Polaris 2009 RANGER 700 Service Manual
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Polaris 2009 RANGER 700 Service Manual

Polaris 2009 RANGER 700 Service Manual

4x4 crew / 6x6
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2009 RANGER 700
4X4 CREW / 6X6
SERVICE MANUAL
PN 9921885

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Summary of Contents for Polaris 2009 RANGER 700

  • Page 1 2009 RANGER 700 4X4 CREW / 6X6 SERVICE MANUAL PN 9921885...
  • Page 2 Publication Printed August 2008 (PN 9921885) © Copyright 2008 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.
  • Page 3 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.
  • Page 4 GENERAL INFORMATION MAINTENANCE ENGINE ELECTRONIC FUEL INJECTION BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...

  • Page 6: Table Of Contents

    GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION MODEL INFORMATION ..........1.2 MODEL IDENTIFICATION .

  • Page 7: Model Information

    GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification R 0 9 W H 6 8 A G Emissions & Model Year Model Option Designation Basic Chassis Engine Designation Designation...

  • Page 8: Vehicle Identification Number (Vin) Location

    GENERAL INFORMATION Vehicle Identification Number (VIN) Location Transmission I.D. Number Location The machine model number and serial number are important for The transmission I.D. number is located on the vehicle identification. The vehicle identification number (A) is right side when installed in the vehicle. stamped on the lower LH frame rail close to the front drive wheel.

  • Page 9: Vehicle Dimensions

    GENERAL INFORMATION VEHICLE DIMENSIONS RANGER 4x4 CREW / 6X6 (Height and Width) 75 in. 190.5 cm 11.5 in. 29.2 cm 60 in. 152.4 cm...

  • Page 10: Ranger 6X6 (Length And Wheel Base)

    GENERAL INFORMATION RANGER 6X6 (Length and Wheel Base) 120 in. 305 cm 42.5 in. 108 cm 27 in. 69 cm 90 in. 229 cm RANGER 4x4 CREW (Length and Wheel Base) 145 in. 386 cm 36.5 in. 92.7 cm 108 in. 274 cm...

  • Page 11: General Specifications

    GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2009 RANGER 4X4 CREW MODEL NUMBER: R09WH68AC, AG, AH, AR ENGINE MODEL: EH68OLE Category Dimension / Capacity Length 145 in. / 386 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 108 in.
  • Page 12 Polaris Full Synthetic AGL Transmission Oil Requirements Compression Ratio 9.40:1 43.6 oz. (1290 ml) Compression Pressure 150-170 psi Polaris ATV Angle Drive Fluid Rear Gearcase Oil Requirements 18 oz. (532 ml) Engine Idle Speed 1150 ± 100 RPM Belt 3211118...
  • Page 13 GENERAL INFORMATION MODEL: 2009 RANGER 6X6 MODEL NUMBER: R09RF68AF, AR ENGINE MODEL: EH068OLE Category Dimension / Capacity Length 120 in. / 305 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 90 in. / 229 cm Ground Clearance 7.2 in.
  • Page 14 Transmission Oil Requirements Compression Ratio 9.40:1 43.6 oz. (1290 ml) Compression Pressure 150-170 psi Polaris ATV Angle Drive Fluid Mid Gearcase Oil Requirements 6.75 oz. (200 ml) Engine Idle Speed 1150 ± 100 RPM Polaris ATV Angle Drive Fluid Lubrication...

  • Page 15: General: 2009 Ranger 4X4 Crew

    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.

  • Page 16: Misc. Specifications And Charts

    GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C 1.11...

  • Page 17: Standard Torque Specifications

    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. 1.12...

  • Page 18: Sae Tap / Drill Sizes

    GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes 1.13...

  • Page 19: Glossary Of Terms

    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.
  • Page 20 SERVICE PRODUCTS AND LUBES......... 2.7 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS ... . 2.7 MAINTENANCE REFERENCES .
  • Page 21 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM ........2.26 BATTERY MAINTENANCE .

  • Page 22: Periodic Maintenance Chart

    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.

  • Page 23: Pre-Ride - 25 Hour Maintenance Interval

    Engine Oil Change 25 H Perform a break-in oil change at one month (Break-In Period) 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.

  • Page 24: 50 - 100 Hour Maintenance Interval

    Engine Oil Change 100 H one month Oil Filter Change 100 H Replace with oil change 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.
  • Page 25 300 H Clean out Auxiliary Brake Inspect daily; adjust as needed Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.

  • Page 26: Transmission

    MAINTENANCE SERVICE PRODUCTS AND LUBES Polaris Lubricants, Maintenance and Service NOTE: Each item can be purchased separately at your local Polaris dealer. Products Part No. Description Part No. Description Additives / Sealants / Thread Locking Agents / Misc. Engine Lubricant 2870585 Loctite™...

  • Page 27: Brakes

    Premium Demand Drive Fluid Drain completely. Add 4. Front Gearcase Change annually*** (PN 2871654) lube to specified quantity. Polaris ATV Angle Drive Fluid Drain completely. Add 5. Middle Gearcase Semi-annually** (PN 2871653) lube to specified quantity. * More often under severe use, such as operated in water or under severe loads.

  • Page 28: Maintenance References, Continued

    **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) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special Yoke 8.

  • Page 29: General Vehicle Inspection And Maintenance

    MAINTENANCE GENERAL VEHICLE INSPECTION Shift Linkage Inspection / Adjustment AND MAINTENANCE Linkage rod adjustment is necessary when symptoms include: • No All Wheel Drive light Pre-Ride / Daily Inspection • Noise on deceleration Perform the following pre-ride inspection daily, and when •...

  • Page 30: Fuel System And Air Intake

    MAINTENANCE Fuel Filter Use this procedure to loosen or tighten the shift linkage cable as needed. The fuel pump on the RANGER 700 EFI is non-serviceable. If Clockwise Inside Jam Nut the internal fuel pump filters require service, the fuel tank and fuel pump must be replaced as an assembly.

  • Page 31: Throttle Freeplay Adjustment

    MAINTENANCE Throttle Freeplay Adjustment Air Filter Service Inspection It is recommended that the air filter be replaced annually. When riding in extremely dusty conditions replacement will be Apply the parking brake. required more often. Put the gear shift lever in the N (Neutral) position. The filter should be inspected periodically before each ride, using the following procedure.

  • Page 32: Air Intake Inspection

    MAINTENANCE Air Intake Inspection NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before Lift the hood. installing. Inspect the foam insert in the engine intake air baffle box. Check air box. If oil or water deposits are found, drain them If the foam insert is dirty, clean the foam with a high flash into a suitable container.

  • Page 33: Engine

    MAINTENANCE ENGINE Engine Oil Level The twin cylinder engine is a wet-sump engine, meaning the oil Compression and Leakdown Test is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below. NOTE: This engine does NOT have decompression components.

  • Page 34: Engine Oil And Filter Change

    NOTE: Due to the dipstick entry angle into the Recommended Engine Oil: crankcase, the oil level will read higher on the Polaris PS-4 PLUS Synthetic 2W-50 bottom side of the dipstick. Proper level indication (PN 2876244) (Quart) is determined on the upper surface of the dipstick as...

  • Page 35: Exhaust Pipe

    12. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn. 13. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris PS-4 PLUS 2W-50 Synthetic engine oil (PN 2876244). Clean Out Plug Place the transmission in Park and start the engine.

  • Page 36: Transmission And Gearcases

    MAINTENANCE TRANSMISSION AND GEARCASES If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the hand brake and block the Transmission Lubrication wheels.

  • Page 37: Front Gearcase Lubrication

    • Check vent hose to be sure it is routed properly and unobstructed. Remove the drain plug and allow lubricant to drain completely. • The correct front gearcase lubricant to use is Polaris Premium Demand Fluid. FRONT GEARCASE Make sure vent is unobstructed Fill Plug 8-30 ft.

  • Page 38: Middle Gearcase Lubrication (6X6)

    MAINTENANCE To change gearcase lubricant: Remove fill plug (8 mm hex) and check the O-ring. Remove gearcase drain plug (B) (11 mm) located on the bottom of the gearcase and drain oil. (The drain plug is Fill Plug accessible through the skid plate.) Catch and discard used oil properly.

  • Page 39: Rear Gearcase Lubrication (4X4 Crew)

    MAINTENANCE Rear Gearcase Lubrication (4x4 CREW) • The correct middle gearcase lubricant to use is ATV Angle Drive Fluid To check the lubricant level: The gearcase must be drained and re-filled with the proper amount of lubricant. Refer to the procedure below. Rear Gearcase Specifications (4x4 CREW) To change middle gearcase lubricant: Specified Lubricant:...

  • Page 40: Rear Gearcase Lubrication (6X6)

    • Check vent hose to be sure it is routed properly and unobstructed. Remove the fill plug. • The correct rear gearcase lubricant to use is Polaris ATV Angle Drive Fluid Place a drain pan under the drain plug. To check the lubricant level: Remove the drain plug and allow the lubricant to drain completely.

  • Page 41: Cooling System

    Overheating of engine could occur if air is not fully purged from system. system. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. 2.22...

  • Page 42: Radiator Coolant Level Inspection

    NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or Polaris 60/40 Anti-Freeze / Coolant repair. However, if the recovery bottle has run dry, or if overheating is evident, the level in the radiator (PN 2871323) should be inspected and coolant added if necessary.

  • Page 43: Radiator

    MAINTENANCE Radiator Remove the drain plug and drain the coolant from the radiator. Drain the coolant into a suitable container and Check radiator (A) air passages for restrictions or damage. properly dispose of the coolant. Remove the outlet radiator hose, inlet radiator hose, surge tank hose, and overflow hose from the radiator.

  • Page 44: Final Drive / Wheel And Tire

    Attach the washers (if applicable) and wheel nuts and finger replace the boot. Refer to Chapter 7 for CV boot replacement, tighten them. or have you Polaris dealer replace the boot. Lower the vehicle to the ground. Securely tighten the wheel nuts to the proper torque listed in the torque table at the beginning of this section.

  • Page 45: Tire Inspection

    MAINTENANCE Tire Inspection ELECTRICAL AND IGNITION SYSTEM • Improper tire inflation may affect vehicle Battery Maintenance maneuverability. Keep battery terminals and connections free of corrosion. If • When replacing a tire always use original equipment cleaning is necessary, remove the corrosion with a stiff wire size and type.

  • Page 46: Battery Fluid Level (Conventional Battery)

    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...

