank vent hose.
7.
Remove the (2) push rivets from the rear of the center
console.
If replacing only the fuel pump assembly, refer to
“Fuel Pump Removal / Installation” within this
section.
If replacing the fuel tank, follow the
procedure below.
1.
Remove the driver and passenger seats along with the rear
service panel.
2.
Disconnect the negative battery cable from the battery
located under the driver’s seat.
3.
Bleed off fuel pressure at the test valve using the Fuel
Pressure Gauge Kit (PU-43506-A).
4.
While holding a shop towel over the fuel line connector,
disconnect the quick connect fuel line from the fuel pump.
NOTE: A small amount of fuel may come out of the
fuel line or tank. Properly drain fuel into a suitable
container.
4.23
ELECTRONIC FUEL INJECTION
8.
Remove the (2) fasteners from the rear seat base and
remove the assembly from the vehicle.
11. Remove the (3) Torx fasteners from the rear RH fender well
and remove the fender well from the vehicle.
9.
Remove the (11) push rivets and (4) Torx screws retaining
the RH rocker panel and remove panel from the vehicle.
NOTE: Lift fender well up over the fuel tank filler
neck and out from the vehicle.
IMPORTANT: Take care not to place any excessive
force on the filler neck
Remove
RH Rocker Panel
10. Remove the lower bolt retaining the seat belt mechanism
near the rear RH portion of the fuel tank. Once removed,
place the mechanism in the rear cargo box to keep it out of
the way.
12. Remove the (2) tank bracket fasteners that retain the fuel
tank in the chassis.
Tank Bracket
Fasteners
13. Lift the rear of the fuel tank up first and carefully pull it out
from the vehicle.
4.24
ELECTRONIC FUEL INJECTION
Fuel Pump Removal / Installation
Fuel Tank Installation
1.
1.
Carefully reinstall the fuel tank assembly.
2.
Reinstall the (2) tank brackets and fasteners.
3.
Reinstall the rear RH fender well and secure with fasteners.
4.
Reinstall the seat belt mechanism and secure the lower bolt.
5.
Reinstall the RH rocker panel and all (15) fasteners.
6.
Reinstall the rear seat base and secure with the (2) fasteners.
7.
Reinstall the push rivets into the rear of the center console.
8.
Install the fuel line and vent hose and verify they are secure.
9.
Reconnect the fuel pump electrical harness.
Remove the (6) mounting screws and carefully remove the
fuel pump from the tank. Take care not to damage the fuel
sender float or fuel pick-up screen.
Remove (6)
mounting Screws
10. Reconnect the negative battery cable. Test the fuel pump
by turning on the key and listening for the pump to activate.
11. Finally, install the rear service panel along with the driver
and passenger seats.
2.
Replace O-ring on fuel pump assembly.
WARNING
Never reuse the O-ring
3.
Clean the tank’s mating surface with Isopropyl Alcohol.
4.
Carefully install the fuel pump into the tank. Take care not
to damage the fuel sender float or fuel pick-up screen.
5.
Install and hand tighten the mounting screws.
6.
Torque screws to specification following the sequence
show in the illustration below.
7.
Apply the final torque using the same sequence.
FUEL PRESSURE REGULATOR
Operation Overview
The fuel pressure regulator maintains the required operating
system pressure of 39 psi + 3psi. A rubber-fiber diaphragm
divides the regulator into two separate sections; the fuel
chamber and the pressure regulating chamber. The pressure
regulating spring presses against the valve holder (part of the
diaphragm), pressing the valve against the valve seat. The
combination of atmospheric pressure and regulating spring
tension equals the desired operating pressure. Any time the fuel
pressure against the bottom of the diaphragm exceeds the
desired (top) pressure, the valve opens, relieving the excess
pressure, returning the excess fuel back to the tank.
Fuel Pressure Regulator Test
Refer to the “Fuel Pump Test” procedure.
See “Fuel Pump Test” on page 4.21.
Fuel Pressure Regulator Replacement
The pressure regulator is a sealed, non-serviceable assembly. If
it is faulty, the fuel pump assembly must be replaced. Refer to
the “Fuel Pump Removal / Installation” procedure.
=T
NOTE: See the “Electronic Parts Catalog” for fuel
pump availability. It may be possible that the fuel
tank assembly must be replaced.
Fuel Pump Mounting Screw Torque:
1st Sequence: 10-14 in. lbs. (1.1-1.6 Nm)
Final Sequence: 25-28 in. lbs. (2.8-3.2 Nm)
4.25
4
ELECTRONIC FUEL INJECTION
THROTTLE POSITION SENSOR (TPS)
Operation Overview
Set up the TPS Tester (PU-47082), according to the instructions
that accompanied the tester. Make sure that the 9 volt battery is
new.
The throttle position sensor (TPS) is used to indicate throttle
plate angle to the ECU.
Mounted on the throttle body and operated directly off the end
of the throttle shaft, the TPS works like a rheostat, varying the
voltage signal to the ECU in direct correlation to the angle of the
throttle plate. This signal is processed by the ECU and compared
to the internal pre-programmed maps to determine the required
fuel and ignition settings for the amount of engine load.
Air Flow Screw
(Factory Set)
Throttle Body
PU-47082 TPS Test
TPS Tester
Use NEW
9V battery
As mentioned in the instructions included with the tester, be sure
the TPS tester is set up along with the TPS Tester Regulator
(4010264).
4010264
TPS Tester Regulator
TPS
Yellow
(Output)
TPS Connector
Blue
(Input)
Black
(Ground)
NOTE: The correct position of the TPS is
established and set at the factory. Do not loosen the
TPS or alter the mounting position. If the TPS is
repositioned, replaced or loosened it must be recalibrated by performing “TPS Initialization.”
NOTE: If your dealership sells Polaris snowmobiles,
you may already have this regulator from TPS tool
PN 2201519. If you do not have this regulator, you
must order one from SPX at 1-800-328-6657.
Typical Tester
Set-up
TPS Test Procedure
The throttle position sensor (TPS) is a non-serviceable item. If
it is faulty, it must be replaced. It can be tested using the
following method:
NOTE: Before proceeding with any of the following
measurements or tests, it’s extremely important to
verify the throttle body bore is clean of any carbon
build-up. Remove the intake boot and inspect the
throttle body bore. If required, remove the throttle
body and clean the bore using carburetor cleaner.
4.26
Test Ports
9 Volt Battery
Regulator
Cable Ties
Install Regulator
Connections Here
R = RED
P = PINK
Bk = BLACK
Y = YELLOW
ELECTRONIC FUEL INJECTION
Verify TPS Tester Reference Voltage
4.
A 5 volt reference voltage from the harness is required for the
TPS test to be accurate. Refer to the instructions provided with
the TPS Test Adapter Harness (PU-47082) or follow the bullet
point steps to check reference voltage.
Move the throttle open and closed slowly while reading the
display. The voltage should increase and decrease
smoothly with no “jumps” when the throttle is applied.
PU-47082 Tester
• Harness Test: Insert black voltmeter probe into the
“Bk” test port.
Black
Red Probe
Probe
• Connect the red meter probe into the “R” port and
verify the voltage is 4.99-5.01 Vdc. If this reading is
low, verify the 9 volt battery is good or try a new 9 volt
battery.
Red Pink
No “Jumps”
in read out
Black
.70 ~ 3.7
4
5.
If voltage varies with throttle movement, continue on to the
next step and measure the idle air flow reading. If the sensor
did not function correctly, replace it.
6.
With voltmeter still attached to the TPS Test Adapter
Harness (PU-47082) as shown below, the voltmeter should
read .735 ± .01 volts at idle position.
PU-47082 Tester
Black
Red Probe
Probe
Red Pink
Black
IMPORTANT: Always use a fresh 9 volt battery.
Should Read
.735 Vdc
Test Procedure
1.
.735
Disconnect the vehicle harness from the TPS.
NOTE: To allow better access to the TPS harness
connection, remove the exhaust pipe and exhaust
silencer.
2.
Plug the TPS tester harness in the TPS harness.
3.
Connect the red volt meter test probe in yellow test port
and black volt meter test probe in the black test port and set
the meter to read VDC.
7.
If the voltage does not read within the specification,
“TPS Initialization” will need to be performed.
4.27
ELECTRONIC FUEL INJECTION
TPS Initialization
6.
NOTE: The correct TPS position is established and
set at the factory. Use this procedure only if the TPS
was repositioned, replaced or loosened.
Back out air flow screw until it no longer is in contact with
throttle plate cam. The throttle plate should seal off throttle
bore completely.
Back Air Flow Screw Out
Until No Contact is Made
STEP 1
Establishing zero offset voltage: This step is crucial as it sets
the TPS position using a fixed physical stop. This will insure
that the correct offset voltage is reached once the correct throttle
body flow is set.
NOTE: Before proceeding, it’s extremely important
to verify the throttle body bore is clean of any carbon
build-up. Remove the intake boot and inspect the
throttle body bore. If required, remove the throttle
body and clean the bore.
Throttle Plate
Must Be Closed
1.
Stop the engine and leave the ignition key in the off
position.
2.
Remove the driver and passenger seats along with the rear
service panel.
3.
4.
5.
7.
Open and close throttle plate a couple of times to ensure full
throttle closing. Do not snap closed, as this could cause
unnecessary throttle plate to throttle body interference and/
or damage.
8.
Assemble the TPS Tester Harness (PU-47082) according to
the instructions. Refer to “TPS Test Procedure” for proper
tester set-up. Verify that the 9 volt battery is new.
9.
Disconnect the vehicle harness from the TPS.
10. Plug the TPS tester harness in the TPS harness.
11. Using a voltmeter check the voltage output of the TPS. It
should read .528 ± .01 volts.
PU-47082 Tester
Black
Red Probe
Probe
Remove the outlet duct from the PVT cover to access the
throttle body.
Loosen the hose clamps that secure the throttle body in the
intake boot and intake adaptor. This will allow you to rotate
the throttle body to access the TPS or allow you to remove
the throttle body to perform this procedure.
Remove the throttle body side cover and disconnect throttle
cable from throttle cam.
4.28
Red Pink
Should Read
.528 Vdc
.528
Black
ELECTRONIC FUEL INJECTION
12. If it does not read .528 ± .01 volts, loosen the screw holding
the TPS to the throttle body. Rotate TPS until voltmeter
reads .528 ± .01 volts.
13. Retighten TPS mounting screw, and verify the voltage did
not change. If changed, repeat the previous steps.
STEP 2
Establishing correct flow: Now that the zero offset voltage has
been set, you can now set the throttle body to the correct air flow
value.
1.
With the voltmeter still attached to the TPS Tester Harness
(PU-47082), turn in the air flow adjustment screw until the
voltmeter reads .735 ± .01 volts. The throttle body is now
adjusted to the correct flow value.
TPS Replacement
NOTE: The correct position of the TPS is
established and set at the factory. Do not loosen the
TPS or alter the mounting position. If the TPS is
repositioned, replaced or loosened it must be recalibrated by performing “TPS Initialization.”
1.
If the vehicle is completely assembled, remove the exhaust
pipe and exhaust silencer from the vehicle to gain access to
the throttle body and TPS.
2.
Disconnect the TPS harness connection (A).
A
TPS
4
Turn Air Flow Screw In
B
3.
Remove the retaining screw (B) and replace the sensor.
4.
Refer to “TPS Initialization” for setting the TPS voltage.
PU-47082 Tester
Black
Probe
Red
Probe
Red Pink
Should Read
.735 Vdc
Black
.735
2.
Reconnect the TPS harness lead
3.
Reinstall throttle cable on throttle cam and install cover.
Adjust cable freeplay.
4.29
ELECTRONIC FUEL INJECTION
ENGINE COOLANT TEMPERATURE
SENSOR (ECT)
ECT Sensor Test
Operation Overview
Mounted on the cylinder head, the engine temperature sensor
measures coolant temperature. The engine temperature sensor
is a Negative Temperature Coefficient (NTC) type sensor, as the
temperature increases the resistance decreases.
ECT
Engine Temperature Sensor
To quickly rule out other components and wiring related to the
ETS, disconnect the harness from the ETS. The fan should turn
on and ‘HOT’ should indicate on the instrument cluster. This
indicates all other components are working properly.
Refer to Chapter 10 for ECT testing. Polaris dealers can also test
the sensor by using the Digital Wrench™ Diagnostic Software
(dealer only). Refer to the Digital Wrench™ User Guide for
more information.
ECT Sensor Resistance Readings
Coolant passes through the cylinder and by the sensor probe,
varying a resistance reading which is relayed to the ECU. This
signal is processed by the ECU and compared to its
programming for determining the fuel and ignition
requirements during operation. The ECU also uses this signal to
determine when to activate the fan during operation. If for any
reason the engine temperature sensor circuit is interrupted, the
fan will default to “ON”.
Temperature ° F (° C)
Resistance
68 ° F (20 ° C)
2.5 kΩ ± 6%
212 ° F (100 ° C)
0.186 kΩ ± 2%
ECT Sensor Replacement
1.
Drain coolant to level below sensor.
2.
Disconnect sensor from engine harness.
3.
Using a wrench, remove and replace the sensor, applying
a light coating of thread sealant to aid installation.
4.
Torque the sensor to 17 ft. lbs. (23 Nm).
=T
ECT Retaining Bolt Torque:
17 ft. lbs. (23 Nm)
4.30
ELECTRONIC FUEL INJECTION
IGNITION COIL
Primary Test
Operation Overview
Measure Between
Connector Pins
The ignition coil is used to provide high voltage to fire the spark
plugs. When the ignition key is on, DC voltage is present in
primary side of the ignition coil windings. During engine
rotation, an AC pulse is created within the crankshaft position
sensor for each passing tooth on the flywheel. The two-tooth
gap creates an “interrupt” input signal, corresponding to specific
crankshaft position for PTO cylinder. This signal serves as a
reference for the control of ignition timing. The ECU then
calculates the time interval between the consecutive pulses, and
determines when to trigger the voltage spike that induces the
voltage from the primary to the secondary coil windings to fire
the spark plugs.
0.4 Ω
4
Ignition Coil
Secondary Test
Ignition Coil Tests
Measure Between
End Caps
The ignition coil can be tested by using an ohm meter. Use the
following illustration and specification table to test the ignition
coil.
Ignition Coil Resistance Readings
Test
Pin
Connection
Primary
Between 1 & 2
Between 3 & 2
0.4 Ω
Between
High Tension
Lead Ends
5kΩ
Secondary
Resistance
5kΩ
Ignition Coil / HT Lead Replacement
1.
Remove the driver and passenger seats.
2.
Remove the rear service panel to access the ignition coil.
3.
Disconnect the ignition coil harness and remove the high
tension leads from the coil.
4.
Remove the fastener retaining the ignition coil and remove
the coil from the vehicle. If replacing the high tension
lead(s), remove the other end of the lead(s) from the spark
plug.
5.
Install the new ignition coil and/or high tension lead(s).
=T
Ignition Coil Retaining Bolt Torque:
75 in. lbs. (8.5 Nm)
4.31
ELECTRONIC FUEL INJECTION
GENERAL TROUBLESHOOTING
3.
Any “blink codes” stored in the ECU will display a
numerical “blink code”, one at a time, in numerical order,
on the instrument cluster display.
4.
The word “End” and/or the number “61” will display after
all of the codes have been displayed or if no codes are
present.
Diagnostic “Blink Codes”
NOTE: The EFI diagnostic mode is intended to
quickly view the cause of the “Check Engine” light.
To recall blink codes (fail codes) from the ECU:
1.
Verify the key switch is off and the transmission is in
neutral with the parking brake applied.
2.
Turn the key switch ON and OFF 3 times within 5 seconds
and leave the key switch in the ON position on the third
turn. The word “Wait” will appear as the ECU searches for
blink codes.
NOTE: To clear codes manually, disconnect the
positive battery lead for 20 seconds.
DIAGNOSTIC “BLINK CODES” CHART
SAE CODE BLINK CODE
P0335
P0122
P0123
P0601
P0914
P0113
P0112
P0117
P0118
P0107
P0108
P1260
P0261
P0262
P1263
P0264
P0265
P0655
P1657
P1658
P1651
P1652
P1653
P1231
P1232
P1233
4.32
21
22
22
23
25
41
41
42
42
45
46
51
51
51
52
52
52
54
54
54
55
55
55
56
56
56
NAME
Loss of Synchronization
TPS: Open or Short Circuit to Ground
TPS: Short Circuit to Battery
RAM Error: Defective ECU
Transmission Input: Invalid Gear
Intake Air Temp Sensor: Open or Short Circuit to +Sensor Voltage (ECU)
Intake Air Temp Sensor: Short Circuit to Ground
Engine Temperature Sensor Circuit: Short To Ground
Engine Temperature Sensor Circuit: Open or Short to Battery
Barometric Pressure Sensor: Circuit Low Input
Barometric Pressure Sensor: Circuit High Input
Injector 1: Open Load
Injector 1: Short Circuit to Ground
Injector 1: Short Circuit to Battery
Injector 2: Open Load
Injector 2: Short Circuit to Ground
Injector 2: Short Circuit to Battery
Engine Temperature Lamp: Open Load
Engine Temperature Lamp: Short Circuit to Ground
Engine Temperature Lamp: Short Circuit to Battery
Diagnostic Lamp: Open Load
Diagnostic Lamp: Short Circuit to Ground
Diagnostic Lamp: Short Circuit To Battery
Pump Relay: Open Load
Pump Relay: Short Circuit to Ground
Pump Relay: Short Circuit to Battery
CHECK ENGINE
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
ELECTRONIC FUEL INJECTION
EFI Troubleshooting
Poor Idle
Fuel Starvation / Lean Mixture
Symptom: Idle Too High (If greater than 1300 RPM when
engine is warm)
Symptoms: Hard start or no start, bog, backfire, popping
through intake / exhaust, hesitation, detonation, low power,
spark plug erosion, engine runs hot, surging, high idle, idle
speed erratic.
• No fuel in tank
• Restricted tank vent, or routed improperly
• Throttle stop screw set incorrect
• Throttle cable sticking, improperly adjusted, routed
incorrectly
Symptom: Idle Too Low (if less than 900 RPM when engine is
warm)
• Fuel lines or fuel injectors restricted
• Plugged air filter
• Fuel filter plugged
• Leaking injector (rich condition)
• Fuel pump inoperative
• Belt dragging
• Air leak in system
• Throttle stop screw tampering
• Intake air leak (throttle shaft, intake ducts, airbox or air
cleaner cover)
• Incorrect throttle stop screw adjustment
4
Symptom: Erratic Idle
• Throttle cable incorrectly adjusted
• Air Leaks, dirty injector
Rich Mixture
• TPS damaged or adjusted
Symptoms: Fouls spark plugs, black, sooty exhaust smoke,
rough idle, poor fuel economy, engine runs rough/ misses, poor
performance, bog, engine loads up, backfire.
• Tight valves
• Ignition timing incorrect
• Belt dragging
• Air intake restricted (inspect intake duct)
• Air filter dirty/plugged
• Poor fuel quality (old fuel)
• Fouled spark plug
• TPS setting incorrect
• Dirty air cleaner
• Engine worn
• Spark Plug fouled
• Throttle stop screw set incorrectly (out of sync with
ECU)
• Injector failure
4.33
ELECTRONIC FUEL INJECTION
EFI SYSTEM BREAKOUT DIAGRAMS
Diagnostic Connector Circuit
Malfunction Indicator Lamp (MIL) Circuit
4.34
ELECTRONIC FUEL INJECTION
Fuel Injector (PTO) Circuit
4
Fuel Injector (MAG) Circuit
4.35
ELECTRONIC FUEL INJECTION
Engine Coolant Temperature Sensor (ECT) Circuit
Engine Overheat Lamp Driver Circuit
4.36
ELECTRONIC FUEL INJECTION
Crankshaft Position Sensor (CPS) Circuit
4
Air Temperature and Barometric Air Pressure Sensor (T-BAP) Circuit
4.37
ELECTRONIC FUEL INJECTION
Throttle Position Sensor (TPS) Circuit
Fuel Pump Circuit
4.38
BODY / STEERING / SUSPENSION
CHAPTER 5
BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
MULTI-FUNCTION PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
CAB FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
ASSEMBLY / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
BODY EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
DASH INSTRUMENTS / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
HOOD / FRONT BODY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
SEAT BELTS / MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
FLOOR / ROCKER PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
REAR CARGO BOX / FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
CHASSIS / MAIN FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
REAR SERVICE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
HOOD AND FRONT BODY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
ROCKER PANELS, CONSOLE AND FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
REAR FENDER, FLAIR AND TIE DOWN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
CARGO BOX ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
5
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
WHEEL HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
FRONT HUB EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
REAR HUB EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
FRONT A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
BALL JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
FRONT STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
SWAY BAR LINKAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
STABILIZER BAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
REAR A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
REAR STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
SHOCKS / SPRINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
SHOCK REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
SHOCK REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
5.1
BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS
ITEM
TORQUE VALUE
ft.lbs. (Nm)
Front LH / RH Upper
A-Arm Bolt
37 ft. lbs. (50 Nm)
Front LH / RH Lower
A-Arm Bolt
37 ft. lbs. (50 Nm)
Rear LH / RH Upper
Control Arm Bolt
37 ft. lbs. (50 Nm)
Rear LH / RH Lower
Control Arm Bolts
37 ft. lbs. (50 Nm)
Lower LH / RH
Rear Bearing Carrier
37 ft. lbs. (50 Nm)
Upper LH / RH
Rear Bearing Carrier
37 ft. lbs. (50 Nm)
Outer Tie Rod to
Bearing Housing
42.5 ft. lbs. (58 Nm)
Front Ball Joint Pinch Bolts
17 ft. lbs. (23 Nm)
Front Upper / Lower
Shock Bolt
27-33 ft. lbs. (37-45 Nm)
Rear Upper / Lower
Shock Bolt
27-33 ft. lbs. (37-45 Nm)
Front Wheel Hub Castle Nut
80 ft. lbs. (108 Nm)
Rear Wheel Hub Castle Nut
80 ft. lbs. (108 Nm)
Wheel Nuts (Cast Rims)
Wheel Nuts (Steel Rims)
90 ft. lbs. (122 Nm)
27 ft. lbs. (37 Nm)
Tie Rod End Jam Nut
12-14 ft. lbs. (17-19 Nm
Seat Belt to Seat Base
40 ft. lbs. (54 Nm)
Steering Wheel to Shaft
25-31 ft. lbs. (34-42 Nm)
Upper Steering Shaft to
U-Joint Shaft
15-19 ft. lbs. (20-26 Nm)
Lower Steering Shaft to Box
30 ft. lbs. (41 Nm)
Steering Box
17 ft. lbs. (23 Nm)
SPECIAL TOOLS
TOOL DESCRIPTION
PART NUMBER
Shock Spanner Wrench
2870872
Shock Spring Compressor Tool
2870623
Multi-Function Pliers
2876389
Multi-Function Pliers
Included in the tool kit, the multi-function pliers is designed to
remove the plastic push rivets used to fasten body components.
NOTE: Refer to exploded views throughout this
chapter for more torque specifications, component
identification, and location of components.
Pliers
Push Rivet
5.2
BODY / STEERING / SUSPENSION
CAB FRAME
Assembly / Removal
NOTE: Finger tighten all components until cab frame is completely assembled on vehicle, then tighten to
specifications listed.
1.
Assemble the rear cab frame and the front cab frame at the coupler joints and secure with four (3/8-16 x 1 1/4) screws and
(3/8-16 Nyloc) nuts. Tighten screws to 25-28 ft. lbs. (34-38 Nm).
2.
Place the assembled cab frame onto the vehicle and align the rear mount holes. Fasten the rear cab frame brackets to vehicle
with four (5/16-18) bolts and (5/16-18) nuts. Tighten bolts to 16-18 ft. lbs. (22-24 Nm). Fasten the two tap screws to the rear
inner portion of the bracket on each side. Tighten tap screws to 15 ft. lbs. (20 Nm).
3.
Fasten the front of the cab frame to the base brackets and secure with four (3/8-16 x 1 1/4) screws and (3/8-16 Nyloc) nuts.
Tighten screws to 25-28 ft. lbs. (34-38 Nm).
4.
Attach the cab frame to the side bars mounted on vehicle. Tighten screws to 8-9 ft. lbs. (11-12 Nm).
5.
To remove the cab frame, reverse the assembly procedure (steps 1-4).
