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:
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.
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
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.
WARNING
CAUTION
CAUTION
1
GENERAL INFORMATION
2
MAINTENANCE
3
ENGINE
4
FUEL INJECTION
5
BODY / STEERING / SUSPENSION
6
CLUTCHING
7
FINAL DRIVE
8
TRANSMISSION
BRAKES 9
ELECTRICAL 10
GENERAL INFORMATION
1.1
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
1.2
GENERAL INFORMATION
MODEL INFORMATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
Engine Designation Number
EH076OLE021.....................................................Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start
VIN Identification
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.
}
Machine Model Number Identification
}
}
Model Year
Designation Basic Chassis
Designation Engine Designation
Emissions &
Model Option
R 0 8 V H 7 6 A D
}
4 X A V H 7 6 A * 8 P 0 0 0 0 0 0
}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
World
Mfg. ID
Engine
Vehicle Description Vehicle Identifier
}
Check Digit
Model
Year
Body Style
Plant No.
Individual Serial No.
* This could be either
a number or a letter
Powertrain
Emissions
1.3
GENERAL INFORMATION
1
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
1.4
GENERAL INFORMATION
GENERAL SPECIFICATIONS
MODEL: 2008 RANGER RZR
MODEL NUMBER: R08VH76AD, AG
ENGINE MODEL: EH076OLE021
Category Dimension / Capacity
Length 102 in. / 259 cm
Width 50 in. / 127 cm
Height 68.5 in. / 174 cm
Wheel Base 77 in. / 196 cm
Ground Clearance 10 in. / 25.4 cm
Dry Weight 945 lbs. / 429 kg
Gross Vehicle Weight 1727 lbs. / 783 kg
Front Storage Capacity 25 lbs. / 11.3 kg
Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm
Cargo Box Capacity 300 lbs. / 136 kg
Maximum Weight
Capacity (Payload)
740 lbs. / 336.4 kg
(Includes rider(s), cargo,
and accessories)
Hitch Towing Capacity 1500 lbs. / 680 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
FRONT
REAR
TOP
SIDE
1.5
GENERAL INFORMATION
1
MODEL: 2008 RANGER RZR
MODEL NUMBER: R08VH76AD, AG
ENGINE MODEL: EH076OLE021
CLUTCH CHART
Engine
Platform Polaris Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
Engine Model Number EH076OLE021
Engine Displacement 760cc
Number of Cylinders 2
Bore & Stroke (mm) 80 x 76.5 mm
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
Exhaust System Single Pipe / Silencer
Fuel System
Fuel System Type Bosch Electronic Fuel Injection
Fuel Delivery Electronic Fuel Pump (in tank)
Fuel Pressure 39 psi
Fuel Filters See Chapter 4
Fuel Capacity / Requirement 7 gal. (26.5 liters)
87 Octane (minimum)
Electrical
Alternator Max Output 500 watts @ 3000 RPM
Lights: Main Headlights 2 - Dual Beam 55 watts / Halogen
Tail / Brake 2 - 27 watts
Worklights 2 - 13 watts
Starting System Electric Start
Ignition System Bosch EFI (ECU Controlled)
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
Drivetrain
Transmission Type Polaris Automatic PVT
Gear Ratio: Front / Rear
High
Low
Rev
3.14:1
8.71:1
5.94:1
Drive Ratio - Front 3.82:1
Drive Ratio - Final 3.70:1
Shift Type In Line Shift - H / L / N / R / P
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
Steering / Suspension
Front Suspension Independent Double A-arm
Front Travel 9 in. / 23 cm
Rear Suspension Independent Double A-arm
Rear Travel 9.5 in. / 24 cm
Shock Preload Adjustment
Front / Rear Cam Adjustment
Toe Out 1/8-1/4 in. / 3-6.35 mm
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)
Brake - Front / Rear Foot Actuated - 4 Wheel
Hydraulic Disc
Brake Fluid DOT 4
Altitude Shift Weight Drive Spring Driven
Spring
Meters
(Feet)
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)
1.6
GENERAL INFORMATION
VEHICLE INFORMATION
Publication Numbers
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
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.
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/.
Model Model No. Owner’s Manual PN Parts Manual PN
2008 RANGER RZR, Red R08VH76AD 9921181 9921207
2008 RANGER RZR, Green R08VH76AG 9921181 9921207
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
Series# Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
Key Series
Number
KEY COVER
P/N 5533534
1.7
GENERAL INFORMATION
1
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
°C to °F: 9/5(°C + 32) = °F °F to °C: 5/9(°F - 32) = °C
1.8
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.
1.9
GENERAL INFORMATION
1
SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents
1.10
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.
MAINTENANCE
2.1
CHAPTER 2
MAINTENANCE 2
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
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
2.2
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
2.3
MAINTENANCE
2
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.
2.4
MAINTENANCE
Pre-Ride - 25 Hour Maintenance Interval
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.
Item
Maintenance Interval
(whichever comes first) Remarks
Hours Calendar Miles
(KM)
Steering - Pre-Ride -
Make adjustments as needed.
See Pre-Ride Checklist on Page 2.9.
Front Suspension - Pre-Ride -
Rear Suspension - Pre-Ride -
Tires - Pre-Ride -
Brake Fluid Level - Pre-Ride -
Brake Pedal Travel - Pre-Ride -
Brake Systems - Pre-Ride -
Wheels / Fasteners - Pre-Ride -
Frame Fasteners - Pre-Ride -
EEngine Oil Level - Pre-Ride -
EAir Filter / Pre-Filter - Pre-Ride - Inspect; clean often; replace as needed
Coolant Level - Daily - Check level daily, change coolant every 2
years
Head Lamp / Tail Lamp - Daily - Check operation; apply dielectric grease if
replacing
EAir Filter,
Main Element - Weekly - Inspect; replace as needed
Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically
Battery 25 H Monthly 250 (400) Check terminals; clean; test
Front Gearcase Oil
(Demand Drive Fluid LT) 25 H Monthly 250 (400) Inspect level; change yearly
Rear Gearcase Oil
(ATV Angle Drive Fluid) 25 H Monthly 250 (400) Inspect level; change yearly
Transmission - Main
(AGL Gearcase Lubricant) 25 H Monthly 250 (400) Inspect level; change yearly
Transmission - Transfer
(AGL Gearcase Lubricant) 25 H Monthly 250 (400) Inspect level; change yearly
EEngine Breather
Filter (if equipped) 25 H Monthly 250 (400) Inspect; replace if necessary
EEngine Oil Change
(Break-In Period) 25 H 1 M 250 (400) Perform a break-in oil change at one month
2.5
MAINTENANCE
2
50 - 300 Hour Maintenance Interval
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.
Item
Maintenance Interval
(whichever comes first) Remarks
Hours Calendar Miles
(KM)
EThrottle Cable / Throttle
Pedal 50 H 6 M 300 (500) Inspect; adjust; lubricate; replace if
necessary
EThrottle Body Air Intake
Ducts / Flange 50 H 6 M 300 (500) Inspect ducts for proper sealing / air leaks
General Lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.
Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust
Steering 50 H 6 M 500 (800) Lubricate
Front Suspension 50 H 6 M 500 (800) Lubricate
Rear Suspension 50 H 6 M 500 (800) Lubricate
Cooling System 50 H 6 M 500 (800) Inspect coolant strength seasonally;
pressure test system yearly
EFuel System 100 H 12 M 600 (1000) Check for leaks at tank cap, fuel line, fuel
pump, and fuel rail.
Replace lines every two years.
ESpark Plug 100 H 12 M 600 (1000) Inspect; replace as needed
EEngine Oil & Filter Change 100 H 6 M 1000 (1600) Perform a break-in oil change at 25 hours or
one month / always replace oil filter when
changing engine oil
Drive Belt 100 H 12 M 1000 (1600) Inspect; replace as needed
Radiator 100 H 12 M 1000 (1600) Inspect; clean external surfaces
Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks
Engine Assembly Mounts 100 H 12 M 1000 (1600) Inspect, torque to specification
Exhaust Muffler / Pipe 100 H 12 M 1000 (1600) Inspect
Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply
dielectric grease to connectors subjected to
water, mud, etc.
Clutches (Drive and Driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed
Brake Fluid 200 H 24 M 2000 (3200) Change every two years (DOT 4)
Spark Arrestor 300 H 36 M 3000 (4800) Clean out
Toe Adjustment - Inspect periodically; adjust when parts are
replaced
Headlight Aim - Adjust as needed
2.6
MAINTENANCE
COMPONENT INSPECTION / SERVICE LOCATIONS
Front and Rear View
2.7
MAINTENANCE
2
RH and LH Side Views
2.8
MAINTENANCE
LUBRICANTS / SERVICE PRODUCTS
Polaris Lubricants, Maintenance and Service
Products
NOTE: Each item can be purchased separately at
your local Polaris dealer.
NOTE: The number count indicated by each part
number in the table above indicates the number of
units that are shipped with each order.
Part No. Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2871281 Premium 4-Cycle Synthetic 0W-40
Engine Oil (Quart) (12 Count)
2871844 Premium 4-Cycle Synthetic 0W-40
Engine Oil (Gallon) (4 Count)
2871567 Premium 4-Cycle Synthetic 0W-40
Engine Oil (16 Gallon) (4-Cycle)
Gearcase / Transmission Lubricants
2873602 AGL - Synthetic ATV Gearcase Lubricant
(1 Qt.) (12 Count)
2873603 AGL - Synthetic ATV Gearcase Lubricant
(1 Gal.) (4 Count)
2873604 AGL - Synthetic ATV Gearcase Lubricant
(2.5 Gal.) (2 Count)
2871653 ATV Angle Drive Fluid
(8 oz.) (12 Count)
2872276 ATV Angle Drive Fluid
(2.5 Gal) (2 Count)
2871654 Premium Demand Drive Fluid LT
(1 Qt.) (12 Count)
2870465 Oil Pump for 1 Gallon Jug
Grease / Specialized Lubricants
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)
Part No. Description
Additives / Sealants / Thread Locking Agents / Misc.
2870585 Loctite™ Primer N, Aerosol, 25 g
2871956 Loctite™ Thread Sealant 565
(50 ml.) (6 Count)
2871949 Loctite™ Threadlock 242
(50 ml.) (10 Count)
2871950 Loctite™ Threadlock 242
(6 ml.) (12 Count)
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 Loctite™ Threadlock 271
(36 ml.) (6 Count)
2870584 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)
2870652 Fuel Stabilizer (16 oz.) (12 Count)
2872189 DOT 4 Brake Fluid (12 Count)
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
2872893 Engine Degreaser (12oz.) (12 Count)
2.9
MAINTENANCE
2
MAINTENANCE REFERENCES
* 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)
Item Ref. Rec. Lube / Fluid Method Frequency*
Engine Oil Page 2.7 Premium 4-Cycle Synthetic
0W-40 (PN 2871281) Add oil to proper level on
dipstick.
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 Coolant Page 2.6 Polaris Antifreeze 60/40
(PN 2871534) Fill recovery bottle between
MAX and MIN lines. Fill as required. Change
coolant every 2 years.
Brake Fluid Page 2.7 DOT 4 (PN 2872189) Fill reservoir between MAX
and MIN lines. Fill as required. Change
brake fluid every 2 years.
Transmission
(Main Gearcase) Page 2.7 AGL Synthetic Gearcase
Lubricant (PN 2873602) Add lube to bottom of fill
plug threads. 24 oz. (710 ml) Change annually***
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
plug threads. 18 oz. (532 ml) Change annually***
Prop Shaft Page 2.7 Polaris Premium U-Joint
Lube (PN 2871551) Locate fitting and grease with
grease gun. Semi-annually**
Control Arm Pivot
Bushings, FT / RR Page 2.6 Polaris Premium All Season
Grease (PN 2871423)
Locate grease fittings on the
upper and lower A-arms of
the front and rear suspension
and grease with grease gun.
(4) Front A-arms
(6) Rear A-arms
Semi-annually**
Stabilizer Bar
Bushings, FT / RR Page 2.7 Polaris Premium All Season
Grease (PN 2871423)
Locate grease fittings on the
front and rear stabilizer bars
and grease with grease gun.
(2) Front Stabilizer Bar
(2) Rear Stabilizer Bar
Semi-annually**
2.10
MAINTENANCE
GENERAL VEHICLE INSPECTION
AND MAINTENANCE
Pre-Ride / Daily Inspection
Perform the following pre-ride inspection daily, and when
servicing the vehicle at each scheduled maintenance.
• Tires - check condition and pressures
• Fuel tank - fill to proper level
• All brakes - check operation and adjustment
• Throttle - check for free operation and closing
• 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
• Steering - check for free operation noting any unusual
looseness in any area
• Loose parts - visually inspect vehicle for any damaged
or loose nuts, bolts or fasteners
• Engine coolant - check for proper level at the recovery
bottle
• 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.
Shift Cable Inspection / 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 into a gear
• Excessive gear clash (noise)
• Gear selector moving out of desired range
1. Locate the shift cable in the rear LH wheel well 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.
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.
Shift Cable
Mount
Dust Boot
Clevis Pin
Shift Cable
Lower
Jam Nut
Upper
Jam Nut
2.11
MAINTENANCE
2
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, the transmission will require
service.
FUEL SYSTEM AND AIR INTAKE
Fuel System
Fuel Line
1. Check the quick-connect fuel line for signs of wear,
deterioration, damage or leakage. Replace if necessary.
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.
NOTE: Neither filter is servicable.
NOTE: For all other information related to the EFI
System, refer to Chapter 4.
Vent Lines
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.
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.
Injector Rail
Connector
Fuel Line
Fuel Pump
Connector
Fuel Pump Asm
Fuel Pump Asm
Located in Fuel Tank
Preliminary Filter
Fine Filter
2.12
MAINTENANCE
Throttle Pedal Inspection
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.
Check the throttle pedal play periodically in accordance with the
Periodic Maintenance Chart and adjust the play if necessary.
Throttle Freeplay Adjustment
Inspection
1. Place the transmission in the P (Park) position.
2. Start the engine, and warm it up thoroughly.
3. 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).
Adjustment
1. Remove the seat and rear service panel.
2. Locate the throttle cable adjuster just above the PVT cover.
3. Squeeze the end of the rubber boot and slide it far enough
to expose the end of the inline cable adjuster.
4. Loosen the adjuster lock nut.
5. 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. Tighten the lock nut.
7. Squeeze the end of the rubber boot and slide it over the
cable adjuster to its original position.
Air Filter Service
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.
The filter should be inspected using the following procedure.
Removal
1. The air box is located just above the rear LH wheel in the
wheel well area.
2. 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.
Throttle Pedal
Throttle Cable
Adjuster
Boot
Adjuster
Lock Nut
Air Box Location
2.13
MAINTENANCE
2
3. Remove air filter assembly and remove the pre-filter sleeve.
4. 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.
NOTE: Service more frequently if vehicle is operated
in wet conditions or at high throttle openings for
extended periods.
Installation
1. Clean the air box thoroughly.
2. Install a new or clean pre-filter over the main air filter
element.
3. 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.
Cap
Seal
Air Filter
Pre-Filter
Sleeve
Secure Clips
Cap
Seal
Clip (2)
Boot
Air Box Can
Air Intake Duct
Breather
Seal
Fitting
T-MAP
Breather
Intake Box
Pre-Filter
Air Filter
Clamps
Intake Duct
Foam Seal
Air Box
Foam Seal
Sleeve
Filter
Hose
Sensor
2.14
MAINTENANCE
ENGINE
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.
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.
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.
6. 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.
7. 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).
NOTE: A rising oil level between checks in cool
weather driving can indicate contaminants such as
gas or moisture collecting in the crankcase. If the oil
level is over the full mark, change the oil
immediately.
8. Reinstall the dipstick and seat the lever lock.
Dipstick
Dipstick
Lever Lock
Lever Lock
Dipstick
SAFE ADD 8 OZ
Dipstick
Always read top side of dipstick to
properly check oil level in crankcase
2.15
MAINTENANCE
2
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.
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.
5. Place a drain pan beneath engine crankcase and remove the
drain plug.
6. Allow oil to drain completely.
7. Replace the sealing washer on drain plug.
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.
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).
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.
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.
19. Dispose of used oil and oil filter properly.
WARNING
Personal injury can occur when handling used
oil. Hot oil can cause burns or skin damage.
Recommended Engine Oil:
Premium 4-Cycle Synthetic OW-40
(PN 2871281) (Quart)
Ambient Temperature Range
-40° F to 120° F
CAUTION
Oil may be hot. Do not allow hot oil to come into
contact with skin, as serious burns may result.
Drain Plug
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
Oil Filter Wrench:
(PV-43527)
Oil Filter
2.16
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 fit-
ted for a proper fit. Follow the breather hose from the side of
the airbox to the engine valve cover.
NOTE: Make sure line is not kinked or pinched.
Engine and Transmission Mount Locations
Periodically inspect engine and transmission mounts for cracks
or damage.
Compression and Leakdown Test
NOTE: This engine does NOT have decompression
components. Compression readings will vary in
proportion to cranking speed during the test.
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).
Exhaust - Spark Arrestor
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).
Breather
Hose
LH Mount
RH Mount
Rear Mount
Cylinder Compression
Standard: 150-200 PSI
Cylinder Leakdown
Service Limit 15%
(Inspect for cause if test exceeds 15%)
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.
Arrestor
Screen
Muffler
Retaining
Screw
2.17
MAINTENANCE
2
TRANSMISSION AND GEARCASES
Transmission / Gearcase Specification Chart
Transmission Lubrication
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.
The transmission lubricant levels should be checked and
changed in accordance with the maintenance schedule.
• Be sure vehicle is positioned on a level surface when
checking or changing fluid.
• Check vent hose to be sure it is routed properly and
unobstructed.
Transfer Case - Lubricant Level Check:
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.
5. Reinstall the level check plug and torque to 30-45 in. lbs.
(3-5 Nm).
6. Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm).
GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN / LEVEL CHECK
PLUG TORQUE
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)
Transmission Specifications
Specified Lubricant:
AGL Synthetic Gearcase Lubricant
(PN 2873602)
Approximate Capacity at Change:
Main Gearcase - 24 oz. (710 ml)
Transfer Case - 14 oz. (414 ml)
Drain / Level Plug Torque:
30-45 in. lbs. (3-5 Nm)
Fill Plug Torque:
40-50 ft. lbs. (54-68 Nm)
Fill Plug
Level Check Plug
Drain Plug
2.18
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.
4. If fluid level is not at fill plug hole, add the recommended
fluid as needed.
5. Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm).
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.
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).
6. Add the recommended fluid through the fill plug hole until
it begins to flow out the check plug hole. Do not overfill.
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:
9. Remove the fill plug (refer to “Main Gearcase - Lubricant
Level Check”).
10. Place a drain pan under the main gearcase drain plug.
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.
Fill Plug /
Level Check Plug
Main Gearcase
Drain Plug
Transfer Case
Drain Plug
2.19
MAINTENANCE
2
Front Gearcase Lubrication
The front gearcase lubricant level should be checked and
changed in accordance with the maintenance schedule.
• Be sure vehicle is positioned on a level surface when
checking or changing fluid.
• Check vent hose to be sure it is routed properly and
unobstructed.
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. Position vehicle on a level surface.
2. Remove the fill plug and check the fluid level.
3. Add the recommended fluid as needed.
4. Reinstall the fill plug and torque to 8-10 ft. lbs. (11-14 Nm).
Lubricant Change:
The drain plug is located on the bottom of the gearcase.
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.
Front Gearcase Specifications
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)
8-10 ft. lbs.
(11-14 Nm)
Fill Plug
Drain Plug
8-10 ft. lbs.
(11-14 Nm)
8-10 ft. lbs.
(11-14 Nm)
Fill Plug
2.20
MAINTENANCE
Rear Gearcase Lubrication
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.
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)
Lubricant Change:
The drain plug is located on the bottom right side of the rear
gearcase.
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).
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.
Rear Gearcase Specifications
Specified Lubricant:
ATV Angle Drive Fluid (PN 2871653)
Capacity: 18 oz. (532 ml)
Fill Plug Torque: 40-50 ft. lbs. (54-68 Nm)
Drain Plug Torque: 30-45 in. lbs. (3-5 Nm)
40-50 ft. lbs.
(54-68 Nm)
Fill Plug
Maintain Level at
Bottom of Threads
Fill Plug
Drain Plug
40-50 ft. lbs.
(54-68 Nm)
Fill Plug
Maintain Level at
Bottom of Threads 30-45 in. lbs.
(3-5 Nm)
Drain Plug
2.21
MAINTENANCE
2
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.
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.
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.
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. View the coolant level in the recovery bottle.
4. If the coolant level is below the MIN line, inspect the
coolant level in the radiator.
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.
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.
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.
• A 50/50 or 60/40 mixture of antifreeze and distilled
water will provide the optimum cooling, corrosion
protection, and antifreeze protection.
• 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.
Recovery Bottle
Pressure Cap
WARNING
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.
Polaris 60/40 Anti-Freeze / Coolant
(PN 2871323)
Antifreeze Hydrometer
2.22
MAINTENANCE
Cooling System Pressure Test
Refer to Chapter 3 for cooling system pressure test procedure.
Cooling System Hoses
1. Inspect all hoses for cracks, deterioration, abrasion or
leaks. Replace if necessary.
2. Check tightness of all hose clamps.
Radiator
1. Check radiator (A) air passages for restrictions or damage.
2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with compressed air or low
pressure water.
Coolant Drain / Radiator Removal
Coolant Drain
1. Remove the front hood.
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.
5. Allow coolant to completely drain.
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).
Recovery
Filler Neck
T-Connector
Bottle
A
Flush radiator fins
in this direction
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.
WARNING
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.
T-Fitting
Drain Here
2.23
MAINTENANCE
2
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. Remove the (2) upper radiator retaining bolts and the (4)
bolts retaining the lower radiator mount bracket. Remove
the bracket from the frame.
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.
FINAL DRIVE / WHEEL AND TIRE
Wheel, Hub, and Spindle Torque Table
NOTE: Do not lubricate the stud or the lug nut.
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.
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.
Recovery
Engine
T-Fitting
Radiator
Fan Motor Asm.
Screws
Grommets
Inserts
Hose
Outlet Hose
Engine
Inlet Hose
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)
Steel Wheel
27 ft. lbs. (37 Nm)
Aluminum Wheel
90 ft. lbs. (122 Nm)
#1 #2
2.24
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.
Tire Inspection
• Improper tire inflation may affect vehicle
maneuverability.
• 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.
Tire Pressure
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.
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.
Wheel Nuts (4)
Hub Nut
Use a new
cotter pin
Note
Tire Rotation
Valve stem
facing outward
Tread
Depth 1/8" (3 mm)
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.
Always replace tires when the tread depth
measures 1/8", (.3 cm) or less.
CAUTION
Maintain proper tire pressure.
Refer to the warning tire pressure decal
applied to the vehicle.
Tire Pressure Inspection (Cold)
Front Rear
8 psi (55 kPa) 8 (55 kPa)
Front Boots
Rear Boots
2.25
MAINTENANCE
2
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
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.
Be careful not to allow cleaning solution or tap water into the
battery
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.
Battery Removal
1. Remove the driver’s seat to access the battery.
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.
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.
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.
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
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.
CAUTION
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
2.26
MAINTENANCE
Battery Off Season Storage
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.
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)
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:
Spark Plug Service
1. Remove both driver and passenger seats.
2. Remove the rear service panel.
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.
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.
STATE OF
CHARGE VOLTAGE ACTION CHARGE
TIME
100% 12.8 - 13 VDC None, check
again in 3
months
None
Required
75% - 100% 12.5 - 12.8 VDC
May need slight
charge, check
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% 11.5 VDC or less Needs Charge
with desulfating
charger
At least 20
hrs
WARNING
A hot exhaust system and engine can cause serious
burns. Allow engine to cool or wear protective
gloves when removing the spark plugs
Inspect electrode for
wear and buildup
2.27
MAINTENANCE
2
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.
10. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if the
incorrect spark plug is used.
11. Apply anti-seize compound to the spark plug threads.
12. Install spark plug and torque to specification.
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.
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.
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 are
replaced, check front end alignment.
Steering Wheel Freeplay
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
Recommended Spark Plug:
Champion RC7YC3
Spark Plug Torque:
18 ft. lbs. (24 Nm)
Gap - .035" (0.90 mm)
Spark Plug Gap
Ground
Terminal Location
Engine
Ground Strap
WARNING
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.
Tie Rod
U-Joints
Gearbox
Tie Rod
2.28
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.
• 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.
• 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.
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.
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).
Check for Loose Wheel or Hub
= In. / mm.
Wheel Toe-Out:
(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)
Measurement “B” Chalk Mark
Measurement “A”
2.29
MAINTENANCE
2
Toe Adjustment
If toe alignment is incorrect, measure the distance between
vehicle center and each wheel. This will tell you which tie rod
needs adjusting.
NOTE: Be sure steering wheel is straight ahead
before determining which tie rod(s) need
adjustment.
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.
• After alignment is complete, torque jam nuts to
specification.
Suspension Spring Preload Adjustment
The front and rear shock absorber springs are adjustable by
rotating the adjustment cam to change spring tension preload.
Suspension Spring Adjustment
1. Position the vehicle on a level surface.
2. Stop the engine.
3. Raise and safely support the front or rear of the vehicle off
the ground to allow the suspension to fully extend.
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.
5. Rotate the adjustment cam clockwise to increase spring
tension or counter-clockwise to decrease spring tension.
6. Each notch of the adjustment will add 6% - 8% more
preload to the spring over the primary position.
CAUTION
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.
= T
Tie Rod Jam Nut Torque:
12-14 ft. lbs. (16-19 Nm)
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.
Shock Spanner Wrench
(PN 2870872)
Increase
Preload
Decrease
Preload
Cam
2.30
MAINTENANCE
BRAKE SYSTEM
Brake Fluid Inspection
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.
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.
Brake Pad / Disc Inspection
1. Check the brake pads for wear, damage, or looseness.
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).
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).
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.