  • Page 47: Spark Plug Service

    MAINTENANCE Spark Plug Service Install spark plug and torque to specification. Remove both spark plug high tension leads (A). Clean Recommended Spark Plug: plug area so no dirt and debris can fall into engine when Champion RC7YC3 plug is removed. Spark Plug Torque: 18 ft.

  • Page 48: Steering And Suspension

    WARNING Measure Here Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be Mark (A), measure, performed by an authorized Polaris MSD- then roll forward and measure (B).

  • Page 49: Front Suspension

    MAINTENANCE Toe Adjustment Front Suspension If toe alignment is incorrect, measure the distance between • Compress and release front suspension. Damping vehicle center and each wheel. This will tell you which tie rod should be smooth throughout the range of travel. needs adjusting.

  • Page 50: Rear Suspension

    MAINTENANCE Rear Suspension Rear Suspension Adjustment (4x4 CREW) The rear suspension may be adjusted to provide a stiffer suspension if necessary. Remove the top shock mounting bolts from the inside mounting holes. Reposition the shocks to the outside mounting holes. Reinstall the shock mounting bolts.

  • Page 51: Brake System

    MAINTENANCE BRAKE SYSTEM Brake Pad / Disc Inspection Check the brake pads for wear, damage, or looseness. Brake Fluid Inspection Inspect the brake pad wear surface for excessive wear. Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation.

  • Page 52: Parking Brake Pad Inspection

    MAINTENANCE Loss of tension in the parking brake cable will cause illumination of the parking brake light and activation of the limiting feature. If this occurs, inspect and adjust parking brake cable tension. If performing this service is difficult due to conditions or location, open the hood and temporarily disconnect the parking brake connector.
  • Page 53 MAINTENANCE NOTES 2.34...
  • Page 54 ENGINE CHAPTER 3 ENGINE ENGINE SPECIFICATIONS ..........3.2 CRANKCASE EXPLODED VIEWS .

  • Page 55: Engine Specifications

    ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views A. Journal Bearings B. Camshaft C. Thrust Plate D. Balance Shaft E. Woodruff Key F. Flange Seal G. Crankshaft H. Oil Pickup I. Journal Bearings J. Baffle K. Oil Plug L. Washer M. O-ring N.
  • Page 56 (6.8 ± .68 Nm) Apply corrosion resistant grease to stator grommet area. 96 ± 3 in.lbs. (10.85 ± 0.35 Nm) Oil Pump Bolt Tighten Sequence Mag Cover Bolt Tighten Sequence Apply Polaris 2W-50 oil to component Apply White Lithium Grease...
  • Page 57 Stator Cover / Starter / Water Pump Exploded View Apply Polaris Water Pump Cover Starter Grease Bolt Tighten Sequence Apply Polaris 2W-50 oil to seal Loctite™ Pipe Sealant (PN 2871956) No Grease or Oil 84 ± 8 ft.lbs. (9.5 ± 0.9 Nm) 96 ±...
  • Page 58 ENGINE Oil Filter / Pressure Relief / Dipstick Assembly Exploded View A. Clamp B. Oil Fill Tube C. Dipstick D. O-ring E. Hex Plug F. Oil Filter Nipple G. Oil Filter H. Dowel I. Galley Plug Asm. J. Screw K. Relief Spring 50 ±...
  • Page 59 A. Head Bolts B. Rocker Arms C. Head Assembly D. Gasket Circlip UP for Install E. Pushrods F. Bushing G. Expansion Plug H. Cylinder I. Piston Assembly J. Circlip K. Gasket L. Hydraulic Lifter Apply Polaris 2W-50 Oil Apply Moly Lube Grease...
  • Page 60 ENGINE Engine Sensors / Valve Cover / General Component Exploded View 84 ± 8 in. lbs. (9.5 ± 0.9 Nm) A. Screws 20 ± 5 in. lbs. B. Rocker Cover (2.5 ± 0.55 Nm) C. Breather D. O-ring Seal 18 ± 2 ft. lbs. E.
  • Page 61 ENGINE EFI Harness / Fuel Injection Exploded View A. Fuel Injector B. Fuel Rail C. EFI Harness 18 ± 2 ft. lbs. (24.5 ± 2.7 Nm) NOTE: See Chapter 4 for more information on the EFI system.

  • Page 62: Engine Fastener Torque Patterns

    ENGINE Engine Fastener Torque Patterns Crankcase Bolt Tighten Sequence 22 ± 2 ft. lbs. (30 ± 3 Nm) Cylinder Head Bolt Tighten Sequence Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, then °...

  • Page 63: Torque Specifications

    ENGINE Torque Specifications Engine Torque Specifications Fastener Size in. lbs. (Nm) ft. lbs. (Nm) Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 115 ± 12 (13 ± 1.35) 9.5 ± 1 (13 ± 1.35) Throttle Body Adaptor Bolts 8 mm 216 ±...

  • Page 64: 700 Efi Engine Service Specifications

    ENGINE 700 EFI Engine Service Specifications Cylinder Head - Engine Specifications Main Component: Cylinder Head EH068OLE Cam Lobe Height - Intake / Exhaust 1.3334" (33.8674 mm) 1.654" ± 0.00039" (42 ± 0.010 mm) Camshaft Journal Outer Diameter - Mag 1.634"± 0.00039" (41.50 ± 0.010 mm) Camshaft Journal Outer Diameter - Center 1.614"...
  • Page 65 ENGINE Cylinder / Piston - Engine Specifications Main Components: Cylinder / Piston / Connecting Rod EH068OLE Cylinder - Surface warp limit 0.004" (0.10 mm) (mating with cylinder head) Cylinder Bore - Standard 3.1495" (80 mm) Cylinder Cylinder Taper Limit 0.00031" (0.008 mm) Cylinder Out of Round Limit 0.00030"...

  • Page 66: Special Tools

    System Capacity 3.25 Quarts (2.13L) • Gear Train Components Radiator Cap Pressure Relief 13 PSI Following Components Require Engine Removal for service: Polaris Premium Antifreeze • Counterbalance Shaft or Bearings 2871534 - Quart • Connecting Rod 2871323 - Gallon • Crankshaft •...

  • Page 67: Cooling System Pressure Test

    The cooling system is under heat dissipation, resulting in possible engine damage. Polaris pressure and serious burns may result. Premium 60/40 Antifreeze/Coolant is recommended for use in Allow the engine and cooling system to cool all cooling systems and comes pre-mixed, ready to use.

  • Page 68: Cooling System Exploded View

    ENGINE Cooling System Exploded View Radiator Inlet Hose Engine Outlet Hose Engine Inlet Hose Radiator Outlet Hose Radiator Cap Surge Tank Radiator Shroud Drain Plug Cooling System Bleeding Procedure Place the vehicle in Neutral and set the parking brake. CAUTION WARNING Be sure the engine has cooled and there is no Always wear safety glasses and proper shop...
  • Page 69 ENGINE Elevate the driver’s side of the vehicle 20” (50.8 cm) off Add Polaris Premium Antifreeze to the radiator if the level the ground so the thermostat housing is at the highest point goes down. on the cylinder head. This will allow any trapped air to Tighten the bleed screw to 70 ±...

  • Page 70: Valve Cover Removal - 6X6 Models (Engine Installed)

    ENGINE Valve Cover Removal - 6x6 Models Remove the heat shield shown below and loosen the exhaust mounts. (Engine Installed) The RANGER 6x6 models have a different engine mounting system that makes it more difficult to access and remove the Loosen Remove engine valve cover.

  • Page 71: Engine Removal

    ENGINE Engine Removal 12. Disconnect the air intake hose (D) from the air box and remove the air intake hose. 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.

  • Page 72: Engine Installation Notes

    ENGINE 16. Remove the crank position sensor (I) located on the mag NOTE: Use caution when lifting the engine out of frame. Use an engine lift or other means if the engine cover. is too heavy to be lifted manually. 17.

  • Page 73: Engine Lubrication Specifications

    - Oil Pressure Specification - 35-39 PSI @ 5500 RPM, Polaris 2W-50 The break-in period for a Polaris RANGER engine is defined as Synthetic, Engine at operating temperature. the first 25 hours of operation, or the time it takes to use 2 full tanks of gasoline.

  • Page 74: Oil Flow Chart

    ENGINE Oil Flow Chart This chart describes the flow of oil through the 700 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.

  • Page 75: Engine Disassembly And Inspection

    ENGINE ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Rocker Arms Retainer Locks (keepers) Push Rods Spring Retainers Springs Valve Seals Valve Spring Seats Cylinder Head Hydraulic Lifters Valves 3.22...

  • Page 76: Rocker Arms / Push Rods

    ENGINE Rocker Arms If the push rod (A) is visibly bent, it should be replaced. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. Cylinder Head Removal Inspect the wear pad at the valve end of the rocker arm for Loosen the six cylinder head bolts evenly 1/8 turn each in indications of scuffing or abnormal wear.

  • Page 77: Cylinder Head Inspection / Warp

    ENGINE Cylinder Head Inspection Valve Seal / Spring Service (On Engine) NOTE: The following procedure is only for servicing Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon. the top end of the valve train when replacing valve springs or replacing valve seals.

  • Page 78: Cylinder Head Disassembly

    ENGINE Cylinder Head Disassembly Remove valve guide seals. Carefully remove the cylinder components. 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. Mark the valves with a white pen.

  • Page 79: Valve Inspection

    ENGINE Valve Inspection Remove all carbon from valves with a soft wire wheel or = In. / mm. brush. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” Valve Stem Diameter: blocks and a dial indicator.

  • Page 80: Combustion Chamber

    Valve Seat Reconditioning Apply cutting oil to valve seat and cutter. ° NOTE: Polaris recommends that the work be done Place 46 cutter on the pilot and make a light cut. by a local machine shop that specializes in this area.
  • Page 81 ENGINE NOTE: When using an interference angle, the seat Inspect the cut area of the seat: contact point on the valve will be very narrow, and is * If the contact area is less than 75% of the circumference of the a normal condition.

  • Page 82: Cylinder Head Reassembly

    ENGINE Cylinder Head Reassembly Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. NOTE: Assemble the valves one at a time to maintain proper order. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the Apply engine oil to valve guides and seats.

  • Page 83: Valve Sealing Test

    ENGINE Valve Sealing Test Valve Lifter Removal / Inspection Clean and dry the combustion chamber area (A). Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand. Thoroughly clean the lifters in cleaning solvent and wipe them with a clean, lint-free cloth.

  • Page 84: Piston Removal

    ENGINE Piston Removal 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 Remove circlip (A). Mark the piston with a white pen to a locating tab on the end which fits into a notch (B) in the upper ensure proper orientation (if reused) during assembly.