5
5.3
BODY / STEERING / SUSPENSION
BODY EXPLODED VIEWS
Dash Instruments / Controls
A. Instrument Cluster (Speedo)
B. Headlight Switch
C. 2WD/AWD Switch
D. 12 Volt Accessory Receptacle
E. Speedometer “Mode” Button
F. Key Switch
G. Work Light Switch
A
E
G
D
C
B
F
5.4
BODY / STEERING / SUSPENSION
Front Bumper
T30
Screws
Front Bumper Support
Front Bumper
Torx
Screw
Radiator Screen
Washer
O-Ring
T25
Screw
T27
Screw
T27
Screw
5
Headlight
Winch Pocket Cover
T25
Screws
Rear Bumper
LH Tail/Work Light
T27
Screw
RH Tail/Work Light
Speed
Nuts
T25
Screws
Rear Bumper
T27
Screws
5.5
BODY / STEERING / SUSPENSION
Hood / Front Body Work
Center Hood Panel
Push Rivets
Front LH
Fender Flair
Pin
Grommet
Grommet
Push Rivets
Hood / Dash
T27
Screws
Push Rivets
Push Rivets
Front RH
Fender Flair
Reflector
Front Bumper
Winch Pocket Cover
5.6
BODY / STEERING / SUSPENSION
Seat Assembly
Seat Back
Seat
Hoop Tube
48 in. lbs.
(5.4 Nm)
Seat Bottom
Latch Body
Nuts
Lever
5
Seat Base Asm.
Spring
Plate
Cap
41-57 in. lbs.
(4.6-6.4 Nm)
41-57 in. lbs.
(4.6-6.4 Nm)
Grommets
Seat Belts / Mounting
Driver
Seat
Passenger
Seat
3 Point
Seat Belt
35 ft. lbs.
(47 Nm)
35 ft. lbs.
(47 Nm)
3 Point
Seat Belt
3 Point
Seat Belt
35 ft. lbs.
(47 Nm)
Latch
Plunger
35 ft. lbs.
(47 Nm)
35 ft. lbs.
(47 Nm)
Rear
Seat Base
5.7
BODY / STEERING / SUSPENSION
Floor / Rocker Panels
Self-Tapping
Screw
Plastic Dart
LH Rocker
Rear
Support Bracket
Push Rivets
Console Cover
Self-Tapping
Screws
Rear
Support Bracket
Self-Tapping
Screw
Cup Holder
Front
Support Bracket
Plastic Dart
T27
Screw
Self-Tapping
Screw
U-Type
Nuts
Push Rivets
Torx
Screws
Front
Support Bracket
Plastic Dart
T27
Screw
RH Rocker
Self-Tapping
Screws
5.8
Main Floor
BODY / STEERING / SUSPENSION
Rear Cargo Box / Fenders
Tie Down
Bracket
Rear LH
Fender Flair
Push
Rivets
Rear LH
Fender
Tie Down
Bracket
Torx Screw
& Nut
Rear
Cargo Box
Torx Screw
& Nut
T25
Screws
Torx
Screws
T27
Screws
5
Rear LH
Panel Divider
Rear RH
Fender
Rear RH
Fender Flair
Pin
Grommet
Push
Rivets
T25
Screws
Rear Main
Service Panel
Bolts
Rear RH
Panel Divider
Sound Foam
Heat Shield
T27
Screws
Cargo Box
Supports
5.9
BODY / STEERING / SUSPENSION
Chassis / Main Frame
15 ft. lbs.
(20 Nm)
Bolt-In Brace
Rear Bumper
Support
Main Frame
15 ft. lbs.
(20 Nm)
17 ft. lbs.
(23 Nm)
Hitch
30 ft. lbs.
(41 Nm)
Skid Plate
6-8 ft. lbs.
(8-11 Nm)
5.10
BODY / STEERING / SUSPENSION
BODY COMPONENT REMOVAL
Front Bumper
Seats
1.
1.
Remove the (4) push rivets from the sides of the front
bumper.
To remove the driver or passenger seat, lift upward on the
latch lever located behind the seat bottom.
Latch
Lever
Push
Rivets
2.
Lift upward and forward on the seat while lifting up on the
latch lever and remove the seat from the vehicle.
Torx
Screws
2.
Remove the (6) Torx screws retaining the upper, middle
and lower portion of the bumper.
3.
Disconnect the front head lamp connectors and remove the
front bumper from the vehicle.
Rear Service Panel
Rear Bumper
1.
Remove driver and passenger seats.
1.
Remove the (4) Torx screws retaining the upper portion of
the rear bumper to the cargo box.
2.
To remove the service panel, pull panel towards the front
of the vehicle to disengage the upper latch pins from the
grommets.
2.
Remove the (4) Torx screws retaining the lower portion of
the rear bumper to the frame.
3.
Remove the (2) fasteners retaining the middle portion of the
rear bumper to the cargo box.
Service
Panel
5.11
5
BODY / STEERING / SUSPENSION
Hood and Front Body Work
4.
Remove the (8) push rivets that attach the dash assembly
to the rocker panels on each side.
5.
Remove the (2) Torx screws and (2) push rivets that retain
the front and rear portions of the dash assembly and remove
the dash assembly from the vehicle.
Hood Removal
1.
To remove the hood, lift up on the rear portion of the hood
to disengage the pins from the grommets.
Lift Up
HERE
Push
Rivets
2.
Tilt the hood back to disengage the front tabs and remove
the hood from the vehicle.
Front Body / Dash Removal
1.
Remove the hood as previously described.
2.
Remove the front bumper (see “BODY COMPONENT
REMOVAL - Front Bumper”).
3.
Remove the front portion of the cab frame assembly to
allow dash removal. Refer to “CAB FRAME - Assembly
/ Removal” for assembly torque specifications.
Torx
Screws
Front Fender Flair Removal
1.
If dash is installed, remove the (2) push rivets that attach
the lower portion of the fender flair to the rocker panels.
2.
Remove the (6) push rivets and remove fender flairs from
the dash assembly.
Remove
Remove
Remove
5.12
BODY / STEERING / SUSPENSION
Rocker Panels, Console and Floor
Rear Fender, Flair and Tie Down Removal
Rocker Panel Removal
1.
Remove the rear bumper (see “BODY COMPONENT
REMOVAL - Rear Bumper”).
2.
Remove the (8) push rivets that retain the rear portion of
the rocker panels to the rear fenders.
3.
Remove the (3) push rivets and remove the fender flair from
the rear fender.
4.
Remove the (3) Torx screws from the bottom side of the
fender and the upper push rivet from the top side. Remove
the fender from the vehicle.
5.
Remove the (4) fasteners that retain the tie-down brackets
to the cargo box and remove from vehicle.
1.
Remove the (11) push rivets and (4) Torx screws from the
RH rocker panel and remove panel from the vehicle.
Remove the (12) push rivets and (4) Torx screws from the
LH rocker panel and remove panel from the vehicle.
Push
Rivets
Tie-Down
Torx
Screws
Torx
Screws
Console and Floor Panel Removal
5
Push
Rivet
Fender
1.
Remove both rocker panels as previously described.
2.
Remove the front body / dash (see “BODY COMPONENT
REMOVAL - Front Body / Dash Removal”).
3.
Remove the (2) push rivets from the rear portion of the
console and remove the (9) Torx screws retaining the
console to the floor panel.
Cargo Box Assembly Removal
Remove the shift handle knob and remove the console.
1.
Remove the seats and rear service panel (see “Seats” and
“Rear Service Panel”).
2.
Remove the (4) Torx screws retaining the lower portion of
the rear bumper to the frame (see “Rear Bumper”).
3.
Remove the (4) screws from the middle of the cargo box.
4.
Remove the (4) Torx screws that attach the front portion of
the cargo box to the frame.
4.
Floor
Panel
Push
Rivets
Push
Rivets
Fender
Flair
Console
5.
Remove the (6) Torx screws from the upper front portion
of the floor panel.
6.
Remove the (4) fasteners retaining the foot pedal bracket.
Disconnect the brake and throttle cables from the pedals
and remove pedals from the vehicle.
7.
Remove the (3) push rivets retaining the fuse box.
8.
Remove the (2) push rivets retaining the rear fender wells
to the floor panel.
5.
Remove the (8) push rivets that attach the rocker panels to
the cargo box on each side.
9.
Remove steering shaft and remove floor panel from the
vehicle.
6.
Cut the panduit strap, disconnect taillight/worklight wire
connections and remove the box assembly from the vehicle.
5.13
BODY / STEERING / SUSPENSION
STEERING ASSEMBLY
Exploded View
Cap
Steering Wheel
15-19 ft. lbs.
(20-26 Nm)
25-31 ft. lbs.
(34-42 Nm)
Wave Washers
Upper
Steering Shaft
23 ft. lbs.
(31 Nm)
Bushing
Lower
Steering Shaft
Pivot Tube
42.5 ft. lbs.
(58 Nm)
Bushing
Bushing
7 ft. lbs.
(10 Nm)
Bushing
27-33 ft. lbs.
(37-45 Nm)
12 ft. lbs.
(16 Nm)
23 ft. lbs.
(31 Nm)
Bushing
LH Boot
Gear Box
Asm.
Oil Locking
Shock Asm.
12-14 ft. lbs.
(16-19 Nm)
RH Boot
42.5 ft. lbs.
(58 Nm)
Boot
17 ft. lbs.
(23 Nm)
12-14 ft. lbs.
(16-19 Nm)
Nut
Cotter Pin
Rod End
5.14
Tie Rod
17 ft. lbs.
(23 Nm)
BODY / STEERING / SUSPENSION
WHEEL HUBS
Front Hub Exploded View
Sealed
Ball Bearing
Stud
Bolts
Wheel Hub
Cone
Washers
Cotter Pin
Bearing Carrier
Castle Nut
Retaining
Ring
80 ft. lbs.
(108 Nm)
Brake Disc
Front Rim
5
Front Tire
Flanged Nuts
27 ft. lbs.
(37 Nm)
Valve
Rear Hub Exploded View
Stud
Sealed
Ball Bearing
Bolts
Wheel Hub
Cotter Pin
Cone
Washers
Bearing Carrier
Castle Nut
80 ft. lbs.
(108 Nm)
Retaining
Ring
Brake Disc
Front Rim
Front Tire
Flanged Nuts
27 ft. lbs.
(37 Nm)
Valve
5.15
BODY / STEERING / SUSPENSION
FRONT A-ARMS
Removal / Replacement
The following procedure details upper and lower A-arm
removal and replacement on one side of the vehicle.
1.
2.
3.
4.
Elevate and safely support the front of the vehicle and
remove the front wheel.
Remove the lower shock fastener (A) from the upper Aarm.
Remove the upper ball joint pinch bolt (B) from the front
bearing carrier.
Using a soft face hammer, tap on bearing carrier to loosen
the upper A-arm ball joint end while lifting upward on the
upper A-arm. Completely remove the ball joint end from
the bearing carrier.
5.
Remove the front bumper to allow A-arm bolt removal.
6.
Loosen and remove the upper A-arm through-bolt fastener
(C) and remove the upper A-arm from the vehicle.
7.
Examine A-arm bushings and pivot tube (see “Exploded
View”). Replace if worn. Discard hardware.
WARNING
The locking agent on the existing bolts was
destroyed during removal. DO NOT reuse old
hardware. Serious injury or death could result if
fasteners come loose during operation.
8.
If not replacing the A-arm, thoroughly clean the A-arm and
pivot tube.
9.
Install new ball joint into A-arm. Refer to “Ball Joint
Replacement” section.
15. Using a soft face hammer, tap on bearing carrier to loosen
the lower A-arm ball joint end while pushing downward on
the lower A-arm. Completely remove the ball joint end
from the bearing carrier.
16. Loosen and remove the lower A-arm through-bolt fastener
(F) and remove the lower A-arm from the vehicle.
17. Examine A-arm bushings and pivot tube (see “Exploded
View”). Replace if worn. Discard hardware.
18. If not replacing the A-arm, thoroughly clean the A-arm and
pivot tube.
19. Install new ball joint into A-arm. Refer to “Ball Joint
Replacement” section.
20. Insert new A-arm bushings and pivot tube into new A-arm.
21. Install new lower A-arm assembly onto vehicle frame.
Torque new bolt to 37 ft. lbs. (50 Nm).
22. Insert lower A-arm ball joint end into the bearing carrier.
Install the lower ball joint pinch bolt (E) into the bearing
carrier and torque bolt to 17 ft. lbs. (23 Nm).
WARNING
Upon A-arm installation completion, test vehicle
at low speeds before putting into service.
Upper / Lower A-arm Bolt Torque:
37 ft. lbs. (50 Nm)
Ball Joint Pinch Bolt Torque:
17 ft. lbs. (23 Nm)
10. Insert new A-arm bushings and pivot tube into new A-arm.
11. Install new upper A-arm assembly onto vehicle frame.
Torque new bolt to 37 ft. lbs. (50 Nm).
12. Insert upper A-arm ball joint end into the bearing carrier.
Install the upper ball joint pinch bolt (B) into the bearing
carrier and torque bolt to 17 ft. lbs. (23 Nm).
D
B
13. Attach shock to A-arm with spacer (D) and fastener (A)
(see “FRONT STABILIZER BAR - Exploded View”).
Torque lower shock bolt to 27-33 ft. lbs. (37-45 Nm).
14. Remove the lower ball joint pinch bolt (E) from the front
bearing carrier.
5.16
C
A
E
F
BODY / STEERING / SUSPENSION
BALL JOINT SERVICE
Exploded View
Removal
IMPORTANT: Do not reuse a ball joint if it has been
removed for any reason. If removed, it must be
replaced. Use this removal procedure only when
replacing the ball joint.
37 ft. lbs.
(50 Nm)
Pivot Tube
Upper
A-arm
1.
The A-arm must be removed to perform this procedure
(see “FRONT A-ARMS - Removal / Replacement”).
Ball Joint
Ball Joint
Grease Zerk
Bushings
37 ft. lbs.
(50 Nm)
Pivot Tube
5
Upper A-arm
Bearing
Carrier
Retaining Ring
Lower
A-arm
Grease
Zerk
Pinch
Bolts
2.
Remove the retaining ring from the ball joint.
3.
A driver must be used for the removal of the ball joint. Use
the dimensions below to fabricate or locate the correct size
driver to use in the following process.
Driver Dimensions
Bushing
17 ft. lbs.
(23 Nm)
1.375 in.
(3.49 cm)
Ball Joint
CV Shield
3 in.
(7.62 cm)
Screws
1.75 in.
(4.45 cm)
- Outside diameter of driver cannot be any
larger than 1.75 in. (4.45 cm).
- Inside diameter cannot be any smaller than
1.375 in. (3.49 cm).
- Driver must be at least 3 in. (7.62 cm) tall.
5.17
BODY / STEERING / SUSPENSION
4.
Use a press and correct size driver to remove the ball joint
from the A-arm.
Installation
1.
Correct
Driver Placement
Place the A-arm in the correct position for ball joint
installation. Face the A-arm end flat on top of the driver.
Carefully drive the ball joint into place until the ball joint
is properly seated.
Press into the A-arm
in this direction
The driver must fit the
inside diameter of the
A-arm end.
Place driver HERE
to support A-arm
Upper A-arm Shown
Upper A-arm Shown
NOTE: The driver must fit the ball joint housing in
the A-arm. This will allow the ball joint to be properly
pressed out of the A-arm without damaging the Aarm.
2.
After the new ball joint is installed into the A-arm, install
a NEW retaining ring.
Ball Joint
Press out of the A-arm
in this direction
Upper A-arm Shown
Upper A-arm
NEW
Retaining Ring
Place driver HERE
to support A-arm
5.18
3.
Reinstall the A-arm (see “FRONT A-ARMS - Removal /
Replacement”).
4.
Repeat the ball joint service procedure for any additional
A-arm ball joint replacements.
BODY / STEERING / SUSPENSION
FRONT STABILIZER BAR
4.
Remove the (2) upper radiator retaining bolts.
5.
Remove the (4) bolts retaining the lower radiator mount
bracket and remove the bracket from the frame.
Sway Bar Linkage Removal
1.
Elevate and safely support the front of the vehicle off the
ground.
2.
Remove the lower shock mounting fasteners and spacers
from both upper A-arms on each side of the vehicle (see
“Exploded View” on page 5.20).
3.
Remove the bolts that attach the upper portion of the
linkages to the sway bar clamps and remove the linkages
from the vehicle (see “Exploded View” on page 5.20).
4.
Inspect the linkage assemblies for signs of excessive wear
or damage. Replace linkage assembly if damaged.
5.
Reverse the procedure for installation. Torque the linkage
fasteners to 27-33 ft. lbs. (37-45 Nm).
5
Stabilizer Bar Removal
1.
If stabilizer bar linkages are installed, remove the bolts that
attach the upper portion of the linkages to the sway bar
clamps (see “Exploded View” on page 5.20).
2.
Remove the front bumper (see “BODY COMPONENT
REMOVAL - Front Bumper”).
3.
Remove the (4) T30 Torx fasteners retaining the front
bumper support to the frame.
Main
Frame
T30
Screws
6.
Allow radiator to sag down to allow access to recovery
bottle retaining screws and filler neck retaining screws.
7.
Remove both sets of retaining screws and allow the
recovery bottle and filler neck to hang down to access the
(4) bolts retaining the upper radiator mount bracket.
Nuts
Bumper
Support
Recovery
Bottle
Filler
Neck
5.19
BODY / STEERING / SUSPENSION
8.
Remove the (4) bolts retaining the upper radiator mount
bracket and remove the bracket from the frame.
Exploded View
Main
Frame
T30
Screws
Grease
Zerk
Clamp
Stabilizer
Bar
Clamp
Mount
Bracket
Bushings
Nuts
9.
Lift up on the stabilizer bar and remove it from the vehicle.
Spacer
10. Inspect the stabilizer bar for straightness. Inspect the
bushings and replace if needed.
11. Reverse the procedure for installation. Torque the linkage
fasteners to 27-33 ft. lbs. (37-45 Nm).
5.20
Linkage
Linkage
27-33 ft. lbs.
(37-45 Nm)
BODY / STEERING / SUSPENSION
REAR A-ARMS
WARNING
Removal
The locking agent on the existing bolts was
destroyed during removal. DO NOT reuse old
hardware. Serious injury or death could result if
fasteners come loose during operation.
The following procedure details upper and lower A-arm
removal and replacement on one side of the vehicle. Repeat the
following steps to remove the A-arm(s) from the opposite side.
NOTE: Use the exploded view in this section as a
reference during the procedure (see page 5.22).
6.
If not replacing the A-arm, thoroughly clean the a-arm and
pivot tubes.
1.
Elevate and safely support the rear of the vehicle off the
ground.
7.
Insert new A-arm bushings and pivot tubes into new A-arm.
2.
Remove the wheel nuts, and rear wheel.
Lower A-arm Removal
8.
While holding the stabilizer bar linkage, remove the lower
nut retaining the linkage to the lower A-arm.
Hold HERE with
open-end wrench
5
Remove lower
linkage nut
Upper A-arm Removal
9.
3.
Remove the fastener (A) attaching the upper A-arm to the
bearing carrier.
Remove the fastener (C) retaining the lower portion of the
shock to the lower A-arm.
B
E
C
A
4.
Remove the fastener (B) attaching the upper A-arm to the
frame and remove the upper A-arm from the vehicle.
5.
Examine A-arm and bearing carrier bushings and pivot
tubes (see “Exploded View” on page 5.22). Replace if
worn. Discard hardware.
D
10. Remove the fastener (D) attaching the lower A-arm to the
bearing carrier.
5.21
BODY / STEERING / SUSPENSION
11. Remove the (2) fasteners (E) attaching the lower A-arm to
the frame and remove the lower A-arm from the vehicle
(see previous illustration).
Exploded View
12. Examine A-arm and bearing carrier bushings and pivot
tubes (see “Exploded View”). Replace if worn. Discard
hardware.
13. If not replacing the A-arm, thoroughly clean the a-arm and
pivot tubes.
37 ft. lbs.
(50 Nm)
Pivot Tube
Upper
A-arm
14. Insert new A-arm bushings and pivot tubes into the new
A-arm.
Bushings
Installation
1.
Install lower A-arm assembly onto vehicle frame. Torque
new fasteners to 37 ft. lbs. (50 Nm).
2.
Attach lower A-arm to bearing carrier.
fastener to 37 ft. lbs. (50 Nm).
Torque new
37 ft. lbs.
(50 Nm)
3.
Route brake line on top of the lower A-arm and between
lower shock mounting tabs.
4.
Reinstall the lower portion of the shock to the lower A-arm.
Torque shock fastener to 27-33 ft. lbs. (37-45 Nm).
5.
Install upper A-arm assembly onto vehicle frame. Torque
new fastener to 37 ft. lbs. (50 Nm).
6.
7.
Attach upper A-arm to bearing carrier.
fastener to 37 ft. lbs. (50 Nm).
Pivot
Tube
WARNING
Upon A-arm installation completion, test vehicle
at low speeds before putting into service.
Bushings
37 ft. lbs.
(50 Nm)
Lower
A-arm
Pivot
Tube
Bushings
Bearing
Carrier
Pivot
Tube
Torque new
Install wheel and torque wheel nuts to specification.
5.22
Grease
Zerk
37 ft. lbs.
(50 Nm)
Screws
CV
Shield
BODY / STEERING / SUSPENSION
REAR STABILIZER BAR
4.
Remove the stabilizer bar and bracket from the frame as an
assembly.
Removal / Installation
1.
Remove the exhaust pipe and exhaust silencer from the
vehicle.
Bushings
Remove
Fasteners
NOTE: The exhaust silencer can be removed
through the side of the vehicle after the exhaust pipe
is detached from the header pipe.
2.
Remove the retaining nut from the upper portion of the
stabilizer bar linkage bushing on each side of the vehicle.
5.
Inspect the stabilizer bar for straightness. Inspect the
bushings and replace if needed.
6.
Inspect the rubber bushings on the linkage rod and replace
if needed.
7.
Reverse the procedure for installation.
stabilizer bolts to 18 ft. lbs. (24 Nm).
Torque the
17 ft. lbs.
(23 Nm)
Bushing
Bushing
Grease
Zerk
Stabilizer Bar
Linkage
Remove Nut
Linkage
3.
Remove the (4) fasteners retaining the stabilizer bar bracket
to the frame.
18 ft. lbs.
(24 Nm)
Bracket
17 ft. lbs.
Bushing (23 Nm)
5.23
5
BODY / STEERING / SUSPENSION
SHOCKS / SPRINGS
DECAL REPLACEMENT
Exploded View
WARNING
Spring
27-33 ft. lbs.
(37-45 Nm)
The following procedure involves the use of an
open flame. Perform this procedure in a well
ventilated area, away from gasoline or other
flammable materials. Be sure the area to be
flame treated is clean and free of gasoline
or flammable residue.
Spring
Retainer
WARNING
Shock
Do not flame treat components that are installed
on the vehicle. Remove the component from the
vehicle before flame treating.
Adjusting Cam
27-33 ft. lbs.
(37-45 Nm)
Shock Removal / Installation
1.
Elevate the vehicle off the ground to relieve the suspension
load.
2.
Remove the upper and lower fasteners retaining the shock
and remove the shock from the vehicle.
3.
Reverse the procedure to reinstall the shock. Torque new
fasteners to 27-33 ft. lbs. (37-45 Nm).
The side panels, front and rear fender cabs are plastic
polyethylene material. Therefore, they must be “flame treated”
prior to installing a decal to ensure good adhesion. A bonus of
the flame treating procedure is it can be used to reduce or
eliminate the whitish stress marks that are sometimes left after
a fender or cab is bent, flexed, or damaged.
To flame treat the decal area:
1.
Pass the flame of a propane torch back and forth quickly
over the area where the decal is to be applied until the
surface appears slightly glossy. This should occur after just
a few seconds of flame treating. Do not hold the torch too
close to the surface (2-3 inches from the flame tip is
recommended). Keep the torch moving to prevent damage.
2.
Apply the decal on one edge first. Slowly lay down
remainder of the decal while rubbing lightly over the decal
surface to eliminate any air bubbles during the application.
Shock Replacement
1.
Using a spring compressor, compress the shock spring far
enough to remove the spring retainer.
Shock Spring
Compressor Tool
2870623
2.
Remove the spring and adjusting cam from the existing
shock and install components onto the new shock.
3.
Compress the shock spring and install the spring retainer.
4.
Reinstall the shock onto the vehicle and torque new
fasteners to 27-33 ft. lbs. (37-45 Nm).