Maximum
Minimum
Master Cylinder
Measure Pad Material
Service Limit:
.040" (1 mm)
Thickness
Measure Brake Disc Thickness
Service Limit:
.170" (4.32 mm)
Front
Disc
Rear
Disc
3.1
CHAPTER 3
ENGINE
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
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
3.2
ENGINE
ENGINE SPECIFICATIONS
Crankcase Exploded Views
3.3
ENGINE
3
Oil Pump / Water Pump / Engine Cover Exploded View
3.4
ENGINE
Stator Cover / Starter / Water Pump Oil Filter / Pressure Relief / Exploded View
3.5
ENGINE
3
Cylinder / Cylinder Head / Piston Exploded View
3.6
ENGINE
Engine EFI Sensors / Valve Cover / General Component Exploded View
NOTE: See Chapter 4 for more information on the EFI System
3.7
ENGINE
3
Engine Fastener Torque Patterns
22 ± 2 ft. lbs. (30 ± 3 Nm)
Crankcase 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)
Cylinder Head Bolt Tighten Sequence
3.8
ENGINE
Torque Specifications
NOTE: * See exploded views for notes or torque sequences.
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 20 ± 5 (2.5 ± 0.55) -
Cylinder Head Bolts 11 mm * 35 ± 4 (47.5 ± 5.5)
Exhaust Manifold 8 mm 216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7)
Flywheel 14 mm 65 ± 7 (88 ± 9.50)
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 35 ± 4 (47.5 ± 5.4)
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 * 22 ± 2 (30 ± 3)
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) -
Temperature Switch 3/8 NPT 17 ± 2 (23 ± 3)
Thermostat Housing 6 mm 84 ± 8 (9.5 ± 0.9) -
Timing Plug 3/4-16 7 - 9 (10 - 12)
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) -
3.9
ENGINE
3
800 EFI Engine Service Specifications
Cylinder Head - Engine Specifications
Main Component: Cylinder Head EH076OLE021
Camshaft
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 Counter Balance End Play 0.005" (0.127 mm)
Cylinder Head Cylinder Head - Surface warp limit 0.00394" (0.1 mm)
Cylinder Head - Standard height 3.478" (88.35 mm)
Valve Seat
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 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
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
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)
3.10
ENGINE
Cylinder / Piston - Engine Specifications
Main Components: Cylinder / Piston / Connecting Rod EH076OLE021
Cylinder
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 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
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
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 EH076OLE021
Piston Ring
Installed
Gap
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
Ring to
Groove
Clearance
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
Connecting Rod Small End I.D. 0.7096"− 0.70846" (18 − 17.995 mm)
Connecting Rod Small End
Radial Clearance 0.0098"± 0.00039" (0.025 ± 0.010mm)
Connecting Rod Big End
Side Clearance 0.01181"± 0.00591" (0.030 ± 0.015mm)
Connecting Rod Big End
Radial Clearance 0.0015"± 0.00006" (0.0038 ± 0.0015mm)
Crankshaft Crankshaft Runout Limit 0.00236" (0.060mm)
3.11
ENGINE
3
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
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
3.12
ENGINE
ENGINE COOLING SYSTEM
Cooling System Specifications
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.
3. 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
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.
Condition Specification
Thermostat Open 180° F (82° C)
Thermostat Full Open Lift 6 mm at 203° F (95° C)
Thermostat Closed 171° F (77° C)
System Capacity 4.8 Quarts (4.5 liters)
Pressure Cap Relief 13 PSI
Polaris Premium Antifreeze
2871534 - Quart
2871323 - Gallon
Remove
Test Here
Cap
WARNING
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.
Pressure Cap
3.13
ENGINE
3
Cooling System Exploded View
Recovery Bottle
Engine Inlet Hose
Engine Outlet Hose
Radiator
Radiator
Shroud
Radiator
Pressure Cap
Fan Motor
(Water Pump Cover)
(Thermostat Housing)
If Built After 4/16/2007
Outlet Hose
Inlet Hose
Filler Neck
To Filler Neck
To Bottle
Coolant Flow Diagram
Radiator
Recovery Bottle
Engine
Water Pump
Engine
Thermostat Housing
Filler Neck
3.14
ENGINE
Cooling System Bleeding Procedure
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. 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.
2. Place the vehicle in Park and block the rear wheels.
3. Remove pressure cap and top off coolant.
4. Remove recovery bottle cap and fill bottle to the full line.
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.
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.
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.
CAUTION
Use caution when performing these procedures.
Coolant may be hot and may cause
severe injury or burns.
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.
Pressure Cap
Recovery Bottle
Pressure Cap
Top LH Side
of Engine
C
3.15
ENGINE
3
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
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.
GENERAL ENGINE SERVICE
Engine Lubrication Specifications
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.
WARNING
Be sure to install the pressure cap before
shutting off the engine.
Coolant may spit out of the radiator.
=
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.
Oil Pressure at Idle: 6 psi
Oil Pressure at 6000 RPM (Engine Hot):
Minimum: 27 psi
Standard: 31 psi
Maximum: 35 psi
3.16
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.
3.17
ENGINE
3
Engine Removal
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.
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.
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.
• 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).
8. Remove the (2) push rivets from the rear of the center
console.
9. Remove the (2) fasteners from the rear seat base and
remove the assembly from the vehicle.
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.
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.
Remove
Push Rivets
3.18
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.
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.
17. Remove the vent lines from the upper bolt-in frame brace
and plug vent lines to prevent fluid leakage during removal.
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.
19. Remove the upper nut and grommet from the stabilizer bar
linkage on both sides of the vehicle.
20. Remove the (4) fasteners retaining the stabilizer bar and
bracket and remove the assembly from the vehicle.
21. Remove the engine breather hose from the valve cover.
Outlet Duct
PVT Cover
Harness
Connection
Ignition
Coil
Frame Brace
PVT Duct
3.19
ENGINE
3
22. Loosen the hose clamp between the throttle body and intake
adaptor.
23. Disconnect the T-MAP and TPS harnesses (see photo).
24. Remove the remaining bolt attaching the airbox to the
frame (see photo).
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.
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.
27. Disconnect the fuel line from the fuel injector rail.
28. Disconnect the shift cable from the transmission bell crank.
Loosen
Clamp
Disconnect Here
DO NOT
Disconnect Here
Fuel
Injector
Harness
Remove
Clip
3.20
ENGINE
29. Mark the upper jam nut and loosen the lower jam nut. Pull
the shift cable out of the mount.
NOTE: If the upper jam nut is moved, shift cable
adjustment will be required during engine
installation (see Chapter 2 “Shift Cable Inspection /
Adjustment”).
30. Disconnect the transmission gear indicator switch harness.
31. Disconnect the CPS harness.
32. Disconnect the stator / alternator harness.
33. Disconnect the transmission speed sensor harness.
34. Remove the castle nuts from both rear wheel hubs.
Lower
Jam Nut
Mark Upper
Jam Nut
Gear Switch
Connector
CPS
Connector
Stator
Connector
Speed Sensor
Connector
Castle Nut
3.21
ENGINE
3
35. Remove the through-bolt that attaches the upper A-arm to
the rear hub on both sides of the vehicle.
36. Pivot the A-arms upward and rear hub carriers downward
and remove the drive shafts from the hub carriers.
37. Grasp the rear drive shafts and pull sharply outward on the
shafts to disengage them from the rear gearcase.
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.
38. Disconnect the engine coolant temperature (ECT) sensor
harness.
39. Loosen the hose clamp and remove the lower coolant hose
from the water pump cover inlet and drain coolant into a
suitable container.
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.
Hub Carrier
ECT
Connector
3.22
ENGINE
44. Remove RH engine mount fastener.
45. Remove the (2) lower bolts that retain the LH transmission
mount to the frame.
46. Remove the (2) rear gearcase mount bracket fasteners and
mount bolt and remove bracket from vehicle.
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.
47. Using an engine hoist, hook a chain between the engine /
transmission mounting plate and the transmission / rear
gearcase mounting plate.
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.
Remove
(2) Lower Bolts
Transmission/Gearcase
Mount Plate
Engine/Transmission
Mount Plate
Allow valve cover
to clear frame
3.23
ENGINE
3
49. Remove propshaft from the transmission output shaft.
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.
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.
3. Remove only the (4) outer fasteners retaining the engine to
the transmission bracket.
NOTE: Vehicles manufactured on or after 5/21/07,
will be assembled with an added support bracket
mounted between 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”).
Support Bracket
3.24
ENGINE
ENGINE DISASSEMBLY AND INSPECTION
Cylinder Head Assembly Exploded View
Push Rods
Hydraulic Lifters
Valves
Cylinder Head
Valve Seals
Springs
Spring Retainers
Rocker Arms
Retainer Locks (keepers)
Valve Spring Seats
3.25
ENGINE
3
Rocker Arms
1. Remove the valve cover.
2. Mark or tag rocker arms in order of disassembly to keep
them in order for reassembly.
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. 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.
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.
5. If the push rod (A) is visibly bent, it should be replaced.
Cylinder Head Removal
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).
WARNING
Always wear safety glasses when working with
compressed air to prevent personal injury.
A
A
B
C
D
3.26
ENGINE
Cylinder Head Inspection
Thoroughly clean cylinder head surface to remove all traces of
gasket material and carbon.
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.
Valve Seal / Spring Service (On Engine)
NOTE: The following procedure is only for servicing
the top end of the valve train when replacing valve
springs or replacing valve seals.
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.
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 (PU-
45652) 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.
NOTE: A small parts magnet (A) can aid in the
removal of the retainers (B).
NOTE: To prevent damage to the valve seals, do not
compress the valve spring more than is needed to
remove the valve keepers.
3. Remove spring retainer and spring.
4. The valve seals are now serviceable.
CAUTION
Use care not to damage sealing surface.
= In. / mm.
Cylinder Head Warp Limit:
.004" (.1016 mm) max
A
B
Measure at different
points on the surface.
WARNING
Wear eye protection or a face shield during
cylinder head disassembly and reassembly.
A
B
PU-45257
3.27
ENGINE
3
Cylinder Head Disassembly
1. Carefully remove the cylinder components.
2. Place the hydraulic lifters (C), pushrods (D), and rocker
arms (E) in a safe, clean area.
3. Measure free length of spring with a Vernier caliper.
Compare to specifications. Replace spring if measurement
is out of specification.
4. Remove valve guide seals.
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.
5. 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.
= In. / mm.
Valve Spring Free Length:
Std: 1.735" (44.069 mm)
D
C
E
Valve Spring
Free Length
Mark the Valves
3.28
ENGINE
Valve Inspection
1. Remove all carbon from valves with a soft wire wheel or
brush.
2. 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.
3. Check end of valve stem for flaring, pitting, wear or damage
(A).
4. 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.
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.
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.
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.
A
B
Measure valve stem in several places.
Rotate the valve 90 degrees and measure
for wear.
= 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)
= In. / mm.
Valve Guide I.D.:
0.23672" + 0.000295"
(6.0617 + 0.0075 mm)
C
3.29
ENGINE
3
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.
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.
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.
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.
WARNING
Wear eye protection or a face shield during
cylinder head disassembly and reassembly.
Combustion Area
3.30
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.
* 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.
* 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).
6. Insert valve into guide and tap valve lightly into place a few
times.
7. 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.
* 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.
* If the seat is too narrow, widen using the 45° cutter and re-
check contact point on the valve face and seat width after each
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).
A
= In. / mm.
Valve Seat Width:
Intake Std: .028" (.7 mm)
Limit: .055" (1.4 mm)
Exhaust Std: .039I (1.0 mm)
Limit: .071" (1.8 mm)
B
A
Proper Seat Contact
on Valve Face
Bottom 60°Seat 45°Top 30°
Seat
Width
3.31
ENGINE
3
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.
NOTE: Lapping is not required with an interference
angle valve job.
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.
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.
Cylinder Head Reassembly
NOTE: Assemble the valves one at a time to
maintain proper order.
1. Apply engine oil to valve guides and seats.
2. Coat valve stem with molybdenum disulfide grease or
0W-40 Synthetic oil.
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.
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.
PU-45257
3.32
ENGINE
Valve Sealing Test
1. Clean and dry the combustion chamber area (A).
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. Follow engine disassembly procedures to remove rocker
cover and cylinder head.
2. Tap cylinder (A) lightly with a rubber mallet in the
reinforced areas only until loose.
3. Rock cylinder forward and backward while lifting it from
the crankcase, supporting pistons and connecting rods.
Support pistons with Piston Support Block (PN 2870390).
Valve Lifter Removal / Inspection
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.
4. Check the lifters for wear or scores.
5. Check the bottom end of lifter to make sure that it has a
slight convex.
6. If the bottom surface has worn flat, it may be used with the
original camshaft only.
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.
A
A
Mark Hydraulic Lifter
Inspect Hydraulic Lifter
3.33
ENGINE
3
Piston Removal
1. Remove circlip (A). Mark the piston with a white pen to
ensure proper orientation (if reused) during assembly.
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. 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.
3. 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.
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
Oil Ring
B
3.34
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.
= In. / mm.
Cylinder Warp: .004" (0.1 mm) Max.
Measure at different
points on surface.
A
B
A
B
C
= In. / mm.
Cylinder Taper Limit:
.002" (9.05mm) Max.
Cylinder Out of Round:
Limit: .002" (.0 mm) Max.
1/2” Down From Top of Cylinder
1/2” Up From Bottom
3.35
ENGINE
3
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.
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:
• 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.
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.
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
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.
Standard Bore Size
(Both Cylinders): 3.1496" (80 mm)
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
3.36
ENGINE
Piston-to-Cylinder Clearance
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.
Piston / Rod Inspection
1. Measure piston pin bore.
2. Measure piston pin O.D. Replace piston and/or piston pin
if out of tolerance.
3. Measure connecting rod small end ID.
Piston to Cylinder Clearance:
See “800 EFI Engine Service
Specifications” on page 3.9
Piston O.D.:
See “800 EFI Engine Service
Specifications” on page 3.9
Piston Pin Bore:
See “800 EFI Engine Service
Specifications” on page 3.9
5 mm
Piston
Piston Pin
Piston Pin O.D.:
See “800 EFI Engine Service
Specifications” on page 3.9
Connecting Rod Small End I.D.:
See “800 EFI Engine Service
Specifications” on page 3.9
Piston Pin Measurement Locations
3.37
ENGINE
3
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.
Piston Ring Installed Gap
1. Place each piston ring (A) inside cylinder (B) using piston
to push ring squarely into place as shown.
NOTE: Ring should be installed with the mark facing
upward.
2. 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. 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.
Starter Drive Bendix Removal / Inspection
1. 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. Remove starter bendix assembly (A). Note the thrust
washers located on both sides of the bendix.
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.
See “800 EFI Engine Service
Specifications” on page 3.9
Piston Ring Installed Gap
See “800 EFI Engine Service
Specifications” on page 3.9
Piston
Ring
Feeler Gauge
A
B
C
25-50 mm
A
B
3.38
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.
Flywheel / Stator Removal / Inspection
1. Remove stator housing bolts and remove housing.
2. Remove flywheel nut and washer.
3. Install Flywheel Puller (PN 2871043) and remove flywheel
(A).
4. 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.
5. Remove the bendix (E) if necessary.
Engine Crankcase Disassembly / Inspection
1. Remove the stator cover (A) and water pump cover (B).
CAUTION
Do not thread the puller bolts into the flywheel
more than 1/4, or stator coils may be damaged.
C
Remove Stator
Cover
A
2871043
E
B
D
A
B
3.39
ENGINE
3
2. Remove the nylok nut (C), washer (D), and water pump
impeller (E). Remove part of the water pump seal behind
the impeller.
3. Remove flywheel nut and washer.
4. Install Flywheel Puller (PN 2871043) and remove flywheel
(F).
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.
6. 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.
7. Note the positions of the gears in the photo.
CAUTION
Do not thread the puller bolts into the flywheel
more than 1/4, or stator coils may be damaged.
D
E
C
F
2871043
G
H
I
J
Counterbalance Gear
Camshaft Gear
Crank Gear
3.40
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.
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.
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.
12. Remove all three springs using one of the tapered pins from
the Tapered Pins (PU-45497-1).
13. With a white marking pen, accent the timing mark on the
gear that contains the springs.
MN
K
Timing Marks
Water Pump Gear
3 Loaded Springs
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.
PU-45497-1
Accent Timing Marks
3.41
ENGINE
3
14. Inspect the gear teeth and the three tabs on the gears for
wear.
15. Install the new springs into the grooves of the cam gear.
16. Insert the pointed dowels from the Tapered Pins (PU-
45497-1) into the cam gear.
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.
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.
Inspect Teeth & Tabs
Replace 3 Springs
Install Springs
PU-45497-1
Cam Gear Spring Installation Tool Kit:
(PU-45497)
Tapered Pins:
(PU-45497-1)
Cam Gear Tooth Align Tool:
(PU-45497-2)
PU-45497-1
Align Timing Marks
3.42
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.
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 (PU-
45497-2) into one assembly hole counter clockwise
from the timing mark.
NOTE: For ease of installing the Cam Gear
Alignment Tool (PU-45497-2), use a twisting motion
when pushing down on the tool.
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.
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.
PU-45497-2
PU-45498
P
2871043
3.43
ENGINE
3
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).
24. Install the two puller bolts (R). Tighten the puller bolts up
so that the bolts are at equal length.
25. Install the Flywheel Puller (PN 2871043) and remove the
crankshaft gear, if needed.
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.
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.
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).
Q
R
2871043
S
Mark Rotors
Max Tip Clearance
0.006” (0.15 mm)
3.44
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.
30. Reinstall the valve (dowel chamfered end first). Install the
spring, washer, and bolt. Torque to specification .
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.
31. Carefully press the gear off the assembly while supporting
the housing assembly.
32. Remove the snap ring from the assembly. Place the housing
in a support and press out the bearing/shaft assembly.
33. Place the shaft in a press to remove the bearing.
= T
22 ± 2 ft. lbs. (30 ± 3 Nm)
22 ± 2 ft. lbs.
(30 ± 3 Nm).
Chamfer
End First
CAUTION
Wear appropriate safety gear during this
procedure. Protective gloves, clothing and eye
wear are required.
Press Off Gear
Press out shaft
and bearing
assembly.
Bearing
Retaining Ring
Press Off Bearing
3.45
ENGINE
3
34. Press shaft into the new bearing..
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.
36. Press gear onto shaft while supporting the housing.
37. Remove thrust plate (U).
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.
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.
Press On Bearing
Press Bearing / Shaft
Assembly using
outer race only
U
Separate
Crankcase Halves
3.46
ENGINE
39. Remove and clean oil pick up (V) and oil baffle weldment
(W).
40. Remove balance shaft and crankshaft.
41. Remove and inspect crankshaft main journal bearings for
abnormal wear. It is recommended to replace the
bearings anytime the engine is disassembled.
Camshaft Inspection
1. Thoroughly clean the cam shaft.
2. Visually inspect each cam lobe for wear, chafing or
damage.
3. Measure height of each cam lobe using a micrometer.
Compare to specification.
4. Measure camshaft journal outside diameters (O.D.).
W
V
= In. / mm.
Cam Lobe Height
(Intake & Exhaust):
Std: 1.3334" (33.8674 mm)
= 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)
Cam Lobe Height
A
B
C
3.47
ENGINE
3
5. Measure ID of camshaft journal bores.
6. Calculate oil clearance by subtracting journal O.D.s from
journal bore I.D.s. Compare to specification.
NOTE: Replace camshaft if damaged or if any part is
worn past the service limit.
NOTE: Replace engine block if camshaft journal
bores are damaged or worn excessively.
ENGINE REASSEMBLY
Crankcase Reassembly
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.
2. Install oil baffle weldment (B). Torque bolts to
specification.
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.
= In. / mm.
Camshaft Journal Bore I.D.:
(Mag): 1.656" ± 0.00039" (42.07± 0.010 mm)
( C t r .) 1 .63 7 " ± 0 . 000 39" ( 41. 5 8 ± 0 .010 mm)
(PTO) 1.617" ± 0.00039" (41.07 ± 0.010 mm)
= In. / mm.
Calculated Camshaft Oil Clearance:
Std: 0.0027" (.070mm)
Limit: .0039" (.10 mm)
CAUTION
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”).
= T
Oil Baffle Weldment & Oil Pick Up Bolt Torque:
60 ± 6 in. lbs. (6.8 ± 0.68 Nm)
B
A
C
3.48
ENGINE
NOTE: Always install new balance shaft bearings.
4. Apply assembly lube to cam journals and balance shaft
bearing surfaces of the MAG case halve. Install camshaft
and balance shaft.
5. Install crankshaft assembly and apply engine oil to crank
pins and rods (D). Apply assembly lube to the main
journals and bearings.
6. Apply Crankcase Sealant (PN 2871557) to the top gearcase
halve.
NOTE: Do not apply sealant to cam relief hole (E).
7. 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.
8. Lubricate cam lobes and valve lifters with Moly Lube
Grease.
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
E
= T
Crankcase Bolt Torque:
22 + 2 ft. lbs. (30 + 3 Nm)
Torque in sequence
Apply Moly Lube Cam Lobes
Lifters
3.49
ENGINE
3
10. Lubricate connecting rods with 0W-40 engine oil.
11. Install new cylinder gasket on crankcase. Align gasket on
the dowel pins for proper gasket alignment.
12. Orientate the piston rings on the piston before installation
into the cylinders. Set the gaps of the rings every 120°
(See Illustration Below).
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.
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.
15. Install the piston pin circlips. The circlip ends should be
installed at the 12 O'clock position.
Piston Ring
Orientation
1
2
3
1. Top Ring 2. Second Ring
3. Oil Ring
Push in Piston Pins
Piston Pin Cirlcip in
12 O’clock position
3.50
ENGINE
NOTE: While installing in piston circlips, cover all
engine passages. The clip could fall into the engine
during installation.
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™.
17. Assemble rotors as marked when disassembled. Use a
cleaner to remove the marks previously made on the rotors.
18. Apply assembly lube or oil to the rotors on the oil pump
shaft.
NOTE: The application of lubrication aids in priming
the oil pump during initial engine start up.
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.
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.
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™.
= T
Thrust Plate Screw Torque:
115 ± 12 in.lbs. (13 ± 1.35 Nm)
G
Line Up Marks
Lubricate Rotors
3.51
ENGINE
3
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.
NOTE: Occasionally spin the oil pump when
installing bolts to check for binding of the rotors.
21. Apply Loctite 242 (PN 2871949) to the crankshaft.
22. Before installing the crankshaft gear (I), heat the crankshaft
gear to 250° F (121°C) on a hot plate (J).
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.
= T
Oil Pump Bolt Torque:
84 ± 8 in.lbs. (9.50 ± 0.90 Nm)
* Torque in Sequence
H
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.
IJ
I
3.52
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.
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.
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.
NOTE: Cam Spanner Wrench (PU-45498) is only
needed to rotate the camshaft when the entire valve
train is assembled.
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.
= T
Balance Shaft Gear Bolt Torque:
22 ± 2 ft. lbs. (30 ± 3 Nm)
PU-45838
J
I
PU-45497-2
M
= T
Counterbalance Gear and Camshaft
Gear Bolt Torque:
22 ± 2 ft. lbs. (30 ± 3 Nm)
PU-45498
MN
K
Timing Marks
Water Pump Gear
Timing Marks
3.53
ENGINE
3
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.
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.
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.
NOTE: Install the crankshaft seal (P) with the seal lip
facing out (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.
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.
PA-44995
O
N
PA-44995
PA-45483
PU-45543
P
P
Seal lip goes towards the crankcase.
PU-45658
Important: Set the direction
of the paper lip seal
PU-45658
3.54
ENGINE
32. Before installing the gear/stator housing cover, install the
Water Pump Seal Saver (PA-45401) onto the water pump
shaft.
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.
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.
35. Install the gear/stator housing gasket onto he crankcase.
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.
PA-45401
= T
Gear/Stator Housing Bolt Torque:
96 ± 3 in. lbs. (10.85 ± 0.35 Nm)
*Torque in proper sequence
Gear / Stator
Housing Gasket
PA-45658
PA-45401
3.55
ENGINE
3
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.
37. Install shaft seal with ceramic surface facing inward.
38. Install water pump impeller (P). Secure the impeller with
the washer and a new nylok nut (Q). Torque the nut to
specification.
39. Install water pump cover (R) with new O-ring seal. Torque
bolts to specification in proper sequence (see Page 3.4).
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.
= T
Water Pump Impeller Nut Torque:
108 ± 6 in. lbs. (6.8 ± 0.68 Nm)
P
Q
= T
Water Pump Housing Bolt Torque:
96 ± 3 in. lbs. (10.85 ± 0.35 Nm)
*Torque in proper sequence
Install the O-ring dry, no lubricants
R
96 ± 3 in. lbs.
(10.85 ± 1.35 Nm)
3.56
ENGINE
Flywheel / Stator Installation
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).
NOTE: Verify stator wires are routed properly under
the wire hold down bracket.
3. Install the flywheel, washer, nut, and key. Torque flywheel
nut to specification.
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.
Cylinder Head Reassembly
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).
2. Install cylinder head on cylinder.
= T
Stator Assembly Bolt Torque:
96 ± 3 in.lbs. (10.85 ± 0.35 Nm)
U
TS
Replace 2 bolts with new bolts
65 ± 7 ft. lbs.
(88 ± 9.50 Nm)
= T
Flywheel Nut Torque
65 ± 7 ft.lbs. (88 ± 9.50 Nm)
= T
Stator Housing Bolt Torque:
96 ± 3 in. lbs. (10.85 ± 0.35 Nm)
96 ± 3 in.lbs.
(10.85 ± 0.35 Nm)
B
A
3.57
ENGINE
3
3. Lubricate threads and top of washers underside of bolt head
with engine oil. Install head bolts (C) and torque to
specification.
4. Lubricate push rods (D) and install into lifters.
5. Lubricate rockers (E) with engine oil.
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
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
C
D
= T
Rocker Arm Bolt Torque
22 + 2 ft. lbs. (30 ± 3 Nm)
E
F
3.58
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.
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.
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. Torque bolts in sequence to
specification.
11. Install thermostat (J), new O-ring, and thermostat housing.
Torque to specification.
12. Install temperature sender (K) and torque to specification.
Oil Pump Priming
= T
Breather Bolt Toque:
20 ± 5 in. lbs. (2.5± 0.55 Nm)
= T
Rocker Cover Bolt Torque:
84 ± 8 in.lbs. (9.5 ± 0.9 Nm)
20 ± 5 in.lbs.