  • Page 85: Cylinder Inspection

    ENGINE Cylinder Inspection Inspect cylinder for wear, scratches, or damage. Remove all gasket material from the cylinder sealing surfaces. 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. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge.

  • Page 86: Cylinder Hone Selection And Honing Procedure

    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 Example of Cross Hatch Pattern honed depending upon the hone manufacturer's recommendations.

  • Page 87: Piston-To-Cylinder Clearance

    ENGINE Piston-to-Cylinder Clearance Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.

  • Page 88: Piston Ring Installed Gap

    ENGINE Measure piston ring to groove clearance by placing the ring If the bottom installed gap measurement exceeds the in the ring land and measuring with a thickness gauge. service limit, replace the rings. If ring gap is smaller than Replace piston and rings if ring-to-groove clearance the specified limit, file ring ends until gap is within exceeds service limits.

  • Page 89: Flywheel / Stator Removal / Inspection

    ENGINE Inspect gear teeth on starter drive (A). Replace starter drive if gear teeth are cracked, worn, or broken. Inspect the bendix bushing (C) in the mag cover for wear. Replace as needed. 2871043 Use caution when removing the wire holddown (B) and the stator assembly (D).
  • Page 90 ENGINE Remove the nylok nut (C), washer (D), and water pump Remove the starter bendix (G), wire holddown plate (H), impeller (E). Remove part of the water pump seal behind and the woodruff key (I) from the crankshaft. The stator the impeller.
  • Page 91 ENGINE Use a white pen to accent the timing marks on the following CAUTION gears: camshaft gear (K), crankshaft gear (M), or counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears. Wear safety glasses at all times. Use caution when working with the top gear.
  • Page 92 ENGINE 14. Inspect the gear teeth and the three tabs on the gears for To Assemble: wear. * Hold the spring with one finger. * Start the pointed end of the tapered pin into the cam gear hole Inspect Teeth & Tabs and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring.
  • Page 93 ENGINE 19. Once the gears are pressed together, firmly hold the gears 21. To remove the balance shaft gear, the flat side of the together with one hand. Carefully remove the Tapered Pins camshaft (P) must face the balance shaft gear. To rotate the (PU-45497-1) by pulling them out one at a time with the camshaft, use the Cam Spanner Wrench (PU-45498) to other hand.
  • Page 94 ENGINE 23. Inspect the crankshaft gear (Q) for broken or worn teeth. If 26. Rotate the water/oil pump gear (S), so that all four bolts are the crankshaft gear does not need to be replaced, it does not visible though the gear. Remove the four bolts with a hex need to be removed.
  • Page 95 ENGINE 29. Remove the oil pressure relief. The oil pressure relief 31. Carefully press the gear off the assembly while supporting consists of a bolt, washer, spring, and valve (dowel). the housing assembly. Inspect the valve (dowel) for signs of possible obstructions. Use compressed air to blow out any debris.
  • Page 96 ENGINE 34. Press shaft into the new bearing.. 37. Remove thrust plate (U). Press On Bearing 35. Press the bearing/shaft assembly using the bearing's outer race. Do not use the shaft to press the assembly into the 38. Remove PTO end engine mount. Remove crankcase bolts. housing, as bearing damage may result.

  • Page 97: Camshaft Inspection

    ENGINE Camshaft Inspection 40. Remove balance shaft and crankshaft. Thoroughly clean the cam shaft. Visually inspect each cam lobe for wear or damage. Measure height of each cam lobe using a micrometer. Compare to specification. 41. Remove and inspect crankshaft main journal bearings for abnormal wear.

  • Page 98: Engine Reassembly

    ENGINE ENGINE REASSEMBLY Measure ID of camshaft journal bores. Crankcase Reassembly = In. / mm. CAUTION Camshaft Journal Bore I.D.: (Mag): 1.656" ± 0.00039" (42.07± 0.010 mm) After any reassembly or rebuild, the engine (Ctr.) 1.637" ± 0.00039" (41.58 ± 0.010 mm) must be primed using the Oil Priming Adapter (PTO) 1.617"...
  • Page 99 ENGINE Install the balance shaft. Inspect balance shaft clearance Apply Crankcase Sealant (PN 2871557) to the top gearcase (C) in both gearcase halves. Rotate balance shaft to ensure halve. there is clearance between it and the oil baffle weldment. NOTE: Do not apply sealant to cam relief hole (E). Assemble the crankcase halves.
  • Page 100 ENGINE NOTE: Always replace the camshaft and lifters as a 12. Orientate the piston rings on the piston before installation set. into the cylinders. Set the gaps of the rings every 120° (See Illustration Below). Piston Ring Orientation 1. Top Ring 2.
  • Page 101 ENGINE NOTE: New bolts have patch lock on the threads 14. Position cylinder and piston assemblies onto the connecting and do not require Loctite™. rods and push the piston pins through the piston and connecting rods. Push in Piston Pins 15.
  • Page 102 ENGINE 19. Align the bolt holes and install oil pump assembly into 21. Apply Loctite™ 242 (PN 2871949) to the crankshaft. 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."...
  • Page 103 ENGINE 24. Install the crankshaft gear (I) onto the crankshaft. 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 NOTE: For assembly of the gears, the cam gear and the Cam Gear Alignment Tool still in place) onto the the crankshaft gear are stamped with This Side Out."...
  • Page 104 ENGINE NOTE: Be sure all of the timing marks are properly IMPORTANT: Due to seal design and construction, aligned. seals MUST be installed DRY (no lubricant) during assembly. Use of lubricants (oil, soapy water, etc.) Water Pump Gear will not allow the seal to wear-in and seal properly. Do not touch seal surface or allow seal surface to come Timing Marks in contact with contaminates during installation.
  • Page 105 ENGINE 30. Once the crankshaft seal is installed into the gear / stator 32. Before installing the gear/stator housing cover, install the housing cover, set the direction of the paper lip by sliding Water Pump Seal Saver (PA-45401) onto the water pump the Main Crankshaft Seal Saver (PA-45658) into the shaft.
  • Page 106 ENGINE NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris. This will ensure proper sealing when installing bolts. 37. Install shaft seal with ceramic surface facing inward. 35. Install the gear/stator housing gasket onto he crankcase. Gear / Stator Housing Gasket 38.

  • Page 107: Flywheel / Stator Installation

    ENGINE Flywheel / Stator Installation 39. Install water pump cover (R) with new O-ring seal. Torque bolts to specification in proper sequence (See front of this NOTE: Before assembly, clean the bolts and bolt chapter). holes with Primer N (PN 2874275) to remove any debris.

  • Page 108: Cylinder Head Reassembly

    ENGINE Lubricate threads and top of washers underside of bolt head with engine oil. Install head bolts (C) and torque to specification. Flywheel Nut Torque 65 ± 7 ft.lbs. (88 ± 9.50 Nm) Install stator housing with new o-rings. Torque the bolts to specification and follow proper bolt torque sequence at the beginning of this chapter.
  • Page 109 ENGINE Lubricate rockers (E) with engine oil. Breather Bolt Toque: ± ± 5 in. lbs. (2.5 0.55 Nm) NOTE: When applying RTV, do not get any RTV inside the reed assembly. Place a new seal (I) into the bottom of the cover. Be sure the seal is seated into the cover properly.

  • Page 110: Oil Pump Priming

    18 ± 2 ft.lbs. (24.4 ± 2.71 Nm) installation, the engine must be properly primed with Polaris PS-4 PLUS 2W-50 Synthetic Oil (PN 2876244). Fill the oil filter three-quarters full with Polaris PS-4 PLUS CAUTION 2W-50 Synthetic Engine Oil (PN 2876244). Let the oil soak into the filter for 8-10 minutes.

  • Page 111: Troubleshooting

    ENGINE TROUBLESHOOTING Engine Idles But Will Not Accelerate • Spark plug fouled/weak spark Engine • Broken throttle cable Spark Plug Fouling • Obstruction in air intake • Spark plug cap loose or faulty • Air box removed (reinstall all intake components) •...

  • Page 112: Cooling System

    ENGINE Cooling System Excessive Smoke and Carbon Buildup • Excessive piston-to-cylinder clearance Overheating • Wet sumping due to over-full crankcase • Low coolant level • Worn rings, piston, or cylinder • Air in cooling system • Worn valve guides or seals •...
  • Page 113 ENGINE NOTES 3.60...
  • Page 114 ELECTRONIC FUEL INJECTION CHAPTER 4 ELECTRONIC FUEL INJECTION GENERAL INFORMATION ..........4.2 SPECIAL TOOLS .

  • Page 115: General Information

    IMPORTANT: For the most recent information on clothing. ™ Digital Wrench software and fileset downloads * Always stop the engine and refuel outdoors or in a please visit the website: www.polaris.diagsys.com well ventilated area.
  • Page 116 NOTE: Voltage Regulator 4010264 is required if using TPS harness PU-47082. If your dealership Adaptor shown is sells Polaris snowmobiles, you may already have included with kit. 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.
  • Page 117 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 (1-800-328-6657). PU-47469...

  • Page 118: Efi Service Notes

    • 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 700 EFI of the same model may be used without damaging system or engine components.

  • Page 119: Fuel Tank Exploded View

    ELECTRONIC FUEL INJECTION Fuel Tank Exploded View PFA Nut Fuel Sender Float Arm Fuel Pump / Regulator PFA Gasket Preliminary Filter Fuel Tank Assembly NOTE: Fuel Pump is NOT Serviceable Fuel Flow Fuel Injectors Fuel Rail Fuel Tank Pressure Regulator Fuel Pump Assembly Fuel Filters Quick Connect Fuel Line...

  • Page 120: Efi System Exploded View

    ELECTRONIC FUEL INJECTION EFI System Exploded View 1. Electronic Control Unit (ECU) 2. Intake Air Temperature / Barometric 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.

  • Page 121: Throttle Body

    ELECTRONIC FUEL INJECTION EFI System Component Locations Fuel Injectors / Fuel Rail Attached to the fuel rail located in the intake track of the Electronic Control Unit (ECU) cylinder head. Located under the seat on the driver’s side. Fuel Pump / Regulator / Fuel Gauge Sender Assembly Intake Air Temperature and Barometric Air Pressure Located in fuel tank as an assembly.