5.24
CLUTCHING
CHAPTER 6
CLUTCHING
SPECIAL TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT SYSTEM FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
MAINTENANCE / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
OVERHEATING / DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
PVT SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT SEALING AND DUCTING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
SPRING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
SHIFT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
ROLLER, PIN, AND THRUST WASHER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6.13
BUTTON TO TOWER CLEARANCE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
MOVEABLE SHEAVE BUSHING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
BUSHING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
6
DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
BUSHING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
6.1
CLUTCHING
SPECIAL TOOLS AND SUPPLIES
PVT SYSTEM OVERVIEW
General Operation
TOOL DESCRIPTION
PART NUMBER
Drive Clutch Puller (Short)
PA-48595
Clutch Holding Wrench
9314177
Clutch Holding Fixture
2871358
Spider Nut Socket
2870338
Drive Clutch Spider Removal and
Installation Tool
2870341
Roller Pin Tool
2870910
Clutch Bushing Replacement
Tool Kit
2871226
Piston Pin Puller
2870386
Clutch Compression Tool
8700220
Clutch Bushing Replacement
Tool Kit
2871025
SPECIAL SUPPLIES
PART NUMBER
Loctite™ 680
2870584
1) The Drive Clutch
RTV Silicone Sealer
8560054
2) The Driven Clutch
WARNING
All PVT maintenance or repairs should be
performed only by a certified Polaris Master
Service Dealer (MSD) technician who has
received the proper training and understands
the procedures outlined in this manual.
Because of the critical nature and precision
balance incorporated into the PVT
components, it is absolutely essential that
no disassembly or repair be made without
factory authorized special tools and
service procedures.
The Polaris Variable Transmission (PVT) consists of three
major assemblies:
3) The Drive Belt
TORQUE SPECIFICATIONS
PVT System Fastener Torques
ITEM
TORQUE VALUE
ft. lbs. (Nm)
Drive Clutch Retaining Bolt
40 ft. lbs. (54 Nm)
Driven Clutch Retaining Bolt
17 ft. lbs. (23 Nm)
PVT Inner Cover Bolts
12 ft. lbs. (16 Nm)
PVT Outer Cover Bolts
45-50 in. lbs (5-5.6 Nm)
Drive Clutch Spider
200 ft. lbs. (271 Nm)
Drive Clutch Spider Lock Nut
(Plastic)
15 ft. lbs. (20.3 Nm)
Drive Clutch Cover Plate
90 in. lbs. (10 Nm)
The internal components of the drive clutch and driven clutch
control engagement (initial vehicle movement), clutch upshift
and backshift. During the development of the Polaris vehicle,
the PVT system is matched first to the engine power curve; then
to average riding conditions and the vehicle’s intended usage.
Therefore, modifications or variations of components at random
are never recommended. Proper clutch setup and careful
inspection of existing components must be the primary
objective when troubleshooting and tuning.
Drive Clutch Operation
Drive clutches primarily sense engine RPM. The two major
components which control its shifting function are the shift
weights and the coil spring. Whenever engine RPM is
increased, centrifugal force is created, causing the shift
weights to push against rollers on the moveable sheave, which
is held open by coil spring preload. When this force becomes
higher than the preload in the spring, the outer sheave moves
inward and contacts the drive belt. This motion pinches the
drive belt between the spinning sheaves and causes it to rotate,
which in turn rotates the driven clutch.
At lower RPM, the drive belt rotates low in the drive clutch
sheaves. As engine RPM increases, centrifugal force causes the
drive belt to be forced upward on drive clutch sheaves.
6.2
CLUTCHING
Driven Clutch Operation
Maintenance / Inspection
Driven clutches primarily sense torque, opening and closing
according to the forces applied to it from the drive belt and the
transmission input shaft. If the torque resistance at the transmission input shaft is greater than the load from the drive belt,
the drive belt is kept at the outer diameter of the driven clutch
sheaves.
Under normal use the PVT system will provide years of trouble
free operation. Periodic inspection and maintenance is required
to keep the system operating at peak performance. The
following list of items should be inspected and maintained to
ensure maximum performance and service life of PVT
components. Refer to the troubleshooting checklist at the end of
this chapter for more information.
As engine RPM and horsepower increase, the load from the
drive belt increases, resulting in the belt rotating up toward the
outer diameter of the drive clutch sheaves and downward into
the sheaves of the driven clutch. This action, which increases
the driven clutch speed, is called upshifting.
Should the throttle setting remain the same and the vehicle is
subjected to a heavier load, the drive belt rotates back up toward
the outer diameter of the driven clutch and downward into the
sheaves of the drive clutch. This action, which decreases the
driven clutch speed, is called backshifting.
In situations where loads vary (such as uphill and downhill) and
throttle settings are constant, the drive and driven clutches are
continually shifting to maintain optimum engine RPM. At full
throttle a perfectly matched PVT system should hold engine
RPM at the peak of the power curve. This RPM should be
maintained during clutch upshift and backshift. In this respect,
the PVT system is similar to a power governor. Rather than vary
throttle position, as a conventional governor does, the PVT
system changes engine load requirements by either upshifting or
backshifting.
PVT Break-In (Drive Belt / Clutches)
1.
Belt Inspection.
2.
Drive and Driven Clutch Buttons and Bushings, Drive
Clutch Shift Weights and Pins, Drive Clutch Spider
Rollers and Roller Pins, Drive and Driven Clutch
Springs.
3.
Sheave Faces. Clean and inspect for wear.
4.
PVT System Sealing. Refer to the appropriate
illustration(s) on the following pages. The PVT system is
air cooled by fins on the drive clutch stationary sheave. The
fins create a low pressure area in the crankcase casting,
drawing air into the system through an intake duct. The
opening for this intake duct is located at a high point on the
vehicle (location varies by model). The intake duct draws
fresh air through a vented cover. All connecting air ducts
(as well as the inner and outer covers) must be properly
sealed to ensure clean air is being used for cooling the PVT
system and also to prevent water and other contaminants
from entering the PVT area. This is especially critical on
units subjected to frequent water forging.
A proper break-in of the clutches and drive belt will ensure a
longer life and better performance. Break in the clutches and
drive belt by operating at slower speeds during the 10 hours as
recommended (see Chapter 3 “Engine Break-In Period” for
break-in example). Pull only light loads. Avoid aggressive
acceleration and high speed operation during the break-in
period.
6.3
6
CLUTCHING
Overheating / Diagnosis
During routine maintenance, or whenever PVT system overheating is evident, it’s important to check the inlet and outlet ducting
for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures. The
vehicle should be operated in Low when plowing or pulling heavy loads, or if extended low speed operation is anticipated.
CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS
Possible Causes
Solutions / What to do
Loading the vehicle into a truck or tall
Shift transmission to Low during loading of the vehicle to prevent belt burning.
trailer when in high range.
Starting out going up a steep incline from When starting out on an incline, use Low gear. Shift transmission to Low
a stopped position.
during loading of the vehicle to prevent belt burning.
Driving at low RPM or low ground speed Drive at higher speed or use Low. The use of Low is highly recommended
(at approximately 3-7 MPH).
for cooler PVT operating temperatures and longer component life.
Warm engine at least 5 min., then with transmission in neutral, advance
Insufficient warm-up of vehicles exposed
throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
to low ambient temperatures.
become more flexible and prevent belt burning.
Slow and easy clutch engagement.
Fast, effective use of the throttle for efficient engagement.
Towing/Pushing at low RPM or low
Use Low only.
ground speed.
Plowing snow, dirt, etc./utility use.
Use Low only.
Shift the transmission to Low, carefully use fast, aggressive throttle
Stuck in mud or snow.
application to engage clutch. WARNING: Excessive throttle may cause loss
of control and vehicle overturn.
Shift the transmission to Low, carefully use fast, aggressive, brief throttle
Climbing over large objects from a
application to engage clutch. WARNING: Excessive throttle may cause loss
stopped position.
of control and vehicle overturn.
Shift the transmission to neutral. Using the throttle, vary the engine rpm from
Belt slippage from water or snow
idle to full throttle. Repeat several times as required. During this procedure,
ingestion into the PVT system.
the throttle should not be held at the full position for more than 10 seconds.
Clutch seals should be inspected for damage if repeated leaking occurs.
Clutch component inspection should be performed by a Polaris MSD certified
Clutch malfunction.
technician.
Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty
Poor engine performance.
fuel pump may cause symptoms similar to clutching malfunction.
Low: Heavy pulling, basic operational speeds less than 7 MPH, riding
GENERAL RANGE OPERATION
through rough terrain (swamps, mountains, ect.), or low ground speeds.
GUIDELINES:
High: High ground speeds, or speeds above 7 MPH.
Operating in Low Gear
“Low” gear should be used when pulling heavy loads, riding through rough terrain, or when basic operational ground speeds are less
than 7 MPH. Use “High” gear when basic operational ground speeds are more than 7 MPH.
IMPORTANT: Using “High” for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance
of drive belt burning.
6.4
CLUTCHING
PVT SYSTEM SERVICE
PVT Sealing and Ducting Components
Clutch
Outlet Duct
Clutch
Inlet Duct
Inner
Clutch Cover
Push
Rivets
Boot
Clamps
Boot
Clamps
Bolt/Washer
Cover
Screws
Retainer
Screws
Outer
Cover Seal
Disassembly
Outer
Clutch Cover
6.
Some fasteners and procedures will vary. Refer to the
appropriate parts manual for proper fasteners and fastener
placement.
1.
Remove driver and passenger seats (see Chapter 5).
2.
Remove the rear service panel to gain access to the outer
clutch cover (see Chapter 5).
3.
Remove the (2) push rivets and (2) fasteners retaining the
rear seat base, and remove the seat base from vehicle to
allow clutch cover removal.
4.
Loosen the hose clamp on the clutch outlet duct.
5.
Remove outer clutch cover screws and remove the clutch
cover.
Mark the drive belt direction of rotation and remove drive
belt (see “DRIVE BELT - Belt Removal”).
Mark Rotation
7.
Remove the driven clutch retaining bolt and driven clutch.
6.5
6
CLUTCHING
8.
Remove driven clutch offset spacers from the transmission
input shaft.
Assembly
1.
Inspect inner clutch cover-to-engine seal. Replace if
cracked or damaged.
2.
Place a new foam seal on transmission input shaft.
3.
Apply RTV silicone sealant to outside edge of inner clutch
cover-to-engine seal, to ensure a water tight fit between the
seal and the cover. Surfaces must be clean to ensure
adhesion of silicone sealant.
Keep Spacers In Order (Note Thickness)
Retaining
Bolt
9.
Apply RTV Silicone Here
Install the Drive Clutch Holder (PN 9314177) (A).
10. Remove drive clutch retaining bolt and remove drive clutch
using the Drive Clutch Puller (PA-48595) (B).
A
4.
Reinstall cover and tighten rear cover bolts just enough to
hold it in place.
5.
Fit lip of inner cover seal (A) to engine. Install seal retainer
plate and tighten screws securely.
B
C
B
A
Drive Clutch Puller ( PA-48595)
Drive Clutch Holder (9314177)
11. Remove the screws that attach the inner clutch cover to the
engine and transmission.
Seal outer edge to cover
with RTV silicone sealant
6.
Torque rear inner clutch cover bolts (B) to specification.
7.
Install clutch offset spacers on transmission input shaft.
Offset Spacers
12. Remove the cover along with foam seal on back of cover
or shaft.
6.6
CLUTCHING
8.
Clean splines inside driven clutch and on the transmission
input shaft.
9.
Apply a light film of grease to the splines on the shaft.
DRIVE BELT
Belt Removal
1.
Remove outer clutch cover as described in PVT
Disassembly.
2.
Mark the drive belt direction of rotation so that it can be
installed in the same direction.
10. Install the driven clutch, washer, lock washer, and retaining
bolt. Torque to specification.
11. Clean end of taper on crankshaft and the taper bore inside
drive clutch.
12. Install drive clutch and torque retaining bolt to
specification.
NOTE: Belt is normally positioned so that the part
number can be easily read.
3.
13. Reinstall drive belt noting direction of belt rotation (see
“DRIVE BELT - Belt Installation”). If a new belt is
installed, install so numbers can be easily read.
To remove drive belt, place the transmission in “Park” and
push down on the belt firmly to open the clutch sheaves.
14. Replace outer clutch cover rubber gasket with the narrow
side out.
15. Reinstall outer clutch cover and secure with screws.
Torque to 45-50 in. lbs. (5-5.6 Nm).
16. Install the clutch cover outlet duct and tighten the clamps.
6
4.
Then lift upward on the belt while pulling it out and down
over the driven clutch outer sheave.
Inner Cover Bolt Torque (Rear):
12 ft. lbs. (16.6 Nm)
Outer Cover Bolt Torque:
45-50 in. lbs. (5-5.6 Nm)
Driven Clutch Retaining Bolt Torque:
17 ft. lbs. (23.5 Nm)
Drive Clutch Retaining Bolt Torque:
40 ft. lbs. (55 Nm)
6.7
CLUTCHING
Belt Inspection
Belt Installation
NOTE: Be sure to position belt in the same position
as when removed or so part number is easily read.
1.
Loop belt over the drive clutch and over top of the driven
sheave.
2.
While pushing down on top of belt, turn the back, or
moveable driven sheave, clockwise.
3.
The belt then should be able to be pushed down into and
between the sheaves.
Projected Belt Width
Belt Width
New: 1.188” (3.02 cm)
Wear Limit: 1.157 (2.94 cm)
1.
Measure belt width and replace if worn severely.
• The top edges have been trimmed on some drive belts.
It will be necessary to project the side profiles and
measure from corner to corner.
• Place a straight edge on each side of the drive belt.
• Place another straight edge on top of belt.
• Measure the distance where the side straight edges
intersect the top.
2.
Inspect belt for loose cords, missing cogs, cracks,
abrasions, thin spots, or excessive wear. Replace if
necessary.
3.
Inspect belt for hour glassing (extreme circular wear in at
least one spot and on both sides of the belt). Hour glassing
occurs when the drive train does not move and the drive
clutch engages the belt.
Belt Outer Circumference
New: 40.89” (103.85 cm)
Wear Limit: 41.08” (104.34 cm)
4.
Measure belt length with a tape measure around the outer
circumference of the belt.
5.
Replace belt if worn past the wear limit. Belts with thin
spots, burn marks, etc., should be replaced to eliminate
noise, vibration, or erratic PVT operation. See the
Troubleshooting Chart at the end of this chapter for
possible causes.
6.8
PVT Break-In (Drive Belt / Clutches)
A proper break-in of the clutches and drive belt will ensure a
longer life and better performance. Break in the clutches and
drive belt by operating at slower speeds during the 10 hour
break-in period as recommended (see Chapter 3 “Engine
Break-In Period” for break-in example). Pull only light loads.
Avoid aggressive acceleration and high speed operation during
the break-in period.
CLUTCHING
DRIVE CLUTCH SERVICE
Spring Specifications
The drive clutch spring has two primary functions:
1.
2.
To control clutch engagement RPM. The springs
which have a higher rate when the clutch is in neutral
will increase clutch engagement RPM.
To control the rate at which the drive belt moves
upward in the drive clutch sheaves. This is referred
to as drive clutch upshift.
There are other components which control upshift, but the
spring is one of the primary components in insuring
optimum performance. It is very important that the spring
is of the correct design and is in good condition.
CAUTION
Never shim a drive clutch spring to increase its
compression rate. This may result in complete
stacking of the coils and subsequent clutch
cover failure.
6
The drive clutch spring is one of the most critical components of the PVT
system. It is also one of the easiest to service. Due to the severe relaxation the
spring is subject to during operation, it should always be inspected for
tolerance limits during any clutch operation diagnosis or repair.
With the spring resting on a flat surface, measure its free length from the outer
coil surfaces as shown. Refer to the spring specification chart for specific free
length measurements and tolerances. Also check to see that spring coils are
parallel to one another. Distortion of the spring indicates stress fatigue,
requiring replacement.
Primary Clutch Springs
PART
NUMBER
7041021
7041022
7041063
7041132
7041168
7041157
7042202
COLOR CODE
Plain
Black
Purple
White
Green
Blue/Green
Blue/Gray
Secondary Clutch Springs
WIRE
DIAMETER
.157"
.140"
.168"
.177"
.177"
.177"
.187"
FREE LENGTH
± .125”
4.38"
4.25"
4.37"
2.92"
3.05"
2.53"
2.55"
PART
NUMBER
DESCRIPTION
3234199
White/Yellow
6.9
CLUTCHING
Shift Weights
Shown below are the shift weights which have been designed for the PVT system. These shift weights have many factors designed
into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having
a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting
pattern.
6.10
CLUTCHING
Exploded View
Bushing
Lock
Washer
Spring
Limiter
Spider
Cover
Bearing
Bolt
Bearing
Non-Braking
Bearing
Spacer
Button
Roller
Button
Cover
Screws
Flat
Washer
Pin
Washers
Nut
Bolt
Washers
6
Shift
Weight
Clutch Disassembly
1.
Using a permanent marker, mark the cover, spider, and
moveable and stationary sheaves for reference, as the cast
in X's may not have been in alignment before disassembly.
3.
Inspect cover bushing (A). The outer cover bushing is
manufactured with a Teflon™ coating. Wear is determined
by the amount of Teflon™ remaining on the bushing.
A
2.
Remove cover bolts evenly in a cross pattern and remove
cover plate.
Cover Bushing Inspection:
Replace the cover bushing if more
brass than Teflon™ is visible on
the bushing. Refer to bushing
replacement in this chapter.
6.11
CLUTCHING
4.
Inspect area on shaft where bushing rides for wear, galling,
nicks, or scratches. Replace clutch assembly if worn or
damaged.
NOTE: It is important that the same number and
thickness of washers are reinstalled beneath the
spider during assembly. Be sure to note the number
and thickness of these washers.
Inspect Shaft
5.
Remove and inspect the clutch spring. See “Drive Clutch
Spring Specifications” for spring inspection.
To maintain proper clutch balance and
belt-to-sheave clearance, be sure to
reinstall original quantity and thickness
washers
Moveable Sheave Bushing Inspection
3.
Spider Removal
1.
Remove the limiter nut using the Clutch Spider Nut Socket
(PN 2870338).
2.
Install clutch in holding fixture (PN 2871358) and loosen
the spider (counterclockwise) using Clutch Spider
Removal Tool (PN 2870341).
Inspect the Teflon™ coating on the moveable sheave
bushing.
TeflonTM
Moveable Sheave Bushing Inspection:
Replace the cover bushing if more brass
than Teflon is visible on the bushing.
Refer to bushing replacement
in this chapter.
Clutch Holding Fixture:
(PN 2871358)
Spider Removal Tool:
(PN 2870341)
6.12
CLUTCHING
Roller, Pin, and Thrust Washer Inspection
Button To Tower Clearance Inspection
1.
1.
Inspect all rollers, bushings and roller pins by pulling a flat
metal rod across the roller. Turn roller with your finger. If
you notice resistance, galling, or flat spots, replace rollers,
pins and thrust washers in sets of three. Also inspect to see
if roller and bushing are separating. Bushing must fit
tightly in roller. Use the Roller Pin Tool (PN 2870910) to
replace rollers and pins. Take care not to damage roller
bushing or bearing surface of the new pin during
installation.
Inspect for any clearance between spider button to tower.
If clearance exists, replace all buttons and inspect surface
of towers. See “Spider Removal” procedure.
Button to Tower Clearance:
000-.001”
2.
2.
Inspect sheave surfaces. Replace the entire clutch if worn,
damaged or cracked.
Rubber backed buttons can be used in all RANGER clutches
if the hollow roller pin is changed to the solid roller pin.
Shift Weight Inspection
NOTE: The rubber side of the button is positioned
toward the solid roller pin.
WARNING
The clutch assembly is a precisely balanced
unit. Never replace parts with used parts from
another clutch assembly!
1.
If clutch is not disassembled, inspect as shown, using a
clutch holding tool to compress the moveable sheave. The
contact surface of the weight should be smooth and free of
dents or gall marks.
6.13
6
CLUTCHING
2.
Remove shift weight bolts and weights. Inspect as shown.
The contact surface of the weight should be smooth and free
of dents or gall marks. Inspect the weight pivot bore and
pivot bolts for wear or galling. If weights or bolts are worn
or broken, replace in sets of three with new bolts.
Clutch Inspection
NOTE: Remove cover, spring, and spider following
instructions for drive clutch removal, then proceed
as follows:
1.
Remove the moveable sheave spacer sleeve (1) and the
thrust washer (2). Visually inspect the washer for damage.
2.
Measure the thickness and compare to specification.
Replace if worn or damaged.
1
Broken
Worn
Good
NOTE: A damaged shift weight is usually caused by
a damaged or stuck roller in the spider assembly.
See “Roller, Pin and Thrust Washer Inspection”.
2
Bearing Inspection
1.
2.
Rotate non-braking clutch bearing in both clockwise and
counter-clockwise directions. The non-braking bearing
should rotate both directions on the shaft with only a slight
amount of drag.
= In. / mm.
Thrust Washer Thickness
Standard: .030” (.76mm)
Service Limit: .025” (.64mm)
Verify there is no binding or rough spots. If problems are
noted in either direction, continue with disassembly.
3.
Remove the moveable clutch sheave.
4.
Lift bearing (3) and thrust washer (4) off shaft. Replace as
an assembly if worn, damaged, or if problems were noted.
3
4
6.14
CLUTCHING
5.
Inspect surface of shaft for pitting, grooves, or damage.
Measure the outside diameter and compare to
specifications. Replace the drive clutch assembly if shaft
is worn or damaged.
Moveable Sheave Bushing Inspection
Inspect the Teflon™ coating (arrow) on the moveable sheave
bushing. Inspect both sheaves for signs of wear, grooving or
cracking. De-glaze sheave surfaces with a 3M™ Scotch-Brite
Pad if needed.
= In. / mm.
Shaft Diameter:
Standard: 1.3745 - 1.375 (
Service Limit: 1.3730”
6.
Moveable Sheave Bushing Inspection:
Replace the cover bushing if more brass
than Teflon™ is visible on the bushing.
Refer to bushing replacement
in this chapter.
Visually inspect PTFE thrust washer for damage. Measure
the thickness and compare to specification. Replace if worn
or damaged.
= In. / mm.
PTFE Washer Thickness
Standard: .030” (.76mm)
Service Limit: .025” (.64mm)
6.15
6
CLUTCHING
Bushing Service
CAUTION
IMPORTANT: Special Tools Required
EBS Clutch Bushing Tool Kit - 2201379
Item
A, B
C
D
Qty.
1
1
1
Part #
5132027
5132501
5132029
1
Part Description
EBS Puller Tool
EBS Puller Nut
EBS Main Adapter
EBS Bushing Removal Tool
E
--
1
Instructions
9915111
Clutch components will be hot! In order to avoid
serious burns, wear insulated gloves during the
removal process.
Moveable Sheave - Bushing Removal
1.
Remove clutch as outlined previously in this chapter.
2.
Install handle end of the Piston Pin Puller (PN 2870386)
securely into bench vise and lightly grease puller threads.
5132028
Additional Special Tools
Qty.
1
1
Part Description
Clutch Bushing Replacement Tool Kit
Piston Pin Puller
Part #
2871226
2870386
Piston Pin Puller (PN 2870386)
3.
Remove nut from puller rod and set aside.
*Clutch Bushing Replacement Tool Kit (PN 2871226)
#2
#3
Piston Pin Puller
(PN 2870386)
#5
Main Puller Adaptor (#8)
(PN 5020632)
#10
#9
#8
Item
Qty.
#2
1
#3
1
#5
1
#8
#9
1
1
#10
1
Part Description
P-90 Drive/Driven Clutch
Bushing Install Tool
Drive Clutch Cover
Bushing Removal/
Installation Tool (all
clutches)
P-90 Driven Clutch Cover
Bushing Removal Tool
Main Puller Adapter
Adapter Reducer
Number Two Puller
Adapter
Install puller adapter (Item 10 from kit PN 2871226).
5.
Install main adapter (Item D) onto puller.
Part #
Puller Tool (A,B)
Side “A” toward
sheave
5020628
Nut (C)
5020629
5020631
5020632
5010279
Puller
Adapter (10)
Main
Adapter (D)
5020633
NOTE: Bushings are installed at the factory using
Loctite™ 609. In order to remove bushings it will be
necessary to apply heat evenly to the area around
each bushing. Clean all residual Loctite™ from
bushing bore prior to installing new bushing.
6.16
4.
Piston Pin
Puller
6.
With towers pointing toward the vise, slide sheave onto
puller rod.
7.
Install removal tool (Item A, B) into center of sheave with
“A side" toward sheave.