(2.5 ± .55 Nm)
G
H
I
= T
Thermostat Housing Bolt Torque:
84 ± 8 in. lbs. (9.5± 0.9 Nm)
= T
Temperature Sender Torque:
17 ± 2 ft.lbs. (23 ± 3 Nm)
CAUTION
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.
J
17 ± 2 ft. lbs.
(23 ± 3 Nm)
84 ± 8 in. lbs.
(9.5 ± 0.9 Nm)
K
K
3.59
ENGINE
3
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.
2. 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.
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. 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.
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.
= T
Primer Plug Torque
18 ± 2 ft.lbs. (24.4 ± 2.71 Nm)
Fill 3/4 full
with 0W-40
PU-45778
Shim Size
Location
23-27 ft. lbs.
(31-37 Nm)
28 ft. lbs.
(38 Nm)
Support Bracket
3.60
ENGINE
2. Lightly tighten all fasteners evenly to eliminate any gaps
that may be present in the mounting areas.
3. Torque fasteners to specification using a 2 part sequence.
• Torque fasteners to half of the specified torque value
• Then torque fasteners to the full specified torque value
Install drive clutch, driven clutch, and belt. Torque to
specification (see Chapter 6).
• 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.
• Install engine / transmission / rear gearcase mounting
hardware and torque to specification.
NOTE: If isolator mounts were removed or replaced,
use the following illustration to ensure proper
orientation during installation.
• 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.”
= T
Engine / Transmission Mounting Fasteners
(2) Lower 3/8” Nuts: 40 ft. lbs. (54 Nm)
(4) Outer M8 Bolts: 28 ft. lbs. (38 Nm)
40 ft. lbs.
(54 Nm)
28 ft. lbs.
(38 Nm)
17 ft. lbs.
(23 Nm)
17 ft. lbs.
(23 Nm)
30 ft. lbs.
(41 Nm)
The protrusion of the mount
must face inward towards
the engine.
The protrusion of the mount
must face the RH side of
the vehicle.
Front Isolator Mounts
Rear Isolator Mounts
Mount Protrusion
3.61
ENGINE
3
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.
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.
CAUTION
Use only Polaris Premium 0-40W All Season
synthetic oil or equivalent.
Never substitute or mix oil brands.
Serious engine damage and voiding of
w a r r an t y c a n r e s u l t .
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.
=
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.
3.62
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
• Fuel quality poor (old) or octane too high
• Low compression
• Restricted exhaust
• Weak ignition (loose coil ground, faulty coil, or stator)
• Restricted air filter (main or pre-cleaner) or breather
system
• 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
• Fuel pump inoperative/restricted
• Tank vent plugged or pinched
• Engine flooded
• Low compression (high cylinder leakage)
• No spark (Spark plug fouled) ignition component
failure
Engine Does Not Turn Over
• Dead battery
• Starter motor does not turn
• Engine seized, rusted, or mechanical failure
Engine Runs But Will Not Idle
• Restricted fuel supply
• Low compression
• Crankcase breather restricted
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
Engine Has Low Power
• Spark plug fouled
• Cylinder, piston, ring, or valve wear or damage (check
compression)
• PVT not operating properly
• 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
• Excessive piston-to-cylinder clearance
• Wet sumping
• Worn rings, piston, or cylinder
• Worn valve guides or seals
• Restricted breather
• Air filter dirty or contaminated
Piston Failure - Scoring
• Lack of lubrication
• Dirt entering engine through cracks in air filter or ducts
• Engine oil dirty or contaminated
3.63
ENGINE
3
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
• Cylinder head gasket leak
• No valve clearance ( cam wear )
• Cylinder or piston worn
• Piston rings worn, leaking, broken, or sticking
• Bent valve or stuck valve
• Valve spring broken or weak
• Valve not seating properly (bent or carbon accumulated
on sealing surface)
• Rocker arm sticking
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 cap cracked / broken
Ignition coil faulty
Ignition or kill switch circuit faulty
Poor connections in ignition system
Ignition timing incorrect
Sheared flywheel key
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)
• Lean mixture (vents, fuel pump or fuel valve)
• Fuel pump output weak
• Electrical malfunction
• Water pump failure/ Loose impeller
• Thermistor failure
• Cooling fan inoperative or turning too slowly (perform
current draw test)
• Low oil level
• 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
• Faulty water pump mechanical seal (coolant leak)
• Faulty pump shaft oil seal (oil leak)
ELECTRONIC FUEL INJECTION
4.1
CHAPTER 4
ELECTRONIC FUEL INJECTION
4
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
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
4.2
ELECTRONIC FUEL INJECTION
GENERAL INFORMATION Special Tools
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.
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
swallow gasoline, seek medical attention immediately.
* 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.
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
4.3
ELECTRONIC FUEL INJECTION
4
TPS Tester Regulator - 4010264
This tester regulator regulates the 9 volt battery voltage to a 5
volt input, required when using the TPS harness PU-47082.
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.
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.
Fuel Pressure Gauge Kit - PU-43506-A
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.
Fuel Pressure Gauge Kit
PU-43506-A
Test Valve
4.4
ELECTRONIC FUEL INJECTION
Digital Wrench™ Diagnostic Software - PU-47063
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.
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 (1-800-328-
6657) or http://polaris.spx.com
Digital Wrench™ - Diagnostic Connector
Located under the dash and accessible from the passenger side.
Digital Wrench™ - Download Website
Located at: www.polaris.diagsys.com
PU-47468
PU-47469
PU-47470
4.5
ELECTRONIC FUEL INJECTION
4
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.
4.6
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
2
3
4
5
6
7
8
9
10
11
12
4.7
ELECTRONIC FUEL INJECTION
4
EFI System Component Locations
1. Electronic Control Unit (ECU)
- Located behind the driver’s seat next to the seat belt
assembly and just above the voltage regulator.
2. Temperature and Barometric Air Pressure Sensor
(T-BAP)
- Located in the rubber intake boot between the air box and
throttle body.
3. Crankshaft Position Sensor (CPS)
- Located in the magneto cover between the engine and
transmission.
4. Fuel Injectors / Fuel Rail
- Attached to the fuel rail located in the intake track of the
cylinder head.
5. Fuel Pump / Regulator / Fuel Gauge Sender Assembly
- Located under the passenger seat and in the fuel tank as a
complete assembly.
ECU
T-BAP
CPS
Fuel Injectors
Fuel Rail
Fuel Pump Assembly
Located in Fuel Tank
Fuel Pump
Regulator
Pump / Sending Unit
Preliminary Filter
Fine Filter
Fuel Line
Connection
Vent Line
Connection
Connection
4.8
ELECTRONIC FUEL INJECTION
6. Throttle Body
- Located between the rubber air box boot and the rubber
cylinder head adaptor.
7. Throttle Position Sensor (TPS)
- Located on the right-hand side of the throttle body.
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.
9. Ignition Coil
- Located behind the driver’s seat and rear service panel just
above the PVT cover.
Throttle Body
TPS
ECT
Ignition Coil
4.9
ELECTRONIC FUEL INJECTION
4
FUEL TANK
Exploded View
Rear
Tank Bracket
Screw
Pad
Fuel Tank
Front
Tank Bracket
Gasket
Cap
Hi-Temp
Flex Conduit
Fuel Pump Asm
Screw
Pad
Quick Connect
Fuel Line
Fuel Flow
Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line
Fuel Rail Fuel Injectors
Pressure Regulator
Fuel Tank
4.10
ELECTRONIC FUEL INJECTION
Fuel Lines - Quick Connect
RANGER EFI models use quick connect fuel lines. Refer to the
steps below for fuel line removal.
1. Place a shop towel around the fuel line to catch any
dripping fuel. Squeeze the connector tabs together and
push the locking slide back.
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.
ELECTRONIC FUEL INJECTION
Principal Components
The Electronic Fuel Injection (EFI) system is a complete engine
fuel and ignition management design. This system includes the
following principal components:
•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.
Squeeze Connector Tabs
4.11
ELECTRONIC FUEL INJECTION
4
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
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).
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.
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 rev-
limiting 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.
ECU
4.12
ELECTRONIC FUEL INJECTION
RANGER RZR 800 EFI RPM Limit:
Hard Limit - Injector suppression occurs
• High: 6500
• Low: 6500
• 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.
ECU Replacement
1. Remove the (2) retaining screws holding the ECU.
2. With the Ignition turned off, disconnect the wire harness
from the ECU.
3. To install, reverse the procedures and tighten screws to
specification.
TEMPERATURE AND BAROMETRIC
AIR PRESSURE SENSOR (T-BAP)
Operation Overview
Mounted in the throttle body intake boot, the T-BAP sensor
performs two functions in one unit.
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
1. Disconnect sensor from engine harness.
2. Using a 3/8” wrench, remove the retaining bolt and remove
the sensor from the intake boot.
= T
ECU Retaining Screws
10 in. lbs. (1.1 Nm)
T-BAP
4.13
ELECTRONIC FUEL INJECTION
4
3. Install new sensor using a light coating of oil on the o-ring
to aid installation.
4. Torque the T-BAP retaining bolt to specification.
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.
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.
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. Disconnect CPS (3-wire) harness connector on the left-
hand side of the vehicle located below the transmission.
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.
= T
T-BAP Retaining Bolt Torque:
29 in. lbs. (3.3 Nm)
T-BAP
Intake Boot
Bolt
CPS
CPS Resistance Specification:
560Ω ± 10% (20° C, 68° F)
CPS
Connector
Yellow
Black
White
CPS Harness
4.14
ELECTRONIC FUEL INJECTION
3. 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. 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.
2. 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.
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.
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.
WARNING
Serious injury may result if machine tips or falls.
Be sure the vehicle is secure before beginning
this service procedure.
Remove
Remove
Silencer
Elbow
Header
Pipe
Pipe
Rear Gearcase
Mounting Bolt
Transmission
Mounting Bolts
4.15
ELECTRONIC FUEL INJECTION
4
8. Lift the mounting bracket straight up and out from the
vehicle.
9. Using a 5 mm hex wrench, remove the CPS retaining bolt
and remove the sensor from the magneto housing.
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.
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.
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
CPS Retaining Bolt Torque:
25 in. lbs. (2.8 Nm)
Remove
Bracket
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.
= T
Mount Bracket Bolt Torque:
23-27 ft. lbs. (31-37 Nm)
Special Tool
PA-48873
4.16
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.
Upper Transmission Bolt
Middle Transmission Bolt
Bottom Transmission Bolt
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.
Bottom Rear Gearcase Bolt
NOTE: Special Tool is not required for this torque.
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
Torque with
an extension
4.17
ELECTRONIC FUEL INJECTION
4
Upper Rear Gearcase Bolt
7. 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 left-
hand threaded bolts.
4.18
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.
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 categories-
electrical, 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.
• 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.
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.
Fuel Injectors
Fuel Rail
4.19
ELECTRONIC FUEL INJECTION
4
Fuel Injector Test
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.
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:
Fuel Injector Replacement
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.
3. Remove the exhaust pipe between the exhaust silencer and
the elbow pipe to allow better access to the fuel injector rail.
4. Remove the engine breather hose from the valve cover.
5. Remove both driver and passenger seats and remove the
rear service panel.
Fuel Injector Resistance Specification:
13.8Ω - 15.2Ω
Disconnect Here
DO NOT
Disconnect Here
Fuel
Injector
Harness
Disconnect
and test here
Test Valve
Remove
Silencer
Elbow
Header
Pipe
Pipe
4.20
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.
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.
7. Thoroughly clean the area around the fuel injectors
including the throttle body manifold.
8. 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.
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.
Fuel Injector
Harnesses
Disconnect Here
DO NOT
Disconnect Here
Fuel
Injector
Harness
= T
Fuel Rail Mounting Screw
16-20 ft. lbs. (22.6-27 Nm)
Fuel Injectors
Fuel Rail
Mounting
Screw
4.21
ELECTRONIC FUEL INJECTION
4
FUEL PUMP
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.
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.
• If the engine fails to start
• If the engine is stopped with the key switch "on" (as in
the case of an accident).
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 Pump Test
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.
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.
Fuel Pump Assembly
Located in Fuel Tank
Fuel Pump
Regulator
Pump / Sending Unit
Preliminary Filter
Fine Filter
Fuel Line
Connection
Vent Line
Connection
Connection
Fuel Sender Resistance Specifications:
Full: 90Ω
Empty: 5Ω
WARNING
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.
4.22
ELECTRONIC FUEL INJECTION
1. Remove the cap from the fuel test valve.
2. 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.
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.
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. 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.
NOTE: If the voltage was below 7 VDC, test the
battery, ignition switch, relay(s), wiring harness and
ECU.
5. 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.
Normal Fuel Pressure: 39 psi. ± 3
Test Valve
Fuel Pressure Gauge Kit
PU-43506-A
Disconnect and Test Here
Pin “A”
Red
Pin “C”
Brown
4.23
ELECTRONIC FUEL INJECTION
4
Fuel Tank / Fuel Pump Replacement
IMPORTANT: Syphon as much fuel from the tank as
possible before attempting to remove it from the
vehicle.
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.
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.
5. Disconnect the fuel pump electrical harness.
6. Remove the fuel tank vent hose.
7. Remove the (2) push rivets from the rear of the center
console.
WARNING
Always wear safety goggles when working with
high pressure or flammable fluids. Failure to do so
could result in serious injury or complications.
Disconnect Here
4.24
ELECTRONIC FUEL INJECTION
8. Remove the (2) fasteners from the rear seat base and
remove the assembly from the vehicle.
9. Remove the (11) push rivets and (4) Torx screws retaining
the RH rocker panel and remove panel from the vehicle.
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.
11. Remove the (3) Torx fasteners from the rear RH fender well
and remove the fender well 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
12. Remove the (2) tank bracket fasteners that retain the fuel
tank in the chassis.
13. Lift the rear of the fuel tank up first and carefully pull it out
from the vehicle.
Remove
RH Rocker Panel
Tank Bracket
Fasteners
4.25
ELECTRONIC FUEL INJECTION
4
Fuel Pump Removal / Installation
1. 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.
2. Replace O-ring on fuel pump assembly.
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 Tank Installation
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.
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.
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.
NOTE: See the “Electronic Parts Catalog” for fuel
pump availability. It may be possible that the fuel
tank assembly must be replaced.
WARNING
Never reuse the O-ring
= T
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)
Remove (6)
mounting Screws
4.26
ELECTRONIC FUEL INJECTION
THROTTLE POSITION SENSOR (TPS)
Operation Overview
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.
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 re-
calibrated by performing “TPS Initialization.”
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.
Set up the TPS Tester (PU-47082), according to the instructions
that accompanied the tester. Make sure that the 9 volt battery is
new.
As mentioned in the instructions included with the tester, be sure
the TPS tester is set up along with the TPS Tester Regulator
(4010264).
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.
TPS Connector
Throttle Body
Air Flow Screw
(Factory Set)
Yellow
(Output)
Blue
(Input) Black
(Ground)
TPS
PU-47082 TPS Test
TPS Tester
Use NEW
9V battery
4010264
TPS Tester Regulator
Typical Tester
9 Volt Battery
Regulator
Cable Ties
Test Ports
Install Regulator
R = RED
P = PINK
Bk = BLACK
Y = YELLOW
Set-up
Connections Here
4.27
ELECTRONIC FUEL INJECTION
4
Verify TPS Tester Reference Voltage
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.
• Harness Test: Insert black voltmeter probe into the
“Bk” test port.
• 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.
IMPORTANT: Always use a fresh 9 volt battery.
Test Procedure
1. 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.
4. 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.
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.
7. If the voltage does not read within the specification,
“TPS Initialization” will need to be performed.
No “Jumps” .70 ~ 3.7
Black
Red Pink Black
Probe
Red
Probe
in read out
PU-47082 Tester
Should Read .735
Black
Red Pink Black
Probe
Red
Probe
.735 Vdc
PU-47082 Tester
4.28
ELECTRONIC FUEL INJECTION
TPS Initialization
NOTE: The correct TPS position is established and
set at the factory. Use this procedure only if the TPS
was repositioned, replaced or loosened.
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.
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. Remove the outlet duct from the PVT cover to access the
throttle body.
4. 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.
5. Remove the throttle body side cover and disconnect throttle
cable from throttle cam.
6. 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.
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.
Throttle Plate
Must Be Closed
Back Air Flow Screw Out
Until No Contact is Made
Should Read .528
Black
Red Pink Black
Probe
Red
Probe
.528 Vdc
PU-47082 Tester
4.29
ELECTRONIC FUEL INJECTION
4
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.
2. Reconnect the TPS harness lead
3. Reinstall throttle cable on throttle cam and install cover.
Adjust cable freeplay.
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 re-
calibrated 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).
3. Remove the retaining screw (B) and replace the sensor.
4. Refer to “TPS Initialization” for setting the TPS voltage.
Turn Air Flow Screw In
Should Read .735
Black
Red Pink Black
Probe
Red
Probe
.735 Vdc
PU-47082 Tester
TPS
A
B
4.30
ELECTRONIC FUEL INJECTION
ENGINE COOLANT TEMPERATURE
SENSOR (ECT)
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.
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”.
ECT Sensor Test
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 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).
ECT
ECT Sensor Resistance Readings
Temperature °F (°C) Resistance
68 °F (20 °C) 2.5 kΩ ± 6%
212 °F (100 °C) 0.186 kΩ ± 2%
= T
ECT Retaining Bolt Torque:
17 ft. lbs. (23 Nm)
Engine Temperature Sensor
4.31
ELECTRONIC FUEL INJECTION
4
IGNITION COIL
Operation Overview
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.
Ignition Coil Tests
The ignition coil can be tested by using an ohm meter. Use the
following illustration and specification table to test the ignition
coil.
Primary Test
Secondary Test
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).
Ignition Coil Resistance Readings
Test Pin
Connection Resistance
Primary Between 1 & 2
Between 3 & 2 0.4 Ω
Secondary Between
High Tension
Lead Ends 5 k Ω
Ignition Coil
= T
Ignition Coil Retaining Bolt Torque:
75 in. lbs. (8.5 Nm)
Measure Between
Connector Pins
0.4 Ω
Measure Between
End Caps
5 k Ω
4.32
ELECTRONIC FUEL INJECTION
GENERAL TROUBLESHOOTING
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.
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.
NOTE: To clear codes manually, disconnect the
positive battery lead for 20 seconds.
DIAGNOSTIC “BLINK CODES” CHART
SAE CODE BLINK CODE NAME CHECK ENGINE
P0335 21 Loss of Synchronization Yes
P0122 22 TPS: Open or Short Circuit to Ground Yes
P0123 22 TPS: Short Circuit to Battery Yes
P0601 23 RAM Error: Defective ECU Yes
P0914 25 Transmission Input: Invalid Gear Yes
P0113 41 Intake Air Temp Sensor: Open or Short Circuit to +Sensor Voltage (ECU) Yes
P0112 41 Intake Air Temp Sensor: Short Circuit to Ground Yes
P0117 42 Engine Temperature Sensor Circuit: Short To Ground Yes
P0118 42 Engine Temperature Sensor Circuit: Open or Short to Battery Yes
P0107 45 Barometric Pressure Sensor: Circuit Low Input Yes
P0108 46 Barometric Pressure Sensor: Circuit High Input Yes
P1260 51 Injector 1: Open Load Yes
P0261 51 Injector 1: Short Circuit to Ground Yes
P0262 51 Injector 1: Short Circuit to Battery Yes
P1263 52 Injector 2: Open Load Yes
P0264 52 Injector 2: Short Circuit to Ground Yes
P0265 52 Injector 2: Short Circuit to Battery Yes
P0655 54 Engine Temperature Lamp: Open Load Yes
P1657 54 Engine Temperature Lamp: Short Circuit to Ground Yes
P1658 54 Engine Temperature Lamp: Short Circuit to Battery Yes
P1651 55 Diagnostic Lamp: Open Load Yes
P1652 55 Diagnostic Lamp: Short Circuit to Ground Yes
P1653 55 Diagnostic Lamp: Short Circuit To Battery Yes
P1231 56 Pump Relay: Open Load Yes
P1232 56 Pump Relay: Short Circuit to Ground Yes
P1233 56 Pump Relay: Short Circuit to Battery Yes
4.33
ELECTRONIC FUEL INJECTION
4
EFI Troubleshooting
Fuel Starvation / Lean Mixture
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
• Fuel lines or fuel injectors restricted
• Fuel filter plugged
• Fuel pump inoperative
• Air leak in system
• Intake air leak (throttle shaft, intake ducts, airbox or air
cleaner cover)
• Incorrect throttle stop screw adjustment
Rich Mixture
Symptoms: Fouls spark plugs, black, sooty exhaust smoke,
rough idle, poor fuel economy, engine runs rough/ misses, poor
performance, bog, engine loads up, backfire.
• Air intake restricted (inspect intake duct)
• Air filter dirty/plugged
• Poor fuel quality (old fuel)
• Fouled spark plug
• TPS setting incorrect
• Injector failure
Poor Idle
Symptom: Idle Too High (If greater than 1300 RPM when
engine is warm)
• 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)
• Plugged air filter
• Leaking injector (rich condition)
• Belt dragging
• Throttle stop screw tampering
Symptom: Erratic Idle
• Throttle cable incorrectly adjusted
• Air Leaks, dirty injector
• TPS damaged or adjusted
• Tight valves
• Ignition timing incorrect
• Belt dragging
• Dirty air cleaner
•Engine worn
• Spark Plug fouled
• Throttle stop screw set incorrectly (out of sync with
ECU)
4.34
ELECTRONIC FUEL INJECTION
EFI SYSTEM BREAKOUT DIAGRAMS
Diagnostic Connector Circuit
Malfunction Indicator Lamp (MIL) Circuit
4.35
ELECTRONIC FUEL INJECTION
4
Fuel Injector (PTO) Circuit
Fuel Injector (MAG) Circuit
4.36
ELECTRONIC FUEL INJECTION
Engine Coolant Temperature Sensor (ECT) Circuit
Engine Overheat Lamp Driver Circuit
4.37
ELECTRONIC FUEL INJECTION
4
Crankshaft Position Sensor (CPS) Circuit
Air Temperature and Barometric Air Pressure Sensor (T-BAP) Circuit
4.38
ELECTRONIC FUEL INJECTION
Throttle Position Sensor (TPS) Circuit
Fuel Pump Circuit
BODY / STEERING / SUSPENSION
5.1
CHAPTER 5
BODY / STEERING / SUSPENSION
5
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
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
5.2
BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS
NOTE: Refer to exploded views throughout this
chapter for more torque specifications, component
identification, and location of components.
SPECIAL TOOLS
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.
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)
TOOL DESCRIPTION PART NUMBER
Shock Spanner Wrench 2870872
Shock Spring Compressor Tool 2870623
Multi-Function Pliers 2876389
Pliers
Push Rivet
5.3
BODY / STEERING / SUSPENSION
5
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).
5.4
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
C
D
E
F
G
B
A
5.5
BODY / STEERING / SUSPENSION
5
Front Bumper
Rear Bumper
Headlight
Radiator Screen
O-Ring
Front Bumper Support
Front Bumper
Winch Pocket Cover
T25
Screws
T25
Screw
T27
Screw
T27
Screw
T30
Screws
Torx
Screw
Washer
RH Tail/Work Light
Rear Bumper
Speed T25
Screws
T27
Screws
T27
Screw
LH Tail/Work Light
Nuts
5.6
BODY / STEERING / SUSPENSION
Hood / Front Body Work
Grommet
Pin
Center Hood Panel
Hood / Dash
Front Bumper
Front RH
Fender Flair
Front LH
Fender Flair
Winch Pocket Cover
Push Rivets
Grommet
Push Rivets
Push Rivets
Push Rivets
T27
Screws
Reflector
5.7
BODY / STEERING / SUSPENSION
5
Seat Assembly
Seat Belts / Mounting
Seat Base Asm.
Cap
Plate
Spring
Lever
Latch Body
Grommets
Seat
Seat Back
Seat Bottom
Hoop Tube
Nuts
41-57 in. lbs.
(4.6-6.4 Nm)
48 in. lbs.
(5.4 Nm)
41-57 in. lbs.
(4.6-6.4 Nm)
Driver 3 Point
Seat Belt
Rear
Seat Base
Latch
Seat
Passenger
Seat
3 Point
Seat Belt 3 Point
Seat Belt
Plunger
35 ft. lbs.
(47 Nm)
35 ft. lbs.
(47 Nm)
35 ft. lbs.
(47 Nm)
35 ft. lbs.
(47 Nm) 35 ft. lbs.
(47 Nm)
5.8
BODY / STEERING / SUSPENSION
Floor / Rocker Panels
RH Rocker
Console Cover
LH Rocker
Main Floor
Cup Holder
Rear
Front
Push Rivets
U-Type
Plastic Dart
Support Bracket
Rear
Support Bracket
Push Rivets
Support Bracket
Front
Support Bracket
Self-Tapping
Screws
Self-Tapping
Screws
Self-Tapping
Screw
Self-Tapping
Screw
Torx
Screws
T27
Screw
Nuts
T27
Screw
Self-Tapping
Screw
Plastic Dart
Plastic Dart
5.9
BODY / STEERING / SUSPENSION
5
Rear Cargo Box / Fenders
Rear RH
Rear RH
Rear
Rear LH
Cargo Box
Push
Sound Foam
Pin
Fender Flair
Rear LH
Fender Flair
Fender
Rear LH
Fender
Cargo Box
Tie Down
Bracket
Panel Divider
Rear RH
Panel Divider
Rear Main
Service Panel
Supports
Heat Shield
Grommet
Push
Rivets
Rivets
T27
Tie Down
Bracket
Torx Screw
Bolts
T25
Screws
T25
Screws
Torx
& Nut
Torx Screw
& Nut
Screws
Screws
T27
Screws
5.10
BODY / STEERING / SUSPENSION
Chassis / Main Frame
Main Frame
Bolt-In Brace
Skid Plate
Rear Bumper
Support
Hitch
15 ft. lbs.
(20 Nm)
15 ft. lbs.
(20 Nm)
17 ft. lbs.
(23 Nm)
30 ft. lbs.
(41 Nm)
6-8 ft. lbs.