  • Page 122: Fuel Lines - Quick Connect Removal / Installation

    ELECTRONIC FUEL INJECTION Fuel Lines - Quick Connect Throttle Position Sensor (TPS) Located on the right-hand side of the throttle body. Removal / Installation CAUTION Verify fuel system has been depressurized before performing this procedure. RANGER 700 EFI models use quick connect fuel lines. Refer to the steps for fuel line removal / installation: Thoroughly clean the connector and place a shop towel around the fuel line to catch any dripping fuel.

  • Page 123: Principal Components / Efi Operation Overview

    ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for air temperature, barometric air pressure, engine temperature, speed Principal Components (RPM), and throttle position (load). These primary signals are The Electronic Fuel Injection (EFI) system is a complete engine compared to the programming in the ECU computer chip, and fuel and ignition management design.

  • Page 124: Electronic Control Unit (Ecu)

    For the purpose of troubleshooting, a known-good ECU from richer running) may be initiated. A technician can determine the another Polaris RANGER 700 EFI of the same model may be cause of the “Check Engine” light by initiating the “Blink Code”...

  • Page 125: Fuel Pump

    ELECTRONIC FUEL INJECTION FUEL PUMP Fuel Sender Test If the fuel gauge reading on the instrument cluster is not Operation Overview working, or if the display reading differs in large comparison to the fuel in the tank, perform a resistance test on the fuel sender. NOTE: All EFI units utilize quick connect lines.

  • Page 126: Fuel Pump / Tank Assembly Replacement

    ELECTRONIC FUEL INJECTION Fuel Pump / Tank Assembly Replacement Connect the hose from the Fuel Pressure Gauge Kit (PU- 43506-A) to the test valve on the Fuel Pressure Gauge NOTE: All EFI units utilize quick connect fuel lines. Adaptor. Route the clear hose into a portable gasoline container or the vehicle’s fuel tank.

  • Page 127: Fuel Pressure Regulator

    ELECTRONIC FUEL INJECTION Fuel Tank Installation Remove the two inner bolts that hold the fuel tank to the frame. Reinstall the fuel pump / tank assembly. Reinstall the four fuel tank mounting bolts that were removed. Reconnect the electrical harness. Install the fuel line and vent line and verify they are secure.

  • Page 128: Fuel Injectors

    ELECTRONIC FUEL INJECTION FUEL INJECTORS NOTE: Do not apply voltage directly to the fuel injector(s). Excessive voltage will burn them out. Do not ground the injector(s) with the ignition on. Operation Overview lnjector(s) will open/turn on if relay is energized. The fuel injectors mount into the intake manifold, and the fuel If an injector is not operating, it can indicate either a bad injector, rail attaches to them at the top end.

  • Page 129: Crankshaft Position Sensor (Cps)

    ELECTRONIC FUEL INJECTION CRANKSHAFT POSITION SENSOR CPS Test (CPS) The crankshaft position sensor is a sealed, non-serviceable assembly. If fault code diagnosis indicates a problem within this Operation Overview area, test and correct as follows: The engine speed sensor is essential to engine operation, Disconnect main harness connector from ECU.

  • Page 130: Temperature / Barometric Air Pressure Sensor (T-Bap)

    ELECTRONIC FUEL INJECTION TEMPERATURE / BAROMETRIC AIR THROTTLE POSITION SENSOR (TPS) PRESSURE SENSOR (T-BAP) Operation Overview Operation Overview The throttle position sensor (TPS) is used to indicate throttle plate angle to the ECU. Mounted on the throttle body intake, the temperature and barometric air pressure sensor (T-BAP) performs two functions Mounted on the throttle body and operated directly off the end in one unit.
  • Page 131 Tester Regulator (4010264). 4010264 TPS Tester Regulator NOTE: If your dealership sells Polaris snowmobiles, you may already have this regulator from TPS Tester Kit (2201519). If you do not have this regulator, you must order one from SPX at 1-800-328-6657.

  • Page 132: Tps Adjustment

    ELECTRONIC FUEL INJECTION Checking TPS Reading Allow the throttle foot pedal to rest in the idle position. The voltmeter should read .660 ± .010 volts. Remove the lower seat base to access the sensor connector. PU-47082 Tester Assemble the TPS Tester according to the instructions. Refer to “TPS Tester / Regulator”...

  • Page 133: Tps Replacement

    This indicates all other components are working properly. Figure 4-19 Refer to Chapter 10 for ECT testing. Polaris dealers can also test the sensor by using the Digital Wrench™ Diagnostic Software Remove the mounting screw (B) and replace the sensor.

  • Page 134: Ignition Coil

    ELECTRONIC FUEL INJECTION IGNITION COIL Primary Test 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.

  • Page 135: General Troubleshooting

    ELECTRONIC FUEL INJECTION GENERAL TROUBLESHOOTING 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. Diagnostic “Blink Codes” The word “End” will display after all of the codes have been NOTE: The EFI diagnostic mode is intended to displayed or if no codes are present.

  • Page 136: Efi Troubleshooting

    ELECTRONIC FUEL INJECTION EFI Troubleshooting Poor Idle Symptom: Idle Too High (If greater than 1300 RPM when Fuel Starvation / Lean Mixture engine is warm) Symptoms: Hard start or no start, bog, backfire, popping • Throttle stop screw set incorrect through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle •...

  • Page 137: Efi System Break-Out Diagrams

    ELECTRONIC FUEL INJECTION EFI SYSTEM BREAK-OUT DIAGRAMS Fuel Injector Circuit (PTO) Fuel Injector Circuit (MAG) 4.24...

  • Page 138: Crankshaft Position Sensor (Cps) Circuit

    ELECTRONIC FUEL INJECTION Crankshaft Position Sensor (CPS) Circuit Fuel Pump Circuit 4.25...

  • Page 139: Engine Coolant Temperature Sensor (Ect)

    ELECTRONIC FUEL INJECTION Engine Coolant Temperature Sensor (ECT) Temperature Overheat Indicator Lamp Circuit 4.26...

  • Page 140: Throttle Position Sensor (Tps) Circuit

    ELECTRONIC FUEL INJECTION Throttle Position Sensor (TPS) Circuit Air Temperature / Barometric Air Pressure Sensor (T-BAP) Circuit 4.27...

  • Page 141: Diagnostic Connector Circuit

    ELECTRONIC FUEL INJECTION Diagnostic Connector Circuit Diagnostic Indicator Lamp Circuit 4.28...

  • Page 142: Body / Steering / Suspension

    BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS..........5.2 SPECIAL TOOLS .

  • Page 143: Torque Specifications

    BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS SPECIAL TOOLS ITEM TORQUE VALUE TOOL DESCRIPTION PART NUMBER ft.lbs. (Nm) Strut and Ball Joint Tool Set 2870871 Front A-Arm Attaching Bolt 30 ft. lbs. (41 Nm) Shock Spanner Wrench 2870872 Front A-Arm Ball Joint Stud Nut 30 ft.

  • Page 144: Body Component Removal

    BODY / STEERING / SUSPENSION BODY COMPONENT REMOVAL Removal Procedures TO REMOVE: PERFORM THESE STEPS: SEAT Pull up on front of seat and then pull forward 1. Remove the gear selector handle 2. Then remove the 4 screws that attach the hood to the dash DASH 3.

  • Page 145: Lower Body, Floor And Fenders (4X4 Crew)

    BODY / STEERING / SUSPENSION Lower Body, Floor and Fenders (4x4 CREW) Speed Foam Rear Floor Foil T-27 Foil Foil Rear Fender Foam T-27 Foam T-27 Floor T-27 Cover Mid Fender Foil Dog House T-27 Cover Main Floor Floor Receptacle Bracket Rear Floor Ext.

  • Page 146: Lower Body, Floor And Fenders (6X6)

    BODY / STEERING / SUSPENSION Lower Body, Floor and Fenders (6x6) Foam Foil Foil Main Floor Foil Foam Floor T-27 Cover T-27 Foam Speed T-27 Foil U-Type Rear Dog House Fender Cover Front Fender T-27 T-27 Speed T-27 Rear Fender T-25 T-27 Front...

  • Page 147: Hood / Dash Components

    BODY / STEERING / SUSPENSION Hood / Dash Components T-27 Glove Box Assembly T-30 Hinges Cup Holder T-27 Hood T-27 Grille Headlights Hood Liner Hood Latch Strap TORQUE SPECIFICATIONS T-30 Screws: 8-10 in. lbs. (0.9-1 Nm) T-27 Screws: 4-5 ft. lbs. (5-6 Nm)

  • Page 148: Dash Instruments And Controls

    BODY / STEERING / SUSPENSION Dash Instruments and Controls A. Speedometer B. Headlight Switch C. 2WD/AWD Switch D. 12 Volt Accessory Receptacle E. Speedometer “Mode” Button F. Key Switch G. Speedometer Mount Plate...

  • Page 149: Cab Frame

    BODY / STEERING / SUSPENSION CAB FRAME Assembly / Removal (6x6) Assemble the two rear cab frames at the coupler joint and secure with two 3/8" screws and nuts. Assemble the front frame in same manner. Leave all fasteners finger tight. Assemble the center cross bracket to the rear cab frame and secure with two 5/16”-18 x .75”...

  • Page 150: Assembly / Removal (4X4 Crew)

    BODY / STEERING / SUSPENSION Assembly / Removal (4x4 CREW) Assemble the two rear cab frames at the coupler joint and secure with two 3/8" screws and nuts. Assemble the center frame and the front frame in same manner. Tighten all 3/8" screws to 25-28 ft. lbs. (34-38 Nm). Assemble the center cross bracket to the rear cab frame and secure with two 5/16”-18 x .75”...

  • Page 151: Seat / Head Rest

    BODY / STEERING / SUSPENSION SEAT / HEAD REST Seat Back / Head Rests Fasten the seat back to the rear cab frame(s) using the Torx-head screws. NOTE: For seats that have staples visible from the rear, the seat back cover will need to be placed between the rear cab frame and seat back assembly. Tighten all Torx- head fasteners to 18-20 in.

  • Page 152: Chassis / Main Frame (4X4 Crew)

    BODY / STEERING / SUSPENSION CHASSIS / MAIN FRAME (4X4 CREW) Exploded View (2) Seat Base Main Frame (2) RH Floor Support Front Cab Support 28-32 ft. lbs. (38-43 Nm) 35 ft. lbs. (47 Nm) Bumper Grills T-27 13-15 ft. lbs. 28-32 ft.

  • Page 153: Chassis / Main Frame (6X6)

    BODY / STEERING / SUSPENSION CHASSIS / MAIN FRAME (6X6) Exploded View Seat Base Frame Extension Front Cab Support RH Floor Support 45 ft. lbs. (61 Nm) Main Frame 28-32 ft. lbs. (38-43 Nm) Bumper Grills 13-15 ft. lbs. (17-20 Nm) LH Floor Support T-27 28-32 ft.