CLUTCHING
NOTE: Use Bushing Tool PA-47336.
Cover Bushing Removal
8.
1.
9.
Install nut (C) onto end of puller rod and hand tighten. Turn
puller barrel to increase tension on sheave if needed. Using
a hand held propane torch, apply heat around outside of
bushing until tiny smoke tailings appear.
Install main adapter (Item 8) on puller.
Removal Tool
(3)
Nut (C)
Turn sheave counterclockwise on puller rod until it comes
free. Lift sheave off puller.
10. Remove nut from puller rod and set aside.
11. Pull bushing removal tool and adapter from puller rod.
Remove bushing from tool and discard.
Adapter Reducer
(9)
Drive Clutch Bushing Installation
1.
Main
Adapter (8)
Place main adapter (Item 8) on puller.
Puller Tool (A,B)
Side “A” toward
sheave
Bushing
Main Adapter
(8)
Piston Pin
Puller
Nut (C)
Piston Pin
Puller
2.
Install adapter reducer (Item 9).
3.
From outside of clutch cover, insert removal tool (Item 3)
into cover bushing.
4.
With inside of cover toward vise, slide cover onto puller.
5.
Install nut onto puller rod and hand tighten. Turn puller
barrel to increase tension as needed.
6.
Turn clutch cover counterclockwise on puller rod until
bushing is removed and cover comes free.
7.
Remove nut from puller rod and set aside.
Remove bushing and bushing removal tool from puller.
Discard bushing.
2.
Apply Loctite™ 609 evenly to bushing bore inside
moveable sheave.
8.
3.
Set bushing in place on sheave.
Cover Bushing Installation
4.
Insert installation puller tool (Item A/B) with “A” side
down, into center of bushing.
NOTE: 800 EFI Clutch - Use Bushing Tool PA-47336.
1.
Apply Loctite™ 609 evenly to bushing bore in cover.
2.
Working from inside of cover, insert new bushing and
bushing installation tool into center of clutch cover.
5.
With towers pointing upward, slide sheave, bushing and
tool onto puller rod.
3.
With main adapter on puller, insert cover onto puller rod,
placing outside of cover toward vise.
6.
Install nut on puller rod and hand tighten. Turn barrel to
apply additional tension if needed.
4.
Install nut on rod and hand tighten. Turn puller barrel to
apply more tension if needed.
7.
Turn sheave counterclockwise, making sure bushing is
drawn straight into bore. Continue until bushing is seated.
5.
Turn clutch cover counterclockwise on puller rod until
bushing is seated.
8.
Remove nut from puller rod and set aside.
6.
9.
Remove sheave from puller.
Remove nut from puller rod. Take installation tool and
clutch cover off rod.
10. Remove installation tool.
6.17
6
CLUTCHING
Clutch Assembly
4.
NOTE: It is important that the same number and
thickness of washers are reinstalled beneath the
spider during assembly. The Teflon bushings are
self-lubricating.
Torque spider to specification using the holding fixture and
spider tool. Torque with smooth motion to avoid damage
to the stationary sheave.
=T
Spider Torque:
200 ft. lbs. (271 Nm)
CAUTION
Do not apply oil or grease to the bushings.
CAUTION
Reassemble the drive clutch in the following sequence. Be sure
the “X”, or the marks that were made earlier are aligned during
each phase of assembly.
Be sure the spider spacer washers are fully
seated in the recessed area in the spider.
Any misalignment will alter clutch balance.
Inverting the clutch while initially tightening the
spider will help position the washers.
5.
Install limiter nut on top of spider using the Clutch Spider
Nut Socket (PN 2870338). Torque to specification.
=T
Spider Nut Torque:
15 ft. lbs. (20 Nm)
6.
1.
Install moveable sheave onto fixed sheave.
2.
Install spider spacers. Use same quantity and thickness as
were removed.
Install shift weights using new lock nuts on the bolts.
Nut on trailing side
Rotation
Spacer washers
3.
Compress spider buttons for each tower and install spider,
making sure that “X”, or the marks that were made earlier,
on spider aligns with “X”, or the marks that were made
earlier, in moveable sheave.
7.
Reinstall clutch spring.
8.
Reinstall cover, aligning “X” mark with other marks.
9.
Torque cover bolts evenly to specification.
=T
Cover Screw Torque:
90 in. lbs. (10.4 Nm)
6.18
CLUTCHING
DRIVEN CLUTCH SERVICE
4.
Clutch Disassembly
1.
Remove driven clutch from the transmission input shaft.
Do not attempt disassembly of the driven clutch from the
outside snap ring. The driven clutch must be disassembled
from the helix side.
Do not disassemble from this side
2.
It is important to mark the position of the shaft, cam cover,
and sheave before disassembly or use the X’s on the
components for reference. This will aid in reassembly and
helps to maintain clutch balance after reassembly.
Place the clutch into the Clutch Compression Tool PN
8700220. Using Compression Extensions PN PS-45909,
press down on top of the spider assembly, compressing the
spider onto the shaft. Remove snap ring (A) and slowly
release the assembly.
Press down on spider
A
5.
Remove the spider assembly, spring (B), and spacer washer
(C).
NOTE: Spring is compression only and has no
torsional wind.
6
B
3.
Remove the four torx screws that secure the cam (helix)
assembly using a T25 torx driver.
C
6.19
CLUTCHING
6.
Remove the inside spider plate (D) and spider dampener
(E). Inspect the spider dampener (E) for wear and replace
if needed.
9.
Press out the spring pins (K) in the inner sheave.
K
D
10. Pull out the clutch roller pins (L) and rollers (M).
E
7.
Remove the E-clips (F), washers (G), and the clutch rollers
(H). Inspect the rollers for wear; replace if worn.
F
G
M
L
H
K
11. Press the shaft and bearing out of the outer sheave using a
press.
8.
Remove the clutch assembly from the holding tool.
Remove the large outer retaining ring (I) and the inner
retaining ring (J).
J
Press Shaft and
Bearing Out
I
Inspect Bearing
6.20
CLUTCHING
12. Inspect the bearing for wear. Spin the bearing, if the
bearing does not spin smoothly, replace it. To remove the
bearing, press the bearing off the shaft.
Bushing Service
IMPORTANT: Special Tools Required
EBS Clutch Bushing Tool Kit - 2201379
Item
A, B
C
D
Qty.
1
1
1
Part #
5132027
5132501
5132029
1
Part Description
EBS Puller Tool
EBS Puller Nut
EBS Main Adapter
EBS Bushing Removal Tool
E
--
1
Instructions
9915111
5132028
Additional Special Tools
Inspect Sheave Surface
13. Inspect the cam (helix) assembly bushing for wear. If the
bushing is worn or the shaft does not fit snug into the
bushing, replace the cam (helix) assembly.
Qty.
1
1
Part Description
Clutch Bushing Replacement Tool Kit
Piston Pin Puller
Part #
2871226
2870386
*Clutch Bushing Replacement Tool Kit (PN 2871226)
#2
Inspect Bushing
#3
#5
6
#10
#9
#8
Item
Qty.
#2
1
#3
1
#5
1
#8
#9
1
1
#10
1
Part Description
P-90 Drive/Driven Clutch
Bushing Install Tool
Drive Clutch Cover
Bushing Removal/
Installation Tool (all
clutches)
P-90 Driven Clutch Cover
Bushing Removal Tool
Main Puller Adapter
Adapter Reducer
Number Two Puller
Adapter
Part #
5020628
5020629
5020631
5020632
5010279
5020633
NOTE: Bushings are installed at the factory using
Loctite™ 609. In order to remove bushings it will be
necessary to apply heat evenly to the area around
each bushing. Clean all residual Loctite™ from
bushing bore prior to installing new bushing.
6.21
CLUTCHING
Clutch Bushing Removal
Clutch Bushing Installation
1.
Install main puller adapter (Item 8) onto puller.
1.
Install puller adapter (Item 10) onto puller.
2.
Install adapter reducer (Item 9).
2.
Install adapter (Item 9) onto puller.
3.
Using a hand held propane torch, apply heat around outside
of bushing until tiny smoke tailings appear.
4.
Flip sheave over so bushing faces downward and install
onto puller.
5.
Install bushing tool (Item 2).
3.
Apply Loctite™ 609 evenly to bushing bore inside
moveable sheave.
4.
Install sheave face down on puller.
5.
Install new bushing on installation tool (Item 2) and install
assembly into sheave.
6.
Install left hand thread nut (C) onto puller rod and hand
tighten against installation tool.
7.
Turn clutch sheave counterclockwise, making sure bushing
is drawn straight into bore. Continue until bushing is
seated.
8.
Remove nut (C) from puller rod and set aside.
9.
Remove installation tool and clutch sheave from puller.
6.
Install left hand nut (C) and spacer onto puller rod and
tighten by hand. Turn puller barrel for further tension if
needed.
7.
Turn clutch sheave counterclockwise until bushing is
removed and sheave comes free.
8.
Remove nut (C) (left hand thread) from puller rod and set
aside.
9.
Remove adapters from puller.
10. Remove bushing and removal tool from adapters. Discard
bushing.
6.22
CLUTCHING
Clutch Assembly
1.
4.
Install a new bearing onto the output shaft using a press.
Line up the “X” on the moveable sheave with the “X” on
the stationary sheave or use the marks previously used. Put
the sheaves together.
Align X’s
2.
Install the shaft/bearing into the outer sheave.
6
3.
Install the small and large retaining rings into the outer
sheave above the bearing.
5.
Install the roller (A) onto the roller pin (B) on both sides.
A
B
6.23
CLUTCHING
6.
7.
Install the roller pin into the sheave assembly on both sides.
The flat side of the roller pin faces downward when the
shaft side is laying flat on the bench.
9.
Install the spring over the shaft.
Flat Side Down
10. Install the clutch rollers (D) onto each side of the outside
spider. Install the washers (E) and E-clips (F) to secure the
rollers. The rollers should spin freely.
Install the spring pins (C) to secure the roller pins. Install
until flush with sheave surface.
11. Install the spider dampener (G) inside the outer spider and
install the inside spider plate (H).
C
Outer Spider
D
E
F
G
H
8.
Install the spacer washer.
Install
Spacer Washer
12. Install the spider assembly onto the shaft with the retaining
ring on top of the spider. NOTE: Use the marks previously
made to align the skip tooth spider, or use the “X” on top
of the spider and align it with the skip tooth on the shaft.
Align Marks
6.24
CLUTCHING
13. Place the clutch into Clutch Compression Tool PN
8700220. Using Compression Extensions PN PS-45909,
press down on the top of the spider assembly, pushing the
spider onto the shaft.
Press down on spider
A
15. Install the cam (helix) assembly over the shaft. Line up the
“X” on the cam, “X” on spider, and “X” on the stationary
sheave or use the marks previously made before
disassembly. NOTE: If the cam assembly (helix) is
difficult to install, be sure the sheaves are aligned. To align
the sheaves place the clutch assembly on a flat surface with
the cam assembly (helix) side down. Press down on the
moveable sheave belt face with both hands and the helix
will release.
Press Down to Loosen Helix
14. Slowly compress the spider into place. If the spider appears
to bind while compressing, stop and make sure the skip
tooth on the shaft and the spider are aligned. Once the
spider passes the retaining ring notch on the shaft, install
the retaining ring (A).
16. Use a T25 torx driver to install the four torx screws and
torque to specification.
6
A
=T
T25 Torx:
42-52 in. lbs. (4.75 - 5.88 Nm)
6.25
CLUTCHING
Exploded View
T25
Screws
E-Ring
Thrust
Washer
Roller
Spider
Dampener
Compression
Spring
Cam
(Helix)
Retaining
Ring
Thrust
Washer
Outer
Spider
Moveable
Sheave
Roller
Pin
Spider
Insert
Clutch
Shaft
Slotted
Spring Pin
Retaining
Ring
Stationary
Sheave
6.26
Ball
Bearing
CLUTCHING
TROUBLESHOOTING
Situation
Engine RPM below
specified operating
range, although
engine is properly
tuned.
Probable Cause
-Wrong or broken drive clutch spring.
Remedy
-Replace with recommended spring.
-Drive clutch shift weight too heavy.
-Install correct shift weight kit to match engine
application.
-Driven clutch spring broken or installed in wrong -Replace spring; refer to proper installation location.
helix location.
-Drive clutch binding.
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.
Erratic engine
operating RPM
-Belt worn unevenly - thin / burnt spots.
during acceleration or
load variations.
-Driven clutch malfunction.
Replace belt.
A. Replace ramp buttons.
B. Inspect movable sheave for excessive bushing
clearance.
-Replace the clutch.
-Sheave face grooved.
-Incorrect drive clutch spring (too high spring rate). -Install correct recommended spring.
-Drive clutch shift weights incorrect for application -Install correct recommended shift weights.
(too light).
6
-Drive clutch binding.
-Disassemble and clean clutch, inspecting shift weights
and rollers. Reassemble without the spring and move
sheaves through entire range to further determine
probable cause.
-Driven clutch binding.
-Disassemble, clean, and inspect driven clutch, noting
worn sheave bushing and ramp buttons and helix spring
location.
-Converter sheaves greasy; belt slipage.
-Clean sheaves with denatured alcohol or brake cleaner,
install new belt.
-Replace belt.
Engine RPM above
specified operating
range.
-Drive belt worn too narrow.
Harsh drive clutch
engagement.
-Excessive belt / sheave clearance with new belt. -Perform belt / sheave clearance adjustment with shim
washers beneath spider.
Drive belt turns over -Wrong belt for application.
-Replace with correct belt.
-Abuse (continued throttle application when
-Caution operator to operate machine within guidelines.
vehicle is stationary, excess load)
Belt burnt, thin spots -Dragging brake
-Slow, easy clutch engagement
-Inspect brake system.
-Fast, effective use of throttle for efficient engagement.
6.27
CLUTCHING
Troubleshooting, Continued.....
Situation
Probable Cause
-Plugged air intake or outlet.
Remedy
-Clear obstruction
-Belt slippage due to water, oil, grease, etc., rubbing -Inspect system. Clean , repair or replace as necessary.
Seal PVT system ducts.
on cover.
PVT cover
-Clutches or weight being applied to cover while in -Remove weight. Inform operator.
overheating (melting)
operation.
-High vs. low range.
-Cover seals or ducts leaking
Water ingestion
Belt slippage
PVT noise
Engagement
erratic or stabby
-Operator error
-Belt worn out
-Instruct operator on guidelines for operation in wet
terrain as outlined in Owner’s Safety and Maintenance
Manual.
-Replace belt.
-Water ingestion
-Inspect and seal PVT system.
-Belt contaminated with oil or grease
-Belt worn or separated, thin spots, loose belt
-Inspect and clean.
-Replace belt.
-Broken or worn clutch components, cover hitting -Inspect and repair as necessary.
clutches
-Thin spots on belt, worn belt
-Replace belt. Refer to belt burnt troubleshooting and
instruct operator.
-Drive clutch bushings stick
6.28
-Instruct operator on guidelines for operation in proper
driving range for different terrain as outlined in Owner’s
Safety and Maintenance Manual.
-Find leak and repair as necessary.
-Inspect and repair clutches.
FINAL DRIVE
CHAPTER 7
FINAL DRIVE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
FRONT BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING CARRIER INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
CV JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
PROPSHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
FRONT GEARCASE / CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
ALL WHEEL DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
GEARCASE DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
GEARCASE ASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
BACKLASH THRUST PLATE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
REAR BEARING CARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
BEARING CARRIER INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
BEARING CARRIER BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
7
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
REAR GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
GEARCASE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
WHEEL HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
FRONT HUB EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
REAR HUB EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
7.1
FINAL DRIVE
SPECIAL TOOLS
PART NUMBER
TOOL DESCRIPTION
2872608
Roller Pin Removal Tool
8700226
CV Boot Clamp Pliers
(earless type)
2.
Check bearings for side play by grasping the top and bottom
of the tire firmly and checking for movement. The tire
should rotate smoothly without binding or rough spots.
3.
Remove the (4) wheel nuts and remove the front wheel.
4.
Remove the cotter pin and loosen the front wheel hub castle
nut. Remove the nut, and (2) cone washers from the front
wheel hub assembly.
TORQUE SPECIFICATIONS
Wheel, Hub, and Spindle Torque Table
ITEM
NUT TYPE
SPECIFICATION
Aluminum Wheels
(Cast)
Lug Nut (1)
90 ft. lbs. (122 Nm)
Steel Wheels
(Black / Camo)
Flange Nut (2)
27 ft. lbs. (37 Nm)
Front Hub
Castle Nut
-
80 ft. lbs. (108 Nm)
Rear Hub
Castle Nut
-
80 ft. lbs. (108 Nm)
Castle Nut
Cone
Washers
#2
#1
Aluminum Wheel
Steel Wheel
(LE Models)
90 ft. lbs. (122 Nm)
(Standard Models)
27 ft. lbs. (37 Nm)
Cotter Pin
5.
Remove the steering tie rod end fastener from the front
bearing carrier.
FRONT BEARING CARRIER
Bearing Carrier Inspection / Removal
1.
Elevate front of vehicle and safely support machine under
the frame area.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
7.2
Steering
Tie Rod End
FINAL DRIVE
6.
Remove the two brake caliper mounting bolts.
CAUTION: Do not hang the caliper by the brake line. Use
wire to hang caliper to prevent damage to the brake line.
Remove
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
outer race.
12. Replace bearing if moisture, dirt, corrosion, or roughness
is evident.
Bearing Replacement
Bearing Removal
1.
7.
Remove the front wheel hub assembly.
8.
Remove the upper and lower ball joint pinch bolts.
Remove outer snap ring.
Snap Ring
Pinch
Bolts
7
9.
2.
From the back side of the bearing carrier, tap on the outer
bearing race with a drift punch in the reliefs as shown.
3.
Drive bearing out evenly by tapping on outer race only.
Once bearing is at bottom of casting, support casting on
outer edges so bearing can be removed.
4.
Inspect the bearing carrier housing for scratches, wear or
damage. Replace front bearing carrier if damaged.
Using a soft faced hammer, lightly tap on the bearing carrier
while removing the upper and lower ball joint ends.
10. Remove the bearing carrier from the front drive shaft.
11. Rotate bearing by hand and check for smooth rotation.
Visually inspect bearing for moisture, dirt, or corrosion.
7.3
FINAL DRIVE
Bearing Installation
3.
5.
Thoroughly clean the front bearing carrier housing and the
outer race on the new bearing. Be sure that all oil residue
has been removed from each surface.
6.
Support the bottom of the bearing carrier housing.
CAUTION
17 ft. lbs.
23 (Nm)
Use an arbor and press only on the outer race,
otherwise bearing damage may occur.
7.
Install pinch bolts and torque to 17 ft. lbs. (23 Nm).
Apply Loctite® RC™ 680 to the outer circumference of
the new bearing race and carefully press the new bearing
into the bearing carrier housing.
Apply
Loctite® RC™ 680
=T
Pinch Bolt Torque:
17 ft. lbs. (23 Nm)
Snap Ring
4.
Apply grease to drive shaft axle splines.
5.
Install front wheel hub assembly, cone washers, and hand
tighten the castle nut. Install washers with domed side out.
Cone Washers
Bearing
Wheel
Hub
NOTE: Use care to not allow any of the Loctite®
compound to get in the bearing.
8.
Wipe the housing clean of any excess compound and install
the snap ring.
Bearing Carrier Installation
1.
2.
Install drive shaft axle through the backside of the bearing
carrier.
Install the upper and lower ball joint ends into the front
bearing carrier.
7.4
Out
6.
Install brake caliper mounting bolts and torque to 30 ft. lbs.
(40 Nm).
30 ft. lbs.
(40 Nm)
FINAL DRIVE
=T
Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a NEW
cotter pin. Tighten nut slightly if necessary to align cotter pin
holes.
Front Caliper Mounting Bolt Torque:
30 ft. lbs. (40 Nm)
80 ft. lbs.
(108 Nm)
CAUTION
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.
7.
Install the steering tie rod end onto the front bearing carrier
and torque fastener to 42.5 ft. lbs. (58 Nm).
NEW Cotter Pin
42.5 ft. lbs.
58 (Nm)
=T
Wheel Hub Castle Nut Torque:
80 ft. lbs. (108 Nm)
8.
Install wheel and (4) wheel nuts. Torque wheel nuts to
specification.
=T
7
Wheel Nut Torque:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 90 ft. lbs. (122 Nm)
=T
9.
Tie Rod End Fastener Torque:
42.5 ft. lbs. (58 Nm)
Rotate wheel and check for smooth operation. Bend both
ends of cotter pin around end of spindle in different
directions.
7.5
FINAL DRIVE
FRONT DRIVE SHAFT
6.
Drive Shaft Removal
1.
Remove the upper ball joint pinch bolt.
Pinch
Bolt
Elevate front of vehicle and safely support machine under
the frame area.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
2.
Remove the (4) wheel nuts and remove the front wheel.
3.
Remove the cotter pin and loosen the front wheel hub castle
nut. Remove the nut, and (2) cone washers from the front
wheel hub assembly.
7.
Using a soft faced hammer, lightly tap on the bearing carrier
while removing the upper ball joint end.
8.
Remove the drive shaft from the front bearing carrier.
9.
With a short, sharp jerk, remove drive shaft from the front
gearcase.
Castle Nut
Cone
Washers
Cotter Pin
4.
Remove the two brake caliper mounting bolts.
CAUTION: Do not hang the caliper by the brake line. Use
wire to hang caliper to prevent damage to the brake line.
Remove
5.
Remove the front wheel hub assembly.
7.6
FINAL DRIVE
Drive Shaft / CV Joint Handling Tips
4.
Care should be exercised during drive shaft removal or when
servicing CV joints. Drive shaft components are precision parts.
It may be necessary to tap the CV joint assembly outward
with a soft faced hammer.
Retaining Ring
Cleanliness and following these instructions is very important to
ensure proper shaft function and a normal service life.
• The complete drive shaft and joint should be handled by
getting hold of the interconnecting shaft to avoid
disassembly or potential damage to the drive shaft
joints.
• Over-angling of joints beyond their capacity could
result in boot or joint damage.
• Make sure surface-ground areas and splines of shaft are
protected during handling to avoid damage.
• Do not allow boots to come into contact with sharp
edges or hot engine and exhaust components.
• The drive shaft is not to be used as a lever arm to
position other suspension components.
• Never use a hammer or sharp tools to remove or to
install boot clamps.
Pull shaft to remove
from CV joint
5.
NOTE: If the vehicle has been operated with a
damaged boot, the CV joint grease may be
contaminated.
Inspect the grease carefully for
contamination and clean the joint thoroughly if
necessary.
6.
• Be sure joints are thoroughly clean and that the proper
amount and type of grease is used to refill when joint
boots are replaced and when joints are cleaned. Refer
to text for grease capacity of CV joints and CV joint
boots.
Inner Plunging Joint:
Boot replacement only - 45g
Boot replacement w/joint cleaning - 90g
CV Boot Clamp Pliers:
Earless Type - 8700226
Remove the large end of the boot from the CV joint and
slide the boot back.
3.
Separate the outer wheel end of the CV joint assembly from
the axle shaft by pulling the shaft sharply outward, away
from the CV joint.
7
Grease Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Remove clamps from rubber boot using the proper boot
clamp pliers.
2.
Refer to information below or Figure 7-8 for grease
capacity requirements.
Boot Replacement Grease Requirement:
CV Joint / Boot Replacement
1.
Remove the small clamp and boot from the drive shaft.
Outer CV Joint:
Boot replacement only - 45g
Boot replacement w/joint cleaning - 90g
7.
Before installing the new boot, remove all grease from the
boot area and shaft.
NOTE: It is very important to use the correct type
and quantity of grease by using the grease
contained in the boot kit. DO NOT use a substitute
grease and DO NOT overfill or under fill the CV joint.
8.
Slide the new clamp and boot (small end first) over the
splined shaft, then slide (tap) the CV joint into the splines
of the axle. Install small boot clamp.
7.7
FINAL DRIVE
9.
Add grease through large end of boot.
10. Position large end of boot on CV joint, purge excess air by
partially compressing axle into CV bell. Lift one edge of
boot to let out excess air. Secure the CV boot with clamp.
Drive Shaft Installation
1.
Install new spring ring on drive shaft. Apply an anti-seize
compound to splines.
NEW
Spring Ring
FRONT DRIVE SHAFT
Joint Capacity**
45 Grams
Plunging
Joint
Apply
Anti-Seize
2.