(8-11 Nm)
5.11
BODY / STEERING / SUSPENSION
5
BODY COMPONENT REMOVAL
Seats
1. To remove the driver or passenger seat, lift upward on the
latch lever located behind the seat bottom.
2. Lift upward and forward on the seat while lifting up on the
latch lever and remove the seat from the vehicle.
Rear Service Panel
1. Remove driver and passenger seats.
2. To remove the service panel, pull panel towards the front
of the vehicle to disengage the upper latch pins from the
grommets.
Front Bumper
1. Remove the (4) push rivets from the sides of the front
bumper.
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 Bumper
1. Remove the (4) Torx screws retaining the upper portion of
the rear bumper to the cargo box.
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.
Latch
Lever
Service
Panel
Push
Rivets Torx
Screws
5.12
BODY / STEERING / SUSPENSION
Hood and Front Body Work
Hood Removal
1. To remove the hood, lift up on the rear portion of the hood
to disengage the pins from the grommets.
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.
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.
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.
Lift Up
HERE
Remove
Push
Rivets
Torx
Screws
Remove
Remove
5.13
BODY / STEERING / SUSPENSION
5
Rocker Panels, Console and Floor
Rocker Panel Removal
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.
Console and Floor Panel Removal
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.
4. Remove the shift handle knob and remove the 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.
9. Remove steering shaft and remove floor panel from the
vehicle.
Rear Fender, Flair and Tie Down 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.
Cargo Box Assembly Removal
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.
5. Remove the (8) push rivets that attach the rocker panels to
the cargo box on each side.
6. Cut the panduit strap, disconnect taillight/worklight wire
connections and remove the box assembly from the vehicle.
Push
Rivets
Torx
Screws
Push
Rivets
Console
Floor
Panel
Fender
Fender
Flair
Tie-Down
Push
Rivets
Torx
Screws Push
Rivet
5.14
BODY / STEERING / SUSPENSION
STEERING ASSEMBLY
Exploded View
Boot
Rod End
Tie Rod
RH Boot
LH Boot
Bushing
Bushing
Wave Washers
Steering Wheel
Cap
Pivot Tube
Upper
Steering Shaft Lower
Steering Shaft
Cotter Pin
Gear Box
Bushing
Bushing
Bushing
Oil Locking
Shock Asm.
Asm.
17 ft. lbs.
(23 Nm)
17 ft. lbs.
(23 Nm)
12-14 ft. lbs.
(16-19 Nm)
Nut
42.5 ft. lbs.
(58 Nm)
42.5 ft. lbs.
(58 Nm)
12-14 ft. lbs.
(16-19 Nm)
27-33 ft. lbs.
(37-45 Nm)
15-19 ft. lbs.
(20-26 Nm)
25-31 ft. lbs.
(34-42 Nm)
23 ft. lbs.
(31 Nm)
23 ft. lbs.
(31 Nm)
7 ft. lbs.
(10 Nm)
12 ft. lbs.
(16 Nm)
5.15
BODY / STEERING / SUSPENSION
5
WHEEL HUBS
Front Hub Exploded View
Rear Hub Exploded View
Flanged Nuts
Front Rim
Valve
Castle Nut
Cotter Pin
Cone
Wheel Hub
Stud
Brake Disc
Bolts
Retaining
Sealed
Ball Bearing
Bearing Carrier
Front Tire
Washers
27 ft. lbs.
(37 Nm)
80 ft. lbs.
(108 Nm) Ring
Flanged Nuts
Front Rim
Valve
Castle Nut
Cotter Pin Cone
Wheel Hub
Stud
Brake Disc
Bolts
Retaining
Sealed
Ball Bearing
Bearing Carrier
Front Tire
Washers
27 ft. lbs.
(37 Nm)
80 ft. lbs.
(108 Nm) Ring
5.16
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. Elevate and safely support the front of the vehicle and
remove the front wheel.
2. Remove the lower shock fastener (A) from the upper A-
arm.
3. Remove the upper ball joint pinch bolt (B) from the front
bearing carrier.
4. 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.
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.
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).
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.
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
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.
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)
A
B
C
D
E
F
5.17
BODY / STEERING / SUSPENSION
5
Exploded View BALL JOINT SERVICE
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.
1. The A-arm must be removed to perform this procedure
(see “FRONT A-ARMS - Removal / Replacement”).
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.
Upper
A-arm
Lower
A-arm
Grease
Screws
Ball Joint
Pinch
Bearing
CV Shield
Bushings
37 ft. lbs.
(50 Nm)
Pivot Tube
Bushing
Grease Zerk
Ball Joint
Carrier
Pivot Tube
Bolts
Zerk
17 ft. lbs.
(23 Nm)
37 ft. lbs.
(50 Nm)
Ball Joint
Upper A-arm
Retaining Ring
1.75 in.
1.375 in.
(3.49 cm)
3 in.
(7.62 cm)
Driver Dimensions
- 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.
(4.45 cm)
5.18
BODY / STEERING / SUSPENSION
4. Use a press and correct size driver to remove the ball joint
from the A-arm.
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 A-
arm.
Installation
1. 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.
2. After the new ball joint is installed into the A-arm, install
a NEW retaining ring.
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.
Correct
Driver Placement
The driver must fit the
inside diameter of the
Upper A-arm Shown
A-arm end.
Press out of the A-arm
in this direction
Upper A-arm Shown
Place driver HERE
to support A-arm
Press into the A-arm
in this direction
Upper A-arm Shown
Place driver HERE
to support A-arm
Ball Joint
Upper A-arm
NEW
Retaining Ring
5.19
BODY / STEERING / SUSPENSION
5
FRONT STABILIZER BAR
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).
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.
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.
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.
Main
Frame
Bumper
Support
T30
Screws
Nuts
Filler
Neck
Recovery
Bottle
5.20
BODY / STEERING / SUSPENSION
8. Remove the (4) bolts retaining the upper radiator mount
bracket and remove the bracket from the frame.
9. Lift up on the stabilizer bar and remove it from the vehicle.
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).
Exploded View
Main
Frame
Mount
Bracket
Clamp
Stabilizer
Bushings
Grease
Zerk
Linkage Nuts
Spacer
Clamp
Bar
27-33 ft. lbs.
(37-45 Nm)
Linkage
T30
Screws
5.21
BODY / STEERING / SUSPENSION
5
REAR A-ARMS
Removal
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).
1. Elevate and safely support the rear of the vehicle off the
ground.
2. Remove the wheel nuts, and rear wheel.
Upper A-arm Removal
3. Remove the fastener (A) attaching the upper A-arm to the
bearing carrier.
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.
6. If not replacing the A-arm, thoroughly clean the a-arm and
pivot tubes.
7. Insert new A-arm bushings and pivot tubes into new A-arm.
Lower A-arm Removal
8. While holding the stabilizer bar linkage, remove the lower
nut retaining the linkage to the lower A-arm.
9. Remove the fastener (C) retaining the lower portion of the
shock to the lower A-arm.
10. Remove the fastener (D) attaching the lower A-arm to the
bearing carrier.
A
B
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.
Hold HERE with
open-end wrench
Remove lower
linkage nut
C
D
E
5.22
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).
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.
14. Insert new A-arm bushings and pivot tubes into the new
A-arm.
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. Torque new
fastener to 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. Attach upper A-arm to bearing carrier. Torque new
fastener to 37 ft. lbs. (50 Nm).
7. Install wheel and torque wheel nuts to specification.
Exploded View
WARNING
Upon A-arm installation completion, test vehicle
at low speeds before putting into service.
Upper
A-arm
Lower
A-arm
Screws
Bearing
CV
Bushings
37 ft. lbs.
(50 Nm)
Pivot Tube
Carrier Pivot
37 ft. lbs.
(50 Nm)
Grease
Zerk
Shield
37 ft. lbs.
(50 Nm)
Tube
37 ft. lbs.
(50 Nm)
Bushings
Pivot
Tube
Pivot
Tube
Bushings
5.23
BODY / STEERING / SUSPENSION
5
REAR STABILIZER BAR
Removal / Installation
1. Remove the exhaust pipe and exhaust silencer from the
vehicle.
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.
3. Remove the (4) fasteners retaining the stabilizer bar bracket
to the frame.
4. Remove the stabilizer bar and bracket from the frame as an
assembly.
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. Torque the
stabilizer bolts to 18 ft. lbs. (24 Nm).
Remove Nut
Remove
Fasteners
Bushings
Stabilizer Bar
Grease
Zerk
Bushing
Bracket
Linkage
Bushing
Linkage 18 ft. lbs.
(24 Nm)
Bushing
17 ft. lbs.
(23 Nm)
17 ft. lbs.
(23 Nm)
5.24
BODY / STEERING / SUSPENSION
SHOCKS / SPRINGS
Exploded View
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).
Shock Replacement
1. Using a spring compressor, compress the shock spring far
enough to remove the spring retainer.
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).
DECAL REPLACEMENT
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.
Spring
Spring
Adjusting Cam
Shock
27-33 ft. lbs.
(37-45 Nm)
Retainer
27-33 ft. lbs.
(37-45 Nm)
Shock Spring
Compressor Tool
2870623
WARNING
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.
WARNING
Do not flame treat components that are installed
on the vehicle. Remove the component from the
vehicle before flame treating.
CLUTCHING
6.1
CHAPTER 6
CLUTCHING
6
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
DRIVEN CLUTCH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
CLUTCH DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
BUSHING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
CLUTCH ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
6.2
CLUTCHING
SPECIAL TOOLS AND SUPPLIES
TORQUE SPECIFICATIONS
PVT System Fastener Torques
PVT SYSTEM OVERVIEW
General Operation
The Polaris Variable Transmission (PVT) consists of three
major assemblies:
1) The Drive Clutch
2) The Driven Clutch
3) The Drive Belt
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.
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
RTV Silicone Sealer 8560054
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)
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.
6.3
CLUTCHING
6
Driven Clutch Operation
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 trans-
mission 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.
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)
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.
Maintenance / Inspection
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.
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.
6.4
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.
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.
CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS
Possible Causes Solutions / What to do
Loading the vehicle into a truck or tall
trailer when in high range. Shift transmission to Low during loading of the vehicle to prevent belt burning.
Starting out going up a steep incline from
a stopped position. When starting out on an incline, use Low gear. Shift transmission to Low
during loading of the vehicle to prevent belt burning.
Driving at low RPM or low ground speed
(at approximately 3-7 MPH). Drive at higher speed or use Low. The use of Low is highly recommended
for cooler PVT operating temperatures and longer component life.
Insufficient warm-up of vehicles exposed
to low ambient temperatures.
Warm engine at least 5 min., then with transmission in neutral, advance
throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
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
ground speed. Use Low only.
Plowing snow, dirt, etc./utility use. Use Low only.
Stuck in mud or snow. Shift the transmission to Low, carefully use fast, aggressive throttle
application to engage clutch. WARNING: Excessive throttle may cause loss
of control and vehicle overturn.
Climbing over large objects from a
stopped position.
Shift the transmission to Low, carefully use fast, aggressive, brief throttle
application to engage clutch. WARNING: Excessive throttle may cause loss
of control and vehicle overturn.
Belt slippage from water or snow
ingestion into the PVT system.
Shift the transmission to neutral. Using the throttle, vary the engine rpm from
idle to full throttle. Repeat several times as required. During this procedure,
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 malfunction. Clutch component inspection should be performed by a Polaris MSD certified
technician.
Poor engine performance. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty
fuel pump may cause symptoms similar to clutching malfunction.
GENERAL RANGE OPERATION
GUIDELINES:
Low: Heavy pulling, basic operational speeds less than 7 MPH, riding
through rough terrain (swamps, mountains, ect.), or low ground speeds.
High: High ground speeds, or speeds above 7 MPH.
6.5
CLUTCHING
6
PVT SYSTEM SERVICE
PVT Sealing and Ducting Components
Disassembly
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.
6. Mark the drive belt direction of rotation and remove drive
belt (see “DRIVE BELT - Belt Removal”).
7. Remove the driven clutch retaining bolt and driven clutch.
Inner
Clutch
Clamps
Outer
Cover
Outer
Push
Rivets
Outlet Duct
Clutch
Inlet Duct
Screws
Clutch Cover
Clutch Cover
Retainer
Screws
Bolt/Washer
Cover Seal
Boot
Boot
Clamps
Mark Rotation
6.6
CLUTCHING
8. Remove driven clutch offset spacers from the transmission
input shaft.
9. 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).
11. Remove the screws that attach the inner clutch cover to the
engine and transmission.
12. Remove the cover along with foam seal on back of cover
or 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.
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.
6. Torque rear inner clutch cover bolts (B) to specification.
7. Install clutch offset spacers on transmission input shaft.
Drive Clutch Puller ( PA-48595)
Drive Clutch Holder (9314177)
Keep Spacers In Order (Note Thickness)
Retaining
Bolt
A
B
Apply RTV Silicone Here
B
C
A
Seal outer edge to cover
with RTV silicone sealant
Offset Spacers
6.7
CLUTCHING
6
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.
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.
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.
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.
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.
NOTE: Belt is normally positioned so that the part
number can be easily read.
3. To remove drive belt, place the transmission in “Park” and
push down on the belt firmly to open the clutch sheaves.
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)
6.8
CLUTCHING
Belt Inspection
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.
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.
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.
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.
Belt Width
New: 1.188” (3.02 cm)
Wear Limit: 1.157 (2.94 cm)
Belt Outer Circumference
New: 40.89” (103.85 cm)
Wear Limit: 41.08” (104.34 cm)
Projected Belt Width
6.9
CLUTCHING
6
DRIVE CLUTCH SERVICE
Spring Specifications
The drive clutch spring has two primary functions:
1. To control clutch engagement RPM. The springs
which have a higher rate when the clutch is in neutral
will increase clutch engagement RPM.
2. 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.
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.
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.
Primary Clutch Springs Secondary Clutch Springs
PART
NUMBER COLOR CODE WIRE
DIAMETER FREE LENGTH
± .125” PART
NUMBER DESCRIPTION
7041021 Plain .157" 4.38"
3234199 White/Yellow
7041022 Black .140" 4.25"
7041063 Purple .168" 4.37"
7041132 White .177" 2.92"
7041168 Green .177" 3.05"
7041157 Blue/Green .177" 2.53"
7042202 Blue/Gray .187" 2.55"
6.10
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.
6.11
CLUTCHING
6
Exploded View
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.
2. Remove cover bolts evenly in a cross pattern and remove
cover plate.
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.
Washers
Bearing
Spring
Cover
Bearing
Bushing Lock
Washer
Bolt
Flat
Washer
Cover
Screws
Button
Pin
Washers
Roller
Nut
Shift
Weight
Bolt
Non-Braking
Bearing Spacer
Limiter Spider
Button
Cover Bushing Inspection:
Replace the cover bushing if more
brass than Teflon is visible on
the bushing. Refer to bushing
replacement in this chapter.
A
6.12
CLUTCHING
4. Inspect area on shaft where bushing rides for wear, galling,
nicks, or scratches. Replace clutch assembly if worn or
damaged.
5. Remove and inspect the clutch spring. See “Drive Clutch
Spring Specifications” for spring inspection.
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).
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.
Moveable Sheave Bushing Inspection
3. Inspect the Teflon™ coating on the moveable sheave
bushing.
Clutch Holding Fixture:
(PN 2871358)
Spider Removal Tool:
(PN 2870341)
Inspect Shaft
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.
To maintain proper clutch balance and
belt-to-sheave clearance, be sure to
reinstall original quantity and thickness
washers
TeflonTM
6.13
CLUTCHING
6
Roller, Pin, and Thrust Washer Inspection
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.
2. Rubber backed buttons can be used in all RANGER clutches
if the hollow roller pin is changed to the solid roller pin.
NOTE: The rubber side of the button is positioned
toward the solid roller pin.
Button To Tower Clearance Inspection
1. Inspect for any clearance between spider button to tower.
If clearance exists, replace all buttons and inspect surface
of towers. See “Spider Removal” procedure.
2. Inspect sheave surfaces. Replace the entire clutch if worn,
damaged or cracked.
Shift Weight Inspection
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.
Button to Tower Clearance:
000-.001”
WARNING
The clutch assembly is a precisely balanced
unit. Never replace parts with used parts from
another clutch assembly!
6.14
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.
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”.
Bearing Inspection
1. 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.
2. Verify there is no binding or rough spots. If problems are
noted in either direction, continue with disassembly.
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.
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.
Broken Worn Good
= In. / mm.
Thrust Washer Thickness
Standard: .030” (.76mm)
Service Limit: .025” (.64mm)
1
2
3
4
6.15
CLUTCHING
6
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.
6. Visually inspect PTFE thrust washer for damage. Measure
the thickness and compare to specification. Replace if 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”
= In. / mm.
PTFE Washer Thickness
Standard: .030” (.76mm)
Service Limit: .025” (.64mm)
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.
6.16
CLUTCHING
Bushing Service
IMPORTANT: Special Tools Required
*Clutch Bushing Replacement Tool Kit (PN 2871226)
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.
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.
3. Remove nut from puller rod and set aside.
4. Install puller adapter (Item 10 from kit PN 2871226).
5. Install main adapter (Item D) onto 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.
EBS Clutch Bushing Tool Kit - 2201379
Item Qty. Part Description Part #
A, B 1 EBS Puller Tool 5132027
C 1 EBS Puller Nut 5132501
D 1 EBS Main Adapter 5132029
E1
EBS Bushing Removal Tool 5132028
-- 1 Instructions 9915111
Additional Special Tools
Qty. Part Description Part #
1 Clutch Bushing Replacement Tool Kit 2871226
1 Piston Pin Puller 2870386
Item Qty. Part Description Part #
#2 1 P-90 Drive/Driven Clutch
Bushing Install Tool 5020628
#3 1
Drive Clutch Cover
Bushing Removal/
Installation Tool (all
clutches)
5020629
#5 1 P-90 Driven Clutch Cover
Bushing Removal Tool 5020631
#8 1 Main Puller Adapter 5020632
#9 1 Adapter Reducer 5010279
#10 1 Number Two Puller
Adapter 5020633
#2 #3 #5
#8
#9
#10
CAUTION
Clutch components will be hot! In order to avoid
serious burns, wear insulated gloves during the
removal process.
Piston Pin Puller (PN 2870386)
Piston Pin Puller
(PN 2870386)
Main Puller Adaptor (#8)
(PN 5020632)
Puller Tool (A,B)
Side “A” toward
sheave
Nut (C)
Main
Adapter (D)
Puller
Adapter (10)
Piston Pin
Puller
6.17
CLUTCHING
6
NOTE: Use Bushing Tool PA-47336.
8. 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.
9. 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.
Drive Clutch Bushing Installation
1. Place main adapter (Item 8) on puller.
2. Apply Loctite 609 evenly to bushing bore inside
moveable sheave.
3. Set bushing in place on sheave.
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.
5. With towers pointing upward, slide sheave, bushing and
tool onto puller rod.
6. Install nut on puller rod and hand tighten. Turn barrel to
apply additional tension if needed.
7. Turn sheave counterclockwise, making sure bushing is
drawn straight into bore. Continue until bushing is seated.
8. Remove nut from puller rod and set aside.
9. Remove sheave from puller.
10. Remove installation tool.
Cover Bushing Removal
1. Install main adapter (Item 8) on 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.
8. Remove bushing and bushing removal tool from puller.
Discard bushing.
Cover Bushing Installation
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.
3. With main adapter on puller, insert cover onto puller rod,
placing outside of cover toward vise.
4. Install nut on rod and hand tighten. Turn puller barrel to
apply more tension if needed.
5. Turn clutch cover counterclockwise on puller rod until
bushing is seated.
6. Remove nut from puller rod. Take installation tool and
clutch cover off rod.
Puller Tool (A,B)
Side “A” toward
sheave
Nut (C)
Bushing
Main Adapter
(8)
Piston Pin
Puller
Removal Tool
(3) Nut (C)
Adapter Reducer
(9)
Piston Pin
Puller
Main
Adapter (8)
6.18
CLUTCHING
Clutch Assembly
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.
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.
1. Install moveable sheave onto fixed sheave.
2. Install spider spacers. Use same quantity and thickness as
were removed.
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.
4. Torque spider to specification using the holding fixture and
spider tool. Torque with smooth motion to avoid damage
to the stationary sheave.
5. Install limiter nut on top of spider using the Clutch Spider
Nut Socket (PN 2870338). Torque to specification.
6. Install shift weights using new lock nuts on the bolts.
7. Reinstall clutch spring.
8. Reinstall cover, aligning “X” mark with other marks.
9. Torque cover bolts evenly to specification.
CAUTION
Do not apply oil or grease to the bushings.
Spacer washers
= T
Spider Torque:
200 ft. lbs. (271 Nm)
CAUTION
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.
= T
Spider Nut Torque:
15 ft. lbs. (20 Nm)
= T
Cover Screw Torque:
90 in. lbs. (10.4 Nm)
Rotation
Nut on trailing side
6.19
CLUTCHING
6
DRIVEN CLUTCH SERVICE
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.
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.
3. Remove the four torx screws that secure the cam (helix)
assembly using a T25 torx driver.
4. 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.
5. Remove the spider assembly, spring (B), and spacer washer
(C).
NOTE: Spring is compression only and has no
torsional wind.
Do not disassemble from this side
Press down on spider
A
B
C
6.20
CLUTCHING
6. Remove the inside spider plate (D) and spider dampener
(E). Inspect the spider dampener (E) for wear and replace
if needed.
7. Remove the E-clips (F), washers (G), and the clutch rollers
(H). Inspect the rollers for wear; replace if worn.
8. Remove the clutch assembly from the holding tool.
Remove the large outer retaining ring (I) and the inner
retaining ring (J).
9. Press out the spring pins (K) in the inner sheave.
10. Pull out the clutch roller pins (L) and rollers (M).
11. Press the shaft and bearing out of the outer sheave using a
press.
E
D
H
G
F
I
J
K
K
ML
Press Shaft and
Bearing Out
Inspect Bearing
6.21
CLUTCHING
6
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.
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.
Bushing Service
IMPORTANT: Special Tools Required
*Clutch Bushing Replacement Tool Kit (PN 2871226)
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.
Inspect Sheave Surface
Inspect Bushing
EBS Clutch Bushing Tool Kit - 2201379
Item Qty. Part Description Part #
A, B 1 EBS Puller Tool 5132027
C 1 EBS Puller Nut 5132501
D 1 EBS Main Adapter 5132029
E1
EBS Bushing Removal Tool 5132028
-- 1 Instructions 9915111
Additional Special Tools
Qty. Part Description Part #
1 Clutch Bushing Replacement Tool Kit 2871226
1 Piston Pin Puller 2870386
Item Qty. Part Description Part #
#2 1 P-90 Drive/Driven Clutch
Bushing Install Tool 5020628
#3 1
Drive Clutch Cover
Bushing Removal/
Installation Tool (all
clutches)
5020629
#5 1 P-90 Driven Clutch Cover
Bushing Removal Tool 5020631
#8 1 Main Puller Adapter 5020632
#9 1 Adapter Reducer 5010279
#10 1 Number Two Puller
Adapter 5020633
#2 #3 #5
#8
#9
#10
6.22
CLUTCHING
Clutch Bushing Removal
1. Install main puller adapter (Item 8) onto puller.
2. Install adapter reducer (Item 9).
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).
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.
Clutch Bushing Installation
1. Install puller adapter (Item 10) onto puller.
2. Install adapter (Item 9) onto puller.
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.
6.23
CLUTCHING
6
Clutch Assembly
1. Install a new bearing onto the output shaft using a press.
2. Install the shaft/bearing into the outer sheave.
3. Install the small and large retaining rings into the outer
sheave above the bearing.
4. 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.
5. Install the roller (A) onto the roller pin (B) on both sides.
Align X’s
A
B
6.24
CLUTCHING
6. 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.
7. Install the spring pins (C) to secure the roller pins. Install
until flush with sheave surface.
8. Install the spacer washer.
9. Install the spring over the shaft.
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.
11. Install the spider dampener (G) inside the outer spider and
install the inside spider plate (H).
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.
Flat Side Down
C
Install
Spacer Washer
Outer Spider
H
G
DEF
Align Marks
6.25
CLUTCHING
6
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.
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).
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.
16. Use a T25 torx driver to install the four torx screws and
torque to specification.
Press down on spider
A
A
= T
T25 Torx:
42-52 in. lbs. (4.75 - 5.88 Nm)
Press Down to Loosen Helix
6.26
CLUTCHING
Exploded View
Compression
Thrust
Washer
Cam
(Helix)
T25
Retaining
Ring
Roller
Pin
Slotted
Ball
E-Ring
Spring
Thrust
Washer
Spider
Dampener
Outer
Spider
Spider
Insert
Stationary
Sheave Bearing
Spring Pin
Moveable
Sheave
Clutch
Shaft
Roller
Retaining
Ring
Screws
6.27
CLUTCHING
6
TROUBLESHOOTING
Situation Probable Cause Remedy
Engine RPM below
specified operating
range, although
engine is properly
tuned.
-Wrong or broken drive clutch spring.
-Drive clutch shift weight too heavy.
-Driven clutch spring broken or installed in wrong
helix location.
-Replace with recommended spring.
-Install correct shift weight kit to match engine
application.
-Replace spring; refer to proper installation location.
Erratic engine
operating RPM
during acceleration or
load variations.
-Drive clutch binding.
-Belt worn unevenly - thin / burnt spots.
-Driven clutch malfunction.
-Sheave face grooved.
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.
Replace belt.
A. Replace ramp buttons.
B. Inspect movable sheave for excessive bushing
clearance.
-Replace the clutch.
Engine RPM above
specified operating
range.
-Incorrect drive clutch spring (too high spring rate).
-Drive clutch shift weights incorrect for application
(too light).
-Drive clutch binding.
-Driven clutch binding.
-Converter sheaves greasy; belt slipage.
-Install correct recommended spring.
-Install correct recommended shift weights.
-Disassemble and clean clutch, inspecting shift weights
and rollers. Reassemble without the spring and move
sheaves through entire range to further determine
probable cause.
-Disassemble, clean, and inspect driven clutch, noting
worn sheave bushing and ramp buttons and helix spring
location.
-Clean sheaves with denatured alcohol or brake cleaner,
install new belt.