  • Page 154: Steering Assembly

    BODY / STEERING / SUSPENSION STEERING ASSEMBLY Exploded View 28 ft. lbs. (38 Nm) Rod End & Jam Nut Steering Wheel Bushing Wave Washers 17 ft. lbs. (23 Nm) 30 ft. lbs. 16 ft. lbs. (41 Nm) (22 Nm) Upper Steering Shaft Tie Rod Lower Steering Shaft 16 ft.

  • Page 155: Steering And Suspension

    BODY / STEERING / SUSPENSION STEERING AND SUSPENSION Exploded View NOTE: To avoid damage to the tie rod ends and Always use new other steering components, be sure to install tie Always use new bolts cotter pins upon rod end bolts in the proper direction. upon reassembly reassembly.

  • Page 156: Front A-Arm

    BODY / STEERING / SUSPENSION FRONT A-ARM Attach A-arm to hub strut assembly. Tighten ball joint nut to 30 ft. lbs. (41 Nm). If cotter pin holes are not aligned, tighten nut slightly to align. Install a new cotter pin with Replacement open ends toward rear of machine.

  • Page 157: Front Strut

    BODY / STEERING / SUSPENSION FRONT STRUT Exploded View Pivot Ball Spring 15 ft. lbs. Retainer (21 Nm) Spacer Rubber Bottom Pivot Ball Washer Spacer Front Strut Clamp Washer 18 ft. lbs. (24 Nm) Spring Bolt 17 ft. lbs. Strut Bumper (23 Nm) Wheel Speed Sensor (Hall Effect Sensor)

  • Page 158: Front Strut Cartridge Replacement

    BODY / STEERING / SUSPENSION Front Strut Cartridge Replacement Remove cotter pin (A) from ball joint castlenut. Remove castle nut (B) and separate A-arm (C) from ball Refer to Front Strut Exploded View. joint stud. Hold strut rod and remove top nut. Remove screws (D) and ball joint retaining plate (E).

  • Page 159: Mid Axle A-Arm (6X6)

    BODY / STEERING / SUSPENSION Apply Loctite™ 242 (PN 2871949) to threads of retaining WARNING plate screws or install new screws with pre-applied locking agent. Torque screws to 8 ft. lbs. (11 Nm). The locking features on the existing bolts were 10.

  • Page 160: Rear A-Arm (4X4 Crew)

    BODY / STEERING / SUSPENSION REAR A-ARM (4X4 CREW) Remove the hub and brake disc assembly by sliding it off of the axle. Replacement NOTE: Use the exploded view on the next page as reference during the procedure. Elevate and safely support vehicle with weight removed from the rear wheel(s).
  • Page 161 BODY / STEERING / SUSPENSION 11. Remove the bottom stabilizer bar nut. 14. Install new A-arm assembly onto vehicle frame. Torque new bolts to 30 ft. lbs. (41 Nm). WARNING Stabilizer Bar The locking features on the existing bolts were destroyed during removal.

  • Page 162: Rear Stabilizer Bar (4X4 Crew)

    BODY / STEERING / SUSPENSION REAR STABILIZER BAR (4X4 CREW) Remove the two bolts that secure the stabilizer bar to the main frame, each side. Removal / Installation Elevate and safely support vehicle with weight removed from the rear wheel(s). Remove the rear wheel to gain access to the stabilizer bar, each side.

  • Page 163: Swing Arm (6X6)

    BODY / STEERING / SUSPENSION SWING ARM (6X6) Removal Support machine on a level surface. Remove rear wheels. NOTE: The rear axle may be removed to ease the removal of the swing arm. Refer to Chapter 7, “REAR AXLE HOUSING REMOVAL/INSPECTION”. Support swing arm, remove rear axle shocks.

  • Page 164: Rear Drive Axle And Swing Arm Exploded View (6X6)

    BODY / STEERING / SUSPENSION REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6X6) Retaining Ring Axle Tube Wheel Screw & Washer Bearing 60 ft. lbs. (81 Nm) Vehicle Frame Screw & Washer 60 ft. lbs. (81 Nm) Swing Arm Axle Wheel Bearing...

  • Page 165: Rear Cargo Box

    BODY / STEERING / SUSPENSION REAR CARGO BOX Cargo Box - Panels 8-10 in. lbs. (0.9-1.0 Nm) Taillight T-20 8-10 in. lbs. (0.9-1.0 Nm) T-30 Tailgate Support T-27 4-6 ft. lbs. (5-8 Nm) T-20 T-30 8-10 in. lbs. (0.9-1.0 Nm) Seal Foam T-20 8-10 in.

  • Page 166: Cargo Box - Tailgate / Box Support

    BODY / STEERING / SUSPENSION Cargo Box - Tailgate / Box Support Tailgate Cap Tailgate Latch 20-25 in. lbs. Cable T-20 (2-3 Nm) T-20 8-10 in. lbs. Outer Panel (0.9-1.0 Nm) Inner Panel Tailgate Tube Box Support Box Latch Assembly Hinge Pin Shock Pins Bolt...
  • Page 167 BODY / STEERING / SUSPENSION Box Removal Lift the cargo box into the dump position. Slide Hinge Pin Out Disconnect the rear wire harness attached to the tail lights. Remove the upper clip and pin attaching the shock to the cargo box.

  • Page 168: Storage Box (4X4 Crew)

    BODY / STEERING / SUSPENSION STORAGE BOX (4X4 CREW) DECAL REPLACEMENT Plastic polyethylene material must be “flame treated” prior to Removal installing a decal to ensure good adhesion. The flame treating procedure can often be used to reduce or eliminate the whitish Remove the two bottom T-27 torx screws.
  • Page 169 BODY / STEERING / SUSPENSION NOTES 5.28...
  • Page 170 CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES ......... . 6.2 TORQUE SPECIFICATIONS.

  • Page 171: Special Tools And Supplies

    The internal components of the drive clutch and driven clutch PVT System Fastener Torques control engagement (initial vehicle movement), clutch upshift and backshift. During the development of a Polaris ATV, the TORQUE VALUE ITEM PVT system is matched first to the engine power curve; then to ft.

  • Page 172: Driven Clutch Operation

    CLUTCHING Driven Clutch Operation Maintenance / Inspection Under normal use the PVT system will provide years of trouble Driven clutches primarily sense torque, opening and closing free operation. Periodic inspection and maintenance is required according to the forces applied to it from the drive belt and the to keep the system operating at peak performance.

  • Page 173: Overheating / Diagnosis

    10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. For inspection of clutch components, please contact your Polaris dealer. Shift Clutch malfunction. transmission to Low during loading of the vehicle to prevent belt burning.

  • Page 174: Pvt System Service

    CLUTCHING PVT SYSTEM SERVICE PVT Sealing, Guard, and Ducting Components SEALING AND DUCTING COMPONENTS Clutch Outlet Duct Inner Cover Clamps Inner Cover Seal Retainer Outer Cover Seal Cover Bolts PVT Outer Cover Disassembly Some fasteners and procedures will vary. Refer to the Install the Drive Clutch Holder (PN 9314177) (A).

  • Page 175: Assembly

    CLUTCHING Remove driven clutch alignment washer(s) from the Apply RTV silicone sealant to outside edge of inner cover- transmission input shaft. to-engine seal, to ensure a water tight fit between the seal and the cover. Surfaces must be clean to ensure adhesion Note Number of Washers of silicone sealant.

  • Page 176: Drive Belt

    CLUTCHING DRIVE BELT 13. Reinstall drive belt noting direction of rotation. If a new belt is installed, install so numbers can be easily read. Belt Removal 14. Replace PVT outer clutch cover rubber gasket. Remove outer PVT cover as described in PVT 15.

  • Page 177: Pvt Break-In (Drive Belt / Clutches)

    CLUTCHING Belt Inspection PVT Break-In (Drive Belt / Clutches) Inspect belt for hour glassing (extreme circular wear in at A proper break-in of the clutches and drive belt will ensure a least one spot and on both sides of the belt). Hour glassing longer life and better performance.

  • Page 178: Clutch Center Distance

    CLUTCHING Place the alignment tool in the sheaves of the driven clutch 10. If the alignment tool touches the shaft bearing but has an and hold firmly as you rotate it down between the sheaves excessive amount of clearance between the tool and of the drive clutch.

  • Page 179: Drive Clutch Service

    CLUTCHING DRIVE CLUTCH SERVICE Spring Specifications The drive clutch spring has two primary functions: To control clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM. Red/White To control the rate at which the drive belt moves 7043349 upward in the drive clutch sheaves.
  • Page 180 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.

  • Page 181: Shift Weights

    CLUTCHING Exploded View Bushing Lock Washer Spring Cover Bearing Spider Bolt Bearing Flat Non-Braking Washer Spacer Bearing Cover Button Screws Roller Washers Button Bolt Shift Washers Weight Clutch Disassembly Using a permanent marker, mark the cover, spider, and Inspect cover bushing (A). The outer cover bushing is ™...

  • Page 182: Spider Removal

    CLUTCHING Inspect area on shaft where bushing rides for wear, galling, NOTE: It is important that the same number and thickness of washers are reinstalled beneath the nicks, or scratches. Replace clutch assembly if worn or damaged. spider during assembly. Be sure to note the number and thickness of these washers.

  • Page 183: Roller, Pin, And Thrust Washer Inspection

    CLUTCHING Roller, Pin, and Thrust Washer Inspection Button To Tower Clearance Inspection Inspect all rollers, bushings and roller pins by pulling a flat Inspect for any clearance between spider button to tower. metal rod across the roller. Turn roller with your finger. If If clearance exists, replace all buttons and inspect surface you notice resistance, galling, or flat spots, replace rollers, of towers.

  • Page 184: Bearing Inspection

    CLUTCHING Clutch Inspection Remove shift weight bolts and weights. Inspect as shown. The contact surface of the weight should be smooth and free NOTE: Remove cover, spring, and spider following of dents or gall marks. Inspect the weight pivot bore and instructions for drive clutch removal, then proceed pivot bolts for wear or galling.

  • Page 185: Moveable Sheave Bushing Inspection

    CLUTCHING Moveable Sheave Bushing Inspection Inspect surface of shaft for pitting, grooves, or damage. Measure outside diameter compare Inspect the Teflon™ coating (arrow) on the moveable sheave specifications. Replace the drive clutch assembly if shaft bushing. Inspect both sheaves for signs of wear, grooving or is worn or damaged.