Align splines of drive shaft with front gearcase and reinstall
the drive shaft. Use a rubber mallet to tap on the outboard
end of the drive shaft if necessary
3.
Install drive shaft into the front bearing carrier.
4.
Install the upper ball joint end into the front bearing carrier.
Boot Capacity
45 Grams
Boot Capacity
45 Grams
Joint Capacity*
45 Grams
CV Joint
*CV joint capacity: 45g if boot is replaced only.
Another 45g (90g total) if joint is cleaned.
**Plunging joint capacity: 45g if boot is replaced
only. Another 45g (90g total) if joint is cleaned.
Figure 7-8
11. Repeat this procedure to service the inner CV plunging
joint.
7.8
FINAL DRIVE
5.
Install the upper pinch bolt and torque to 17 ft. lbs. (23 Nm).
=T
17 ft. lbs.
(23 Nm)
Wheel Hub Castle Nut Torque:
80 ft. lbs. (108 Nm)
Install brake caliper mounting bolts and torque to 30 ft. lbs.
(40 Nm).
30 ft. lbs.
(40 Nm)
=T
Pinch Bolt Torque:
17 ft. lbs. (23 Nm)
6.
Apply grease to drive shaft axle splines.
7.
Install front wheel hub assembly, cone washers, and hand
tighten the castle nut. Install washers with domed side out.
=T
Cone Washers
Front Caliper Mounting Bolt Torque:
30 ft. lbs. (40 Nm)
Wheel
Hub
7
CAUTION
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.
Out
Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a NEW
cotter pin. Tighten nut slightly if necessary to align cotter pin
holes.
8.
80 ft. lbs.
(108 Nm)
Install wheel and (4) wheel nuts. Torque wheel nuts to
specification.
=T
Wheel Nut Torque:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 90 ft. lbs. (122 Nm)
9.
Rotate wheel and check for smooth operation. Bend both
ends of cotter pin around end of spindle in different
directions.
NEW Cotter Pin
7.9
FINAL DRIVE
PROPSHAFT SERVICE
6.
Remove the fasteners retaining the plastic skid plate and
remove the skid plate from the vehicle.
Removal / Installation
1.
Locate the propshaft roll pin and use the Roll Pin Removal
Tool (PN 2872608), to remove the roll pin.
NOTE: Front wheel can be removed to gain better
access to the propshaft roll pin.
Cupped
Washers
Screws
Roll Pin Removal Tool (PN 2872608)
7.
Remove the propshaft from the vehicle.
8.
Reverse removal steps to reinstall propshaft. Use a NEW
Roll Pin (Spring Pin) upon reassembly.
PROPSHAFT U-JOINT SERVICE
Disassembly
2.
Remove the gear selector cap and remove the retaining
screw.
3.
Remove the push rivets and Torx screws retaining center
console to access the propshaft.
Cap
1.
Remove internal or external snap ring from bearing caps.
CAUTION
Always wear eye protection.
Screw
Push Rivets
Torx Screws
4.
Slide prop shaft back far enough to remove it from the front
gearcase input shaft.
5.
Pull sharply forward to remove it from transmission shaft.
NOTE: You may have to loosen the front gearcase
mounting bolts to allow for propshaft removal.
7.10
NOTE: If yoke or bearing is removed, cross bearing
must be replaced. Note orientation of grease fitting
and mark inner and outer yoke for correct repositioning during installation.
FINAL DRIVE
2.
Support inner yoke as shown and drive outer yoke down
(bearing cap out) with a soft face hammer.
3.
Support U-joint in vise as shown and drive inner yoke down
to remove remaining bearing caps.
2.
Tighten vise to force bearing caps in.
3.
Using a suitable arbor, fully seat the bearing cap in one side.
Continually check for free movement of bearing cross as
bearing caps are assembled.
7
4.
Force U-joint cross to one side and lift out of inner yoke.
4.
Install snap ring to contain bearing cap just installed.
Repeat procedure for other side.
5.
Install outer yoke, aligning marks made at disassembly and
repeat Steps 1-3 to install bearing caps on outer yoke.
6.
Seat all bearing caps against snap rings by supporting cross
shaft and tapping on each corner as shown.
7.
When installation is complete, yokes must pivot freely in
all directions without binding. If the joint is stiff or binding,
tap the yoke lightly to center the joint until it pivots freely.
Assembly
1.
Install new bearing caps in yoke by hand. Carefully install
U-joint cross with grease fitting properly positioned
inward toward center of shaft. Take care not to dislodge
needle bearings upon installation of cross joint.
7.11
FINAL DRIVE
FRONT GEARCASE / CENTRALIZED HILLIARD
Centralized Hilliard Exploded View
9
5
7
5
2
8
6
4
3
10
1
7-11 ft. lbs.
(10-15 Nm)
REF#
DESCRIPTION
QTY
REF#
DESCRIPTION
QTY
1
Cover Screws
6
6
Roll Cage Assembly with H-Springs
1
2
Cover Plate Assembly
1
7
Rollers
20
3
Thrust Plate
1
8
Clutch Housing / Ring Gear
1
4
Armature Plate
1
9
Gearcase Housing
1
5
Output Hub Assembly
2
10
Wire Harness Retainer
1
7.12
FINAL DRIVE
All Wheel Drive Operation
Front Gearcase Engagement: The AWD switch may be
turned on or off while the vehicle is moving. Initially, the
vehicle’s electronic system will not enable the AWD until the
engine RPM is below 3100. Once enabled, AWD will remain
engaged until the rear wheels regain traction and the propshaft
speed matches the front axle speed .
4x4 Engagement: When the AWD switch is turned on, a 12
Vdc current charges the hub coil and creates a magnetic field.
This magnetic field attracts an armature plate keyed to a roller
cage that contains 20 rollers. The difference in rpm between the
input shaft (propshaft) and the front axles, forces the rollers into
the external cam of the Hilliard clutch assembly. The rollers are
forced inward to engage themselves to the output hubs that link
directly to both front axles, resulting in True All Wheel Drive.
Engage the AWD switch before getting into conditions where
the front wheel drive may be needed. If the rear wheels are
spinning, release the throttle before switching to AWD.
CAUTION
Switching to AWD while the rear wheels are
spinning may cause severe drive shaft and
gearcase damage. Always switch to AWD while
the rear wheels have traction or are at rest.
CAUTION
If the rear wheels are spinning, release the
throttle before turning the AWD switch on.
If AWD is engaged while the wheels are
spinning, severe drive shaft and clutch
damage could result.
Roller cage and roller’s rotate inward and grip the output hubs
for AWD engagement.
Normal Operation: With the AWD switch off the vehicle
drives only the rear wheels (2 wheel drive). When the AWD
switch is activated it electronically activates the Hilliard Clutch,
and enables the front wheels to provide driving torque when
needed.
7
Output Hubs
Rollers
Roller Cage
& H-springs
Mechanical Disengagement: As the front and rear wheels gain
traction, rotating very close to the same speed, the front wheels
“overdrive” the output hubs and the rollers are forced outward,
disengaging the AWD. The vehicle is now back to rear wheel
drive until the rear wheels lose traction again.
7.13
FINAL DRIVE
AWD Diagnosis
5.
Symptom: AWD Will Not Engage
1.
Check the gearcase coil resistance. To test the coil
resistance, measure between the Grey and Brown/White
wires. The measurement should be within specification.
Check to make sure the coil is seated in the U-shaped insert
that is pressed into the gearcase cover. The top of the coil
should be seated below the U-shaped insert. The U-shaped
insert controls the pole gap. If the top of the coil is above
the surface of the U-shaped insert it raises the armature
plate, thereby increasing pole gap. If the pole gap increases
the coil will not be strong enough to engage the AWD
system. If this is found, replace the cover plate assembly.
Gearcase Cover Plate Asm.
Coil
U-shaped insert
Side cutaway view of
Centralized Hilliard cover
Front Gearcase Coil Resistance:
21.6 - 26.4 Ohms
6.
2.
Turn the ignition and AWD switches on and place gear
selector in High or Low gear. Check for minimum battery
voltage at the Gray and Brown/White chassis wires that
power the coil. A minimum of 11 Vdc should be present.
Inspect the rollers for nicks and scratches. The rollers must
slide up, down, in and out freely within the roll cage sliding
surfaces and H-springs.
Roll Cage Assembly
Rollers
3.
If electrical tests are within specification, remove gearcase
(see “Gearcase Removal”) and inspect components.
4.
Inspect the armature plate for a consistent wear pattern.
There should be two distinct wear bands (one band inside
the other). If only one band of wear is present (or if there
is wear between the two bands), inspect the coil area as
indicated in Step 5. A wear band with an interrupted wear
mark may indicate a warped plate, which may cause
intermittent operation. See the following illustrations:
Check for
wear bands
7.
Armature Plate
7.14
Inspect the roll cage assembly for cracks or excessive wear.
If damaged, replace the roll cage assembly.
FINAL DRIVE
Gearcase Removal
7.
1.
Stop engine and place gear selector in Park.
2.
Refer to “FRONT DRIVE SHAFT - Drive Shaft Removal”
and remove both front drive shafts from the front gearcase.
3.
Remove the propshaft (see “PROPSHAFT SERVICE”).
4.
Disconnect the wire harness above the front gearcase and
remove the harness from the retaining dart.
Remove the gearcase from the front LH wheel well area and
slide it between the upper and lower A-arm.
AWD Harness
Gearcase Disassembly / Inspection
1.
2.
5.
Remove the vent line from the front gearcase.
6.
Remove the (4) bolts securing the front gearcase to frame.
Drain and properly dispose of gearcase fluid. Remove any
metal particles from the drain plug magnet.
Remove the (6) cover screws and remove the cover plate.
7
Remove
Vent Line
Disconnect
Harness
3.
4.
Remove 4 Bolts
Check the gearcase coil resistance (see “AWD Diagnosis”).
The resistance value should meet the specification.
Remove and inspect the armature plate and thrust plate.
Refer to “AWD Diagnosis” for detailed inspection process.
Armature
Plate
Thrust
Plate
7.15
FINAL DRIVE
NOTE: The backlash for the centralized hilliard is set
at the factory. No adjustment is required unless the
cover plate assembly is replaced, or the backlash
adjustment screw is removed. See the "Backlash
Adjustment” procedure later in this chapter for
details on backlash setting.
5.
8.
Remove the (4) screws retaining the pinion shaft assembly
and remove the assembly from the gearcase housing.
Inspect and clean the gearcase housing and replace the seal.
Replace
Seal
Remove the LH output hub assembly from the clutch
housing.
9.
Clean and inspect all parts. Check for excessive wear or
damage.
10. Inspect the coil located in the cover plate assembly. Refer
to “AWD Diagnosis” for detailed inspection process.
Replace the cover plate seal and O-ring.
6.
Remove the clutch housing from the gearcase housing.
Inspect
Coil
Replace
O-Ring & Seal
7.
Remove the RH output hub assembly from the gearcase
housing.
11. Disassemble the pinion shaft assembly. Inspect the
bearings and replace if needed. Replace the pinion cover
seal and O-ring.
Inspect
Bearings
7.16
Replace
O-Ring & Seal
FINAL DRIVE
12. Remove the roll cage assembly and rollers from the clutch
housing. Use a shop towel to cover the housing in order to
retain all the rollers.
16. Inspect both output hub assemblies. Inspect the bearings
and replace if needed.
Thrust
Bearing
NOTE: Rollers are spring loaded. Take care not to
allow them to fall out or lose them upon removal of
the roll cage.
Bearing
13. Thoroughly clean all parts and inspect the rollers (A) for
nicks and scratches. The rollers must slide up and down and
in and out freely within the roll cage sliding surfaces and
H-springs.
C
Spacer
B
Gearcase Assembly / Inspection
A
14. Inspect the roll cage assembly (B) sliding surfaces and Hsprings. The sliding surfaces must be clean and free of
nicks, burrs or scratches. If damaged, replace the roll cage
assembly.
H-Spring
Roller
Surface
B
1.
As mentioned during gearcase disassembly section,
replace all O-rings, seals, and worn components.
2.
Press the pinion shaft seal into the pinion cover, until the
seal is flush with the sealing surface.
3.
If bearing replacement was required, press new bearings on
to the pinion shaft assembly.
4.
Install pinion shaft, bearings, and pinion cover with new
O-ring and torque screws to 7-11 ft. lbs. (10-15 Nm).
Torque
Screws
Pinion Cover Screw Torque:
15. Inspect clutch housing ring gear (C) for a consistent wear
pattern. Inspect the ring gear for chipped, broken, or
missing teeth.
7-11 ft. lbs. (10-15 Nm)
7.17
7
FINAL DRIVE
5.
Carefully install the rollers into the roll cage assembly
while installing the assembly into the clutch housing.
9.
Install the RH output hub into the clutch housing assembly.
RH Hub
Clutch
Housing
IMPORTANT: To ensure gearcase is assembled
properly, assemble the gearcase components
starting with the cover plate and build upward.
6.
10. While holding the hub in the clutch housing, flip the clutch
housing over and install the armature plate. Engage the tabs
into the slots in the roll cage assembly.
NOTE: Be sure armature plate tabs are placed into
the slots on roll cage (see reference photo).
Install a new O-ring on the cover plate assembly.
NOTE: Be sure the square O-ring is placed flat on
the cover surface. If the O-ring is twisted fluid
leakage may occur.
7.
Carefully install the LH output hub assembly with the thrust
bearing into the cover plate. Take care not to damage the
new cover plate seal while installing the output hub.
Thrust
Plate
LH Hub
11. While holding the hub in the clutch housing and the
armature plate in the roll cage, flip the clutch housing
assembly over and set it on the cover plate.
NOTE: Be sure to hold armature plate in place until
the housing is completely resting on the cover plate.
8.
Place the thrust plate onto the adjuster button located in the
cover plate assembly using a light film of grease to hold it
in place.
Armature
Plate
7.18
FINAL DRIVE
12. Line up the gearcase housing with the cover plate assembly.
Set the gearcase housing on top of the assembled cover
plate. Take care not to damage the new seal when installing
the gearcase housing.
NOTE: Rotate the input shaft while setting the
gearcase housing in place.
Backlash Thrust Plate Adjustment
NOTE: Ring gear backlash is set from the factory.
No adjustment is required unless the cover plate,
ring gear/clutch housing, or pinion gear assembly is
replaced. Adjustment is also required if the thrust
plate adjustment screw is removed.
1.
Lay the gearcase on its side with the cover plate facing up.
NOTE: The backlash adjustment screw is held in
place with Loctite. Use a heat gun to loosen the
Loctite on the screw.
13. While holding the gearcase together, flip it over and install
the cover plate screws. Torque screws to 7-11 ft. lbs.
(10-15 Nm).
Torque
Screws
Adjustment
Screw
2.
Cover Plate Screw Torque:
Using a hex wrench, turn the backlash screw out 3-4 turns.
Re-apply red Loctite onto the bottom of the screw threads.
Apply
Loctite
7-11 ft. lbs. (10-15 Nm)
3.
Tighten the adjustment screw until it is lightly seated or
until it bottoms out.
7.19
7
FINAL DRIVE
4.
Set the gearcase upright.
5.
Back the adjustment screw out while rotating the pinion
shaft. The pinion shaft should rotate freely during four
complete rotations. The four pinion shaft rotations ensures
that the ring gear completes one full rotation.
4.
Install the vent line.
Install
Vent Line
Connect
Harness
30 ft. lbs.
(41 Nm)
=T
6.
If a tight spot is felt during rotation, loosen the backlash
adjustment screw further and repeat pinion shaft rotation.
Repeat this procedure until the pinion shaft rotates
smoothly four complete times (1 revolution of ring gear).
Front Gearcase Mounting Bolt Torque:
30 ft. lbs. (41 Nm)
5.
AWD Harness
Gearcase Installation
1.
Connect the AWD wire harness.
Install the gearcase back into the vehicle through the LH
wheel well area, between the upper and lower A-arms.
2.
Install the propshaft assembly onto the front gearcase input
shaft. Use a NEW spring pin in the front propshaft.
3.
Install the (4) bolts that secure the front gearcase to the
frame and torque to 30 ft. lbs. (41 Nm).
7.20
6.
Refer to “FRONT DRIVE SHAFT - Drive Shaft
Installation” and install both front drive shafts into the front
gearcase.
7.
Add the proper lubricant to the front gearcase. Refer to
Chapter 2 for fluid fill and change information.
Premium Demand Drive Fluid LT
(PN 2876251)
Front Housing Capacity
6.75 fl. oz. (200 ml)
FINAL DRIVE
REAR BEARING CARRIER
6.
Remove the rear wheel hub assembly.
7.
Remove the bolts that attach the rear bearing carrier to the
upper and lower A-arms.
Bearing Carrier Inspection / Removal
1.
Elevate rear of vehicle and safely support machine under
the frame area.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
2.
Check bearings for side play by grasping the top and bottom
of the tire firmly and checking for movement. The tire
should rotate smoothly without binding or rough spots.
3.
Remove the (4) wheel nuts and remove the rear wheel.
4.
Remove the cotter pin and loosen the rear wheel hub castle
nut. Remove the nut, and (2) cone washers from the rear
wheel hub assembly.
Castle Nut
Cone
Washers
5.
7
8.
Remove the bearing carrier from the rear drive shaft.
9.
Rotate bearing by hand and check for smooth rotation.
Visually inspect bearing for moisture, dirt, or corrosion.
Cotter Pin
Remove the two brake caliper attaching bolts.
CAUTION: Do not hang the caliper by the brake line. Use
wire to hang caliper to prevent damage to the brake line.
Remove
7.21
FINAL DRIVE
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
outer race.
Bearing Installation
5.
Thoroughly clean the rear bearing carrier housing and the
outer race on the new bearing. Be sure that all oil residue
has been removed from each surface.
6.
Support the bottom of the bearing carrier housing.
CAUTION
10. Replace bearing if moisture, dirt, corrosion, or roughness
is evident.
Bearing Replacement
Use an arbor and press only on the outer race,
otherwise bearing damage may occur.
7.
Bearing Removal
1.
Remove outer snap ring.
Apply Loctite® RC™ 680 to the outer circumference of the
new bearing race and carefully press the new bearing into
the bearing carrier housing.
Apply
Loctite® RC™ 680
Snap Ring
Snap Ring
Bearing
NOTE: Use care to not allow any of the Loctite®
compound to get in the bearing.
2.
From the back side of the bearing carrier, tap on the outer
bearing race with a drift punch in the reliefs as shown.
8.
Wipe the housing clean of any excess compound and install
the snap ring.
Bearing Carrier Bushing Replacement
Check bearing carrier bushings and pivot tubes for excessive
wear or damage. If replacement is required, slide pivot tubes out
and remove bushings with a drift punch. Install new bushings
by pressing them into the bearing carrier.
Pivot Tube
Control Arm
Bushing
3.
Drive bearing out evenly by tapping on outer race only.
Once bearing is at bottom of casting, support casting on
outer edges so bearing can be removed.
4.
Inspect the bearing carrier housing for scratches, wear or
damage. Replace rear bearing carrier if damaged.
7.22
Pivot
Bushing
Pivot Tube
Control Arm
Bushing
FINAL DRIVE
Bearing Carrier Installation
1.
5.
Install brake caliper mounting bolts and torque to 18 ft. lbs.
(24 Nm).
Install drive shaft axle through the backside of the bearing
carrier. Be sure bushings and pivot tubes are installed.
18 ft. lbs.
24 (Nm)
=T
2.
Install the fasteners that attach the rear bearing carrier to the
upper and lower A-arms. Torque bolts to 37 ft. lbs.
(50 Nm).
Rear Caliper Mounting Bolt Torque:
18 ft. lbs. (24 Nm)
CAUTION
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.
37 ft. lbs.
50 (Nm)
6.
Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a
NEW cotter pin. Tighten nut slightly if necessary to align
cotter pin holes.
=T
Rear Bearing Carrier Bolt Torque:
37 ft. lbs. (50 Nm)
3.
Apply grease to drive shaft axle splines.
4.
Install rear wheel hub assembly, cone washers, and hand
tighten the castle nut. Install washers with domed side out.
80 ft. lbs.
(108 Nm)
NEW Cotter Pin
Cone Washers
=T
Wheel
Hub
Wheel Hub Castle Nut Torque:
80 ft. lbs. (108 Nm)
Out
7.23
7
FINAL DRIVE
7.
Install wheel and (4) wheel nuts. Torque wheel nuts to
specification.
4.
Remove the two brake caliper attaching bolts.
CAUTION: Do not hang the caliper by the brake line. Use
wire to hang caliper to prevent damage to the brake line.
=T
Wheel Nut Torque:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 90 ft. lbs. (122 Nm)
8.
Remove
Rotate wheel and check for smooth operation. Bend both
ends of cotter pin around end of spindle in different
directions.
REAR DRIVE SHAFT
Removal
1.
Elevate rear of vehicle and safely support machine under
the frame area.
5.
Remove the rear wheel hub assembly.
6.
Remove the bolt that attaches the rear bearing carrier to the
upper A-arm.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
2.
Remove the (4) wheel nuts and remove the rear wheel.
3.
Remove the cotter pin and loosen the rear wheel hub castle
nut. Remove the nut, and (2) cone washers from the rear
wheel hub assembly.
Castle Nut
Cone
Washers
7.24
Cotter Pin
FINAL DRIVE
7.
Slide the rear drive shaft out of the bearing carrier by
pulling the bearing carrier assembly outward and tipping it
down to remove the shaft.
Outer CV Joint / Boot Replacement
1.
Place the drive shaft in a soft-jawed vise.
2.
Using side cutters, cut away and discard the boot clamps.
3.
Slide the boot down the shaft and wipe the grease away
from the face of the joint to access the snap ring located in
the recess of CV joint.
Snap Ring
8.
Grasp the rear drive shaft and pull sharply outward on the
shaft to disengage it from the rear gearcase.
NOTE: Take care
damaging the seal.
when
removing
to
prevent
4.
Hold open the snap ring using a snap ring pliers or duckbill
pliers.
Spread ends of snap ring
to remove joint from shaft
7
9.
Inspect the axle splines and CV boots for any damage.
5.
While holding the snap ring open, strike the outer housing
with a soft faced hammer to drive the joint off the shaft. If
the joint refused to budge, a brass drift can be used against
the face of the inner race to drive the joint off.
7.25
FINAL DRIVE
6.
Remove boot from the shaft.
CAUTION
Complete disassembly of the CV joint is NOT
recommended. The internal components are a
precision fit and develop their own characteristic
wear patterns. Intermixing the internal
components could result in looseness, binding,
and/or premature failure of the joint.
IMPORTANT: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint should
be replaced.
7.
8.
Thoroughly clean the joint with an appropriate solvent and
dry the joint to prevent any residual solvent from being left
in the joint upon reassembly.
Visually inspect the joint by tilting the inner race to one side
to expose each ball. Severe pitting, galling, play between
the ball and its cage window, any cracking or damage to the
cage, pitting or galling or chips in raceways call for joint
replacement.
NOTE: Shiny areas in ball tracks and on the cage
spheres are normal. Do not replace CV joints
because parts have polished surfaces. Replace CV
joint only if components are cracked, broken, worn
or otherwise unserviceable.
9.
Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
10. If required, place a new snap ring in the groove of the CV
joint inner hub with tabs facing the shaft as shown.
Tabs face the shaft
11. Before you assemble the CV joint, slide the new clamp and
new boot onto the splined shaft.
12. If a new joint is being installed, grease it with the special
CV joint grease provided in the kit. Fill the cavity behind
the balls and the splined hole in the joint’s inner race. Pack
the ball tracks and outer face flush with grease. Place any
remaining grease into the boot.
CAUTION
The grease provided in the replacement kit is
specially formulated for wear resistance and
durability. DO NOT use substitutes
or mix with other lubricants.
NOTE: The amount of grease that’s provided is premeasured, so use all the grease.
13. Refer to information below or Figure 7-28 at the end of this
section for grease capacity requirements.
Boot Replacement Grease Requirement:
Grease Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Outer CV Joint:
Boot replacement only - 30g
Boot replacement w/joint cleaning - 60g
7.26
FINAL DRIVE
14. Slide the joint onto the shaft splines while holding the snap
ring in the face of the inner race open. Push or tap the joint
onto the drive shaft until it “clicks” into place. Pull on the
joint to make sure it is securely locked in place.
Tap joint onto shaft
Inner Plunging Joint / Boot Replacement
1.
Place the drive shaft in a soft-jawed vise.
2.
Using a side cutters, cut away and discard the boot clamps.
3.
Slide the boot down the shaft and wipe the grease away
from the face of the joint.
4.