Harsh drive clutch
engagement.
-Drive belt worn too narrow.
-Excessive belt / sheave clearance with new belt.
-Replace belt.
-Perform belt / sheave clearance adjustment with shim
washers beneath spider.
Drive belt turns over -Wrong belt for application. -Replace with correct belt.
Belt burnt, thin spots
-Abuse (continued throttle application when
vehicle is stationary, excess load)
-Dragging brake
-Slow, easy clutch engagement
-Caution operator to operate machine within guidelines.
-Inspect brake system.
-Fast, effective use of throttle for efficient engagement.
6.28
CLUTCHING
Troubleshooting, Continued.....
Situation Probable Cause Remedy
PVT cover
overheating (melting)
-Plugged air intake or outlet.
-Belt slippage due to water, oil, grease, etc., rubbing
on cover.
-Clutches or weight being applied to cover while in
operation.
-High vs. low range.
-Clear obstruction
-Inspect system. Clean , repair or replace as necessary.
Seal PVT system ducts.
-Remove weight. Inform operator.
-Instruct operator on guidelines for operation in proper
driving range for different terrain as outlined in Owner’s
Safety and Maintenance Manual.
Water ingestion
-Cover seals or ducts leaking
-Operator error
-Find leak and repair as necessary.
-Instruct operator on guidelines for operation in wet
terrain as outlined in Owner’s Safety and Maintenance
Manual.
Belt slippage
-Belt worn out
-Water ingestion
-Belt contaminated with oil or grease
-Replace belt.
-Inspect and seal PVT system.
-Inspect and clean.
PVT noise
-Belt worn or separated, thin spots, loose belt
-Broken or worn clutch components, cover hitting
clutches
-Replace belt.
-Inspect and repair as necessary.
Engagement
erratic or stabby
-Thin spots on belt, worn belt
-Drive clutch bushings stick
-Replace belt. Refer to belt burnt troubleshooting and
instruct operator.
-Inspect and repair clutches.
FINAL DRIVE
7.1
CHAPTER 7
FINAL DRIVE
7
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
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
7.2
FINAL DRIVE
SPECIAL TOOLS
TORQUE SPECIFICATIONS
Wheel, Hub, and Spindle Torque Table
FRONT BEARING CARRIER
Bearing Carrier Inspection / Removal
1. Elevate front of vehicle and safely support machine under
the frame area.
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.
5. Remove the steering tie rod end fastener from the front
bearing carrier.
PART NUMBER TOOL DESCRIPTION
2872608 Roller Pin Removal Tool
8700226 CV Boot Clamp Pliers
(earless type)
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)
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.
Steel Wheel
(Standard Models)
27 ft. lbs. (37 Nm)
Aluminum Wheel
(LE Models)
90 ft. lbs. (122 Nm)
#1 #2
Castle Nut
Cotter Pin
Cone
Washers
Steering
Tie Rod End
7.3
FINAL DRIVE
7
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.
7. Remove the front wheel hub assembly.
8. Remove the upper and lower ball joint pinch bolts.
9. 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.
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. Remove outer snap ring.
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.
Remove
Pinch
Bolts
Snap Ring
7.4
FINAL DRIVE
Bearing Installation
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.
7. Apply Loctite® RC™ 680 to the outer circumference of
the new bearing race and carefully press the new bearing
into the bearing carrier housing.
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. Install drive shaft axle through the backside of the bearing
carrier.
2. Install the upper and lower ball joint ends into the front
bearing carrier.
3. Install pinch bolts and torque to 17 ft. lbs. (23 Nm).
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.
6. Install brake caliper mounting bolts and torque to 30 ft. lbs.
(40 Nm).
CAUTION
Use an arbor and press only on the outer race,
otherwise bearing damage may occur.
Apply
Loctite® RC™ 680
Bearing
Snap Ring
= T
Pinch Bolt Torque:
17 ft. lbs. (23 Nm)
17 ft. lbs.
23 (Nm)
Out
Cone Washers
Wheel
Hub
30 ft. lbs.
(40 Nm)
7.5
FINAL DRIVE
7
7. Install the steering tie rod end onto the front bearing carrier
and torque fastener to 42.5 ft. lbs. (58 Nm).
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. Install wheel and (4) wheel nuts. Torque wheel nuts to
specification.
9. Rotate wheel and check for smooth operation. Bend both
ends of cotter pin around end of spindle in different
directions.
= T
Front Caliper Mounting Bolt Torque:
30 ft. lbs. (40 Nm)
CAUTION
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.
= T
Tie Rod End Fastener Torque:
42.5 ft. lbs. (58 Nm)
42.5 ft. lbs.
58 (Nm) = T
Wheel Hub Castle Nut Torque:
80 ft. lbs. (108 Nm)
= T
Wheel Nut Torque:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 90 ft. lbs. (122 Nm)
80 ft. lbs.
NEW Cotter Pin
(108 Nm)
7.6
FINAL DRIVE
FRONT DRIVE SHAFT
Drive Shaft Removal
1. Elevate front of vehicle and safely support machine under
the frame area.
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.
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.
5. Remove the front wheel hub assembly.
6. Remove the upper ball joint pinch bolt.
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.
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.
Castle Nut
Cotter Pin
Cone
Washers
Remove
Pinch
Bolt
7.7
FINAL DRIVE
7
Drive Shaft / CV Joint Handling Tips
Care should be exercised during drive shaft removal or when
servicing CV joints. Drive shaft components are precision parts.
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.
• 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.
CV Joint / Boot Replacement
1. Remove clamps from rubber boot using the proper boot
clamp pliers.
2. 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.
4. It may be necessary to tap the CV joint assembly outward
with a soft faced hammer.
5. Remove the small clamp and boot from the drive shaft.
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. Refer to information below or Figure 7-8 for grease
capacity requirements.
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.
CV Boot Clamp Pliers:
Earless Type - 8700226
Boot Replacement Grease Requirement:
Grease Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Inner Plunging Joint:
Boot replacement only - 45g
Boot replacement w/joint cleaning - 90g
Outer CV Joint:
Boot replacement only - 45g
Boot replacement w/joint cleaning - 90g
Retaining Ring
Pull shaft to remove
from CV joint
7.8
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.
11. Repeat this procedure to service the inner CV plunging
joint.
Drive Shaft Installation
1. Install new spring ring on drive shaft. Apply an anti-seize
compound to splines.
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.
FRONT DRIVE SHAFT
Joint Capacity**
45 Grams
Boot Capacity
45 Grams
*CV joint capacity: 45g if boot is replaced only.
Boot Capacity
45 Grams
Joint Capacity*
45 Grams
Another 45g (90g total) if joint is cleaned.
only. Another 45g (90g total) if joint is cleaned.
**Plunging joint capacity: 45g if boot is replaced
Plunging
Joint
CV Joint
Figure 7-8
Apply
Anti-Seize
NEW
Spring Ring
7.9
FINAL DRIVE
7
5. Install the upper pinch bolt and torque to 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.
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.
Install brake caliper mounting bolts and torque to 30 ft. lbs.
(40 Nm).
8. Install wheel and (4) wheel nuts. Torque wheel nuts to
specification.
9. Rotate wheel and check for smooth operation. Bend both
ends of cotter pin around end of spindle in different
directions.
= T
Pinch Bolt Torque:
17 ft. lbs. (23 Nm)
17 ft. lbs.
(23 Nm)
Out
Cone Washers
Wheel
Hub
80 ft. lbs.
NEW Cotter Pin
(108 Nm)
= T
Wheel Hub Castle Nut Torque:
80 ft. lbs. (108 Nm)
= T
Front Caliper Mounting Bolt Torque:
30 ft. lbs. (40 Nm)
CAUTION
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.
= T
Wheel Nut Torque:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 90 ft. lbs. (122 Nm)
30 ft. lbs.
(40 Nm)
7.10
FINAL DRIVE
PROPSHAFT SERVICE
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.
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.
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.
6. Remove the fasteners retaining the plastic skid plate and
remove the skid plate from the vehicle.
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
1. Remove internal or external snap ring from bearing caps.
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 re-
positioning during installation.
Roll Pin Removal Tool (PN 2872608)
Screw
Torx Screws
Push Rivets
Cap
CAUTION
Always wear eye protection.
Screws
Cupped
Washers
7.11
FINAL DRIVE
7
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.
4. Force U-joint cross to one side and lift out of inner yoke.
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.
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.
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.
7.12
FINAL DRIVE
FRONT GEARCASE / CENTRALIZED HILLIARD
Centralized Hilliard Exploded View
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
1
2
3
4
5
6
7
8
9
10
7-11 ft. lbs.
(10-15 Nm)
5
7.13
FINAL DRIVE
7
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 .
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.
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.
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.
Roller cage and roller’s rotate inward and grip the output hubs
for AWD engagement.
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.
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
& H-springs
Rollers
Output Hubs
7.14
FINAL DRIVE
AWD Diagnosis
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.
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.
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:
5. 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.
6. 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.
7. Inspect the roll cage assembly for cracks or excessive wear.
If damaged, replace the roll cage assembly.
Front Gearcase Coil Resistance:
21.6 - 26.4 Ohms
Check for
Armature Plate
wear bands
Gearcase Cover Plate Asm.
Coil
U-shaped insert
Side cutaway view of
Centralized Hilliard cover
Rollers
Roll Cage Assembly
7.15
FINAL DRIVE
7
Gearcase Removal
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.
5. Remove the vent line from the front gearcase.
6. Remove the (4) bolts securing the front gearcase to frame.
7. Remove the gearcase from the front LH wheel well area and
slide it between the upper and lower A-arm.
Gearcase Disassembly / Inspection
1. Drain and properly dispose of gearcase fluid. Remove any
metal particles from the drain plug magnet.
2. Remove the (6) cover screws and remove the cover plate.
3. Check the gearcase coil resistance (see “AWD Diagnosis”).
The resistance value should meet the specification.
4. Remove and inspect the armature plate and thrust plate.
Refer to “AWD Diagnosis” for detailed inspection process.
AWD Harness
Remove 4 Bolts
Remove
Vent Line
Disconnect
Harness
Thrust
Plate
Armature
Plate
7.16
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. Remove the LH output hub assembly from the clutch
housing.
6. Remove the clutch housing from the gearcase housing.
7. Remove the RH output hub assembly from the gearcase
housing.
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.
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.
11. Disassemble the pinion shaft assembly. Inspect the
bearings and replace if needed. Replace the pinion cover
seal and O-ring.
Replace
Seal
Inspect
Coil
Replace
O-Ring & Seal
Inspect
Bearings Replace
O-Ring & Seal
7.17
FINAL DRIVE
7
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.
NOTE: Rollers are spring loaded. Take care not to
allow them to fall out or lose them upon removal of
the roll cage.
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.
14. Inspect the roll cage assembly (B) sliding surfaces and H-
springs. The sliding surfaces must be clean and free of
nicks, burrs or scratches. If damaged, replace the roll cage
assembly.
15. Inspect clutch housing ring gear (C) for a consistent wear
pattern. Inspect the ring gear for chipped, broken, or
missing teeth.
16. Inspect both output hub assemblies. Inspect the bearings
and replace if needed.
Gearcase Assembly / Inspection
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).
A
C
B
B
H-Spring
Pinion Cover Screw Torque:
7-11 ft. lbs. (10-15 Nm)
Bearing
Spacer Roller
Thrust
Bearing
Surface
Torque
Screws
7.18
FINAL DRIVE
5. Carefully install the rollers into the roll cage assembly
while installing the assembly into the clutch housing.
IMPORTANT: To ensure gearcase is assembled
properly, assemble the gearcase components
starting with the cover plate and build upward.
6. 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.
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.
9. Install the RH output hub into the clutch housing assembly.
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).
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.
LH Hub
Thrust
Plate
RH Hub
Clutch
Housing
Armature
Plate
7.19
FINAL DRIVE
7
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.
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).
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.
2. Using a hex wrench, turn the backlash screw out 3-4 turns.
Re-apply red Loctite onto the bottom of the screw threads.
3. Tighten the adjustment screw until it is lightly seated or
until it bottoms out.
Cover Plate Screw Torque:
7-11 ft. lbs. (10-15 Nm)
Torque
Screws
Adjustment
Screw
Apply
Loctite
7.20
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.
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).
Gearcase Installation
1. 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).
4. Install the vent line.
5. Connect the AWD wire harness.
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.
= T
Front Gearcase Mounting Bolt Torque:
30 ft. lbs. (41 Nm)
Premium Demand Drive Fluid LT
(PN 2876251)
Front Housing Capacity
6.75 fl. oz. (200 ml)
30 ft. lbs.
Install
Vent Line
Connect
Harness
(41 Nm)
AWD Harness
7.21
FINAL DRIVE
7
REAR BEARING CARRIER
Bearing Carrier Inspection / Removal
1. Elevate rear of vehicle and safely support machine under
the frame area.
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.
5. 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.
6. Remove the rear wheel hub assembly.
7. Remove the bolts that attach the rear bearing carrier to the
upper and lower A-arms.
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.
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.
Castle Nut
Cotter Pin
Cone
Washers
Remove
7.22
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.
10. Replace bearing if moisture, dirt, corrosion, or roughness
is evident.
Bearing Replacement
Bearing Removal
1. Remove outer snap ring.
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 rear bearing carrier if damaged.
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.
7. Apply Loctite® RC™ 680 to the outer circumference of the
new bearing race and carefully press the new bearing into
the bearing carrier housing.
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 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.
Snap Ring
CAUTION
Use an arbor and press only on the outer race,
otherwise bearing damage may occur.
Apply
Loctite® RC™ 680
Bearing
Snap Ring
Pivot Tube
Pivot
Control Arm
Bushing
Control Arm
Bushing
Bushing
Pivot Tube
7.23
FINAL DRIVE
7
Bearing Carrier Installation
1. Install drive shaft axle through the backside of the bearing
carrier. Be sure bushings and pivot tubes are installed.
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).
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.
5. Install brake caliper mounting bolts and torque to 18 ft. lbs.
(24 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)
37 ft. lbs.
50 (Nm)
Out
Cone Washers
Wheel
Hub
= T
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.
= T
Wheel Hub Castle Nut Torque:
80 ft. lbs. (108 Nm)
18 ft. lbs.
24 (Nm)
80 ft. lbs.
(108 Nm)
NEW Cotter Pin
7.24
FINAL DRIVE
7. Install wheel and (4) wheel nuts. Torque wheel nuts to
specification.
8. 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.
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.
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.
5. Remove the rear wheel hub assembly.
6. Remove the bolt that attaches the rear bearing carrier to the
upper A-arm.
= T
Wheel Nut Torque:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 90 ft. lbs. (122 Nm)
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.
Castle Nut
Cotter Pin
Cone
Washers
Remove
7.25
FINAL DRIVE
7
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.
8. Grasp the rear drive shaft and pull sharply outward on the
shaft to disengage it from the rear gearcase.
NOTE: Take care when removing to prevent
damaging the seal.
9. Inspect the axle splines and CV boots for any damage.
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.
4. Hold open the snap ring using a snap ring pliers or duckbill
pliers.
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.
Snap Ring
Spread ends of snap ring
to remove joint from shaft
7.26
FINAL DRIVE
6. Remove boot from the shaft.
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 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.
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.
NOTE: The amount of grease that’s provided is pre-
measured, so use all the grease.
13. Refer to information below or Figure 7-28 at the end of this
section for grease capacity requirements.
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.
Tabs face the shaft
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.
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
7.27
FINAL DRIVE
7
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.
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.
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.
19. Install the small clamp on the boot and tighten using an
appropriate clamp pliers.
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.
IMPORTANT: Hammer on inner race only!
5. Make sure the circlip is still on the shaft and not left in the
joint.
6. Remove the boot from the shaft.
CAUTION
Be careful not to cut through the bridge of the
clamp when tightening.
Tap joint onto shaft
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.
7.28
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.
10. Install a NEW circlip on the end of the shaft.
NOTE: The amount of grease that’s provided is pre-
measured, so use all the grease.
11. Refer to information below or Figure 7-28 at the end of this
section for grease capacity requirements.
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.
14. Use a soft-faced hammer to assemble the shaft into the inner
race until you reach the end of the splines.
15. Pull on the joint to test that the circlip is seated and that the
joint is securely fastened to the shaft.
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.
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
Shown without
grease for clarity
Shown without
grease for clarity
7.29
FINAL DRIVE
7
16. Add any remaining grease to the boot.
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.
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.
Installation
1. Install new spring ring on drive shaft. Apply anti-seize
compound to splines.
2. 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.
3. Slide the rear drive shaft into the rear bearing carrier.
REAR SHAFT
Joint Capacity
40 Grams
Boot Capacity
30 Grams
Boot Capacity
40 Grams
Joint Capacity
30 Grams
CV Joint
Figure 7-28
Plunging
Spring Ring
Gear Side
Boot Kit
Wheel Side
Boot Kit
Joint
Apply
Anti-Seize
NEW
Spring Ring
7.30
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).
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.
7. Install brake caliper mounting bolts and torque to 18 ft. lbs.
(24 Nm).
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.
9. Install wheel and (4) wheel nuts. Torque wheel nuts to
specification.
= T
Rear Bearing Carrier Bolt Torque:
37 ft. lbs. (50 Nm)
37 ft. lbs.
50 (Nm)
Out
Cone Washers
Wheel
Hub
18 ft. lbs.
24 (Nm)
= T
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.
= T
Wheel Hub Castle Nut Torque:
80 ft. lbs. (108 Nm)
= T
Wheel Nut Torque:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 90 ft. lbs. (122 Nm)
80 ft. lbs.
(108 Nm)
NEW Cotter Pin
7.31
FINAL DRIVE
7
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.
4. Remove the (2) rear gearcase mount bracket fasteners and
mount bolt and remove bracket from vehicle.
NOTE: Some vehicles will require the bolt to be
removed from the receiver hitch to gain enough
clearance to remove the 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.
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.
Remove
Remove
Silencer
Elbow
Header
Pipe
Pipe
Remove
7.32
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.
3. Remove the ring gear/axle spool assembly. The bearings
are a slip-fit and will slide off the axel spool.
NOTE: Record the thickness of the shim pack
located under each bearing. Keep the shims
together for reassembly.
4. Inspect each axle spool bearing and race for signs of wear
or damage. Replace races if required using standard bearing
puller tools.
7.33
FINAL DRIVE
7
5. Inspect the ring gear teeth for chipped, worn, or broken
teeth. If damaged, replace the ring gear and pinion gear as
a set.
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. 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.
NOTE: In the event damage to the gears, pinion
bearings or housing requires replacement, the entire
assembly must be replaced.
Inspect
7.34
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.
7.35
FINAL DRIVE
7
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.
5. Install the ring gear/axle spool assembly into the housing.
6. Install the gearcase cover. Verify the o-ring is in position.
Install the cover screws onto the rear gearcase. Torque to
specification.
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.
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.
= T
Cover Screw Torque:
23-27 ft. lbs. (31-37 Nm)
=
Rear Gearcase Capacity:
18 fl. oz. (532 ml)
or to bottom of fill plug hole threads
See Chapter 2
= T
Drain / Fill Plug Torque:
Drain Plug - 30-45 in.lbs. (3-5 Nm)
Fill Plug - 40 ft.lbs. (54 Nm)
Special Tool
PA-48873
7.36
FINAL DRIVE
Gearcase Exploded View
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
1
2
3
4
56
78
910
7
13
14
15
16
17
18
19
20
12
21
30-45 in. lbs.
(3-5 Nm)
40 ft. lbs.
(54 Nm)
23-27 ft. lbs.
(31-37 Nm)
10
9
6
16
7
7
70-80 ft. lbs.
(95-108 Nm)
23-27 ft. lbs.
(31-37 Nm)
23-27 ft. lbs.
(31-37 Nm)
7.37
FINAL DRIVE
7
WHEEL HUBS
Front Hub Exploded View
Rear Hub Exploded View
Flanged Nuts
Front Rim
Valve
Castle Nut
Cotter Pin
Cone
Wheel Hub
Stud
Brake Disc
Bolts
Retaining
Sealed
Ball Bearing
Bearing Carrier
Front Tire
Washers
See Page 7.2
for Torque Value
80 ft. lbs.
(108 Nm) Ring
Flanged Nuts
Front Rim
Valve
Castle Nut
Cotter Pin Cone
Wheel Hub
Stud
Brake Disc
Bolts
Retaining
Sealed
Ball Bearing
Bearing Carrier
Front Tire
Washers
See Page 7.2
for Torque Value
80 ft. lbs.
(108 Nm) Ring
TRANSMISSION
8.1
CHAPTER 8
TRANSMISSION
8
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
8.2
TRANSMISSION
TORQUES / SPECIFICATIONS
Maintain and check/change these items in accordance with the
maintenance schedule in Chapter 2 or during service repairs.
SHIFT LEVER
Removal
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.
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)
= T
Shift Cable Nut Torque:
130-155 in. lbs. (14.7-17.5 Nm)
8.3
TRANSMISSION
8
Shift Cable Inspection / 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
• Excessive gear clash (noise)
• Gear selector moving out of desired range
1. Locate the shift cable in the rear LH wheel well 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.
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.
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.
Shift Cable
Mount
Dust Boot
Clevis Pin
Shift Cable
Lower
Jam Nut
Upper
Jam Nut
8.4
TRANSMISSION
TRANSMISSION SERVICE
Transmission Removal / Service Notes
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.
NOTE: Exploded views are located at the end of this
chapter for additional information.
1. Place the transmission in neutral position.
2. Drain both the transfer case and transmission case halves.
3. Remove the (7) bolts retaining the transmission support
bracket.
4. Remove the connector tube bolts securing the rear gear case
and transmission transfer case.
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).
Transmission Gearcase
Drain Plug
Transfer Case
Drain Plug
x 7
x 4
x 3
1
2
3
4
5
6
7
8
8.5
TRANSMISSION
8
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.
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.
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.
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.
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.
x 3
8.6
TRANSMISSION
13. Remove the front output pinion shaft assembly. The shaft
can be disassembled as shown using a press and standard
bearing removal tools.
14. Remove the upper snap ring from the top side of the 21T
main pinion gear and remove the gear.
15. Remove the lower snap ring from under the gear.
16. Remove the intermediate shaft seal using a seal puller or
other suitable method.
8.7
TRANSMISSION
8
Transfer Case Reassembly
1. Install the intermediate shaft seal (circled) flush or slightly
below the case. Install circlips and gear onto the input
intermediate shaft as shown.
2. Install the front output pinion shaft assembly.
NOTE: Bearing is pressed onto the shaft
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.
= T
Output Pinion Shaft Bracket Screws:
23-27 ft. lbs. (31-37 Nm)
x 3
x 2
8.8
TRANSMISSION
5. Reinstall the intermediate pinion shaft assembly and
bearing cup.
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.
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.
Apply Sealant PN 2871557
To Case Mating Surfaces
2871557
= T
Transfer Case Cover Screws:
23-27 ft. lbs. (31-37 Nm)
1
2
3
4
5
6
7
8
8.9
TRANSMISSION
8
Transmission Shift Housing Disassembly
IMPORTANT: Shift housing repairs are not possible
without performing transfer case disassembly. Read
and understand all instructions before beginning
disassembly.
1. 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: Shift cable bracket removal is required.
2. Place the transmission shift housing onto a flat surface as
shown. Lift the transmission case half straight up and
remove.
NOTE: Shaft components may “catch” during
transmission case half disassembly. Work slowly
and deliberately to avoid component loss or
damage.
3. 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.
Reverse Gear
8.10
TRANSMISSION
4. Remove the (5) screws retaining the park flange. Inspect the
park flange dogs for wear or damage. Replace as required.
5. Inspect the shaft bearing. Use a standard bearing puller to
remove the shaft bearing if 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.
NOTE: The reverse idler shaft is a non-serviceable
item and should not be pressed out of the housing.
7. Remove the input shaft seal and clutch intermediate shaft
seal using a seal puller or punch.
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.
Neutral
8.11
TRANSMISSION
8
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.
NOTE: The clutch yoke side uses the short, "black"
detent screw and the gear selector side detent uses
the longer, "silver" detent screw.
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.
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.
13. Inspect the inner and outer gear teeth and splines on both
ends of the shift collar for excessive wear or damage.
INSPECT
8.12
TRANSMISSION
14. Remove the sliding shoes from the clutch yoke.
15. Remove the clutch shaft from the housing. Note that the
forward gear assembly will remain in the housing.
16. Remove the forward clutch gear assembly from the
housing. Note the two needle bearings and washer on the
bottom of the gear assembly.
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.
18. Remove the clutch yoke pivot pin set screw.
19. Remove the clutch yoke pivot pin using a 10/24 x 2" bolt.
High Gear
Low Gear
Retaining Plate
10/24 x 2”
8.13
TRANSMISSION
8
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.
NOTE: Do not pull bearings from case for
inspection, as the removal process damages the
bearing.
8.14
TRANSMISSION
Transmission Shift Housing Reassembly
1. 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.
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.
= T
Shift Lever Screw Torque:
15-20 ft. lbs. (20 - 27 Nm)
“X” out
8.15
TRANSMISSION
8
6. 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.
7. Install the forward clutch gear assembly into the housing.
Note the two needle bearings and washer on the bottom of
the gear assembly.
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.
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.
8.16
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.
NOTE: The clutch yoke side uses the short, "black"
detent screw and the gear selector side detent uses
the longer, "silver" detent screw.
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.
12. Complete shift detent screw installation. Torque the inner
screws to specification.
= T
Detent (outer) Sleeve Screws:
40-45 ft. lbs. (54-61 Nm)
T
T
=
Apply Lubricant to shift drum components
= T
Shift Position Sensor Screws:
25-40 in. lbs. (2.8-4.5 Nm)
= T
Shift Detent (inner) Screws:
23-27 ft. lbs. (31-36.6 Nm)
T
H
P
R
N
L
Neutral
8.17
TRANSMISSION
8
13. Install the reverse idler lower washer, needle bearing, gear,
upper washer and snap ring onto the idler shaft of the
transmission case half.
14. Install a new shaft bearing (if required).
15. Install the park flange and torque the (5) screws to
specification.
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.
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)
8.18
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.
19. Install the shift cable bracket (7) shift housing case screws
to the front of the transmission. Torque to specification.