  • Page 186: Bushing Service

    CLUTCHING Bushing Service CAUTION IMPORTANT: Special Tools Required EBS Clutch Bushing Tool Kit - 2201379 Clutch components will be hot! In order to avoid serious burns, wear insulated gloves during the Item Qty. Part Description Part # removal process. A, B EBS Puller Tool 5132027 Moveable Sheave - Bushing Removal...
  • Page 187 CLUTCHING NOTE: Use Bushing Tool PA-47336. Cover Bushing Removal Install main adapter (Item 8) on puller. Install nut (C) onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Using Removal Tool Nut (C) a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear.

  • Page 188: Clutch Assembly

    CLUTCHING Clutch Assembly Torque spider to specification using the holding fixture and spider tool. Torque with smooth motion to avoid damage NOTE: It is important that the same number and to the stationary sheave. thickness of washers are reinstalled beneath the spider during assembly.

  • Page 189: Driven Clutch Service

    CLUTCHING DRIVEN CLUTCH SERVICE Exploded View DRIVEN CLUTCH Compression Spring Outer Spring Retainer Secondary Stationary Sheave Retaining Ring Inner Spring Retainer Moveable Inner Sheave Clutch Disassembly / Inspection Place the clutch into the Clutch Compression Tool PN 8700220. Using Compression Extensions PN PS-45909, apply and hold downward pressure on the outer spring CAUTION retainer.
  • Page 190 CLUTCHING With the snap ring (A) removed and spring pressure Remove the inner spring retainer from the inner sheave. relieved, remove the outer spring retainer (B), compression Inspect for wear and replace as needed. spring (C), and inner spring retainer (D). Inspect for Abnormal Wear Check the rollers in the stationary sheave for wear.

  • Page 191: Clutch Assembly

    CLUTCHING 10. Inspect the Teflon™ coating on the moveable sheave bearings. 11. Inspect driven clutch sheave faces for wear or damage. 12. Clean and inspect splines on helix and transmission input shaft. 13. Lube splines with a light film of grease. Do not lubricate the bearings! Clutch Assembly Assemble Sheaves...

  • Page 192: Troubleshooting

    CLUTCHING TROUBLESHOOTING Situation Probable Cause Remedy -Wrong or broken drive clutch spring. -Replace with recommended spring. Engine RPM below specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine range, although application. engine is properly tuned.
  • Page 193 CLUTCHING Troubleshooting, Continued..Situation Probable Cause Remedy -Plugged air intake or outlet. -Clear obstruction -Belt slippage due to water, oil, grease, etc., rubbing -Inspect system. Clean , repair or replace as necessary. on cover. Seal PVT system ducts. PVT cover -Clutches or weight being applied to cover while in -Remove weight.
  • Page 194 FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIAL TOOLS ............7.3 TORQUE SPECIFICATIONS.
  • Page 195 FINAL DRIVE REAR DRIVE SHAFT (4X4 CREW) ........7.41 REMOVAL .

  • Page 196: Special Tools

    FINAL DRIVE SPECIAL TOOLS FRONT HUB Hub Removal / Inspection PART NUMBER TOOL DESCRIPTION Elevate front end and safely support machine under Roller Pin Removal Tool 2872608 footrest / frame area. CV Boot Clamp Pliers 8700226 Axle Boot Clamp Tool CAUTION PU-48951 Serious injury may result if machine tips or falls.

  • Page 197: Hubstrut Bearing Replacement

    FINAL DRIVE Remove hub cap, cotter pin, front spindle nut, and washer. 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. Rotate each bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion.

  • Page 198: Hub Installation

    FINAL DRIVE Hub Installation 10. Install brake caliper using new bolts. Tighten bolts to specified torque. Inspect the hubstrut bearing surface for wear or damage. Apply grease to drive axle spindle. Install spindle through the backside of the hubstrut. Install the hub onto the spindle.

  • Page 199: Front Hub Exploded View

    FINAL DRIVE Front Hub Exploded View Disc Brake Stud Front Hub Tire 18 ft. lbs. (24 Nm) Use new bolts with pre-applied locking agent. Wheel Nut (Spec on page 7.3) Dust Cover Washer Slotted Nut Cotter Pin 70 ft. lbs. (95 Nm)

  • Page 200: Front Drive Shaft

    FINAL DRIVE FRONT DRIVE SHAFT Remove the front wheel hub. Removal Elevate front of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.

  • Page 201: Drive Shaft / Cv Joint Handling Tips

    FINAL DRIVE Pull strut assembly out while pivoting front drive shaft • Never use a hammer or sharp tools to remove or to downward until it clears strut assembly. 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.
  • Page 202 FINAL DRIVE IMPORTANT: If the grease in the joint is obviously 13. Slide the joint onto the drive shaft splines and align the contaminated with water and/or dirt, the joint should circlip with the lead-in chamfer on the inner race of the be replaced.

  • Page 203: Inner Plunging Joint / Boot Replacement

    FINAL DRIVE Inner Plunging Joint / Boot Replacement 12. Grease the joint with the special CV joint grease provided in the boot replacement kit. Fill the cavity behind the balls Remove the front drive shaft from the vehicle (see and the splined hole in the joint’s inner race. Pack the ball “FRONT DRIVE SHAFT - Removal”).

  • Page 204: Exploded View

    FINAL DRIVE Installation 20. 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 Install new spring ring on drive shaft. Apply an anti-seize between the large end of the boot and the joint housing and compound to splines.

  • Page 205: Front Propshaft

    FINAL DRIVE FRONT PROPSHAFT NOTE: Remove the drive shaft floor cover to help align the roll pin removal tool. The drive shaft can be removed through the floor covering. 6x6 Removal Elevate and safely support vehicle under the frame. The use of a vehicle hoist is recommended for this procedure.

  • Page 206: Propshaft U-Joint Service

    FINAL DRIVE PROPSHAFT U-JOINT SERVICE Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps. Disassembly Remove internal or external snap ring from all bearing caps. CAUTION Always wear eye protection. Force U-joint cross to one side and lift out of inner yoke. NOTE: If yoke or bearing is removed, cross bearing must be replaced.
  • Page 207 FINAL DRIVE Using a suitable arbor, fully seat bearing cap in one side. When installation is complete, yokes must pivot freely in Continually check for free movement of bearing cross as all directions without binding. If the joint is stiff or binding, bearing caps are assembled.

  • Page 208: Centralized Hilliard Exploded View

    FINAL DRIVE FRONT GEARCASE / CENTRALIZED HILLIARD Centralized Hilliard Exploded View 17 ft. lbs. (23 Nm) 10 ft. lbs. (14 Nm) 8-30 ft. lbs. (11-41 Nm) 17 ft. lbs. (23 Nm) ESCRIPTION ESCRIPTION Thrust Button Asm. w/O-ring Seal Kit (Includes O-rings and Seals) Screw (5/16-18) Roller Ball Bearing Dowel Pin...

  • Page 209: All Wheel Drive Operation

    FINAL DRIVE All Wheel Drive Operation AWD Engagement: When the AWD switch is activated, the AWD coil is powered by a 12 Vdc input which creates a The AWD switch may be turned on or off while the vehicle is magnetic field.

  • Page 210: Awd Diagnosis

    FINAL DRIVE AWD Diagnosis Possible Symptom: AWD Will Not Engage Wear Ring on Armature Plate Check the gearcase coil resistance. To test the coil resistance, measure between the Grey and Brown/White wires. The measurement should be within specification. OK Condition Bad Condition (Wear from coil on armature plate)

  • Page 211: Gearcase Removal

    FINAL DRIVE The front gearcase and drive shafts can be accessed from Roll Cage both sides of the vehicle and limited access from the top. Asm. Rollers Top View - From under hood Inspect the roll cage assembly for cracks or excessive wear. If damaged, replace the roll cage assembly.

  • Page 212: Gearcase Disassembly / Inspection

    FINAL DRIVE Gearcase Disassembly / Inspection Remove the roll cage assembly, rollers, and H-springs. Drain and properly dispose of used oil. Remove any metal particles from the drain plug magnet. Remove bolts and output shaft cover. Thoroughly clean all parts. Inspect the rollers (A) for nicks and scratches.
  • Page 213 FINAL DRIVE 10. Use a flat head screwdriver to remove the retaining ring 13. Remove the output hub (G) from the cover. remove the from the output cover. thrust bearing (F) from the output hub (G). Inspect the thrust bearing (F) and the dowel (H). Retaining Ring 11.

  • Page 214: Gearcase Reassembly / Inspection

    FINAL DRIVE 16. Remove the other output hub (K) from the main gearcase. 19. Install new seals into the gearcase housing and use new O- Inspect the inner bearing (L) for wear. If there is excessive rings for the gearcase input and output covers. wear, replace bearing as needed.
  • Page 215 FINAL DRIVE Install the output hub (A) into the gearcase housing. The Install the retaining ring (F) into the output cover. Be sure output hub should spin freely. the retaining ring is properly seated into the cover. Install the other output hub (B) and thrust bearing (C) into Install the ring gear (G) onto the output hub on the output the output cover.

  • Page 216: Backlash Pad (Thrust Pad) Adjustment

    FINAL DRIVE Backlash Pad (Thrust Pad) Adjustment 11. Install the output cover assembly onto the main gearcase. Lay the gearcase on the side with the output cover facing The backlash screw has Loctite applied to it. Use a heat gun to lightly heat up the Loctite on the screw (A).

  • Page 217: Gearcase Installation

    FINAL DRIVE MID DRIVE HUB / BEARING CARRIER If a tight spot is felt during rotation, loosen the backlash screw another 1/8 turn. Perform the previous step again. (6X6) Repeat this procedure until the pinion shaft rotates smoothly 4 times (1 revolution of ring gear). Removal Lock the emergency parking brake.
  • Page 218 FINAL DRIVE Remove the upper and lower control arm bolts. NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, Upper Bolt support casting on outer edges so bearing can be removed. Lower Bolt Remove the bearing carrier from the A-arm assembly.

  • Page 219: Hub Installation

    FINAL DRIVE Start bearing (B) in housing (A). Install upper A-arm bolt and torque both upper and lower bolts. Lower Control Arm Bolt Torque: 35 ft. lbs. (47 Nm) Upper Control Arm Bolt Torque: 35 ft. lbs. (47 Nm) Pull drive shaft outward and install hub onto drive shaft splines.