Using a soft-faced hammer, or brass drift, strike the inner
race of the joint to drive the joint off the shaft.
15. Remove excess grease from the CV joint's external
surfaces.
16. Pull the boot over the joint and position the boot lips into
the grooves on the joint housing and shaft. Make sure the
boot is not dimpled or collapsed, then slide the clamps into
place.
17. Tighten the large clamp using an appropriate clamp pliers.
IMPORTANT: Hammer on inner race only!
5.
18. While pulling out on the CV shaft, fully extend the CV joint
and slide a straight O-ring pick or a small slotted screw
driver between the small end of the boot and the shaft. This
will allow the air pressure to equalize in the CV boot in the
position that the joint will spend most of its life. Before you
remove your instrument, be sure the small end of the boot
is in its correct location on the shaft.
Make sure the circlip is still on the shaft and not left in the
joint.
7
6.
Remove the boot from the shaft.
CAUTION
19. Install the small clamp on the boot and tighten using an
appropriate clamp pliers.
CAUTION
Complete disassembly of the plunging joint is
NOT recommended. The internal components
are a precision fit and develop their own
characteristic wear patterns. Intermixing the
internal components could result in looseness,
binding, and/or premature failure of the joint.
Be careful not to cut through the bridge of the
clamp when tightening.
7.27
FINAL DRIVE
IMPORTANT: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint should
be replaced.
7.
Thoroughly clean the joint with an appropriate solvent and
dry the joint to prevent any residual solvent from being left
in the joint upon reassembly.
8.
Visually inspect the joint for damage. Replace if needed.
9.
Slide the boot clamp and boot (small end first) onto the
drive shaft and position the boot in its groove machined in
the shaft.
12. Grease the inner and outer joint races. Fully compress the
joint and push the drive shaft firmly into the inner race.
13. Align the circlip with the lead-in chamfer.
Shown without
grease for clarity
10. Install a NEW circlip on the end of the shaft.
14. Use a soft-faced hammer to assemble the shaft into the inner
race until you reach the end of the splines.
CAUTION
The grease provided in the replacement kit is
specially formulated for wear resistance and
durability. DO NOT use substitutes
or mix with other lubricants.
NOTE: The amount of grease that’s provided is premeasured, so use all the grease.
11. Refer to information below or Figure 7-28 at the end of this
section for grease capacity requirements.
Boot Replacement Grease Requirement:
Grease Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Inner Plunging Joint:
Boot replacement only - 40g
Boot replacement w/joint cleaning - 80g
7.28
15. Pull on the joint to test that the circlip is seated and that the
joint is securely fastened to the shaft.
Shown without
grease for clarity
FINAL DRIVE
16. Add any remaining grease to the boot.
Installation
17. Pull the boot over the joint and position the boot lips into
the grooves on the joint housing and shaft. Make sure the
boot is not dimpled or collapsed.
1.
Install new spring ring on drive shaft. Apply anti-seize
compound to splines.
NEW
Spring Ring
18. Tighten the small clamp using an appropriate clamp pliers.
19. Pull out on the drive shaft to center the joint in the housing.
Slide a straight O-ring pick or a small slotted screw driver
between the large end of the boot and the joint housing and
lift up to equalize the air pressure in the boot.
20. Position the boot lip in its groove in the outer race and
secure with a boot clamp.
Apply
Anti-Seize
REAR SHAFT
Spring Ring
2.
Joint Capacity
40 Grams
Plunging
Joint
Boot Capacity
40 Grams
Align splines of drive shaft with rear gearcase and reinstall
the drive shaft. Use a rubber mallet to tap on the outboard
end of the drive shaft if necessary.
NOTE: Take care when installing the drive shaft to
prevent damaging the seal.
Gear Side
Boot Kit
7
Boot Capacity
30 Grams
Wheel Side
Boot Kit
3.
Slide the rear drive shaft into the rear bearing carrier.
Joint Capacity
30 Grams
CV Joint
Figure 7-28
7.29
FINAL DRIVE
4.
Lift bearing carrier into place and install the bolt attaching
the bearing carrier to the upper A-arm. Torque fastener to
37 ft. lbs. (50 Nm).
=T
Rear Caliper Mounting Bolt Torque:
18 ft. lbs. (24 Nm)
CAUTION
37 ft. lbs.
50 (Nm)
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.
8.
Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a
NEW cotter pin. Tighten nut slightly if necessary to align
cotter pin holes.
=T
Rear Bearing Carrier Bolt Torque:
37 ft. lbs. (50 Nm)
80 ft. lbs.
(108 Nm)
5.
Apply grease to drive shaft axle splines.
6.
Install rear wheel hub assembly, cone washers, and hand
tighten the castle nut. Install washers with domed side out.
Cone Washers
NEW Cotter Pin
Wheel
Hub
=T
Out
7.
Install brake caliper mounting bolts and torque to 18 ft. lbs.
(24 Nm).
Wheel Hub Castle Nut Torque:
80 ft. lbs. (108 Nm)
9.
Install wheel and (4) wheel nuts. Torque wheel nuts to
specification.
=T
18 ft. lbs.
24 (Nm)
7.30
Wheel Nut Torque:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 90 ft. lbs. (122 Nm)
FINAL DRIVE
REAR GEARCASE
5.
Remove the fasteners and bracket that secure the rear
gearcase to the transmission.
6.
Remove the (4) fasteners and remove the rear mount from
the rear gearcase.
Gearcase Removal
1.
Drain the fluid from the rear gearcase.
2.
Remove the rear drive shafts from each side of the rear
gearcase.
See “REAR DRIVE SHAFT” on page 7.24
3.
Remove the exhaust pipe and exhaust silencer to allow for
gearcase removal.
Silencer
Remove
Remove
Elbow
Pipe
Header
Pipe
Remove
7
4.
Remove the (2) rear gearcase mount bracket fasteners and
mount bolt and remove bracket from vehicle.
7.
Pull the rear gearcase towards the rear of the vehicle to
disengage it from the transmission.
NOTE: If the splined coupler doesn’t slide off the
input shaft on the rear gearcase, use a screwdriver
to hold back the coupler while pulling the rear
gearcase back further to disengage it.
8.
Remove the vent line and lift the rear gearcase upward and
on its side to remove it from the vehicle.
NOTE: Some vehicles will require the bolt to be
removed from the receiver hitch to gain enough
clearance to remove the rear gearcase.
7.31
FINAL DRIVE
Gearcase Disassembly
IMPORTANT: Due to the manufacturing process, the
pinion and ring gear assembly are NOT intended to be
disassembled and replaced.
Pinion and ring gear shimming information is NOT
provided. The components are matched at the factory
which requires special OEM tooling in order to
properly assemble and shim the gears.
In the event damage to the gears or housing requires
replacement, the entire assembly must be replaced.
1.
Drain and properly dispose of used gearcase fluid.
2.
Remove the remaining cover screws from the rear gearcase.
NOTE: Record the thickness of the shim pack
located under each bearing. Keep the shims
together for reassembly.
4.
3.
Remove the ring gear/axle spool assembly. The bearings
are a slip-fit and will slide off the axel spool.
7.32
Inspect each axle spool bearing and race for signs of wear
or damage. Replace races if required using standard bearing
puller tools.
FINAL DRIVE
5.
Inspect the ring gear teeth for chipped, worn, or broken
teeth. If damaged, replace the ring gear and pinion gear as
a set.
7.
Remove the input shaft seal using a seal puller or other
suitable method.
8.
Inspect the input shaft by rotating the assembly in the
gearcase housing while checking for any looseness or
roughness. Inspect the pinion gear teeth for chipped, worn,
or broken teeth. If damaged, replace the ring gear and
pinion gear as a set.
Inspect
NOTE: In the event damage to the gears or housing
requires replacement, the entire assembly must be
replaced.
6.
Remove the seals from each side of the gearcase housing.
Replace the o-ring in the gearcase cover.
7
NOTE: In the event damage to the gears, pinion
bearings or housing requires replacement, the entire
assembly must be replaced.
7.33
FINAL DRIVE
Gearcase Assembly
1.
Install a new input shaft seal using a standard seal installer
or other suitable method.
2.
Install new seals on each side of the gearcase housing using
a standard seal installer or other suitable method. Install a
new o-ring in the gearcase cover.
3.
If removed, install each axle spool bearing race using
standard bearing installation tools and a shop press.
WARNING
Wear the appropriate safety equipment while
installing bearing races to
reduce the risk of injury.
7.34
FINAL DRIVE
4.
Install the shim(s) previously removed onto the appropriate
sides of the axle spool. Install the bearings. The bearings
are a slip-fit and will slide onto the axle spool.
Gearcase Installation
1.
Install the rear gearcase by reversing the procedure listed
under “REAR GEARCASE - Gearcase Removal” at the
beginning of this section.
IMPORTANT: When reinstalling the transmission to
rear gearcase mount bracket, it is extremely important
to torque all (7) fasteners to specification. Refer to the
“Installation” procedure listed on page 4.15.
NOTE: Special tool (PA-48873) will be required to
torque the mounting bracket fasteners when the
transmission and rear gearcase are installed in the
vehicle. Refer to the “Installation” procedure listed
on page 4.15.
5.
Install the ring gear/axle spool assembly into the housing.
Special Tool
PA-48873
7
6.
Install the gearcase cover. Verify the o-ring is in position.
Install the cover screws onto the rear gearcase. Torque to
specification.
2.
Add Polaris ATV Angle Drive Fluid to rear gearcase. Refer
to maintenance information in Chapter 2 for more details.
Torque drain and fill plugs to specification.
=
Rear Gearcase Capacity:
18 fl. oz. (532 ml)
or to bottom of fill plug hole threads
See Chapter 2
=T
=T
Cover Screw Torque:
23-27 ft. lbs. (31-37 Nm)
Drain / Fill Plug Torque:
Drain Plug - 30-45 in.lbs. (3-5 Nm)
Fill Plug - 40 ft.lbs. (54 Nm)
7.35
FINAL DRIVE
Gearcase Exploded View
14
6
13
9
16
10
4
12
6
5
3
9
7
1
17
10
8
18
23-27 ft. lbs.
(31-37 Nm)
70-80 ft. lbs.
(95-108 Nm)
15
7
7
2
23-27 ft. lbs.
(31-37 Nm)
23-27 ft. lbs.
(31-37 Nm)
16
21
40 ft. lbs.
(54 Nm)
20
30-45 in. lbs.
(3-5 Nm)
19
7
REF#
DESCRIPTION
QTY
REF#
DESCRIPTION
QTY
1
Screw
2
12
Axle, Spool
1
2
Screw
2
13
O-Ring
1
3
Bracket, Rear Mount, RH
1
14
Housing, Rear, LH
1
4
Bracket, Rear Mount, LH
1
15
Screw, Flange Head
2
5
Mount, Rear
1
16
Seal, Oil
2
6
Nut, Flanged
4
17
Screw, Flange Head
4
7
Assembly, Rear Housing, RH
1
18
Screw
8
8
Bearing Retainer Ring
1
19
Dowel
2
9
Assembly, Tapered Roller Bearing
2
20
Plug, Drain w/O-Ring
1
10
Shim
2
21
Plug, Fill w/O-Ring
1
11
Assembly, Gear and Pinion
1
7.36
FINAL DRIVE
WHEEL HUBS
Front Hub Exploded View
Sealed
Ball Bearing
Stud
Bolts
Wheel Hub
Cone
Washers
Cotter Pin
Bearing Carrier
Castle Nut
Retaining
Ring
80 ft. lbs.
(108 Nm)
Brake Disc
Front Rim
Front Tire
Flanged Nuts
See Page 7.2
for Torque Value
Valve
7
Rear Hub Exploded View
Stud
Sealed
Ball Bearing
Bolts
Wheel Hub
Cotter Pin
Cone
Washers
Bearing Carrier
Castle Nut
80 ft. lbs.
(108 Nm)
Retaining
Ring
Brake Disc
Front Rim
Front Tire
Flanged Nuts
See Page 7.2
for Torque Value
Valve
7.37
TRANSMISSION
CHAPTER 8
TRANSMISSION
TORQUES / SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TRANSMISSION REMOVAL / SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TRANSFER CASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TRANSFER CASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
TRANSMISSION SHIFT HOUSING DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
TRANSMISSION SHIFT HOUSING REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
TROUBLESHOOTING CHECKLIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
TRANSMISSION EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
SHIFT HOUSING / TRANSFER CASE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . 8.20
8
8.1
TRANSMISSION
TORQUES / SPECIFICATIONS
SHIFT LEVER
Maintain and check/change these items in accordance with the
maintenance schedule in Chapter 2 or during service repairs.
Removal
ITEM
TORQUE VALUE
Transmission Fill Plugs
40-50 ft. lbs.(54-67 Nm)
Transmission Drain /
Level Plugs
30-45 in. lbs.(0.2-0.3 Nm)
Transmission Case
Screws
23-27 ft. lbs. (31-36 Nm)
Shift Lever Screw
15-20 ft. lbs. (20-27 Nm)
Detent Sleeve Screw
40-45 ft. lbs.(54-61 Nm)
Detent Adjustment Screw
23-27 ft. lbs. (31-36 Nm)
Drain Plugs / Check Plug
30-45 in. lbs.(0.2-0.3 Nm)
Speed Sensor Screw
130-155 in. lbs.(0.9-1.09 Nm)
Position Sensor Screw
25-40 in. lbs.(0.17-0.28 Nm)
Park Flange Screws
130-155 in. lbs.(0.9-1.09 Nm)
Transmission Isolator
Mounting Screws
23-27 ft. lbs. (31-36 Nm)
Transmission Lubricant
Capacity
AGL PN 2873602
24 oz. (710 ml)
Transfer Case Lubricant
Capacity
AGL PN 2873602
14 oz. (414 ml)
Rear Carrier Lubricant
Capacity
ADF PN 2871653
18 oz. (532 ml)
1.
Pry the shift lever cover using a suitable tool and remove
the screw. Pull knob off the shifter.
2.
Refer to Chapter 5 for console cover removal.
3.
Disconnect cable from shifter.
4.
Remove the clip attaching the gear selector to the machine
frame.
5.
Lift the gear shift selector out of mounting bracket and
away from frame.
Installation
1.
Perform the steps in reverse order to install the gear shift
selector. (shifter, cable, console, shift knob)
2.
Tighten the shift cable nut to specification.
=T
Shift Cable Nut Torque:
130-155 in. lbs. (14.7-17.5 Nm)
8.2
TRANSMISSION
Shift Cable Inspection / Adjustment
4.
Adjust the shift cable so there is the same amount of cable
travel when shifting slightly past the detents of HIGH (H)
gear and PARK (P).
5.
Thread the upper or lower jam nut as required to obtain
proper cable adjustment.
Shift cable adjustment may be necessary if symptoms include:
• No AWD or gear position display on instrument cluster
• Ratcheting noise on deceleration
• Inability to engage a gear
1.
• Excessive gear clash (noise)
NOTE: This procedure may require a few attempts to
obtain the proper adjustment.
• Gear selector moving out of desired range
6.
Once the proper adjustment is obtained, place the shift
cable and upper jam nut into the mount. Tighten the lower
jam nut against the mount.
7.
Start engine and shift through all gears to ensure the shift
cable is properly adjusted. If transmission still ratchets after
cable adjustment, check the CVT system for belt movement
at idle. If difficulty shifting persists, the transmission may
require service.
Locate the shift cable in the rear LH wheel well area.
Clevis Pin
Shift Cable
Mount
Shift Cable
Dust Boot
2.
Inspect shift cable, clevis pin, pivot bushings, and dust
boot. Replace if worn or damaged.
3.
If adjustment is required, loosen the lower jam nut and pull
the cable out of the mount to move the upper jam nut.
Upper
Jam Nut
8
Lower
Jam Nut
8.3
TRANSMISSION
TRANSMISSION SERVICE
3.
Remove the (7) bolts retaining the transmission support
bracket.
Transmission Removal / Service Notes
x7
The engine, transmission and rear differential are bolted
together as a unit. Removal of the transmission is not possible
without removing the engine and differential.
The shift housing cannot be removed without first
disassembling the transfer case.
NOTE: Refer to the “Engine Removal” section in
Chapter 3 to remove the engine and drivetrain.
Transfer Case Disassembly
IMPORTANT: Shift housing repairs are not possible
without performing transfer case disassembly. Read
and understand all instructions before beginning
disassembly.
4.
Remove the connector tube bolts securing the rear gear case
and transmission transfer case.
NOTE: Exploded views are located at the end of this
chapter for additional information.
x4
1.
Place the transmission in neutral position.
2.
Drain both the transfer case and transmission case halves.
x3
Transfer Case
Drain Plug
Transmission Gearcase
Drain Plug
5.
Inspect the driveshaft splines for wear and the O-rings for
damage. Replace if found to be worn or damaged.
6.
Remove the LH front isolator mount bracket. Refer to
Chapter 3.
7.
Remove the screws from the transfer case cover and
remove the cover (note position of the longest screw #4).
1
4
8
3
2
5
8.4
7
6
TRANSMISSION
8.
After removing the cover, remove the intermediate shaft
bearing cup and shims from the cover. Bearing cup is a
slip-fit. Note and record the number and thickness of shims
and set aside. Also note the two alignment dowels (circle)
in the cover for installation.
10. Remove the intermediate pinion shaft assembly from the
housing. Check bearings and gear teeth for wear or damage
and replace as needed. The shaft can be disassembled as
shown using a press and standard bearing removal tools.
NOTE: Record the number and thickness of shims
for reassembly.
9.
Disassemble the cover as required, replacing components
that are failed or worn. Check bearings for wear or damage
and replace as needed using a press and standard bearing
removal tools. Discard removed bearings as they become
damaged by the removal process.
11. Disassemble the output pinion shaft assembly by removing
the retaining screws on the bearing cup/bracket assembly.
Replace the output shaft seal. The output pinion shaft can
be disassembled as shown using a press and standard
bearing removal tools.
x3
8
12. Output shaft bearing cup is a slip-fit. Remove, note and
record the number and thickness of shims and set aside.
Note the alignment dowels (circled) in the cover for
installation.
8.5
TRANSMISSION
13. Remove the front output pinion shaft assembly. The shaft
can be disassembled as shown using a press and standard
bearing removal tools.
15. Remove the lower snap ring from under the gear.
16. Remove the intermediate shaft seal using a seal puller or
other suitable method.
14. Remove the upper snap ring from the top side of the 21T
main pinion gear and remove the gear.
8.6
TRANSMISSION
Transfer Case Reassembly
1.
2.
3.
Install the shims, bearing cup and alignment dowels into the
retaining bracket.
4.
Install a new output shaft seal flush with the case. Install
the output pinion shaft assembly and bearing cup/bracket
assembly as shown. Verify the alignment dowels are
seated. Torque the bracket screws evenly to specification.
Install the intermediate shaft seal (circled) flush or slightly
below the case. Install circlips and gear onto the input
intermediate shaft as shown.
Install the front output pinion shaft assembly.
NOTE: Bearing is pressed onto the shaft
x3
x2
8
=T
Output Pinion Shaft Bracket Screws:
23-27 ft. lbs. (31-37 Nm)
8.7
TRANSMISSION
5.
Reinstall the intermediate pinion shaft assembly and
bearing cup.
7.
Install the transfer case cover. Align the dowels (#1 & #7)
and insert the cover screws (note position of the longest
screw #4). Torque the screws evenly to specification in
sequence as shown.
1
4
8
6
3
2
6.
Assemble the transfer case cover using new components as
required. Press in new bearings and a seal using standard
installation tools. (needle bearing is installed round edge
inward) Install a new shaft seal flush with the surface, the
shims and bearing cup. Apply a thin coat of sealant to the
mating surfaces. Apply lubricant to the seal lip.
2871557
Apply Sealant PN 2871557
To Case Mating Surfaces
8.8
5
7
=T
Transfer Case Cover Screws:
23-27 ft. lbs. (31-37 Nm)
TRANSMISSION
Transmission Shift Housing Disassembly
2.
IMPORTANT: Shift housing repairs are not possible
without performing transfer case disassembly. Read
and understand all instructions before beginning
disassembly.
1.
Place the transmission shift housing onto a flat surface as
shown. Lift the transmission case half straight up and
remove.
Verify transmission is in neutral. Remove the (7) shift
housing case screws from the front of the transmission and
(2) from the backside as shown.
NOTE: Shaft components may “catch” during
transmission case half disassembly. Work slowly
and deliberately to avoid component loss or
damage.
3.
NOTE: Shift cable bracket removal is required.
Using a suitable tool, pry the reverse retaining plate up from
the (2) roll pins and remove the reverse clutch/gear
assembly from the housing. Note the orientation of the (2)
thrust washers (top / bottom of gear assembly) and needle
bearing. Inspect these components and replace as required.
8
Reverse Gear
8.9
TRANSMISSION
4.
Remove the (5) screws retaining the park flange. Inspect the
park flange dogs for wear or damage. Replace as required.
7.
Remove the input shaft seal and clutch intermediate shaft
seal using a seal puller or punch.
5.
Inspect the shaft bearing. Use a standard bearing puller to
remove the shaft bearing if required.
8.
Remove the (2) screws that attach the shift switch to the
shift housing. Inspect the O-ring, switch poles and spring
pins for wear or damage. Replace parts as required.
NOTE: Do not pull bearing from cases for
inspection, as the removal process damages the
bearing.
6.
Remove the reverse idler snap ring, upper washer, gear,
needle bearing, and lower washer from the idler shaft.
Neutral
NOTE: The reverse idler shaft is a non-serviceable
item and should not be pressed out of the housing.
8.10
TRANSMISSION
9.
Remove the plate, pins, springs, drum gear and thrust
washer from the shift housing. Replace any worn or
damaged components.
10. Remove the inner shift detent screws, springs, and balls
from each side of the shift housing.
11. Remove the park flange sleeve from the clutch shaft.
12. Pull back fully on gear selector arm to bring shift collar up
and disengage the shift collar from the clutch yoke. Lifting
on the clutch shaft may aid in shift collar removal.
NOTE: The clutch yoke side uses the short, "black"
detent screw and the gear selector side detent uses
the longer, "silver" detent screw.
13. Inspect the inner and outer gear teeth and splines on both
ends of the shift collar for excessive wear or damage.
INSPECT
NOTE: Never remove the outer shift detent screw
first. Removal of the outer screw will allow the detent
ball and spring to fall into the shift housing.
8.11
8
TRANSMISSION
14. Remove the sliding shoes from the clutch yoke.
17. From the back side of the high gear assembly, separate the
high and low gear assemblies by tapping the gear retaining
plate from the roll pins using a brass punch. Note the order
of disassembly on the entire gear assembly (plate, thrust
washer, bearing, thrust washer). Inspect all parts for wear
or damage and replace as required.
High Gear
Low Gear
15. Remove the clutch shaft from the housing. Note that the
forward gear assembly will remain in the housing.
Retaining Plate
18. Remove the clutch yoke pivot pin set screw.
16. Remove the forward clutch gear assembly from the
housing. Note the two needle bearings and washer on the
bottom of the gear assembly.
19. Remove the clutch yoke pivot pin using a 10/24 x 2" bolt.
10/24 x 2”
8.12
TRANSMISSION
20. Remove the clutch yoke from the gear selector shaft and
spring.
21. Remove the transmission input shaft from the housing.
Inspect the shaft bearing and replace if required using a
shop press. Inspect the gears for damage and/or wear.
Replace the shaft if required.
22. Remove the screw from the end of the gear selector shaft
assembly and remove the assembly from the housing.
Note the clips, spring and plate orientation.
23. Inspect the gear selector shaft and housing for excessive
wear or damage. Replace components as required.
24. Inspect and replace the case bearings if required.
8
NOTE: Do not pull bearings from case for
inspection, as the removal process damages the
bearing.
8.13
TRANSMISSION
Transmission Shift Housing Reassembly
1.
3.
Install the input shaft assembly.
4.
Install clutch yoke into the gear selector shaft and spring.
Align the pivot pin holes and install clutch yoke pivot pin.
5.
Apply sealant to the clutch yoke set screw threads and
install flush with the case. Do not torque.
Install a new shift lever seal flush with the case. Apply
lubricant to the seal lip. Press new bearings (if required)
into the housing.
NOTE: Drive bearings and seals using the outer
edge only.
2.
Assemble the spring and clips onto the shaft as shown.
Lubricate the shaft and install the assembly into the
housing. Install the shift lever (“X” facing out) and screw
onto the gear selector shaft. Torque to specification.
“X” out
=T
Shift Lever Screw Torque:
15-20 ft. lbs. (20 - 27 Nm)
8.14
TRANSMISSION
6.