20. Install the (2) shift housing case screws to the backside as
shown. Torque to specification.
NOTE: Shift cable bracket installation is required.
21. Proceed with transfer case reassembly.
See “Transfer Case Reassembly” on page 8.7
Apply Sealant PN 2871557
To Case Mating Surfaces
= T
Shift Housing Screws:
23-27 ft. lbs. (31-36.6 Nm)
2871557
= T
Shift Housing Screws:
23-27 ft. lbs. (31-36.6 Nm)
8.19
TRANSMISSION
8
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.
8.20
TRANSMISSION
TRANSMISSION EXPLODED VIEWS
Shift Housing / Transfer Case Exploded View
Transfer Case
Shift Housing
BRAKES
9.1
CHAPTER 9
BRAKES
9
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
BRAKE SYSTEM SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
HYDRAULIC BRAKE SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
BRAKE SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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
9.2
BRAKES
GENERAL SPECIFICATIONS
TORQUE SPECIFICATIONS SPECIAL TOOLS
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)
Front Brake Disc Runout - .010" (.254mm)
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)
Rear Brake Disc Runout - .010" (.254 mm)
Item Torque
ft. lbs. Torque
Nm
Front Caliper Mounting Bolts 30 40
Rear Caliper Mounting Bolts 18 24
Brake Line Flare 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
Brake Switch 12-15 16-20
Master Cylinder to Frame 17 23
Brake Pedal Mounting
Bracket to Frame 15 23
Part Number Tool Description
2870975 Mity Vac™ Pressure Test Tool
9.3
BRAKES
9
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 Remedy
Dirt, dust, or imbedded material on pads or disc 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)
Set to proper level
Clean compensating port
Inspect. Repair as necessary
Clean piston(s) seal
Educate operator
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
9.4
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.
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.
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.
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.
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!
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
Caliper Banjo Style Fittings:
15 ft. lbs. (20 Nm).
All Caliper Bleed Screws:
47 in. lbs. (5.3 Nm)
Master Cylinder Side View
Cross
MC Rear
Brake Line
RH Rear Line
RH Rear Caliper
RH Front
Brake Line
RH Front Caliper
Brake
Master Cylinder
LH Front
LH Rear Caliper
LH Front Caliper
Brake Line
LH Rear Line
1
2
1
1
2
2
1
3All Flare Style Fittings:
12-15 ft. lbs. (16-20 Nm)
3
1
1
2
2
15 ft. lbs.
(20 Nm)
3
Fitting
Switch
9.5
BRAKES
9
MASTER CYLINDER
Removal
1. Locate the master cylinder above the LH front tire in the
wheel well area.
2. Remove the clip (A) from the clevis pin (B) that attaches
the master cylinder to the brake pedal lever.
3. Place a container to catch brake fluid under the master
cylinder brake line banjo bolts (C).
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
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.
Pedal Installation
1. Reverse “Removal” steps to install brake pedal lever.
Brake pedal freeplay should not exceed .090” (2.28 mm).
Master Cylinder
A
15 ft. lbs.
(20 Nm)
B
C
D
D
17 ft. lbs.
(23 Nm)
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact
with finished surfaces.
Brake Pedal Freeplay:
.090” (2.28 mm)
B
A
L
E
9.6
BRAKES
BRAKE BLEEDING / FLUID CHANGE
NOTE: When bleeding the brakes or replacing the
fluid always start with the furthest caliper from the
master cylinder.
1. Clean master cylinder reservoir cover thoroughly and
remove the cover.
2. If changing fluid, remove old fluid from reservoir with a
Mity Vac™ pump or similar tool.
3. Add brake fluid to the indicated MAX level of reservoir.
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: Do not release foot pedal before bleeder
screw is tight or air may be drawn into master
cylinder.
7. 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.
11. Install master cylinder reservoir cover.
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.
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.
Mity Vac™ (PN 2870975)
Polaris DOT 4 Brake Fluid
(P/N 2872189)
Master Cylinder
Remove
Cover
CAUTION
Maintain at least 1/2"(1.27 cm) of brake fluid in
the reservoir to prevent air from
entering the master cylinder.
Master Cylinder Fluid Level
Between the MIN and MAX line shown
on the reservoir.
9.7
BRAKES
9
FRONT BRAKE PADS
Pad Removal
1. Elevate and support front of vehicle.
2. Remove the front wheel. Loosen pad adjuster screw 2-3
turns.
3. 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.
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.
5. Push mounting bracket inward and slip outer brake pad past
edge. Then remove inner pad.
Pad Inspection
1. Measure the thickness of the pad material. Replace pads if
worn beyond the service limit.
CAUTION
Use care when supporting vehicle so that it
does not tip or fall.
Severe injury may occur if machine tips or falls.
Front Brake Pad Thickness
New: .300” ± .007” (7.6 mm ± .178 mm)
Service Limit: .180” (4.6 mm)
Measure
Thickness
9.8
BRAKES
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.
2. Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
other.
3. Install caliper onto front hub and torque mounting bolts.
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
stationary pad contacts disc, then back off 1/2 turn
(counterclockwise).
6. Verify fluid level in reservoir is up to MAX line inside
reservoir and install reservoir cap.
7. Install wheel and torque wheel nuts.
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.
WARNING
If brake pads are contaminated with grease, oil,
or liquid soaked do not use the pads.
Use only new, clean pads.
= T
Front Caliper Mount Bolt Torque:
30 ft. lbs. (40 Nm)
30 ft. lbs.
(40 Nm)
Master Cylinder Fluid
Up to MAX line inside reservoir
= T
Front Wheel Nut Torque:
27 ft. lbs. (37 Nm)
1/2 Turn
9.9
BRAKES
9
FRONT CALIPER SERVICE
Caliper Exploded View
Caliper Removal
1. Elevate and safely support the front of the vehicle.
2. Remove the (4) wheel nuts and the front wheel.
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.
5. Loosen brake pad adjustment set screw 2-3 turns to allow
brake pad removal after the caliper is removed.
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
A
B
C
D
E
F
G
H
Apply Polaris All Purpose
Grease
Apply Polaris DOT 4 Brake Fluid
to Component
I
47 in. lbs.
(5.3 Nm)
D
CAUTION
Use care when supporting vehicle so that it does not
tip or fall. Severe injury may occur.
Remove
Brake Line
9.10
BRAKES
6. Remove the two caliper mounting bolts and remove the
caliper assembly from the front hub.
Caliper Disassembly
1. Push brake pad retainer pin inward and slip brake pads past
the edge.
2. Remove both brake pads from the caliper.
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.
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. 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.
Remove
CAUTION
Use caution and always wear safety glasses
when working with compressed air.
9.11
BRAKES
9
8. Clean the caliper body, piston, and retaining bracket with
brake cleaner or alcohol.
NOTE: Be sure to clean seal grooves in caliper
body.
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.
2. Inspect piston for nicks, scratches, pitting or wear. Measure
piston diameter and 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.
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.
= In. / mm.
Caliper Piston Bore I.D.:
Std: 1.004” (25.5 mm)
Service Limit: 1.006” (25.55 mm)
Clean
Components
= In. / mm.
Caliper Piston O.D.:
Std: 1.002” (25.45 mm)
Service Limit: 1.000” (25.4 mm)
New
Seal
Grooves
O-Rings
9.12
BRAKES
3. Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install the rubber
dust seal boots.
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.
Caliper Installation
5. Install caliper and torque mounting bolts to specification.
6. Install brake line and tighten securely with a line wrench.
Torque the banjo bolt brake line(s) to the proper torque
specification.
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.
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)
30 ft. lbs.
(40 Nm)
= T
Front Wheel Nut Torque:
27 ft. lbs. (37 Nm)
15 ft.lbs.
(20 Nm)
9.13
BRAKES
9
FRONT BRAKE DISC
Disc Inspection
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.
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.
Disc Replacement
1. Remove front brake caliper (see “FRONT CALIPER
SERVICE”).
2. Remove wheel hub cotter pin, castle nut and washers.
3. Remove the hub assembly from the vehicle and remove the
(4) bolts retaining the disc to the hub.
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).
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.
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
Brake Disc Runout
Service Limit .010” (.254 mm)
Measure
Thickness
Front
View Side
View
CAUTION
Always use new brake disc mounting bolts. The
bolts have a pre-applied locking agent which is
destroyed upon removal.
Cotter
Pin
Washers
Nut
(4) Bolts
28 ft. lbs.
(38 Nm)
9.14
BRAKES
REAR BRAKE PAD
Pad Removal
1. Elevate and support rear of vehicle.
2. Remove the rear wheel.
3. Loosen pad adjuster screw 2-3 turns.
4. 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.
5. Push caliper piston into the caliper bore slowly using a C-
clamp or locking pliers with pads installed.
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.
6. Push caliper mounting bracket inward and slip outer brake
pad past the edge to remove.
7. Remove the inner brake pad.
CAUTION
Use care when supporting vehicle so that it
does not tip or fall.
Severe injury may occur if machine tips or falls.
9.15
BRAKES
9
Pad Inspection
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.
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.
2. Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
other.
3. Install caliper and torque mounting bolts to specification.
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.
7. Install wheel and torque wheel nuts.
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.
Rear Brake Pad Thickness
New .298” ± .007” (7.57 mm ± .178 mm)
Service Limit .180” (4.6 mm)
WARNING
If brake pads are contaminated with grease,
oil, or liquid soaked do not use the pads.
Use only new clean pads.
Measure
Thickness
= T
Rear Caliper Mount Bolt Torque:
18 ft. lbs. (24 Nm)
Master Cylinder Fluid
Up to MAX line inside reservoir
= T
Rear Wheel Nut Torque:
27 ft. lbs. (37 Nm)
18 ft. lbs.
(24 Nm)
9.16
BRAKES
REAR CALIPER SERVICE
Caliper Exploded View
Caliper Removal
1. Elevate and safely support the rear of the vehicle.
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.
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.
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
B
C
D
EF
G
H
I
K
Apply Polaris DOT 4 Brake Fluid
to Component
Apply Polaris All Purpose
Grease
47 in. lbs.
(5.3 Nm)
CAUTION
Use care when supporting vehicle so that it does not
tip or fall. Severe injury may occur.
Remove
Brake Line
Remove
9.17
BRAKES
9
Caliper Disassembly
1. Remove brake pad adjustment set screw (K).
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).
4. 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).
5. Clean the caliper body, piston, and retaining bracket with
brake cleaner or alcohol.
NOTE: Be sure to clean seal grooves in caliper
body.
Caliper Inspection
1. 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.
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn beyond
service limit.
3. Inspect the brake disc and pads as outlined in this chapter.
H
G
C
K
D
B
Pads
F
E
Clean Components
= In. / mm.
Rear Caliper Piston Bore I.D.
Standard: 1.191” (30.25 mm)
Service Limit: 1.192” (30.28 mm)
= In. / mm.
Rear Caliper Piston O.D.
Standard: 1.1875” (30.16 mm)
Service Limit: 1.186” (30.12 mm)
9.18
BRAKES
Caliper Assembly
1. 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.
2. 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.
3. Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install the rubber
dust seal boots.
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.
Caliper Installation
5. Install the rear caliper with the mounting bolts. Torque
mounting bolts to 18 ft. lbs. (24 Nm).
6. Install brake line banjo bolt and torque to specification.
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.
NOTE: If new brake pads are installed, brake
burnishing is recommended (see “REAR BRAKE
PADS - Brake Burnishing Procedure”).
Polaris Premium All Season Grease
(PN 2871423)
A
B
D
= T
Rear Caliper Mount Bolt Torque:
18 ft. lbs. (24 Nm)
= T
Rear Wheel Nut Torque:
27 ft. lbs. (37 Nm)
18 ft. lbs.
(24 Nm)
15 ft. lbs.
(21 Nm)
9.19
BRAKES
9
REAR BRAKE DISC
Disc Inspection
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.
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.
Disc Replacement
1. Remove rear brake caliper (see “REAR CALIPER
SERVICE”).
2. Remove wheel hub cotter pin, castle nut and washers.
3. Remove the hub assembly from the vehicle and remove the
(4) bolts retaining the disc to the hub.
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).
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.
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
Brake Disc Runout
Service Limit .010” (.254 mm)
Measure
Thickness
Front
View Side
View
CAUTION
Always use new brake disc mounting bolts. The
bolts have a pre-applied locking agent which is
destroyed upon removal.
Cotter
Pin
Washers
Nut
(4) Bolts
28 ft. lbs.
(38 Nm)
9.20
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
ELECTRICAL
10.1
CHAPTER 10
ELECTRICAL
10
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
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
FUSE BOX LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
FUSES / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
10.2
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
10.3
ELECTRICAL
10
GENERAL INFORMATION
Special Tools
Electrical Service Notes
Keep the following notes in mind when diagnosing an electrical
problem:
• 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.
• For resistance readings, isolate the component to be
tested. Disconnect it from the wiring harness or power
supply.
Under-Dash Components
The following switches and components can be accessed
underneath the instrument / dash panel:
• Speedometer
• Speedometer Mode Switch
• Digital Wrench Diagnostic Connector
• Digital Wrench / ECU Reflash 9 Vdc Battery Plug
• AWD Switch
• Headlamp Switch
• 12 Vdc Accessory Power Point
• Ignition Switch
• Work Light Switch
• Fuse / Relay Panel
Part Number Tool Description
PV-43568 Fluke™ 77 Digital Multimeter
2870630 Timing Light
2870836 Battery Hydrometer
2460761 Hall Effect Sensor Probe Harness
2871745 Static Timing Light Harness
- Digital Wrench™ (see Chapter 4)
10.4
ELECTRICAL
SWITCHES / CONTROLS
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.
AWD Switch
1. 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.
2. Test the switch connections and check for continuity at the
pins shown in the illustration.
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.
12345678
ON X X X
OFF
SWITCH
BACK
LIGHT XX
HEADLAMP SWITCH
BACK VIEW OF SWITCH
12345678
ON X X X
OFF
SWITCH
BACK
LIGHT XX
AWD SWITCH
BACK VIEW OF SWITCH
10.5
ELECTRICAL
10
INSTRUMENT CLUSTER
Overview
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.
NOTE: In addition to showing vehicle speed, the
speedometer needle flashes when a low fuel
condition exists.
NOTE: Use the “Mode Button” shown below to
toggle between Instrument Cluster display screens.
Rider Information Display
The rider information display is located in the instrument
cluster. All segments will light up for 2.5 seconds at start-up.
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.
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.
3. Engine Hour Display Indicator
4. Service Interval / Diagnostic Mode Indicator
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
Speedometer
Speedometer
Needle
1
2
345
67
8
10.6
ELECTRICAL
Standard Display Modes
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.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
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.
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:
1. Turn the key switch off and wait 10 seconds.
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.
Clock Screen
To reset the clock:
1. Enter the diagnostic mode.
2. Toggle to the clock screen.
3. Press and hold the mode button until the hour display
flashes. Release the button.
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.
5. When the desired hour is displayed, wait approximately
four seconds, until the minute display flashes.
6. When the display stops flashing, the mode has been set.
7. Use the same procedure to reset the minutes.
Battery Voltage Screen
View this screen to check battery voltage level.
Tachometer Screen
View the tachometer to check engine speed.
10.7
ELECTRICAL
10
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.
10.8
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: 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.
3. Press and hold the mode button for 2-3 seconds, until the
wrench icon flashes. Release the button.
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.
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.
Viewing Diagnostic Codes
Use the following procedure to view diagnostic blink codes
(failure codes) from the EFI module:
1. Engage the parking brake.
2. Stop the engine.
3. Turn the key switch to the ON position.
10.9
ELECTRICAL
10
4. 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.
5. 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”.
6. The number “61” and/or the word “End” displays after all
codes have been transmitted.
Instrument Cluster Removal
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.
2. Push the instrument cluster out from the back side of the
dash while securely holding the dash and rubber mount.
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. 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.
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.
Rubber Mount
Instrument Cluster
Bezel
Push Instrument
Cluster Outward Dash Panel
10.10
ELECTRICAL
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS
TEST 1 - No All Wheel Drive
#(%#+
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.
9
.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 ORANGEWHITE 4HE GEAR
SWITCH ONLY INTERFACES WITH THE INSTRUMENT
CLUSTER 4O ENABLE !7$ THE CLUSTER MUST BE
DISPLAYING LOW HIGH OR REVERSE GEAR
0%2&/2-
4%34 
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.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
 2ED 6 #ONSTANT
 2ED  7HITE 6 3WITCHED
 'REY /RANGE -ODE BUTTON
 .#
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 "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
 0IN #ONNECTOR
10.11
ELECTRICAL
10
TEST 2 - No Display
TEST 3 - Vehicle Speed Sensor
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OREQUIVALENT JUMPER WIRES
4O TEST WHEEL SPEED SENSOR
 $ISCONNECT  0IN CONNECTOR FROM SPEEDOMETER
 #ONNECT WIRES FROM TEST LIGHT TO SENSOR  0IN
CONNECTOR AS SHOWN AT RIGHT USING THE (ALL 3ENSOR
0ROBE (ARNESS 0.  OR JUMPER LEADS
 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
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10.12
ELECTRICAL
TEST 4 - No AWD Hub Safety Limiter
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10.13
ELECTRICAL
10
TEST 5 - Fuel Gauge Display Not Working
TEST 6 - Gear Indicator Not Working (Transmission Switch)
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10.14
ELECTRICAL
ALL WHEEL DRIVE COIL
Operation Overview
• When the AWD switch is “ON”, 12 VDC power is
present at the hub coil.
• If the criteria is met, the instrument cluster provides a
ground path at pin #16. When this occurs the AWD
icon should display in the instrument cluster.
• The AWD system must be grounded to operate.
Diagnosing System Failures
• Verify the AWD switch is functional and that a
minimum of 11 volts is present at the hub coil.
• Verify the AWD hub coil is functional. Test the AWD
hub coil using an ohm meter. See specifications below:
• Verify the wiring harness, wiring, connectors,
connector pins and grounds are undamaged, clean and
connect properly.
• Verify continuity of wire connections with a known
good volt/ohm meter.
IMPORTANT: Verify all wires and wiring connections
have been tested properly with a known good volt/
ohm meter before suspecting a component failure.
80% of all electrical issues are caused by bad/failed
connections and grounds.
GEAR POSITION INDICATOR SWITCH
Test Diagram
NOTE: See “Instrument Cluster Troubleshooting”
for additional switch circuit information.
SPEED SENSOR
Location / Testing
The speed sensor is located in the transmission transfer case
cover and can be accessed through the rear LH wheel well area.
To test the Speed Sensor, refer to “TEST 3” under
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS.
AWD Hub Coil Resistance:
24 Ω ± 5%
7HVW5HVLVWDQFH
5HDGLQJVVKRXOGEH
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Continuity Table
ABCDEF
HIGH XX
LOW XX
NEU XX
REV XX
PARK XX
Speed Sensor
10.15
ELECTRICAL
10
HEAD LIGHTS
Headlight Adjustment
The headlight beam is adjustable.
1. Place the vehicle on a level surface with the headlight
approximately 25 ft. (7.6 m) from a wall.
2. Measure the distance from the floor to the center of the
headlight and make a mark on the wall at the same height.
3. With the machine in Park, start the engine and turn the
headlight switch to on.
4. The most intense part of the headlight beam should be
aimed 8 in. (20 cm) below the mark placed on the wall in
Step 2.
NOTE: Rider weight must be included in the seat
while performing this procedure.
5. Adjust the beam to the desired position by loosening the
adjustment screw (A) and moving the lamp to the
appropriate height.
6. Adjust the beam to desired position. Repeat the procedure
to adjust the other headlight.
Headlamp Bulb Replacement
1. Disconnect the headlamp bulb from the wiring harness. Be
sure to pull on the connector, not on the wiring.
2. Turn the lamp counterclockwise to remove it.
3. Insert new bulb. Reinstall the harness assembly into the
headlight assembly.
NOTE: Make sure the tab on the lamp locates
properly in the housing.
A
WARNING
Due to the nature of light utility vehicles and
where they are operated, headlight lenses
become dirty. Frequent washing is necessary to
maintain lighting quality. Riding with poor
lighting can result in severe injury or death.
10.16
ELECTRICAL
Headlamp Housing Removal
1. Disconnect the headlamp from the wiring harness. Be sure
to pull on the connector, not on the wiring.
2. Remove the O-rings (A) from the headlamp brackets on
both sides of the headlamp.
3. Remove the headlamp from the front bumper.
Headlamp Housing Installation
1. To install the headlamp housing back into the front
bumper.
2. Secure the headlamp housing with the rubber O-rings (A)
on both sides of the headlamp.
3. Reconnect wire harness or re-insert bulb if previously
removed.
4. Adjust headlights using the “Headlight Adjustment”
procedure in this section.
TAIL / BRAKE / WORK LIGHTS
Bulb Replacement
Before replacing the bulb, use a digital multi-meter to test the
harness to ensure the lamp is receiving 12 volts and that a ground
path is present.
If a tail light, brake light, or work light does not work the bulb
may need to be replaced.
1. Remove bulb by turning the rubber base 1/4 turn and
pulling the bulb out. Replace it with recommended bulb.
Apply Dielectric Grease (PN 2871329).
2. Test the tail light, brake light, and work light to verify it is
working properly.
A
AWork Tail / Brake
Light
Light
10.17
ELECTRICAL
10
COOLING SYSTEM SCHEMATIC
Cooling System Break-Out Diagram
10.18
ELECTRICAL
Fan Control Circuit Operation / Testing
Power is supplied to the fan via the Orange/Black wire when the
relay is ON. The ground path for the fan motor is through the
Brown harness wire. Refer to “RELAYS” later in this chapter
for more information on fan functions.
NOTE: The fan may not function or operation may
be delayed if coolant level is low or if air is trapped in
the cooling system. Be sure cooling system is full
and purged of air. Refer to Maintenance Chapter 2
for cooling system information.
Fan Control Circuit Bypass Test
1. Disconnect harness from coolant temperature sensor on
engine cylinder head.
2. With the transmission in Park, turn the ignition key “ON”.
The fan should start running.
3. If the fan does not run or runs slowly, check the fan motor
wiring, ground, motor condition and mechanical relay for
proper operation. Repair or replace as necessary. If the fan
runs with the sensor harness disconnected, but will not turn
on when the engine is hot, check the coolant temperature
sensor and connector terminals.
Coolant Temperature Sensor
The coolant temperature sensor can be tested using an ohmmeter
or voltmeter.
1. With the engine and temperature sensor at room
temperature (68°F = 20°C), disconnect the harness
connector.
2. With the meter in the ohms mode, place the meter leads
onto the sensor contacts.
3. Use the table Temperature / Resistance table to determine
if the sensor needs to be replaced.
NOTE: If the coolant temperature sensor or circuit
malfunctions the radiator fan will default to 'ON'.
EFI DIAGNOSTICS
EFI Component Testing
All EFI component information and diagnostic testing
procedures are located in Chapter 4.
Refer to Chapter 4 “Electronic Fuel Injection System (EFI)”
when diagnosing an EFI system or component.
FUEL SENDER
Testing
1. Drain the fuel from the fuel tank.
2. Carefully remove the fuel pump assembly from the fuel
tank (see chapter 4).
3. Attach an ohm meter to the fuel sender harness Violet/
White wire (B) and Brown wire (C).
4. Allow the sender float to sit in the empty position and
compare to specification.
5. Slowly lift the sender float to the full position and compare
to specification.
6. If the readings are out of specification, or if the reading is
erratic or LCD display “sticks”, check the following before
replacing the fuel pump assembly:
• Loose float
• Float contact with tank
• Bent float rod
If none of the conditions exist, the fuel sender assembly is faulty.
Replace the fuel pump assembly (see chapter 4).
CAUTION
Keep hands away from fan blades during
operation. Serious personal injury could result.
TEMPERATURE °F (°C) RESISTANCE
68 °F (20 °C) 2.5 k Ω ± 6%
212 °F (100 °C) 0.186 Ω ± 2%
Fuel Sender - Empty: 5 Ω ± 5%
Fuel Sender - Full: 90 Ω ± 5 %
Connection
Full: 90Ω ± 5%
Half: 57Ω ± 5%
Empty: 5Ω ± 5%
Full
Empty
10.19
ELECTRICAL
10
RELAYS
Operation
Located in the fuse box under the dash, the relays assist with
component operation like the fan, fuel pump, and EFI system.
The fan relay, controlled by the ECU and Temp Sensor, operates
the fan.
The EFI relay, controlled by the ECU, turns on power for
components such as the fuel pump, injectors, and ignition coils.
FUSE BOX LAYOUT
FAN RELAY
COLOR FUNCTION
Red / White Key-On battery power supply, switched on
by key switch, enables power to relay.
Orange / Black Fused 20-Amp power, switched by relay,
provides power to Fan Motor.
Yellow / Black ECU input to connect relay Fused 20-Amp
power to Fan Motor output.
Red Fused 20-Amp, constant battery power IN
supply for EFI component operation.
EFI RELAY
COLOR FUNCTION
Orange Fused 15-amp, constant battery power IN
supply for EFI component operation.
Red / White Key-On battery power supply, switched on
by key switch, enables power to relay.
Red / Black
EFI power output. Switched by relay when
ECU sends a signal on the GRY/W wire,
closing the relay. Supplies 15-amp power
for ECU-controlled operation of EFI
components.
Gray / White
ECU input to enable relay. The ECU
supplies a ground which closes the relay,
supplying power to run the fuel pump,
injectors, etc.
Located under
the dash
10.20
ELECTRICAL
FUSES / CIRCUIT BREAKER
Operation
Located in the fuse box under the dash, the fuse panel provides current protection for components such as the Instrument Cluster,
ECU, EFI system, Chassis Power and Accessories.
A separate 20-amp circuit breaker protects the fan motor circuit (see wire diagram for details).
10.21
ELECTRICAL
10
CHARGING SYSTEM
Current Draw - Key Off
Connect an ammeter in series with the negative battery cable.
Check for current draw with the key off. If the draw is excessive,
loads should be disconnected from the system one by one until
the draw is eliminated. Check component wiring as well as the
component for partial shorts to ground to eliminate the draw.
Charging System “Break Even” Test
The “break even” point of the charging system is the point at
which the alternator overcomes all system loads (lights, etc.)
and begins to charge the battery. Depending on battery condition
and system load, the break even point may vary slightly. The
battery should be fully charged before performing this test.