  • Page 220: Mid Drive Exploded View

    FINAL DRIVE Mid Drive Exploded View 35 ft. lbs. (47 Nm) BUSHING SHAFT MID UPPER A-ARM 35 ft. lbs. (47 Nm) MID DRIVE AXLE BEARING CARRIER 35 ft. lbs. (47 Nm) BEARING SHAFT BUSHING SNAP RING 35 ft. lbs. MID LOWER A-ARM BUSHING (47 Nm) MID DRIVE SHAFT (6X6)

  • Page 221: Installation

    FINAL DRIVE Installation Install the flat washer (A) and cone washer (B) with domed side facing outward. (Refer to next photo) Apply Anti-Seize compound onto the mid gearcase output Install the castle nut (C), wheel, and wheel nuts. shaft splines. Slide mid drive shaft (A) onto the mid gearcase output shaft (B).

  • Page 222: Mid Drive Gearcase (6X6)

    FINAL DRIVE MID DRIVE GEARCASE (6X6) Gearcase Removal Use the Roll Pin Removal Tool (PN 2872608) to remove the roll pins that secure the rear prop shaft and middle prop NOTE: To ease the removal of the middle axle shaft to the mid drive gearcase. gearcase, remove the box from the frame.

  • Page 223: Gearcase Disassembly

    FINAL DRIVE Gearcase Disassembly Remove the output shaft and ring gear assembly (E) from the gearcase. Inspect the ring gear for abnormal wear, Drain the oil from the mid drive gearcase. Properly dispose broken, or chipped teeth. Inspect and spin the bearings (F), of the oil.
  • Page 224 FINAL DRIVE Remove the input cover bolts (I). Remove the input cover Inspect the pinion gear (K) and 26T output gear (L) for nics (H) and pinion gear assembly from the gearcase. or uneven wear. Inspect the bearing (M), the bearing should spin smoothly.

  • Page 225: Gearcase Assembly

    FINAL DRIVE 12. Carefully pull the output thru shaft (Q) through the gearcase. 15. Replace all O-ring, seals, and worn components. Replace 13. Remove the retaining ring (O), shim (P), and input gear (R) the seals as shown in the photo. from the output shaft (Q).
  • Page 226 NOTE: When replacing the 26T output, be sure the step of the gear is facing towards the bearing (see below). Apply Polaris Crankcase Sealant (PN 2871557) to the Pinion Shaft Assembly inside surface of the input cover (J). Step Of Gear...
  • Page 227 18 - 23 ft. lbs. (24 - 31 Nm) disassembly process. 12. Remove the fill plug (P) and fill the mid gearcase with 6.75 oz. (200 ml) of Polaris ATV Angle Drive Fluid (PN 2871653). Torque the fill plug to 14 ft. lbs. (19 Nm). 7.34...

  • Page 228: Gearcase Installation

    FINAL DRIVE Middle Gearcase Specifications: Capacity: 6.75 oz. (200 ml) Specified Lubricant: ATV Angle Drive Fluid (PN 2871653) Fill Plug Torque: 14 ft. lbs. (19 Nm) Gearcase Installation Place the middle gearcase in the frame assembly. Attach the mid and rear prop shafts to the mid gearcase, but do not install the new roll pins yet.

  • Page 229: Mid Gearcase Exploded

    FINAL DRIVE Mid Gearcase Exploded 18-23 ft. lbs. (24-31 Nm) 30 ft. lbs. (41 Nm) 18-23 ft. lbs. (24-31 Nm) ESCRIPTION ESCRIPTION Screw (5/16-18 x 1.0) Washer, Thrust Plug, Square Socket Bearing, Plain Flanged Seal, Dual Lip Gearcase Tube, Vent 1/4” Hose Bushing Cover, Output Pinion, 10T...
  • Page 230 FINAL DRIVE REAR HUB / BEARING CARRIER (4X4) Remove hub cap, cotter pin, front spindle nut, and washer. Hub Inspection Support machine securely with rear wheels elevated. Grasp wheel / hub and check for movement. If movement is detected, inspect hub, hub nut torque and bearing condition and correct as necessary.
  • Page 231 FINAL DRIVE Hub Disassembly Hub Assembly Remove outer snap ring (A). Support bottom of bearing carrier housing. (A) Bearing Carrier Housing; (B) Bearing; (C) Snap Ring From the back side, tap on the outer bearing race with a drift Start bearing (B) in housing (A). punch in the reliefs as shown.
  • Page 232 FINAL DRIVE Hub Installation Install the washer with domed side out. Install the spindle retainer nut. Start the wheel bearing carrier onto the drive shaft. Align the bottom of carrier housing and lower control arm. Slide the lower control arm bushings into place. Secure with the lower control arm bolt.
  • Page 233 FINAL DRIVE Exploded View Rear Gearcase 30 ft. lbs. (41 Nm) Coil A-arm bolts Shaft Bushings Shock Upper A-arm Bushings 30 ft. lbs. (41 Nm) Caliper Rear Drive Axle 18 ft. lbs. A-arm bolts (24 Nm) Nuts Bearing Lower A-arm Bushings Carrier Bolt Snap Ring...

  • Page 234: Rear Drive Shaft (4X4 Crew)

    FINAL DRIVE REAR DRIVE SHAFT (4X4 CREW) Outer CV Joint / Boot Replacement Using a side cutters, cut away and discard the boot clamps. Removal Repeat all steps of the “Rear Hub / Bearing Carrier, Hub Removal” section. Remove upper carrier bolt. 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.
  • Page 235 FINAL DRIVE NOTE: Shiny areas in ball tracks and on the cage Make sure the circlip is on the shaft and not left in the joint. spheres are normal. Do not replace CV joints Circlip because parts have polished surfaces. Replace CV joint only if components are cracked, broken, worn or otherwise unserviceable.
  • Page 236 FINAL DRIVE 14. Slide the joint onto the drive shaft splines and align the 20. While pulling out on the CV shaft, fully extend the CV joint circlip with the lead-in chamfer on the inner race of the and slide a straight O-ring pick or a small slotted screw joint.

  • Page 237: Inner Plunging Joint / Boot Replacement

    FINAL DRIVE Inner Plunging Joint / Boot Replacement Make sure the circlip is still on the shaft and not left in the joint. Using a side cutters, cut away and discard the boot clamps. Circlip Remove the boot from the shaft. Remove the large end of the boot from the plunging joint CAUTION and slide the boot down the shaft.
  • Page 238 FINAL DRIVE 12. Install a NEW circlip on the end of the shaft. 18. Remove excess grease from the plunging joint’s external surfaces and place the excess grease in the boot. 13. Grease the joint with the special CV joint grease provided in the boot replacement kit.

  • Page 239: Drive Shaft Exploded View

    FINAL DRIVE Drive Shaft Exploded View REAR SHAFT Spring Ring Plunging Joint Gear Side Boot Kit Grease Capacity 100 Grams Grease Capacity 90 Grams Wheel Side Boot Kit CV Joint 7.46...

  • Page 240: Installation

    FINAL DRIVE Installation Lift bearing carrier into place and install the bolt into the upper control arm. Torque bolt to 30 ft. lbs. (41 Nm). Slide the rear drive axle into the bearing carrier hub. 30 ft. lbs. (41 Nm) Install hub, domed washer (domed side out) and nut.

  • Page 241: Rear Propshaft (4X4 Crew)

    FINAL DRIVE REAR PROPSHAFT (4X4 CREW) Slide the propshaft off the transmission shaft and rear gearcase input shaft. Orientate the shaft so that it’s parallel with the frame supports as shown below. Removal Remove the pin clips from upper and lower cargo box shock pins and remove shock.

  • Page 242: Rear Gearcase (4X4 Crew)

    FINAL DRIVE REAR GEARCASE (4X4 CREW) Differential - Unlock General Operation Clutch Gear The RANGER rear gearcase has three traction operational Shift Yoke modes: AWD, Differential Lock, and Differential Unlock. Locking the rear differential is beneficial in low traction and rough terrain conditions.

  • Page 243: Operation Modes

    FINAL DRIVE Operation Modes When the clutch gear is unlocked the rear drive shafts are dependent on the differential allowing tighter turns. When it’s locked it becomes a solid rear axle increasing traction. AWD Mode Differential Clutch Gear Rear Wheels rotate at same speed. Front Wheels rotate at same speed when AWD activated.

  • Page 244: Gearcase Removal

    FINAL DRIVE Gearcase Removal Gearcase Disassembly IMPORTANT: The pinion gear assembly is NOT Follow “Rear Drive Shaft Removal” procedure to remove the rear drive shafts from each side of the rear differential. intended to be disassembled from the case, as it requires special OEM tooling in order to properly Disconnect the differential solenoid 2-wire harness.
  • Page 245 FINAL DRIVE Remove the differential assembly from the housing. Remove the shims from the differential assembly. Be sure to keep the shims together for reassembly. Inspect the bevel gear teeth for chipped, worn, or broken teeth. Remove the large bearing from the differential assembly. Inspect the bearing for smoothness and wear.
  • Page 246 FINAL DRIVE If the solenoid was removed for servicing, inspect the tip 12. Loosen the lock assembly pin. of the solenoid for wear. If the tip of the solenoid is flattened the solenoid must be replaced. 13. Remove the pin from the gearcase cover. 10.

  • Page 247: Rear Gearcase Assembly

    Replace the drive shaft oil seals located in the main gearcase and gearcase cover Rear Gearcase Assembly NOTE: Grease all seals and O-rings with Polaris All Season Grease (PN 2871322) upon assembly. Remove the pinion shaft oil seal using a seal puller and replace with a new seal.
  • Page 248 FINAL DRIVE Install the original shims (A) onto the differential assembly If previously removed; assembly the shift lever (A), shift (B) on both sides. Install the bearings (C), replace with new lever spring (B), shift return springs (C), shift yoke (D), and bearings if needed.

  • Page 249: Rear Gearcase Installation

    Reverse the removal procedure for the rest of the installation. Add Polaris ATV Angle Drive Fluid (PN 2871653) to rear carrier. Refer to maintenance information in Chapter 2 for more details. Torque drain plug to 30-45 in. lbs. (3-5 Nm).

  • Page 250: Rear Gearcase Exploded View (4X4 Crew)

    FINAL DRIVE Rear Gearcase Exploded View (4x4 CREW) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm) 25-35 ft. lbs. (34-48 Nm) 30-40 ft. lbs. (41-54 Nm) ESCRIPTION ESCRIPTION ESCRIPTION Hypoid Gear Assembly Bearing Cone - Diff Pinion Nut Carrier Housing Half Bearing Cup - Diff Oil Seal - Pinion...