7.
Assemble the high and low gear assemblies as shown.
Complete the assembly by aligning the roll pin holes and
tapping the roll pins through the retaining plate and into the
high gear using a brass punch.
8.
Install the clutch shaft into the housing. Note that the
forward gear assembly is loose in the housing and that
alignment of the shaft, gear assembly, thrust washer and
bearing is necessary for shaft installation.
9.
Install the sliding shoes onto the clutch yoke.
Install the forward clutch gear assembly into the housing.
Note the two needle bearings and washer on the bottom of
the gear assembly.
10. Install the shift collar onto the shaft. Pull back fully on gear
selector arm to bring the shift yoke arms up and engage the
shift shoes onto the center groove of the shift collar.
Shifting the clutch shaft position may aid in shift collar
installation. Install the park flange sleeve on top of the shift
collar with the lip down as shown.
8.15
8
TRANSMISSION
11. Install the outer sleeve screws and inner shift detent screws,
springs, and balls from each side of the shift housing. Use
new o-rings anytime these screws are removed. Torque the
outer sleeve screws to specification. TURN INNER
DETENT SCREWS ONLY UNTIL LIGHT SHIFTING
RESISTANCE IS FELT AT THIS TIME. PLACE THE
TRANSMISSION IN NEUTRAL.
With the transmission in neutral, lubricate and install the thrust
washer, drum gear, plate, springs, pins and the shift position
sensor/o-ring assembly into the shift housing. Verify the shift
drum pins are aligned as shown with the transmission in neutral.
Torque the retaining screws to specification.
NOTE: The clutch yoke side uses the short, "black"
detent screw and the gear selector side detent uses
the longer, "silver" detent screw.
T
T
=
Apply Lubricant to shift drum components
P
R
T
Neutral
H
L
=T
Detent (outer) Sleeve Screws:
40-45 ft. lbs. (54-61 Nm)
N
=T
Shift Position Sensor Screws:
25-40 in. lbs. (2.8-4.5 Nm)
12. Complete shift detent screw installation. Torque the inner
screws to specification.
=T
Shift Detent (inner) Screws:
23-27 ft. lbs. (31-36.6 Nm)
8.16
TRANSMISSION
13. Install the reverse idler lower washer, needle bearing, gear,
upper washer and snap ring onto the idler shaft of the
transmission case half.
16. Install the reverse clutch/gear assembly onto the park
flange. Note the orientation of the (2) thrust washers (top /
bottom of gear assembly), and needle bearing. Complete
the assembly by aligning the roll pin holes and tapping the
roll pins through the retaining plate and into the reverse gear
using a brass punch.
14. Install a new shaft bearing (if required).
15. Install the park flange and torque the (5) screws to
specification.
8
17. Install the input shaft seal and verify it is fully seated. Install
the intermediate shaft seal (circled) flush or slightly below
the case. Apply lubricant to both seal lips.
=T
Park Flange Screws:
130-155 in. lbs. (14.6-17.5 Nm)
8.17
TRANSMISSION
18. Place the transmission shift housing onto a flat surface as
shown. Apply a bead of crankcase sealant onto the mating
surfaces. Align the dowels and install the transmission case
half onto the shift housing while rotating the input shaft,
using care not to damage the seal surfaces.
20. Install the (2) shift housing case screws to the backside as
shown. Torque to specification.
NOTE: Shift cable bracket installation is required.
2871557
Apply Sealant PN 2871557
To Case Mating Surfaces
19. Install the shift cable bracket (7) shift housing case screws
to the front of the transmission. Torque to specification.
=T
Shift Housing Screws:
23-27 ft. lbs. (31-36.6 Nm)
21. Proceed with transfer case reassembly.
See “Transfer Case Reassembly” on page 8.7
=T
Shift Housing Screws:
23-27 ft. lbs. (31-36.6 Nm)
8.18
TRANSMISSION
TROUBLESHOOTING
Troubleshooting Checklist
Check the following items when shifting difficulty is encountered:
• Idle speed adjustment
• PVT alignment
• Transmission oil type/quality
• Transmission torque stop adjustment (where applicable)
• Engine torque stop adjustment (where applicable)
• Drive belt deflection
• Loose fasteners on rod ends
• Loose fasteners on selector box
• Worn rod ends, clevis pins, or pivot arm bushings
• Linkage rod adjustment and rod end positioning
• Shift selector rail travel
• Worn, broken or damaged internal transmission components
NOTE: To determine if shifting difficulty is caused by an internal transmission problem, isolate the
transmission by disconnecting the shifter from transmission bellcrank. Verify the engine RPM is set to
specification. Manually select each gear range at the transmission bellcrank, and test ride vehicle. If it
functions properly, the problem is outside the transmission.
If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding),
damage. Inspect all bearings, circlips, thrust washers and shafts for wear.
8
8.19
TRANSMISSION
TRANSMISSION EXPLODED VIEWS
Shift Housing / Transfer Case Exploded View
Shift Housing
Transfer Case
8.20
BRAKES
CHAPTER 9
BRAKES
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE SYSTEM SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2
9.2
9.2
9.3
9.3
9.4
9.4
9.5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
BRAKE PEDAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
PEDAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
PEDAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
PAD ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
CALIPER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
REAR BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
PAD ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
REAR CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
BRAKES SQUEAL / POOR BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
PEDAL VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
BRAKES LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.1
BRAKES
GENERAL SPECIFICATIONS
FRONT BRAKE SYSTEM
Item
Standard
Service Limit
Front Brake Pad Thickness
.300 ± .007" (7.62 ± .178 mm)
.180" (4.6 mm)
Front Brake Disc Thickness
.188" (4.76 mm)
.170" (4.32 mm)
-
.010" (.254mm)
Front Brake Disc Runout
REAR BRAKE SYSTEM
Item
Standard
Service Limit
Rear Brake Pad Thickness
.298 ± .007" (7.57 ± .178 mm)
.180" (4.6 mm)
Rear Brake Disc Thickness
.188" (4.76 mm)
.170" (4.32 mm)
-
.010" (.254 mm)
Rear Brake Disc Runout
TORQUE SPECIFICATIONS
SPECIAL TOOLS
Item
Torque
ft. lbs.
Torque
Nm
Front Caliper Mounting Bolts
30
40
Rear Caliper Mounting Bolts
18
24
12-15
16-20
Brake Line Banjo Bolts
(Caliper Attachment)
15
20
Brake Line Banjo Bolt
(Master Cylinder Attachment)
15
20
Front Brake Disc to Hub Bolts
28
38
Rear Brake Disc to Hub Bolts
28
38
12-15
16-20
Master Cylinder to Frame
17
23
Brake Pedal Mounting
Bracket to Frame
15
23
Brake Line Flare
Brake Switch
9.2
Part Number
Tool Description
2870975
Mity Vac™ Pressure Test Tool
BRAKES
BRAKE SYSTEM SERVICE NOTES
Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely encounter. There
are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function
and maximum pad service life.
• Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment.
• Do not over-fill the master cylinder fluid reservoir.
• Make sure the brake pedal returns freely and completely.
• Adjust stop pin on front caliper after pad service.
• Check and adjust master cylinder reservoir fluid level after pad service.
• Make sure atmospheric vent on reservoir is unobstructed.
• Test for brake drag after any brake system service and investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins (where applicable).
• Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.
• Perform a brake burnishing procedure after installing new pads to maximize service life.
• DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake cleaning
products.
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, Permatex™ Disc Brake Quiet (PN 2872113) can be applied to the back of the pads.
Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance of squeaks caused by
dirt or dust.
Brake Noise Troubleshooting
Possible Cause
Dirt, dust, or imbedded material on pads or disc
Remedy
Spray disc and pads with CRC Brakeleen™ or an equivalent
non-flammable aerosol brake cleaner. Remove pads and/or disc
hub to clean imbedded material from disc or pads.
Pad(s) dragging on disc (noise or premature pad wear) because
of improper adjustment
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)
Adjust pad stop (front calipers)
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 (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
9
Set to proper level
Clean compensating port
Inspect. Repair as necessary
Clean piston(s) seal
Educate operator
9.3
BRAKES
HYDRAULIC BRAKE SYSTEM OPERATION
The Polaris brake system consists of the following components
or assemblies: brake pedal, master cylinder, hydraulic brake
lines, brake calipers, brake pads, and brake discs, which are
secured to the drive line.
Brake fluid level is critical to proper system operation. Too little
fluid will allow air to enter the system and cause the brakes to
feel spongy. Too much fluid could cause brakes to drag due to
fluid expansion.
When the foot activated brake lever is applied it applies pressure
on the piston within the master cylinder. As the master cylinder
piston moves inward it closes a small opening (compensating
port) within the cylinder and starts to build pressure within the
brake system. As the pressure within the system is increased,
the pistons located in the brake calipers move outward and apply
pressure to the moveable brake pads. These pads contact the
brake discs and move the calipers in their floating bracket,
pulling the stationary side pads into the brake discs. The
resulting friction reduces brake disc and vehicle speed.
Located within the master cylinder is the compensating port
which is opened and closed by the master cylinder piston
assembly. As the temperature within the hydraulic system
changes, this port compensates for fluid expansion or
contraction. Due to the high temperatures created within the
system during heavy braking, it is very important that the master
cylinder reservoir have adequate space to allow for fluid
expansion. Never overfill the reservoir! Do not fill the
reservoir beyond the MAX LEVEL line!
The friction applied to the brake pads will cause the pads to
wear. As these pads wear, the piston within the caliper moves
further outward and becomes self adjusting. Fluid from the
reservoir fills the additional area created when the caliper piston
moves outward.
When servicing Polaris brake systems use only Polaris DOT 4
Brake Fluid (PN 2872189). WARNING: Once a bottle is
opened, use what is necessary and discard the rest in accordance
with local laws. Do not store or use a partial bottle of brake fluid.
Brake fluid is hygroscopic, meaning it rapidly absorbs moisture.
This causes the boiling temperature of the brake fluid to drop,
which can lead to early brake fade and the possibility of serious
injury.
BRAKE SYSTEM EXPLODED VIEW
LH Front Caliper
LH Rear Line
3
1
2
Cross
Fitting
Brake
Switch
LH Front
Brake Line
Master Cylinder
2
1
RH Front Caliper
3
2
LH Rear Caliper
2
1
MC Rear
Brake Line
1
1
RH Rear Line
RH Front
Brake Line
RH Rear Caliper
Caliper Banjo Style Fittings:
Master Cylinder Side View
1 15 ft. lbs. (20 Nm).
All Caliper Bleed Screws:
2 47 in. lbs. (5.3 Nm)
All Flare Style Fittings:
3 12-15 ft. lbs. (16-20 Nm)
9.4
15 ft. lbs.
(20 Nm)
BRAKES
MASTER CYLINDER
CAUTION
Removal
1.
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact
with finished surfaces.
Locate the master cylinder above the LH front tire in the
wheel well area.
Master Cylinder
NOTE: Make note of front and rear brake line
locations to master cylinder.
4.
Loosen the brake line banjo bolts (C) and allow fluid to
drain.
NOTE: Dispose of fluid properly. Do not re-use.
5.
Remove the two mounting fasteners (D) that secure the
master cylinder to the frame.
Installation
1.
Reverse Steps 1-5 for master cylinder installation.
Refer to the torque specifications in the illustration.
2.
After installing the foot brake check pedal freeplay. Pedal
freeplay should not exceed .090” (2.286 mm).
BRAKE PEDAL LEVER
2.
Remove the clip (A) from the clevis pin (B) that attaches
the master cylinder to the brake pedal lever.
17 ft. lbs.
(23 Nm)
B
Pedal Removal
1.
Locate the brake pedal lever (L) and remove the master
cylinder clevis pin (B) and clip (A).
2.
Remove the E-ring (E) from the pedal mount and remove
the brake pedal lever (L) from the vehicle.
D
L
E
B
A
C
15 ft. lbs.
(20 Nm)
3.
9
A
D
Place a container to catch brake fluid under the master
cylinder brake line banjo bolts (C).
Pedal Installation
1.
Reverse “Removal” steps to install brake pedal lever.
Brake pedal freeplay should not exceed .090” (2.28 mm).
Brake Pedal Freeplay:
.090” (2.28 mm)
9.5
BRAKES
BRAKE BLEEDING / FLUID CHANGE
4.
Begin bleeding procedure with the caliper that is farthest
from the master cylinder. Install a box end wrench on
caliper bleeder screw. Attach a clean, clear hose to fitting
and place the other end in a clean container. Be sure the
hose fits tightly on fitting.
5.
Have an assistant slowly pump foot pedal until pressure
builds and holds.
6.
Hold brake pedal on to maintain pedal pressure, and open
bleeder screw. Close bleeder screw and release foot pedal.
NOTE: When bleeding the brakes or replacing the
fluid always start with the furthest caliper from the
master cylinder.
CAUTION
Always wear safety glasses.
CAUTION
Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished
surfaces. This procedure should be used to
change fluid or bleed brakes during
regular maintenance.
1.
NOTE: Do not release foot pedal before bleeder
screw is tight or air may be drawn into master
cylinder.
7.
CAUTION
Clean master cylinder reservoir cover thoroughly and
remove the cover.
Maintain at least 1/2"(1.27 cm) of brake fluid in
the reservoir to prevent air from
entering the master cylinder.
Master Cylinder
Remove
Cover
Repeat procedure until clean fluid appears in bleeder hose
and all air has been purged. Add fluid as necessary to
maintain level in reservoir.
8.
Tighten bleeder screw securely and remove bleeder hose.
Torque bleeder screw to 47 in. lbs. (5.3 Nm).
9.
Repeat procedure Steps 5 - 8 for the remaining calipers.
10. Add brake fluid to MAX level inside reservoir.
Master Cylinder Fluid Level
Between the MIN and MAX line shown
on the reservoir.
11. Install master cylinder reservoir cover.
2.
If changing fluid, remove old fluid from reservoir with a
Mity Vac™ pump or similar tool.
Mity Vac™ (PN 2870975)
3.
Add brake fluid to the indicated MAX level of reservoir.
Polaris DOT 4 Brake Fluid
(P/N 2872189)
9.6
12. Field test machine at low speed before putting into service.
Check for proper braking action and pedal reserve. With
pedal firmly applied, pedal reserve should be no less than
1/2"(1.3 cm).
13. Check brake system for fluid leaks.
BRAKES
FRONT BRAKE PADS
5.
Push mounting bracket inward and slip outer brake pad past
edge. Then remove inner pad.
Pad Removal
1.
Elevate and support front of vehicle.
CAUTION
Use care when supporting vehicle so that it
does not tip or fall.
Severe injury may occur if machine tips or falls.
2.
Remove the front wheel. Loosen pad adjuster screw 2-3
turns.
Pad Inspection
1.
3.
Measure the thickness of the pad material. Replace pads if
worn beyond the service limit.
Remove the upper and lower caliper mounting bolts and
remove the caliper from the front hub.
NOTE: When removing caliper, use care not to
damage brake line. Support caliper so to avoid
kinking or bending brake line.
4.
Push caliper piston into caliper bore slowly using a
C-clamp or locking pliers with pads installed.
9
Measure
Thickness
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
Front Brake Pad Thickness
New: .300” ± .007” (7.6 mm ± .178 mm)
Service Limit: .180” (4.6 mm)
9.7
BRAKES
Pad Assembly / Installation
1.
5.
Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease (PN 2871423), and
install rubber dust boots.
Install the adjustment set screw and turn clockwise until
stationary pad contacts disc, then back off 1/2 turn
(counterclockwise).
1/2 Turn
6.
2.
Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
other.
Master Cylinder Fluid
WARNING
Up to MAX line inside reservoir
If brake pads are contaminated with grease, oil,
or liquid soaked do not use the pads.
Use only new, clean pads.
3.
Verify fluid level in reservoir is up to MAX line inside
reservoir and install reservoir cap.
7.
Install wheel and torque wheel nuts.
=T
Install caliper onto front hub and torque mounting bolts.
30 ft. lbs.
(40 Nm)
Front Wheel Nut Torque:
27 ft. lbs. (37 Nm)
Brake Burnishing Procedure
It is required that a burnishing procedure be performed after
installation of new brake pads to extend service life and reduce
noise.
Start machine and slowly increase speed to 30 mph. Gradually
apply brakes to stop machine. Allow pads and disc to cool
sufficiently during the procedure. Do not allow pads or disc to
become hot or warping may result. Repeat this procedure 10
times.
=T
Front Caliper Mount Bolt Torque:
30 ft. lbs. (40 Nm)
4.
Slowly pump the brake pedal until pressure has been built
up. Maintain at least 1/2, (12.7 mm) of brake fluid in the
reservoir to prevent air from entering the brake system.
9.8
BRAKES
FRONT CALIPER SERVICE
Caliper Exploded View
Apply Polaris DOT 4 Brake Fluid
to Component
C
E
Apply Polaris All Purpose
Grease
A
47 in. lbs.
(5.3 Nm)
B
F
G
D
H
I
D
A. Socket Set Screw
B. Bleeder Screw
C. Caliper Assy.
D. Boot
E. Square O-ring (thick)
F. Square O-ring (thin)
G. Piston
H. Caliper Mount
I. Brake Pads
Caliper Removal
1.
Elevate and safely support the front of the vehicle.
2.
Remove the (4) wheel nuts and the front wheel.
5.
Loosen brake pad adjustment set screw 2-3 turns to allow
brake pad removal after the caliper is removed.
CAUTION
Use care when supporting vehicle so that it does not
tip or fall. Severe injury may occur.
3.
Clean caliper area before removal.
4.
Place a container below the caliper to catch brake fluid
when removing the line. Remove brake line from caliper.
9
Remove
Brake Line
9.9
BRAKES
6.
Remove the two caliper mounting bolts and remove the
caliper assembly from the front hub.
3.
Remove mounting bracket, pin assembly and dust boot.
4.
Thoroughly clean the brake caliper before disassembly and
prepare a clean work area to disassembly the caliper.
5.
Use low pressure compressed air to remove the pistons
from the caliper.
Remove
Caliper Disassembly
1.
Push brake pad retainer pin inward and slip brake pads past
the edge.
CAUTION
Use caution and always wear safety glasses
when working with compressed air.
6.
While holding the caliper and covering the pistons with a
shop towel, carefully apply compressed air to the brake line
inlet to force the pistons out from the caliper.
IMPORTANT: Do not remove the caliper pistons with
a pliers. The piston sealing surfaces will become
damaged if a pliers is used.
7.
2.
Remove both brake pads from the caliper.
9.10
Once the pistons are removed, use a pick to carefully
remove the square O-rings from the caliper. O-rings should
be replaced during caliper service.
BRAKES
8.
Clean the caliper body, piston, and retaining bracket with
brake cleaner or alcohol.
2.
Clean
Components
Inspect piston for nicks, scratches, pitting or wear. Measure
piston diameter and replace if damaged or worn beyond
service limit.
NOTE: Be sure to clean seal grooves in caliper
body.
= In. / mm.
Caliper Piston O.D.:
Std: 1.002” (25.45 mm)
Service Limit: 1.000” (25.4 mm)
Caliper Inspection
1.
Inspect caliper body for nicks, scratches, pitting or wear.
Measure bore size and compare to specifications. Replace
if damaged or worn beyond service limit.
3.
Inspect the brake disc and pads as outlined in this chapter.
Caliper Assembly
1.
Install new O-rings in the caliper body. Be sure the
grooves are clean and free of residue or brakes may drag
upon assembly.
Seal
Grooves
= In. / mm.
New
O-Rings
Caliper Piston Bore I.D.:
Std: 1.004” (25.5 mm)
Service Limit: 1.006” (25.55 mm)
2.
Coat pistons with clean Polaris DOT 4 Brake Fluid. Install
pistons with a twisting motion while pushing inward.
Piston should slide in and out of bore smoothly, with light
resistance.
9.11
9
BRAKES
3.
Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install the rubber
dust seal boots.
6.
Install brake line and tighten securely with a line wrench.
Torque the banjo bolt brake line(s) to the proper torque
specification.
15 ft.lbs.
(20 Nm)
4.
Compress the mounting bracket and make sure the dust seal
boots are fully seated. Install the brake pads. Clean the disc
and pads with brake parts cleaner or denatured alcohol to
remove any dirt, oil or grease.
7.
Install the pad adjustment screw and turn until stationary
pad contacts disc, then back off 1/2 turn.
8.
Perform brake bleeding procedure as outlined earlier in this
chapter.
9.
Install wheel and torque wheel nuts to specification.
Caliper Installation
5.
Install caliper and torque mounting bolts to specification.
30 ft. lbs.
(40 Nm)
=T
Front Wheel Nut Torque:
27 ft. lbs. (37 Nm)
NOTE: If new brake pads are installed, brake
burnishing is recommended (see “FRONT BRAKE
PADS - Brake Burnishing Procedure”).
=T
Front Caliper Mount Bolt Torque:
30 ft. lbs. (40 Nm)
9.12
BRAKES
FRONT BRAKE DISC
3.
Remove the hub assembly from the vehicle and remove the
(4) bolts retaining the disc to the hub.
Disc Inspection
(4) Bolts
1.
Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident.
2.
Use a 0-1” micrometer and measure the disc thickness at
eight different points around the pad contact surface.
Replace disc if worn beyond service limit.
Cotter
Pin
Washers
Measure
Thickness
Nut
Front
View
Side
View
4.
Clean the wheel hub mating surface and install new disc on
wheel hub.
5.
Install new bolts and torque to 28 ft. lbs. (38 Nm).
28 ft. lbs.
(38 Nm)
Brake Disc Thickness
New .188” (4.76 mm)
Service Limit .170” (4.32 mm)
Brake Disc Thickness Variance
Service Limit .002” (.051 mm)
difference between measurements
3.
Mount a dial indicator and measure disc runout. Slowly
rotate the disc and read total runout on the dial indicator.
Replace the disc if runout exceeds specifications.
CAUTION
Always use new brake disc mounting bolts. The
bolts have a pre-applied locking agent which is
destroyed upon removal.
Brake Disc Runout
Service Limit .010” (.254 mm)
6.
Install wheel hub assembly, washers, and castle nut.
Torque castle nut to 80 ft. lbs. (108 Nm) and install a new
cotter pin.
7.
Install front brake caliper (see “FRONT CALIPER
SERVICE”). Follow the bleeding procedure outlined
earlier in this chapter.
8.
Field test unit for proper braking action before putting into
service. Inspect for fluid leaks and firm brakes. Make sure
the brake is not dragging when pedal is released. If the brake
drags, re-check assembly and installation.
Disc Replacement
1.
Remove front brake caliper (see “FRONT CALIPER
SERVICE”).
2.
Remove wheel hub cotter pin, castle nut and washers.
9.13
9
BRAKES
REAR BRAKE PAD
5.
Push caliper piston into the caliper bore slowly using a Cclamp or locking pliers with pads installed.
Pad Removal
1.
Elevate and support rear of vehicle.
CAUTION
Use care when supporting vehicle so that it
does not tip or fall.
Severe injury may occur if machine tips or falls.
2.
Remove the rear wheel.
3.
Loosen pad adjuster screw 2-3 turns.
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
4.
6.
Push caliper mounting bracket inward and slip outer brake
pad past the edge to remove.
7.
Remove the inner brake pad.
Remove the two caliper mounting bolts and lift caliper off
the brake disc.
NOTE: When removing caliper, be careful not to
damage brake line. Support caliper so as not to kink
or bend brake line.
9.14
BRAKES
Pad Inspection
3.
1.
Clean the caliper with brake cleaner or alcohol.
2.
Measure the thickness of the pad material. Replace pads if
worn beyond the service limit.
Install caliper and torque mounting bolts to specification.
18 ft. lbs.
(24 Nm)
Measure
Thickness
=T
Rear Brake Pad Thickness
New .298” ± .007” (7.57 mm ± .178 mm)
Service Limit .180” (4.6 mm)
Rear Caliper Mount Bolt Torque:
18 ft. lbs. (24 Nm)
4.
Slowly pump the brake pedal until pressure has been built
up. Maintain at least 1/2, (12.7 mm) of brake fluid in the
reservoir to prevent air from entering the brake system.
5.
Install the adjustment set screw and turn clockwise until the
stationary pad contacts the disc, then back off 1/2 turn
(counterclockwise).
6.
Verify fluid level in reservoir is up to the MAX line inside
reservoir and install reservoir cap.
Pad Assembly / Installation
1.
Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease (PN 2871423), and
install rubber dust boots.
Master Cylinder Fluid
Up to MAX line inside reservoir
7.