1. Connect a tachometer to the engine.
2. Using an inductive amperage metering device, (set to DC
amps) connect to the negative battery cable.
3. With engine off and the key, kill switch, and lights in the
ON position, the ammeter should read negative amps
(battery discharge). Reverse meter lead if a positive reading
is indicated.
4. Shift transmission into neutral with the park brake on and
start the engine. With the engine running at idle, observe
meter readings.
5. Increase engine RPM while observing ammeter and
tachometer.
6. Note RPM at which the battery starts to charge (ammeter
indication is positive).
7. With lights and other electrical loads off, the “break even”
point should occur at approximately 1500 RPM or lower.
8. With the engine running, turn the lights on and engage
parking brake lock to keep brake light on.
9. Repeat test, observing ammeter and tachometer. With
lights on, charging should occur at or below 2000 RPM.
Alternator Output
RPM AMPS VOLTS
2500 20 13.2 Vdc
CAUTION
Do not connect or disconnect the battery cable
or ammeter with the engine running. Damage will
occur to electrical components.
Current Draw - Key Off:
Maximum of .01 DCA (10 mA)
Current Draw Inspection
Key Off
30 Amp
CAUTION
Do not allow the battery cables to become
disconnected with the engine running. Follow the
steps below as outlined to reduce the chance of
damage to electrical components.
WARNING
Never start the engine with an ammeter
connected in series. Damage to the meter or
meter fuse will result.
Do not run test for extended period of time.
Do not run test with high amperage accessories.
10.22
ELECTRICAL
Charging System Alternator Tests
Three tests can be performed using a multi-meter to determine
the condition of the stator (alternator).
TEST 1: Resistance Value of Each Stator Leg
1. Measure the resistance value of each of the three stator
legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3.
Each test should measure: 0.19Ω ± 15%
NOTE: If there are any significant variations in ohm
readings between the three legs it is an indication
that one of the three stator legs maybe weak or
failed.
TEST 2: Resistance Value of Each Stator Leg to Ground
1. Measure the resistance value of each of the stator legs to
ground: Y1 to Ground, Y2 to Ground, Y3 to Ground.
Each test should measure: Open Line (OL)
NOTE: Any measurement other than Infinity (open)
will indicate a failed or shorted stator leg.
TEST 3: Measure AC Voltage Output of Each Stator Leg at
Charging RPM
1. Set the selector dial to measure AC Voltage.
2. Start the engine and let it idle.
3. While holding the engine at a specified RPM, separately
measure the voltage across each ‘leg’ of the stator by
connecting the meter leads to the wires leading from the
alternator (Y1 to Y2, Y1 to Y3, Y2 to Y3).
4. Refer to the following table for approximate AC Voltage
readings according to RPM. Test each leg at the specified
RPM in the table.
Example: The alternator current output reading should be
approximately 18 VAC at 1300 RPM between each ‘leg’.
NOTE: If one or more of the stator leg output AC
voltage varies significantly from the specified value,
the stator may need to be replaced.
Test Connect Meter
Leads To: Ohms Reading
Battery Charge Coil Y1 to Y2 0.19Ω ± 15%
Battery Charge Coil Y1 to Y3 0.19Ω ± 15%
Battery Charge Coil Y2 to Y3 0.19Ω ± 15%
Test Connect Meter
Leads To: Ohms Reading
Battery Charge Coil Y1, Y2, or Y3
to Ground Open Line
(Infinity)
Y1
Y2
Y3
RPM Reading AC Voltage (VAC) Reading
1300 18 VAC ± 25 %
3000 42 VAC ± 25 %
5000 64 VAC ± 25 %
10.23
ELECTRICAL
10
Charging System Testing Flow Chart
Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good
condition, connected and not exposed or pinched.:
Using a multitester set on D.C. volts, mea-
sure the battery open circuit voltage (See
earlier test). It should be 12.4 volts or more.
Is it?
Meter Setting: DC Volts
With the transmission in Park, start the
Meter Setting: DC Amps
Perform system “Break Even Amperage”
Meter Setting: DC Volts
Reconnect the alternator wires. Note: Red
wire must be connected to harness. Battery
voltage must be present on red wire terminal
on harness side of voltage regulator connector.
Is voltage present?
If all of the previous tests indicate a good
Yes
No
No
Yes
Yes
Remove the battery and properly ser-
vice. Reinstall the fully charged battery
or a fully charged shop battery.
No
Check Key off Current Draw.
Yes
Check for owner modification, and
discuss operating habits. The battery
will continually discharge if operated
below the “Break Even” RPM. Con-
tinued problems would call for battery
inspection.
Yes
Inspect the wiring harness between
the panel and the stator for
remove the recoil and flywheel.
Inspect the flywheel magnets, stator
coils and stator wires for damage.
No
Check stator, regulator, ground, battery
and battery connections. Also check
wire connections and wire condition.
Repair or replace faulty wiring or
No
engine and increase RPM to between 3000
test outlined in this chapter.
Does charging occur as specified?
Ohm stator wires, if bad replace stator, if good,
continue with alternator output test.
Meter Setting: AC Volts
Disconnect the Yellow wires from the regulator /
rectifier. Using a multitester, perform an Alternator
Output test. See test procedure on Page 10.22.
damage. If no damage is found,
Repair or replace any damaged
components.
components.
and 4000. Read battery voltage with the
multitester. Readings should increase to
between 13.0 and 14.6 V D.C.Are they?
Does output meet specification?
condition, but the charging voltage does not
rise above battery voltage at the connector
or wire harness, replace the voltage regulator.
10.24
ELECTRICAL
BATTERY SERVICE
Battery Identification
IMPORTANT: Identify what type of battery you have
installed in your vehicle. Different types of batteries
require different service procedures. Proper servicing
and upkeep of your battery is very important for
maintaining long battery life.
Your vehicle may have a Conventional Battery or a Sealed Low
Maintenance Battery. To identify which type of battery your
vehicle has, refer to the illustration below and follow the correct
service and charging procedures that follow in the manual.
CONVENTIONAL BATTERY
Battery Activation
To ensure maximum service life and performance from a new
battery, perform the following steps. NOTE: Do not service the
battery unless it will be put into regular service within 30 days.
After initial service, add only distilled water to the battery.
Never add electrolyte after a battery has been in service.
NOTE: New Battery: Battery must be fully charged
before use or battery life will be significantly
reduced 10-30% of the battery’s full potential.
To activate a new battery:
1. Remove vent plug from vent fitting. Remove cell caps.
2. Fill battery with electrolyte to upper level marks on case.
3. Set battery aside to allow for acid absorption and
stabilization for 30 minutes.
CONVENTIONAL BATTERY
Top View
Electrolyte Level
Side View
SEALED
LOW MAINTENANCE BATTERY
No Caps
(Non-removable
sealed Top)
Top View
Side View
Polaris Sticker
Removable
Caps
Indicator
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.
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
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.
WARNING
The gases given off by a battery are explosive.
Any spark or open flame near a battery can
cause an explosion which will spray battery acid
on anyone close to it. Should there be contact
with battery acid, wash the affected area with
large quantities of cool water and seek
immediate medical attention.
10.25
ELECTRICAL
10
4. Add electrolyte to bring level back to upper level mark on
case.
NOTE: This is the last time that electrolyte should
be added. If the level becomes low after this point,
add only distilled water.
5. Charge battery at 1/10 of its amp/hour rating. Examples: 1/
10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4
amp; 1/10 of 18 amp battery = 1.8 amp (recommended
charging rates).
6. Check specific gravity of each cell with a hydrometer to
assure each has a reading of 1.270 or higher.
Battery Inspection
Remove the driver’s seat to access the battery.
Inspect the battery fluid level. When the battery fluid nears the
lower level, remove the battery and fill with distilled water only
to the upper level line.
Battery Removal
1. Remove the battery holder strap.
2. Disconnect battery negative (-) (black) cable first, followed
by the positive (+) (red) cable.
3. Remove the battery.
4. Remove the filler caps and add distilled water as needed to
bring each cell to the proper level. Do not overfill.
Refill using only distilled water. Tap water contains
minerals which are harmful to a battery.
Do not allow cleaning solution or tap water inside the
battery. Battery life may be reduced.
5. Reinstall the battery caps.
Battery Installation
1. Clean battery cables and terminals with a stiff wire brush.
Corrosion can be removed using a solution of one cup
water and one tablespoon baking soda. Rinse well with
clean water and dry thoroughly.
2. Route the cables correctly and reinstall battery, attaching
positive (+) (red) cable first and then the negative (-) (black)
cable. Coat terminals and bolt threads with Nyogel™
Grease (PN 2871329).
3. Install clear battery vent tube from vehicle to battery vent.
WARNING: Vent tube must be free from obstructions and
kinks and securely installed. If not, battery gases could
accumulate and cause an explosion. The vent tube should
be routed away from frame and body to prevent contact
with electrolyte. Avoid skin contact with electrolyte, as
severe burns could result. If electrolyte contacts the vehicle
frame, corrosion will occur.
4. Reinstall the holder strap.
Conventional Battery Testing
Whenever a service complaint is related to either the starting or
charging systems, the battery should be checked first.
Following are three tests which can easily be made on a battery
to determine its condition: OCV Test, Specific Gravity Test and
Load Test.
Maintain
between upper
and lower level
marks
CAUTION
Whenever removing or reinstalling the battery,
disconnect the negative (black) cable first and
reinstall the negative cable last!
10.26
ELECTRICAL
OCV - Open Circuit Voltage Test
Battery voltage should be checked with a digital multitester.
Readings of 12.6 volts or less require further battery testing and
charging. See the following charts and Load Test.
NOTE: Lead-acid batteries should be kept at or near
a full charge as possible. Electrolyte level should be
kept between the low and full marks. If the battery is
stored or used in a partially charged condition, or
with low electrolyte levels, hard crystal sulfation will
form on the plates, reducing the efficiency and
service life of the battery.
Specific Gravity Test
A tool such as a Battery Hydrometer (PN 2870836) can be used
to measure electrolyte strength or specific gravity. As the battery
goes through the charge/discharge cycle, the electrolyte goes
from a heavy (more acidic) state at full charge to a light (more
water) state when discharged. The hydrometer can measure
state of charge and differences between cells in a multi-cell
battery. Readings of 1.270 or greater should be observed in a
fully charged battery. Differences of more than .025 between the
lowest and highest cell readings indicate a need to replace the
battery.
Load Test
NOTE: This test can only be performed on machines
with electric starters. This test cannot be performed
with an engine or starting system that is not working
properly.
A battery may indicate a full charge condition in the OCV test
and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system.
For this reason, a battery capacity or load test should be
conducted whenever poor battery performance is encountered.
To perform this test, hook a multitester to the battery in the same
manner as was done in the OCV test. The reading should be 12.6
volts or greater. Engage the starter and observe the battery
voltage while cranking the engine. Continue the test for 15
seconds. During cranking the observed voltage should not drop
below 9.5 volts. If the beginning voltage is 12.6 volts or higher
and the cranking voltage drops below 9.5 volts during the test,
replace the battery.
OPEN CIRCUIT VOLTAGE
State of Charge Conventional
Lead-Acid YuMicron™ Type
100% Charged 12.60 V 12.70 V
75% Charged 12.40 V 12.50 V
50% Charged 12.10 V 12.20 V
25% Charged 11.90 V 12.0 V
0% Charged less than
11.80 V less than
11.9 V
1.10
1.15
1.20
1.25
1.30
Detail A
Battery Hydrometer (PN 2870836)
SPECIFIC GRAVITY
State of Charge* Conventional
Lead-Acid YuMicron™ Type
100% Charged 1.265 1.275
75% Charged 1.210 1.225
50% Charged 1.160 1.175
25% Charged 1.120 1.135
0% Charged less than 1.100 less than 1.115
* At 80° F
NOTE: Subtract .01 from the specific gravity reading at 40° F.
CAUTION
To prevent shock or component damage,
remove spark plug high tension leads and
connect securely to engine ground
before proceeding.
10.27
ELECTRICAL
10
Off Season Storage
To prevent battery damage during extended periods of non-use,
the following basic battery maintenance items must be
performed:
• Remove the battery from the vehicle and wash the case
and battery tray with a mild solution of baking soda and
water. Rinse thoroughly with fresh water after cleaning.
NOTE: Do not get any of the baking soda into the
battery or the acid will be neutralized.
• Using a wire brush, remove any corrosion from the
cables and terminals.
• Make sure that the electrolyte is at the proper level. Add
distilled water if necessary.
• Charge at a rate no greater than 1/10 of the battery’s
amp/hr capacity until the electrolyte’s specific gravity
reaches 1.270 or greater.
• Store the battery either in the machine with the cables
disconnected, or store in a cool place.
NOTE: Recharge to full capacity every 30 to 60 days
during a non-use period. If the battery is stored
during the winter months, electrolyte will freeze at
higher temperatures as the battery discharges. The
chart below indicates freezing points by specific
gravity.
Charging Procedure (Conventional)
1. Remove the battery to prevent damage from leaking or
spilled acid during charging.
2. Charge the battery with a charging output no larger than
1/10 of the battery’s amp/hr rating. Charge as needed to
raise the specific gravity to 1.270 or greater.
3. Install battery in vehicle with positive terminal toward the
front. Coat threads of battery bolt with a corrosion resistant
dielectric grease.
4. Connect battery cables.
5. After connecting the battery cables, install the cover on the
battery and attach the hold down strap.
6. Install clear battery vent tube from vehicle to battery vent.
WARNING: Vent tube must be free from obstructions and
kinks and securely installed. If not, battery gases could
accumulate and cause an explosion. Vent should be routed
away from frame and body to prevent contact with
electrolyte. Avoid skin contact with electrolyte, as severe
burns could result. If electrolyte contacts the vehicle frame,
corrosion will occur.
7. Route cables so they are tucked away in front and behind
battery.
Electrolyte Freezing Points
Specific Gravity
of Electrolyte Freezing Point
1.265 -75° F
1.225 -35° F
1.200 -17° F
1.150 +5° F
1.100 +18° F
1.050 +27° F
Dielectric Grease
(PN 2871329)
WARNING
To avoid the possibility of explosion, connect
positive (+) cable first and negative (-) cable last.
10.28
ELECTRICAL
LOW MAINTENANCE BATTERY
General Battery Information
NOTE: All Low Maintenance batteries are fully
charged and tested at the factory before installation.
Expected shelf life varies upon storage conditions.
As a general rule before placing the battery into
service, check the battery condition and charge
accordingly.
1. Check the date label on the side of the battery to calculate
when to check voltage. The battery should be checked
every 3 months.
2. Check the voltage with a voltmeter or multimeter. A fully
charged battery should be 12.8 V or higher.
3. If the voltage is below 12.8 V, the battery will need to be
recharged.
Low Maintenance batteries are permanently sealed at the time of
manufacture. The use of lead-calcium and AGM technology
instead of lead-antimony allows the battery acid to be fully
absorbed. For this reason, a Low Maintenance battery case is
dark and the cell caps are not removable, since there is no need
to check electrolyte level.
NOTE: New Batteries: 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.
NEVER attempt to add electrolyte or water to a Low
Maintenance battery. Doing so will damage the case and shorten
the life of the battery.
To service a Low Maintenance battery:
1. Remove battery from the vehicle.
2. Test battery with a voltage meter or load tester to determine
battery condition. This will determine the length of time
required to charge the battery to full capacity. Refer to
capacity table.
3. Charge battery using a variable rate charger.
Battery Removal
1. Remove the driver’s seat to access the battery and remove
battery holder strap.
2. Disconnect battery negative (-) (black) cable first, followed
by the positive (+) (red) cable.
3. Remove the battery.
Battery Installation
1. Clean battery cables and terminals with a stiff wire brush.
Corrosion can be removed using a solution of one cup
water and one tablespoon baking soda. Rinse well with
clean water and dry thoroughly.
2. Route the cables correctly and reinstall battery, attaching
positive (+) (red) cable first and then the negative (-) (black)
cable. Coat terminals and bolt threads with Nyogel™
Grease (PN 2871329).
3. Reinstall the holder strap.
CAUTION
Whenever removing or reinstalling the battery,
disconnect the negative (black) cable first and
reinstall the negative cable last!
10.29
ELECTRICAL
10
Battery Testing
Whenever a service complaint is related to either the starting or
charging systems, the battery should be checked first.
Following are two tests which can easily be made on a Sealed
Low Maintenance battery to determine its condition: OCV Test
and a Load Test.
OCV - Open Circuit Voltage Test
Battery voltage should be checked with a digital multitester.
Readings of 12.8 volts or less require further battery testing and
charging. See charts and Load Test.
NOTE: Lead-acid batteries should be kept at or near
a full charge as possible. If the battery is stored or
used in a partially charged condition, or with low
electrolyte levels, hard crystal sulfation will form on
the plates, reducing the efficiency and service life of
the battery.
NOTE: Use a voltmeter or multimeter to test batter
voltage.
Load Test
NOTE: This test can only be performed on machines
with electric starters. This test cannot be performed
with an engine or starting system that is not working
properly.
A battery may indicate a full charge condition in the OCV test
and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system.
For this reason, a battery capacity or load test should be
conducted whenever poor battery performance is encountered.
To perform this test, hook a multitester to the battery in the same
manner as was done in the OCV test. The reading should be 12.6
volts or greater. Engage the starter and observe the battery
voltage while cranking the engine. Continue the test for 15
seconds. During cranking the observed voltage should not drop
below 9.5 volts. If the beginning voltage is 12.6 volts or higher
and the cranking voltage drops below 9.5 volts during the test,
replace the battery.
Off-Season Storage
To prevent battery damage during extended periods of non-use,
the following basic battery maintenance items must be
performed:
• Remove the battery from the machine and wash the
case and battery tray with a mild solution of baking
soda and water. Rinse thoroughly with fresh water after
cleaning.
• Using a wire brush, remove any corrosion from the
cables and terminals.
• Charge at a rate no greater than 1/10 of the battery’s
amp/hr capacity.
• Store the battery either in the machine with the cables
disconnected, or store in a cool place.
NOTE: Stored batteries lose their charge at the rate
of 1% per day. Recharge to full capacity every 30 to
60 days during a non-use period. If the battery is
stored during the winter months, electrolyte will
freeze at higher temperatures as the battery
discharges.
OPEN CIRCUIT VOLTAGE
State of Charge Maintenance
Free YuMicron™ Type
100% 13.0 V 12.70 V
75% Charged 12.80 V 12.50 V
50% Charged 12.50 V 12.20 V
25% Charged 12.20 V 12.0 V
0% Charged less than 12.0 V less than 11.9 V
* At 80° F
NOTE: Subtract .01 from the specific gravity reading at 40° F.
CAUTION
To prevent shock or component damage,
remove spark plug high tension leads and
connect securely to engine ground
before proceeding.
10.30
ELECTRICAL
Charging Procedure (Low Maintenance)
If battery voltage is 12.8 V or less, the battery may need
recharging. When using an automatic charger, refer to the
charger manufacturer’s instructions for recharging. When using
a constant current charger, use the following guidelines for
recharging.
NOTE: Always verify battery condition before and
1-2 hours after the end of charging.
Battery Charging Reference Table
STARTING SYSTEM
Troubleshooting
Starter Motor Does Not Run
• Battery discharged - Low specific gravity
• Loose or faulty battery cables or corroded connections
(see Voltage Drop Tests)
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter motor
or starter solenoid (see Voltage Drop Tests)
• Faulty key switch
• Faulty kill switch
• Faulty Start Diode. Use a digital multi-meter to test
diode operation. Unplug the diode from the harness
under the dash and measure between the Orange and
Orange/Green diode connections. Continuity should
flow one direction only.
• Faulty starter solenoid or starter motor
• Engine problem - seized or binding (can engine be
rotated easily)
Starter Motor Turns Over Slowly
• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections (see
Voltage Drop Test)
• Engine problem - seized or binding (can engine be
rotated easily)
• Faulty or worn brushes in starter motor
Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel
WARNING
An overheated battery could explode, causing
severe injury or death. Always watch charging
times carefully. Stop charging if the battery
becomes very warm to the touch.
Allow it to cool before resuming charging.
State of
Charge Voltage Action Charge Time
100% 12.8-13 V
None, check
voltage at 3 mos.
after manufacture
date
None Required
75-100% 12.5-12.8 V May need slight
charge 3-6 hours
50-75% 12.0-12.5 V Needs Charge 5-11 hours
25-50% 11.5-12.0 V Needs Charge At least 13
hours, verify
state of charge
0-25% 11.5 V or less Needs Charge At least 20 hours
WARNING
To avoid the possibility of sparks and explosion,
connect positive (red) cable first and negative
(black) cable last.
10.31
ELECTRICAL
10
Voltage Drop Test
The Voltage Drop Test is used to test for bad connections. When
performing the test, you are testing the amount of voltage drop
through the connection. A poor or corroded connection will
appear as a high voltage reading. Voltage shown on the meter
when testing connections should not exceed .1 VDC per
connection or component.
To perform the test, place the meter on DC volts and place the
meter leads across the connection to be tested. Refer to the
voltage drop tests on the starter system in this chapter.
Starter Motor Removal / Disassembly
NOTE: Use electrical contact cleaner to clean starter
motor parts. Some solvents may leave a residue or
damage internal parts and insulation.
1. Remove the starter from the engine.
2. Remove the two bolts, washers, and sealing O-Rings.
Inspect O-Rings and replace if damaged.
NOTE: Note the alignment marks on both ends of
the starter motor casing. These marks must align
during reassembly.
3. Remove the front bracket assembly and the rear bracket
assembly. Remove the shims from the armature shaft and
inspect the O-rings located on the armature housing.
NOTE: The shims will be replaced during
reassembly.
Brush Inspection / Replacement
1. Measure resistance between starter input terminal and
insulated brushes. The reading should be .3 ohms or less.
Remember to subtract meter lead resistance.
Voltage should not exceed
.1 DC volts per connection
O-Rings
Shims
10.32
ELECTRICAL
2. Measure resistance between insulated brush and starter
housing. Reading should be infinite (OL). Inspect
insulation on brush wires for damage and repair or replace
as necessary.
3. Slide positive brush springs to the side, pull brushes out of
their guides and remove brush plate. Slide brush end frame
off end of starter.
NOTE: The electrical input post must stay with the
field coil housing.
4. Measure resistance between ground brush and brush plate.
Resistance should be .3 ohms or less.
Brush Inspection
1. Measure length of each carbon brush. Replace brush
assembly when worn to 5/16” (8 mm) or less. The brushes
must slide freely in their holders.
Brush Replacement
1. Remove terminal nut with lock washer, flat washer, large
phenolic washer, the small phenolic spacers, and sealing
O-ring. Inspect O-ring and replace if damaged.
2. Slide positive brush springs to the side, pull brushes out of
their guides and remove brush plate.
Armature Testing
1. Remove armature from starter casing. Note order of shims
on drive end for reassembly.
2. Inspect surface of commutator. Replace if excessively
worn or damaged.
3. Using a digital multitester, measure the resistance between
each of the commutator segments. The reading should be
.3 ohms or less.
Limit 5/16” (8 mm)
Brush Length
CAUTION
Some cleaning solvents may damage the
insulation in the starter. Care should be
exercised when selecting an appropriate
solvent. If the commutator needs cleaning use
only electrical contact cleaner.
10.33
ELECTRICAL
10
4. Measure the resistance between each commutator segment
and the armature shaft. The reading should be infinite (no
continuity).
5. Check commutator bars for discoloration. Bars discolored
in pairs indicate shorted coils, requiring replacement of the
starter motor.
6. Place armature in a growler. Turn growler on and position
a hacksaw blade or feeler gauge lengthwise 1/8” (.3 cm)
above armature coil laminates. Rotate armature 360°. If
hacksaw blade is drawn to armature on any pole, the
armature is shorted and must be replaced.
Starter Reassembly / Installation
1. Install brush plate to field magnet housing aligning index
tab.
2. Install O-ring, two small phenolic spacers, large phenolic
washer, flat washer, lock washer, and terminal nut.
3. While holding brush springs away from brushes, push
brushes back and hold in place.
4. Slide armature into field magnet housing. Release brushes.
5. Lightly grease the drive roller bearing and reinstall drive
end frame on armature. Inspect seal for wear or damage.
Replace drive end cap if necessary.
6. Be sure wire insulation is in place around positive brush
wire and pushed completely into slot on phenolic plate.
7. Using Dielectric Grease (PN 2871329), lubricate brush end
bushing and install shims.
8. Align brush plate and install cover and screws.
9. Lightly grease pinion shaft and install pinion, spring
stopper, and snap ring.
10. Completely assemble starter motor and torque set bolts to
35 - 52 in. lbs. (3.9 - 5.9 Nm).
11. Install the starter onto the engine case. Hand tighten each
of the starter bolts. Torque the bottom bolt first to 9 ft.lbs.
(12 Nm). Then torque the top bolt to the same specification.
CAUTION
Use care when handling starter housing. Do not
drop or strike the housing as magnet damage is
possible. If magnets are damaged, starter must be
replaced.
Roller Bearing
Seal
Set Bolt Torque: 35-52 in. lbs. (3.9-5.9 Nm)
10.34
ELECTRICAL
NOTE: It is important to tighten the bottom starter
bolt first (circle), as the bottom hole acts as a pilot
hole to properly align the starter drive (bendix) with
the flywheel. This helps to prevent binding and
starter damage.
Starter Drive
If the garter spring is damaged, the overrun clutch may fail to
return properly. Use either of the following methods to remove
and install a new garter spring:
1. Screw the overrun clutch out to the engaged position on the
pinion shaft assembly. Use a small piece of wire with the
end bent in a hook and pick the old spring out of its
channel. Slide it off the end of the shaft. Slide the new
spring over the overrun clutch and into the spring groove.
Make sure the spring is positioned between the shoe
alignment pins and the back flange of the anti kick-out
shoes.
2. Remove the retaining ring, thrust washer, spring retainers
and clutch return spring. Screw the overrun clutch off the
end of the pinion shaft. Remove the old spring and install
a new one. Lightly grease the pinion shaft and reinstall the
clutch, spring, retainers, end washer and lock ring in the
reverse order. Make sure the end washer is positioned
properly so that it will hold the lock ring in its groove.