Install wheel and torque wheel nuts.
9
=T
2.
Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
other.
WARNING
If brake pads are contaminated with grease,
oil, or liquid soaked do not use the pads.
Use only new clean pads.
Rear Wheel Nut Torque:
27 ft. lbs. (37 Nm)
Brake Burnishing Procedure
It is required that a burnishing procedure be performed after
installation of new brake pads to extend service life and reduce
noise.
Start machine and slowly increase speed to 30 mph. Gradually
apply brakes to stop machine. Allow pads and disc to cool
sufficiently during the procedure. Do not allow pads or disc to
become hot or warping may result. Repeat this procedure 10
times.
9.15
BRAKES
REAR CALIPER SERVICE
Caliper Exploded View
Apply Polaris DOT 4 Brake Fluid
to Component
D
47 in. lbs.
(5.3 Nm)
G
Apply Polaris All Purpose
Grease
I
K
A. Brake Pad
B. Mount Bracket
C. Piston
D. Caliper Assy.
E. Square Ring (thick)
F. Square Ring (thin)
G. Boot, Pin Bushing
H. Boot, Pin Seal
I. Bleeder Screw
K. Set Screw
A
H
E
F
C
B
Caliper Removal
1.
Elevate and safely support the rear of the vehicle.
CAUTION
Use care when supporting vehicle so that it does not
tip or fall. Severe injury may occur.
2.
Remove the (4) wheel nuts and rear wheel.
3.
Clean caliper area before removal.
4.
Place a container below the caliper to catch the brake fluid
when removing the line. Remove brake line from caliper.
Remove
Brake Line
9.16
5.
Loosen the brake pad adjustment set screw to allow brake
pad removal after the caliper is removed.
6.
Remove the two caliper mounting bolts and remove the
caliper.
Remove
BRAKES
Caliper Disassembly
Caliper Inspection
1.
Remove brake pad adjustment set screw (K).
1.
2.
Push upper pad retainer pin inward and slip brake pads past
the edge and remove from the caliper.
3.
Remove mounting bracket (B) and dust boots (G) and (H).
Inspect caliper body for nicks, scratches or wear. Measure
bore size and compare to specifications. Replace if damage
is evident or if worn beyond service limit.
D
G
K
Pads
H
E F
C
B
4.
= In. / mm.
Using a hammer and a small punch, remove the piston (C)
from the caliper body (D). Then remove the square O-rings
(E) and (F) from the caliper body (D).
Rear Caliper Piston Bore I.D.
Standard: 1.191” (30.25 mm)
Service Limit: 1.192” (30.28 mm)
2.
5.
Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn beyond
service limit.
Clean the caliper body, piston, and retaining bracket with
brake cleaner or alcohol.
9
NOTE: Be sure to clean seal grooves in caliper
body.
Clean Components
= In. / mm.
Rear Caliper Piston O.D.
Standard: 1.1875” (30.16 mm)
Service Limit: 1.186” (30.12 mm)
3.
Inspect the brake disc and pads as outlined in this chapter.
9.17
BRAKES
Caliper Assembly
Caliper Installation
1.
5.
Install new caliper seals (A) in the caliper body (B). Be
sure groove is clean and free of residue or brakes may drag
upon assembly.
Install the rear caliper with the mounting bolts. Torque
mounting bolts to 18 ft. lbs. (24 Nm).
18 ft. lbs.
(24 Nm)
B
D
A
2.
3.
Coat piston with clean Polaris DOT 4 Brake Fluid (PN
2872189). Install piston (D) with a twisting motion while
pushing inward. Piston should slide in and out of bore
smoothly with light resistance.
Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install the rubber
dust seal boots.
=T
Rear Caliper Mount Bolt Torque:
18 ft. lbs. (24 Nm)
6.
Install brake line banjo bolt and torque to specification.
15 ft. lbs.
(21 Nm)
Polaris Premium All Season Grease
7.
Install the pad adjustment screw and turn until stationary
pad contacts disc, then back off 1/2 turn.
8.
Perform brake bleeding procedure as outlined earlier in this
chapter.
9.
Install wheel and torque wheel nuts to specification.
(PN 2871423)
4.
Compress the mounting bracket and make sure the dust
seals are fully seated. Install the brake pads. Clean the disc
and pads with brake parts cleaner or denatured alcohol to
remove any dirt, oil or grease.
=T
Rear Wheel Nut Torque:
27 ft. lbs. (37 Nm)
NOTE: If new brake pads are installed, brake
burnishing is recommended (see “REAR BRAKE
PADS - Brake Burnishing Procedure”).
9.18
BRAKES
REAR BRAKE DISC
3.
Remove the hub assembly from the vehicle and remove the
(4) bolts retaining the disc to the hub.
Disc Inspection
1.
2.
(4) Bolts
Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident.
Cotter
Pin
Use a 0-1” micrometer and measure the disc thickness at
eight different points around the pad contact surface.
Replace disc if worn beyond service limit.
Front
View
Washers
Side
View
Nut
Measure
Thickness
4.
Clean the wheel hub mating surface and install new disc on
wheel hub.
5.
Install new bolts and torque to 28 ft. lbs. (38 Nm).
28 ft. lbs.
(38 Nm)
Brake Disc Thickness
New: .188” (4.76 mm)
Service Limit: .170” (4.32 mm)
Brake Disc Thickness Variance
Service Limit .002” (.051 mm)
difference between measurements
3.
Mount a dial indicator and measure disc runout. Slowly
rotate the disc and read total runout on the dial indicator.
Replace the disc if runout exceeds specifications.
CAUTION
Always use new brake disc mounting bolts. The
bolts have a pre-applied locking agent which is
destroyed upon removal.
Brake Disc Runout
Service Limit .010” (.254 mm)
6.
Install wheel hub assembly, washers, and castle nut.
Torque castle nut to 80 ft. lbs. (108 Nm) and install a new
cotter pin.
7.
Install rear brake caliper (see “REAR CALIPER
SERVICE”). Follow the bleeding procedure outlined
earlier in this chapter.
8.
Field test unit for proper braking action before putting into
service. Inspect for fluid leaks and firm brakes. Make sure
the brake is not dragging when pedal is released. If the brake
drags, re-check assembly and installation.
Disc Replacement
1.
Remove rear brake caliper (see “REAR CALIPER
SERVICE”).
2.
Remove wheel hub cotter pin, castle nut and washers.
9.19
9
BRAKES
TROUBLESHOOTING
Brakes Squeal / Poor Brake Performance
• Air in system
• Water in system (brake fluid contaminated)
• Caliper or disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Damaged break pad noise insulator
• Brake pads dragging
• Brake caliper dragging
Pedal Vibration
• Disc damaged
• Disc worn (runout or thickness variance exceeds
service limit)
Caliper Overheats (Brakes Drag)
• Compensating port plugged
• Pad clearance set incorrectly
• Brake pedal binding or unable to return fully
• Residue build up under caliper seals
• Operator riding brakes
Brakes Lock
• Alignment of caliper to disc
• Caliper pistons sticking
• Improper assembly of brake system components
9.20
ELECTRICAL
CHAPTER 10
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
UNDER-DASH COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
AWD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
STANDARD DISPLAY MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
DIAGNOSTIC DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
VIEWING DIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
INSTRUMENT CLUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
INSTRUMENT CLUSTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . . . . . . . 10.10
TEST 1 - NO ALL WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
TEST 2 - NO DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
TEST 3 - VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
TEST 4 - NO AWD HUB SAFETY LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
TEST 5 - FUEL GAUGE DISPLAY NOT WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
TEST 6 - GEAR INDICATOR NOT WORKING (TRANSMISSION SWITCH) . . . . . . . 10.13
ALL WHEEL DRIVE COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
DIAGNOSING SYSTEM FAILURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
GEAR POSITION INDICATOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
TEST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
LOCATION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
HEAD LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
HEADLAMP BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
HEADLAMP HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
HEADLAMP HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
TAIL / BRAKE / WORK LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
BULB REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
COOLING SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
FAN CONTROL CIRCUIT OPERATION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
FAN CONTROL CIRCUIT BYPASS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
EFI DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
EFI COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
10
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
FUSE BOX LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
FUSES / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
10.1
ELECTRICAL
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
CHARGING SYSTEM ALTERNATOR TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
BATTERY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
CONVENTIONAL BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
BATTERY ACTIVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
OCV - OPEN CIRCUIT VOLTAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
CHARGING PROCEDURE (CONVENTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
LOW MAINTENANCE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
GENERAL BATTERY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
BATTERY TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
OCV - OPEN CIRCUIT VOLTAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
OFF-SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
CHARGING PROCEDURE (LOW MAINTENANCE) . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
STARTER MOTOR REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
BRUSH INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
ARMATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
STARTER REASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
STARTER SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
STARTER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
STARTING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
CONDITION: STARTER FAILS TO TURN OVER THE ENGINE. . . . . . . . . . . . . . . . . 10.36
ELECTRICAL BREAKOUT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
12V KEY-ON POWER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
STARTING SYSTEM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
INSTRUMENT CLUSTER CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
TRANSMISSION SWITCH CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
WHEEL SPEED SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
AWD CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
FUEL GAUGE DISPLAY CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
COOLING FAN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
CHARGING SYSTEM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
10.2
ELECTRICAL
GENERAL INFORMATION
Under-Dash Components
Special Tools
The following switches and components can be accessed
underneath the instrument / dash panel:
Part Number
Tool Description
• Speedometer
PV-43568
Fluke™ 77 Digital Multimeter
• Speedometer Mode Switch
2870630
Timing Light
• Digital Wrench Diagnostic Connector
2870836
Battery Hydrometer
• Digital Wrench / ECU Reflash 9 Vdc Battery Plug
2460761
Hall Effect Sensor Probe Harness
• AWD Switch
2871745
Static Timing Light Harness
• Headlamp Switch
Digital Wrench™ (see Chapter 4)
• 12 Vdc Accessory Power Point
-
Electrical Service Notes
Keep the following notes in mind when diagnosing an electrical
problem:
• Ignition Switch
• Work Light Switch
• Fuse / Relay Panel
• Refer to wiring diagram for stator and electrical
component resistance specifications.
• When measuring resistance of a component that has a
resistance value under 10 Ohms, remember to subtract
meter lead resistance from the reading. Connect the
leads together and record the resistance. The resistance
of the component is equal to tested value minus the lead
resistance.
• Become familiar with the operation of your meter. Be
sure leads are in the proper jack for the test being
performed (i.e. 10A jack for current readings). Refer to
the Owner’s Manual included with your meter for more
information.
• Voltage, amperage, and resistance values included in
this manual are obtained with a Fluke™ 77 Digital
Multimeter (PV-43568). This meter is used when
diagnosing electrical problems. Readings obtained with
other meters may differ.
• Pay attention to the prefix on the multimeter reading (K,
M, etc.) and the position of the decimal point.
10
• For resistance readings, isolate the component to be
tested. Disconnect it from the wiring harness or power
supply.
10.3
ELECTRICAL
SWITCHES / CONTROLS
AWD SWITCH
Headlamp Switch
1.
Disconnect the headlamp switch harness (Brown, Green,
and Red/Yellow), by depressing the connector lock and
pulling on the connector. Do not pull on the wiring.
2.
Test the switch connections and check for continuity at the
following pins as shown in the illustration.
HEADLAMP SWITCH
BACK VIEW OF SWITCH
1
ON
2
3
X
X
4
5
6
7
8
X
X
X
OFF
SWITCH
BACK
LIGHT
Brake Light Switch
1.
The brake light switch is located under the driver’s seat
along the lower frame. The brake pressure switch is
installed into this cross fitting block.
2.
Disconnect wire harness from switch.
3.
Connect an ohmmeter across switch contacts. Reading
should be infinite (•).
4.
Apply foot brake and check for continuity between switch
contacts. If there is no continuity or greater than .5 ohms
resistance when the brake is applied with slight pressure,
first clean the switch contacts and re-test. Replace switch
if necessary.
BACK VIEW OF SWITCH
1
ON
2
3
X
X
4
5
6
7
8
X
OFF
SWITCH
BACK
LIGHT
X
X
AWD Switch
1.
2.
Disconnect the switch harness (Grey, Red/White, and
Brown), by depressing the connector lock and pulling on
the connector. Do not pull on the wiring.
Test the switch connections and check for continuity at the
pins shown in the illustration.
10.4
ELECTRICAL
INSTRUMENT CLUSTER
Rider Information Display
Overview
The rider information display is located in the instrument
cluster. All segments will light up for 2.5 seconds at start-up.
The instrument cluster senses vehicle speed from the right
front wheel. The instrument cluster measures distance in miles
as well as time, hours of operation and engine RPM.
Speedometer
NOTE: If the instrument cluster fails to illuminate, a
battery over-voltage may have occurred and the
instrument cluster may have shut off to protect the
electronic speedometer.
6
3
4
5
7
8
Speedometer
Needle
2
1
1.
Gear Indicator - This indicator displays gear shifter
position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
2.
AWD Indicator - This indicator illuminates when the
AWD switch is in the AWD position.
NOTE: In addition to showing vehicle speed, the
speedometer needle flashes when a low fuel
condition exists.
3.
Engine Hour Display Indicator
4.
Service Interval / Diagnostic Mode Indicator
NOTE: Use the “Mode Button” shown below to
toggle between Instrument Cluster display screens.
5.
Low Battery and Over Voltage - This warning usually
indicates that the vehicle is operating at an RPM too low to
keep the battery charged. It may also occur when the engine
is at idle and high electrical load (lights, cooling fan,
accessories) is applied. Drive at a higher RPM or recharge
the battery to clear the warning.
6.
Odometer/Tachometer/Tripmeter/ Hour Meter/Clock
7.
Fuel Gauge - The segments of the fuel gauge show the level
of fuel in the fuel tank. When the last segment clears, a low
fuel warning is activated. All segments will flash, FUEL
will display in the LCD, and the speedometer needle will
blink. Refuel immediately.
8.
Check Engine Warning Indicator - This indicator serves
two purposes. The word HOT displays if the engine
overheats. It also appears if an EFI-related fault occurs. Do
not operate the vehicle if this warning appears. Serious
engine damage could result.
Rider
Information
Display
10.5
10
ELECTRICAL
Standard Display Modes
Clock Screen
Use the mode button (location shown in the illustration on page
10.5) to toggle through the mode options.
Odometer Mode
The odometer records the miles or kilometers traveled by the
vehicle.
Trip Meter Mode
The trip meter records the miles or kilometers traveled by the
vehicle on each trip if it's reset before each trip. To reset the trip
meter, select the trip meter mode. Press and hold the mode
button until the display reads 0.
NOTE: In the Rider Information Display, the trip
meter display contains a decimal point, but the
odometer displays without a decimal point.
To reset the clock:
1.
2.
3.
4.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
5.
Tachometer Mode
The engine RPM is displayed digitally.
NOTE: Small fluctuations in the RPM from day to
day may be normal because of changes in humidity,
temperature and elevation.
6.
7.
Enter the diagnostic mode.
Toggle to the clock screen.
Press and hold the mode button until the hour display
flashes. Release the button.
Press and release the mode button once to advance the
setting by one hour. Press and hold the mode button to
advance the hours quickly.
When the desired hour is displayed, wait approximately
four seconds, until the minute display flashes.
When the display stops flashing, the mode has been set.
Use the same procedure to reset the minutes.
Battery Voltage Screen
View this screen to check battery voltage level.
Clock Mode
The clock displays time in a 12-hour format. To reset the clock,
see “Clock Screen” in the “Diagnostic Display Mode” section.
Diagnostic Display Mode
The wrench icon will display when the gauge is in the diagnostic
mode. To exit the diagnostic mode, turn the key switch off and
on. Any movement of the tires will also cause the gauge to exit
the diagnostic mode.
To enter the diagnostics mode:
Tachometer Screen
1.
Turn the key switch off and wait 10 seconds.
View the tachometer to check engine speed.
2.
Lock the parking brake.
3.
Place the transmission in neutral.
4.
Hold the mode button and turn the key switch to the “ON”
position. Release the mode button as soon as the display is
activated.
5.
Use the mode button to toggle through the diagnostic
screens.
10.6
ELECTRICAL
AWD Diagnostic Screen
The gauge indicates whether or not current is flowing through
the AWD coil.
Gear Circuit Diagnostic Screen
This screen displays the resistance value (in ohms) being read at
the gear switch input of the gauge.
NOTE: A 10 - 20% variance from these readings is
within normal parameters.
10
10.7
ELECTRICAL
Programmable Service Interval
When the hours of engine operation equal the programmed
service interval setting, the wrench icon will flash for 5 seconds
each time the engine is started. When this feature is enabled, it
provides a convenient reminder to perform routine
maintenance.
NOTE: If you scroll past the intended number, press
and hold the button until the hours cycle back to
zero.
5.
When the desired setting is displayed, wait until the wrench
icon stops flashing. The new service interval is now
programmed.
Miles / Kilometers Toggle
The display in the tripmeter and odometer can be changed to
display either standard or metric units of measurement.
1.
Enter the diagnostic mode.
2.
Toggle to the screen that displays either kilometers (KM)
or miles (MP).
3.
Press and hold the mode button until the letters flash, then
press and release the button once. When the display stops
flashing, the mode has been set.
NOTE: The service interval is programmed to 50
hours at the factory.
To enable or disable the service interval:
1.
Enter the diagnostic mode.
2.
Toggle to the service interval screen.
3.
Press and hold the mode button for about seven (7) seconds,
until either ON or OFF appears in the Rider Information
Display, depending on your preference.
To reset the service interval:
1.
Enter the diagnostic mode.
2.
Toggle to the service interval screen.
Viewing Diagnostic Codes
3.
Press and hold the mode button for 2-3 seconds, until the
wrench icon flashes. Release the button.
Use the following procedure to view diagnostic blink codes
(failure codes) from the EFI module:
4.
Press and release the mode button once to advance the
setting by one hour. Press and hold the mode button to
advance the hours quickly.
1.
Engage the parking brake.
2.
Stop the engine.
3.
Turn the key switch to the ON position.
10.8
ELECTRICAL
4.
5.
Turn the key switch off and on three times in less than five
seconds, then leave the switch on. The word “Wait” will
appear on the screen along with a flashing “Check Engine”
light.
2.
Push the instrument cluster out from the back side of the
dash while securely holding the dash and rubber mount.
Push Instrument
Cluster Outward
Dash Panel
Any blink code numbers stored in the EFI module will
display, one at a time, on the screen.
Example below shows a Blink Code of “42”.
Rubber Mount
Bezel
Instrument Cluster
NOTE: Do not remove the rubber mount from the
dash panel. Only remove the rubber mount if
necessary. The bezel is a snap-on assembly and is a
serviceable part.
Instrument Cluster Installation
1.
6.
The number “61” and/or the word “End” displays after all
codes have been transmitted.
Spray a soap and water mixture onto the outer surface area
of the instrument cluster. This will help the instrument
cluster slide into the rubber mount more easily.
10
Instrument Cluster Removal
2.
Be sure the rubber mount inside the dash is fully installed
and that the indexing key on the rubber mount is lined up
with the keyway in the dash.
3.
Hold the dash securely and insert the instrument cluster into
the dash. Twist the instrument cluster gently in a clockwise
motion to properly seat the instrument cluster into the
rubber mount. Apply pressure on the bezel while pressing
down on the instrument cluster.
NOTE: Do not allow alcohol or petroleum products
to come in contact with the instrument cluster lens.
1.
Disconnect the wire harness connectors from the back side
of the instrument cluster.
10.9
ELECTRICAL
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS
TEST 1 - No All Wheel Drive
.OTE )F !7$ ICON COMES ON INSTRUMENT
CLUSTER IS /+ 0ROCEED TO MECHANICAL TESTS
OUTLINED IN #HAPTER #HECK THE !7$ ICON
ON INSTRUMENT CLUSTER TO VERIFY ITS OPERATION
4HE !7$ SWITCH IS DIRECTLY POWERED BY
SWITCHED VOLTS ORANGEWHITE 4HE GEAR
SWITCH ONLY INTERFACES WITH THE INSTRUMENT
CLUSTER 4O ENABLE !7$ THE CLUSTER MUST BE
DISPLAYING LOW HIGH OR REVERSE GEAR
34!24 (%2%
30%%$
2%!$/54
/+
.
#(%#+
30%%$/-%4%2
0%2&/24%34
9
+%9 37)4#( /.
42!.3-)33)/. ).
'%!2
!7$ 37)4#( /.
0IN #ONNECTOR
9
/. (5" #/),
#/..%#4/2
,%!6% )4 #/..%#4%$
-%!352% &/2 6 &2/"2/7.7()4% 4/ 4(%
.
2ED 6 #ONSTANT
2ED 7HITE 6 3WITCHED
'REY /RANGE -ODE BUTTON
.#
'REEN
"LUE
9ELLOW 20- )NPUT
"ROWN 'ROUND
"LUE 7HITE %NGINE /VERHEAT 3WITCH
.#
"LK 7HITE -ALFUNCTION )NDICATOR
6IOLET 7HITE &UEL 'AUGE
"ROWN 2ED 'ROUND
7HITE 'EAR )NDICATOR )NPUT
.#
"ROWN 7HITE !7$ #ONTROL
./4 !. ).3425-%.4
#,534%2 02/",%-
#(%#+ !7$ 37)4#(
!.$ 7)2).'
#/), "/$9
'2/5.$
.OTE 2EVERSING POLARITY WHEN CONNECTING
THE BATTERY OR OTHER $# POWER SOURCE
BACKWARDS WILL FAIL THE !7$ CONTROL AND
THE INSTRUMENT CLUSTER IF THE KEY SWITCH
AND THE !7$ SWITCH ARE TURNED ON
9
,%!6% !7$
37)4#( /.
452. +%9 37)4#( /&&
$)3#/..%#4 0).
#/..%#4/2 &2/- #,534%2
452. +%9 37)4#( /.
#(%#+ &/2 6
&2/- "2.7()4%
4/ '2/5.$
9
452. +%9 37)4#( /&&
2%#/..%#4 #,534%2
3()&4 4/ ,/7 /2 ()'(
,%!6% !7$ /.
10.10
.
7)2).'
02/",%2%0,!#%
).3425-%.4
#,534%2
9
.
02/#%%$ 4/
-%#(!.)#!, !7$
#/-0/.%.43
)& !7$ 02/",%0%23)343
ELECTRICAL
TEST 2 - No Display
1RWH %HIRUH VWDUWLQJ GLDJQRVLV WXUQ RII VSHHGRPHWHU DQG ZDLW VHFRQGV
WKHQ WXUQ RQ DJDLQ WR VHH LI SUREOHP FOHDUV
67$57 +(5(
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3,1 $
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9'& 21 3,1 $ 72 3,1
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5(3$,5
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63(('2
5(3/$&(
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1
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7(67
'5,9(
9(+,&/(
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&+$1*("
<
32,17(5
029("
<
63(('2
2.
TEST 3 - Vehicle Speed Sensor
6%()#,% 30%%$ 3%.3/2
4OOLS 2EQUIRED
"RN
'3TATIC 4IMING ,IGHT (ARNESS 0.
'(ALL 3ENSOR 0ROBE (ARNESS 0.
OR EQUIVALENT JUMPER WIRES
7
4O TEST WHEEL SPEED SENSOR
$ISCONNECT 0IN CONNECTOR FROM SPEEDOMETER
7HT
,%$
4O 3ENSOR
7HITE
"LK
4O 3ENSOR
"LACK
6
#ONNECT WIRES FROM TEST LIGHT TO SENSOR 0IN
CONNECTOR AS SHOWN AT RIGHT USING THE (ALL 3ENSOR
0ROBE (ARNESS 0. OR JUMPER LEADS
4O 3ENSOR 2ED
2EMOVE THE SPEED SENSOR FROM THE TRANSMISSION
0ASS A SCREW DRIVER BACK AND FORTH IN FRONT OF SENSOR TIP
)F LIGHT FLASHES SENSOR IS /+ "E SURE CONNECTIONS
ARE GOOD AND VOLT BATTERY IS IN GOOD CONDITION
10
3TATIC 4IMING ,IGHT (ARNESS
0.
10.11
ELECTRICAL
TEST 4 - No AWD Hub Safety Limiter
127( ,) 7+( $:' ,&21 '2(6 127 &20( 21 25 ,)
9'& ,6 127 5(*,67(5,1* $1' $:' ,6 (1*$*,1*
$%29( 530,7 0$< %( $ 0(&+$1,&$/ 352%/(0
,6
63(('2
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<
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<
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