Starter Solenoid Bench Test
Test the start solenoid by powering the solenoid via the 2-wire
connection. With the solenoid energized, resistance should read
about 0.5Ω ± 10% between terminal (A) and (B). If resistance
measurement is out of specification, replace the starter solenoid.
Starter Solenoid Operation
To energize the Starter Solenoid the following must occur:
• The brake must be applied to provide a ground path via
the Orange / Green wire.
• The key switch must be turned to the “start” position to
provide 12V power via the White / Red wire.
• Once the pull-in coil is energized, the solenoid provides
a current path for 12V power to reach the starter motor.
A. Gear Assembly
B. Thrust Washer
C. Busing
D. Retaining Ring
E. Thrust Washer
F. Stopper
G. Cover
H. Spring
A
B
C
D
E
F
G
H
AB
Energize
Here
10.35
ELECTRICAL
10
Starter Exploded View
1. Rubber Ring*
2. Brush Spring
3. Thrust Washer
4. Gear Assembly
5. O-Ring*
6. Brush Complete
7. O-Ring*
8. Thrust Washer
9. Shaft Complete
10. Gear Assembly
11. Through Bolt
12. Cover
13. Stopper
14. Snap Ring
15. Washer
16. Flange Bolt
17. Thrust Washer
18. Flange Bushing
* Indicates - Do not reuse.
Replace with new parts.
10.36
ELECTRICAL
STARTING SYSTEM TESTING FLOW CHART
Condition: Starter fails to turn over the engine.
With the tester on the VDC position, place the
tester's black lead on the battery negative and the
red lead on the battery positive. Reading should
be 12.4 V D. C. or greater.
Remove battery and properly service. Install
fully charged shop battery to continue test.
Disconnect 2-wire connector at the solenoid.
Using a multi-meter, connect the black meter lead
to the Orange/Green harness wire and the red
meter lead to the White/Red harness wire. Apply
the brake and turn ignition switch to the “start”
position. Meter should read battery voltage.
Check for voltage at the chassis 20 Amp fuse
and then check for voltage entering the
ignition switch. Battery voltage should be
present. If battery voltage is present at the
ignition switch, but not the solenoid, replace
the switch. NOTE: The brake MUST be
applied when performing these tests.
Test the start solenoid by powering the solenoid via the 2-wire connection.
With the solenoid energized, resistance should read about 0.5Ω ± 10%
between the two terminals. If resistance measurement is out of specification,
replace the starter solenoid (see “Starter Solenoid Bench Test”)
Reconnect the solenoid. Connect the tester black lead
to the battery positive and the red lead to the solenoid
end of the battery-to-solenoid wire. Turn the ignition
key to the “start” position. Reading should be less
than .1 V D.C.
Clean the battery-to-solenoid cable ends
or replace the cable.
Connect the black tester lead to solenoid end of
battery-to-solenoid cable. Connect red tester lead
to solenoid end of solenoid-to-starter cable. Turn
the ignition key to the “start” position. Reading
should be less than .1 V D.C.
Replace the starter solenoid.
Connect the black tester lead to the solenoid end of
the solenoid-to-starter cable. Connect the red
tester lead to the starter end of the same cable.
Turn the ignition key to the “start” position. The
reading should be less than .1 V D.C.
Clean the solenoid-to-starter cable ends or
replace the cable.
If all of these indicate a good condition, yet the starter still fails to
turn, the starter must be removed for static testing and inspection.
Yes
Yes
Yes
Yes
No
No
No
Yes
No
No
Voltage Drop
Testing
10.37
ELECTRICAL
10
ELECTRICAL BREAKOUT DIAGRAMS
12V Key-On Power Circuit
Starting System Circuit
10.38
ELECTRICAL
Instrument Cluster Circuit
Transmission Switch Circuit
10.39
ELECTRICAL
10
Wheel Speed Sensor Circuit
AWD Circuit
10.40
ELECTRICAL
Fuel Gauge Display Circuit
Cooling Fan Circuit
10.41
ELECTRICAL
10
Charging System Circuit
IX.1
IX
A
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
All Wheel Drive (AWD) Coil . . . . . . . . . . . . . . . . . . . 10.14
AWD Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
AWD, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
AWD, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
B
Balance Shaft Gear, Removal . . . . . . . . . . . . . . . . . . . . . 3.42
Ball Joint Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Battery, Conventional . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
Battery, Sealed Low Maintenance . . . . . . . . . . . . . . . . 10.28
Body Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Brake Burnishing . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8, 9.15
Brake Caliper Assembly, Front . . . . . . . . . . . . . . . 9.9, 9.11
Brake Caliper Assembly, Rear . . . . . . . . . . . . . . . . . . . . 9.16
Brake Caliper Inspection, Front . . . . . . . . . . . . . . . . . . . 9.11
Brake Caliper Installation, Front . . . . . . . . . . . . . . . . . . 9.12
Brake Caliper Removal, Front . . . . . . . . . . . . . . . . . . . . . 9.9
Brake Disc, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Brake Disc, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
Brake Front Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . 9.8
Brake Hose and Fitting Inspection . . . . . . . . . . . . . . . . . 2.30
Brake Pad Assembly, Front . . . . . . . . . . . . . . . . . . . . . . . 9.8
Brake Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Brake Pad Thickness, Front . . . . . . . . . . . . . . . . . . . . . . . 9.7
Brake Pad, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
Brake Pads, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Brake Pads, Removal, Front . . . . . . . . . . . . . . . . . . . . . . . 9.7
Brake Pedal, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Brake Pedal, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Brake System Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Brake System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
Brake System, Exploded View . . . . . . . . . . . . . . . . . . . . . 9.4
Brake System, Operation . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Break-In, PVT System (Belt) . . . . . . . . . . . . . . . . . . . . . . 6.3
Breather Hose Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.16
C
Cab Frame, Assembly / Removal . . . . . . . . . . . . . . . . . . . 5.3
Caliper, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
Caliper, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
Cam Gear, Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
Cam Gear, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
Cargo Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Centralized Hilliard, Exploded View . . . . . . . . . . . . . . . 7.12
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
Charging System, Alternator Tests . . . . . . . . . . . . . . . . 10.22
Chassis / Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.20
Clock, Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
Console and Floor Panel Removal . . . . . . . . . . . . . . . . .5.13
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7
Coolant Level Inspection . . . . . . . . . . . . . . . . . . . . . . . .2.21
Coolant Strength and Type . . . . . . . . . . . . . . . . . . . . . . .2.21
Cooling System Bleeding Procedure . . . . . . . . . . . . . . . .3.14
Cooling System Hoses . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
Cooling System Specifications . . . . . . . . . . . . . . . . . . . .3.12
Cooling System, Pressure Test . . . . . . . . . . . . . . . . . . . .3.12
Crankshaft Gear, Removal . . . . . . . . . . . . . . . . . . . . . . .3.42
Crankshaft Position Sensor (CPS) . . . . . . . . . . . . . . . . . .4.13
CV Shaft Boot Inspection . . . . . . . . . . . . . . . . . . . . . . . .2.24
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . .3.31
Cylinder Head Assembly Exploded View . . . . . . . . . . .3.24
Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . .3.27
Cylinder Honing To De-glaze . . . . . . . . . . . . . . . . . . . . .3.35
Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34
D
Dash Instruments / Controls . . . . . . . . . . . . . . . . . . . . . . .5.4
Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . .1.9
Diagnostic Codes, Instrument Cluster . . . . . . . . . . . . . . .10.8
Diagnostics, AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7
Diagnostics, Gear Circuit . . . . . . . . . . . . . . . . . . . . . . . .10.7
Drive Belt, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8
Drive Belt, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8
Drive Belt, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7
Drive Clutch, Assembly . . . . . . . . . . . . . . . . . . . . . . . . .6.18
Drive Clutch, Exploded View . . . . . . . . . . . . . . . . . . . . .6.11
Drive Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
Drive Clutch, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9
Drive Clutch, Shift Weights . . . . . . . . . . . . . . . . . . . . . .6.10
Drive Clutch, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9
Driven Clutch Service . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19
Driven Clutch, Exploded View . . . . . . . . . . . . . . . . . . . .6.26
Driven Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . .6.3
Driveshaft / CV Joint, Handling Tips . . . . . . . . . . . . . . . .7.7
E
EFI Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . .4.10
EFI Priming / Starting Procedure . . . . . . . . . . . . . . . . . .4.11
EFI System Breakout Diagrams . . . . . . . . . . . . . . . . . . .4.34
Electrical Breakout Diagrams . . . . . . . . . . . . . . . . . . . .10.37
Electrical, Cooling System Breakout Diagram . . . . . . .10.17
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . .4.11
Engine and Transmission Separation . . . . . . . . . . . . . . .3.23
Engine Assembly and Installation . . . . . . . . . . . . . . . . . .3.59
Engine Balance Shaft Removal . . . . . . . . . . . . . . . . . . . .3.46
Engine Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . .3.61
Engine Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . .3.46
Engine Camshaft Installation . . . . . . . . . . . . . . . . . . . . .3.48
Engine Coolant Temperature Sensor (ECT) . . . . . . . . . .4.30
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
IX.2
Engine Cooling System Troubleshooting . . . . . . . . . . . .3.63
Engine Crankcase Assembly . . . . . . . . . . . . . . . . . . . . . .3.47
Engine Crankshaft Gear Removal . . . . . . . . . . . . . . . . . .3.43
Engine Crankshaft Installation . . . . . . . . . . . . . . . . . . . .3.48
Engine Cylinder Head Assembly . . . . . . . . . . . . . 3.31, 3.56
Engine Cylinder Head Inspection . . . . . . . . . . . . . . . . . .3.26
Engine Cylinder Head Removal . . . . . . . . . . . . . . . . . . .3.25
Engine Cylinder Head Warp . . . . . . . . . . . . . . . . . . . . . .3.26
Engine Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . .3.35
Engine Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . .3.34
Engine Cylinder Installation . . . . . . . . . . . . . . . . . . . . . .3.49
Engine Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . .3.32
Engine Designation Number . . . . . . . . . . . . . . . . . . . . . . .1.2
Engine Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . .4.32
Engine Exploded Views . . . . . . . . . . . . . . .3.2, 3.3, 3.4, 3.6
Engine Fastener Torques . . . . . . . . . . . . . . . . . . . . . . . . . .3.7
Engine Flywheel / Stator Installation . . . . . . . . . . . . . . .3.56
Engine Flywheel / Stator Removal . . . . . . . . . . . . . . . . .3.38
Engine Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . .3.39
Engine Gear(s) Removal . . . . . . . . . . . . . . . . . . . . . . . . .3.39
Engine Gears, Installation . . . . . . . . . . . . . . . . . . . . . . . .3.51
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 3.15, 3.61
Engine Oil and Filter Change . . . . . . . . . . . . . . . . . . . . .2.15
Engine Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
Engine Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . .3.15
Engine Oil Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
Engine Oil Pump Installation . . . . . . . . . . . . . . . . . . . . .3.50
Engine Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . .3.43
Engine Piston Installation . . . . . . . . . . . . . . . . . . . . . . . .3.49
Engine Piston Removal, Inspection . . . . . . . . . . . . . . . .3.33
Engine Piston Ring Installed Gap . . . . . . . . . . . . . . . . . .3.37
Engine Piston to Cylinder Clearance . . . . . . . . . . . . . . .3.36
Engine Piston to Rod Clearance . . . . . . . . . . . . . . . . . . .3.36
Engine Pushrod Inspection . . . . . . . . . . . . . . . . . . . . . . .3.25
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17
Engine Rocker Arm Inspection . . . . . . . . . . . . . . . . . . . .3.25
Engine Serial Number Location . . . . . . . . . . . . . . . . . . . .1.2
Engine Service Specifications . . . . . . . . . . . . . . . . . . . . . .3.9
Engine Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
Engine Starter Drive Removal . . . . . . . . . . . . . . . . . . . .3.37
Engine Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . .3.39
Engine Stator Gear Cover Seal(s) Installation . . . . . . . .3.53
Engine Stator Installation . . . . . . . . . . . . . . . . . . . . . . . .3.56
Engine Temperature Sensor Replacement . . . . . . . . . . .4.30
Engine Temperature Sensor Test . . . . . . . . . . . . . . . . . .4.30
Engine Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8
Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .3.62
Engine Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . .3.28
Engine Valve Lifter Removal, Inspection . . . . . . . . . . . .3.32
Engine Valve Seal/Spring Service . . . . . . . . . . . . . . . . .3.26
Engine Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . .3.32
Engine Valve Seat Reconditioning . . . . . . . . . . . . . . . . .3.29
Engine, Accessible Components . . . . . . . . . . . . . . . . . . .3.15
Exhaust, Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . .2.16
F
Fan Control Circuit Bypass Test . . . . . . . . . . . . . . . . . 10.18
Fan Control Circuit Operation . . . . . . . . . . . . . . . . . . . 10.18
Floor / Rocker Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Flywheel / Stator Removal . . . . . . . . . . . . . . . . . . . . . . . 3.38
Flywheel, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
Front A-arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . 5.16
Front Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Front Body / Dash Removal . . . . . . . . . . . . . . . . . . . . . . 5.12
Front Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5, 5.11
Front Caliper, Piston Bore I.D. . . . . . . . . . . . . . . . . . . . 9.11
Front Driveshaft, CV Joint / Boot Replacement . . . . . . . 7.7
Front Driveshaft, Installation . . . . . . . . . . . . . . . . . . . . . . 7.8
Front Driveshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Front Fender Flair Removal . . . . . . . . . . . . . . . . . . . . . . 5.12
Front Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . 2.19
Front Gearcase, Assembly . . . . . . . . . . . . . . . . . . . . . . . 7.17
Front Gearcase, Backlash Adjustment . . . . . . . . . . . . . . 7.19
Front Gearcase, Centralized Hilliard . . . . . . . . . . . . . . . 7.12
Front Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.15
Front Gearcase, Installation . . . . . . . . . . . . . . . . . . . . . . 7.20
Front Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.15
Front Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Fuel Injection Troubleshooting . . . . . . . . . . . . . . . . . . . 4.33
Fuel Injection, Component Locations . . . . . . . . . . . . . . . 4.7
Fuel Injection, Exploded View . . . . . . . . . . . . . . . . . . . . 4.6
Fuel Injection, Service Notes . . . . . . . . . . . . . . . . . . . . . . 4.5
Fuel Injection, Special Tools . . . . . . . . . . . . . . . . . . . . . . 4.2
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Fuel Lines, Quick Connect . . . . . . . . . . . . . . . . . . . . . . . 4.10
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
Fuel Pump / Tank Assembly . . . . . . . . . . . . . . . . . . . . . 4.21
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . . . .4.21, 10.18
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Fuel Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
Fuel Tank, Exploded View . . . . . . . . . . . . . . . . . . . . . . . 4.9
Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
G
Gear / Stator Housing Seal Replacement . . . . . . . . . . . . 3.53
Gear Circuit Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Gear Position Indicator Switch Test . . . . . . . . . . . . . . 10.14
General Specifications, Brakes . . . . . . . . . . . . . . . . . . . . 9.2
Ground, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
H
Head Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
Hood / Front Body Work . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Hood Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
I
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
IX.3
IX
Ignition Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . 4.31
Ignition Coil Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
Indicator, Service Interval . . . . . . . . . . . . . . . . . . . . . . . 10.8
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
K
Keys, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Kilometers to Miles Toggle . . . . . . . . . . . . . . . . . . . . . . 10.8
L
Leakdown Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
M
Maintenance, Brake System . . . . . . . . . . . . . . . . . . . . . . 2.30
Maintenance, Cooling System . . . . . . . . . . . . . . . . . . . . 2.21
Maintenance, Electrical and Ignition . . . . . . . . . . . . . . . 2.25
Maintenance, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Maintenance, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . 2.23
Maintenance, Fuel System . . . . . . . . . . . . . . . . . . . . . . . 2.11
Maintenance, General Vehicle Inspection . . . . . . . . . . . 2.10
Maintenance, References . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
Maintenance, Service Products and Lubricants . . . . . . . . 2.8
Maintenance, Steering . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Maintenance, Transmission and Gearcases . . . . . . . . . . 2.17
Master Cylinder, Installation . . . . . . . . . . . . . . . . . . . . . . 9.5
Master Cylinder, Removal . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Miles to Kilometers Toggle . . . . . . . . . . . . . . . . . . . . . . 10.8
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
O
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Oil Pump Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
Oil Pump, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
Oil Pump, Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
Oil Pump, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
P
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Periodic Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . 2.3
Piston Ring Installed Gap . . . . . . . . . . . . . . . . . . . . . . . . 3.37
Piston to Cylinder Clearance . . . . . . . . . . . . . . . . . . . . . 3.36
Piston to Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
Pre-Ride / Daily Inspection . . . . . . . . . . . . . . . . . . . . . . 2.10
Programmable Service Interval . . . . . . . . . . . . . . . . . . . 10.8
Propshaft Removal / Installation . . . . . . . . . . . . . . . . . . 7.10
Propshaft, U-Joint Service . . . . . . . . . . . . . . . . . . . . . . . 7.10
Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PVT System, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
PVT System, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT System, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 6.3
PVT System, Overheating Diagnostics . . . . . . . . . . . . . . 6.4
PVT System, Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT System, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28
PVT, Button to Tower Clearance . . . . . . . . . . . . . . . . . . 6.13
PVT, Drive Clutch Disassembly . . . . . . . . . . . . . . . . . . 6.11
PVT, Drive Clutch Spider Removal . . . . . . . . . . . . . . . . 6.12
PVT, Driven Clutch Bushing Service . . . . . . . . . . . . . . . 6.21
PVT, Driven Clutch Disassembly . . . . . . . . . . . . . . . . . .6.19
PVT, Driven Clutch Reassembly . . . . . . . . . . . . . . . . . .6.23
PVT, EBS Drive Clutch Bushing Service . . . . . . . . . . . .6.16
PVT, EBS Drive Clutch Cover Bushing Remove/Install 6.17
PVT, Moveable Sheave Inspection . . . . . . . . . . . . . . . . .6.15
R
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
Radiator, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
Rear A-arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . .5.21
Rear Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.21
Rear Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5, 5.11
Rear Cargo Box / Fenders . . . . . . . . . . . . . . . . . . . . . . . . .5.9
Rear Driveshaft, CV Joint / Boot Replacement . . . . . . .7.25
Rear Driveshaft, Installation . . . . . . . . . . . . . . . . . . . . . .7.29
Rear Driveshaft, Plunging Joint / Boot Replacement . . .7.27
Rear Driveshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . .7.24
Rear Fender, Flair, and Tie Down Removal . . . . . . . . . .5.13
Rear Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.31
Rear Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . .2.20
Rear Gearcase, Assembly . . . . . . . . . . . . . . . . . . . . . . . .7.34
Rear Gearcase, Disassembly . . . . . . . . . . . . . . . . . . . . . .7.32
Rear Gearcase, Exploded View . . . . . . . . . . . . . . . . . . . .7.36
Rear Gearcase, Installation . . . . . . . . . . . . . . . . . . . . . . .7.35
Rear Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . . . . .7.31
Rear Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
Rear Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.19
Rocker Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
S
Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7
Seat Belts / Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
Service Interval Indicator . . . . . . . . . . . . . . . . . . . . . . . .10.8
Service Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6
Shift Cable Inspection and Adjustment . . . . . . . . . . . . . . .8.3
Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
Shift Lever, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
Shift Lever,Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
Shift Linkage Inspection and Adjustment . . . . . . . . . . . .2.10
Shocks and Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
Spark Plug Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
Special Tool, Cam Gear Installation Kit . . . . . . . . . . . . .3.41
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6
Special Tools, Body/Steering/Suspension . . . . . . . . . . . . .5.2
Special Tools, Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2
Special Tools, Clutching . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
Special Tools, Electrical . . . . . . . . . . . . . . . . . . . . . . . . .10.3
Special Tools, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11
Special Tools, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .7.2
Specification Chart, Maintenance . . . . . . . . . . . . . . . . . .2.17
Specification, Balance Shaft Gear Bolt Torque . . . . . . .3.52
Specification, Cam Lobe Height . . . . . . . . . . . . . . . . . . .3.46
Specification, Cam Thrust Plate Fastener Torque . . . . . .3.50
Specification, Camshaft Gear Bolt Torque . . . . . . . . . . .3.52
Specification, Coolant Sensor Resistance . . . . . . . . . . .10.18
IX.4
Specification, Cylinder Head Warp . . . . . . . . . . . . . . . . .3.26
Specification, Cylinder Taper Limit . . . . . . . . . . . . . . . .3.34
Specification, Cylinder Warp Limit . . . . . . . . . . . . . . . .3.34
Specification, Oil Pump Bolt Torque . . . . . . . . . . . . . . .3.51
Specification, Oil Pump Rotor Clearance . . . . . . . . . . . .3.43
Specification, Timing Gear Alignment . . . . . . . . . . . . . .3.39
Specification, Valve Seat Contact Width . . . . . . . . . . . .3.30
Specification, Valve Spring Free Length . . . . . . . . . . . .3.27
Specification, Valve Stem Diameter . . . . . . . . . . . . . . . .3.28
Specification, Valve Stem Guide I.D. . . . . . . . . . . . . . . .3.28
Specification, Wheel Toe-Out . . . . . . . . . . . . . . . . . . . . .2.28
Specifications, Cam Shaft . . . . . . . . . . . . . . . . . . . . . . . .3.46
Specifications, Cooling System . . . . . . . . . . . . . . . . . . . .3.12
Specifications, Crankcase Fastener Torque . . . . . . . . . . .3.48
Specifications, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2
Specifications, Engine Lubrication . . . . . . . . . . . . 3.15, 3.61
Specifications, Engine Oil Pressure . . . . . . . . . . . . . . . .3.15
Specifications, General . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4
Specifications, Oil Baffle Bolt Torque . . . . . . . . . . . . . .3.47
Specifications, Oil Pick-up Bolt Torque . . . . . . . . . . . . .3.47
Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.14
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5
Speedometer Installation . . . . . . . . . . . . . . . . . . . . . . . . .10.9
Speedometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
Speedometer Troubleshooting Tests . . . . . . . . . . . . . . .10.10
Starter Armature Testing . . . . . . . . . . . . . . . . . . . . . . . .10.32
Starter Assembly Exploded View . . . . . . . . . . . . . . . . .10.35
Starter Brush Inspection / Replacement . . . . . . . . . . . .10.31
Starter Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.34
Starter Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37
Starter Motor, Removal . . . . . . . . . . . . . . . . . . . . . . . . .10.31
Starter Reassembly / Installation . . . . . . . . . . . . . . . . . .10.33
Starter Solenoid, Test . . . . . . . . . . . . . . . . . . . . . . . . . .10.34
Starter System Flow Chart . . . . . . . . . . . . . . . . . . . . . .10.36
Starter System, Troubleshooting . . . . . . . . . . . . . . . . . .10.30
Stator, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38
Steering Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
Steering Wheel Freeplay . . . . . . . . . . . . . . . . . . . . . . . . .2.27
Steering, Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
Steering, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . .5.14
Steering, Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . . .2.29
Steering, Wheel Toe Alignment . . . . . . . . . . . . . . . . . . .2.28
Suspension, Spring Preload Adjustment . . . . . . . . . . . . .2.29
Sway Bar Linkage Removal . . . . . . . . . . . . . . . . . . . . . .5.19
Switch, AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
Switch, Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
Switch, Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
T
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
Tail Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.16
Tap/Drill Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9
Temperature / Barometric Air Pressure Sensor (T-BAP) 4.12
Throttle Freeplay Adjustment . . . . . . . . . . . . . . . . . . . . .2.12
Throttle Pedal Inspection . . . . . . . . . . . . . . . . . . . . . . . .2.12
Throttle Position Sensor (TPS) . . . . . . . . . . . . . . . . . . . .4.26
Throttle Position Sensor Initialization . . . . . . . . . . . . . . 4.28
Throttle Position Sensor Replacement . . . . . . . . . . . . . . 4.29
Timing Gear Mark Alignment . . . . . . . . . . . . . . . . . . . . 3.39
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
Toe Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Torque Specifications - Engine . . . . . . . . . . . . . . . . . . . . 3.8
Torque Specifications, Body/Steering/Suspension . . . . . 5.2
Torque Specifications, Brakes . . . . . . . . . . . . . . . . . . . . . 9.2
Torque Specifications, Clutching . . . . . . . . . . . . . . . . . . . 6.2
Torque Specifications, Final Drive . . . . . . . . . . . . . . . . . 7.2
Torque Specifications, Transmission . . . . . . . . . . . . . . . . 8.2
Torque Specifications, Wheel, Hub, and Spindle . . . . . 2.23
Transfer Case, Disassembly . . . . . . . . . . . . . . . . . . . . . . . 8.4
Transfer Case, Reassembly . . . . . . . . . . . . . . . . . . . . . . . 8.7
Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . . . 2.17
Transmission, Exploded View . . . . . . . . . . . . . . . . . . . . 8.20
Transmission, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
Transmission, Shift Housing Disassembly . . . . . . . . . . . 8.9
Transmission, Shift Housing Reassembly . . . . . . . . . . . 8.14
Trip Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Troubleshooting, Brake Noise . . . . . . . . . . . . . . . . . . . . . 9.3
Troubleshooting, Brake System . . . . . . . . . . . . . . . . . . . 9.20
Troubleshooting, Clutching . . . . . . . . . . . . . . . . . . . . . . 6.27
Troubleshooting, No AWD . . . . . . . . . . . . . . . . . . . . . 10.10
Troubleshooting, No AWD Hub Safety Limiter . . . . . 10.12
Troubleshooting, No Fuel Gauge Display . . . . . . . . . . 10.13
Troubleshooting, No Gear Indicator Display . . . . . . . . 10.13
Troubleshooting, No Instrument Display . . . . . . . . . . . 10.11
Troubleshooting, Transmission . . . . . . . . . . . . . . . . . . . 8.19
Troubleshooting, Vehicle Speed Sensor . . . . . . . . . . . 10.11
V
Valve Seal/Spring Service . . . . . . . . . . . . . . . . . . . . . . . 3.26
Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . . . . 3.29
Vent Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
VIN Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
W
Wheel Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Wheel, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
Wheel, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
11.1
WIRE DIAGRAM
2008 RANGER RZR
11.2
WIRE DIAGRAM
2008 RANGER RZR

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