  • Page 251: Rear Axle / Gearcase Service (6X6)

    FINAL DRIVE REAR AXLE / GEARCASE SERVICE Remove the bottom shock bolts and shocks (both sides). (6X6) Rear Axle Removal Jack up vehicle and support on frame and swing arm. CAUTION Serious injury could occur if machine tips or falls. Remove rear wheels.

  • Page 252: Axle Tube Removal

    FINAL DRIVE Axle Tube Removal 10. Loosen the four U-bolts. Loosen each U-bolt nut a few turns at a time, this will reduce stress on all of the U-bolts during Place the rear axle assembly on a clean surface. U-bolt removal. Remove the bolts that secure the rear gearcase to the axle tubes and remove the rear gearcase skid plate Loosen U-bolts...

  • Page 253: Axle Tube Bearing Replacement

    FINAL DRIVE Axle Tube Bearing Replacement Gearcase Disassembly / Inspection Remove the retaining ring from the axle tube. Drain and properly dispose of used oil. Remove the differential housing cover bolts and the gearcase housing cover. Remove the bearings from the axle tube with a bearing puller.

  • Page 254: Gearcase Assembly

    FINAL DRIVE Remove the wave spring from the differential assembly. Inspect the pinion shaft bushing for wear. Wave Spring Remove the four bolts that secure the pinion gear cover to the differential. Remove the pinion gear cover and O-ring. Gearcase Assembly Pinion Gear Cover Replace all O-rings, seals, and worn components.

  • Page 255: Gearcase / Axle Installation

    FINAL DRIVE NOTE: The O-ring is a smaller diameter than the Replace the pinion shaft cover O-ring and install the cover. gearcase. Use two hands to work the O-ring onto the Install the four pinion shaft cover bolts and torque the bolts to 26 ft.
  • Page 256 FINAL DRIVE NOTE: The two top gearcase / axle tube bolts (B) on Install the four U-bolts. Align the U-bolts with the white the left side are installed into the frame later in this marks previously made on the axle tube for proper rear axle assembly procedure.
  • Page 257 FINAL DRIVE Torque the U-bolts nuts to 40 ft. lbs. (54 Nm). 13. Install the brake caliper. Torque the bolts to 18 ft. lbs. (24.8 Nm). U-Bolt Nut Torque: 40 ft. lbs. (54 Nm) Brake Caliper Torque: 18 ft. lbs. (24.8 Nm) 10.

  • Page 258: Rear Gearcase Exploded View (6X)

    FINAL DRIVE Rear Gearcase Exploded View (6x6) 26 ft. lbs. (35 Nm) 30 ft. lbs. (41 Nm) ESCRIPTION ESCRIPTION Seal, Triple Lip O-Ring Screw (5/16-18 x 1.0) Spring, Wave Cover, Input Bearing, Ball O-Ring Shaft, Output Bearing, Ball Gear, Ring 37T Pinion, 10T Bearing, Ball Bearing, Plain...
  • Page 259 FINAL DRIVE NOTES 7.66...
  • Page 260 TRANSMISSION CHAPTER 8 TRANSMISSION TORQUE SPECIFICATIONS..........8.2 SHIFT LEVER .

  • Page 261: Torque Specifications

    TRANSMISSION TORQUE SPECIFICATIONS Remove the shift lever cover and then remove the screw. Pull off the shifter knob. Shift Lever ITEM TORQUE VALUE 10-14 ft. lbs. Transmission Fill Plug (14-19 Nm) 10-14 ft. lbs. Transmission Drain Plug (14-19 Nm) 27-34 ft. lbs. Transmission Case Bolts (37-46 Nm) 12-18 ft.

  • Page 262: Adjustment

    TRANSMISSION Adjustment TRANSMISSION SERVICE Place gear selector in neutral. Make sure the transmission Transmission Removal bell crank is engaged in the neutral position detents. Remove the PVT system from the left side of the transmission. Drive roll pin from rear driveshaft yoke. 4x4 Shown Neutral Position Roll Pin...
  • Page 263 TRANSMISSION Disconnect the transmission switch. Remove the mounting bolts from the transmission mounting on both sides of the transmission. General Transmission Mounting Transmission Switch Remove the cotter pin from the shift linkage rod. Remove the shift linkage rod and a washer from the bellcrank. Remove the four bottom transmission to frame bolts.

  • Page 264: Transmission Disassembly

    TRANSMISSION Transmission Disassembly Mark the detent gear with a white pen. Remove the detent gear from the case. NOTE: Refer to the exploded view at the end of this chapter. NOTE: It may be helpful to place a mark just above the keyed spline.
  • Page 265 TRANSMISSION Note the transmission gear position and mark the two shift 11. Remove the shift drum. gears before removing them to aid with reassembly. NOTE: You may have to tap the shift drum from the Remove the shift gears from the case. backside of the case to aid in removal.
  • Page 266 TRANSMISSION 14. Remove the shift forks from the assembly. Note the correct 17. Remove the bearing from the input shaft with a puller. position of each fork. Shift Fork 18. Remove the snap ring and washer from the reverse shaft. NOTE: The picture above depicts a transmission with a “Park”...
  • Page 267 TRANSMISSION 21. Remove the rest of the bearings from the shafts. 24. Remove the gear, split bearing, and washer from the reverse shaft. 22. Use a press to remove the gear from the shaft. 25. Slide off the shift dogs and wave springs. 23.
  • Page 268 TRANSMISSION 27. Remove bearing and the helical gear. 30. Remove the front housing cover, shim, thrust button, and thrust button shim. 28. Remove the pinion shaft retainer plate and the pinion shaft. 31. Remove the shafts as an assembly. 29. Remove the front housing cover screws. 32.

  • Page 269: Transmission Assembly

    Before installing the cover make sure the sealing surfaces are clean and dry, and shafts are fully seated in the IMPORTANT: New seals should be installed after the transmission case. Apply Polaris Crankcase Sealant to the transmission is completely assembled. mating surfaces.
  • Page 270 TRANSMISSION Apply Loctite™ 262 (Red) (PN 2871951) to screw threads 11. Slide the reverse shaft assembly through the silent chain. and torque screws to 6-12 ft. lbs. (8-16 Nm). 12. Install a new needle bearing, the low gear, the thrust washer and the snap ring.
  • Page 271 TRANSMISSION 16. Carefully install the shaft assembly and gear cluster as a 20. Lift the shift rail slightly and rotate the rail/fork assembly unit into their respective bearing case recesses. Tap with a so it meshes with the tracks on the shift drum. Be sure the soft face hammer to seat shaft assemblies.
  • Page 272 TRANSMISSION 25. Install drain plug with a new sealing washer. Torque drain 28. Install the lockout disc with the raised edge facing outward. plug to 10-14 ft. lbs. (14-19 Nm). Use the white mars that was previously applied for reference. Lockout Disc 29.

  • Page 273: Transmission Installation

    Tighten mounting fasteners in order A-D as shown. Bellcrank Nut Torque: 12-18 ft. lbs. (16-24 Nm) 34. Install transmission and add Polaris AGL Gearcase Lubricant (PN 2873602). Transmission Mounting Bolts Torque 25 ft. lbs. (34.5 Nm) NOTE: Be sure to tighten the lower transmission...

  • Page 274: Troubleshooting

    TRANSMISSION TROUBLESHOOTING Troubleshooting Checklist Check the following items when shifting difficulty is encountered. • Idle speed adjustment • PVT alignment • Transmission oil type/quality • Transmission torque stop adjustment (where applicable) • Engine torque stop adjustment (where applicable) • Drive belt deflection •...

  • Page 275: Transmission Exploded Views

    (10-12 Nm) 15-19 ft. lbs. (20-26 Nm) 10-14 ft. lbs. (14-19 Nm) 27-34 ft. lbs. (37-46 Nm) 12-18 ft. lbs. (16-24 Nm) FOR REASSEMBLY Apply White Lithium Based Grease. Apply Polaris Crankcase Sealant. Apply Loctite 262 to the bolt threads. 8.16...
  • Page 276 TRANSMISSION Exploded View, Continued Ref. Qty. Description Ref. Qty. Description Plug, Fill Sprocket, 22T Plug, Drain, Magnetic Lockout Disc Screw, Self-Tapping 1/4-20 Detent Pawl Screw, 5/16-18 Detent Star Screw, 1/4-20 Bellcrank, Shift Drum Screws, Self-Tapping 5/16-18 Output Shaft, Front Main Nut, Nylon Lock Thrust Button Nut, Nylon Lock...
  • Page 277 TRANSMISSION NOTES 8.18...
  • Page 278 BRAKES CHAPTER 9 BRAKES GENERAL SPECIFICATIONS..........9.2 TORQUE SPECIFICATIONS.

  • Page 279: General Specifications

    BRAKES GENERAL SPECIFICATIONS FRONT BRAKE SYSTEM Item Standard Service Limit Front Brake Pad Thickness .298 ± .007" / 7.56 ± .178 mm .180" (4.6 mm) Front Brake Disc Thickness .158" ( 4.01mm) .140" (3.56mm) Front Brake Disc Runout .010" (.254mm) REAR BRAKE SYSTEM Item Standard...

  • Page 280: Brake System Service Notes

    BRAKES BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life.

  • Page 281: Hydraulic Brake System Operation

    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.

  • Page 282: Brake System Exploded View

    BRAKES BRAKE SYSTEM EXPLODED VIEW LH Front Caliper Master Cylinder Top View LH Front Brake Line Master Cylinder 15 ft. lbs. LH Rear Line (20 Nm) RH Front Caliper LH Rear Caliper Cross Fitting Cross Fitting RH Front MC Rear Brake Line Brake Line Brake...

  • Page 283: Master Cylinder

    BRAKES MASTER CYLINDER FOOT BRAKE PEDAL Removal Pedal Removal Open the hood. Locate the master cylinder. Open the hood. Locate the master cylinder. Remove the retaining clip (A) from the clevis pin (B) that Remove the nut, bushing, tube, and bolt from the brake attaches the master cylinder to the brake pedal lever.

  • Page 284: Brake Bleeding / Fluid Change

    11. Add brake fluid to MAX level inside reservoir. Mity Vac™ (PN 2870975) Add brake fluid to the indicated MAX level of reservoir. Maximum Polaris DOT 4 Brake Fluid Minimum (P/N 2872189) Begin bleeding procedure with the caliper that is farthest from the master cylinder.

  • Page 285: Parking Brake

    BRAKES PARKING BRAKE Exploded View (4x4 CREW) Parking Brake Lever Nuts Clevis Washers Parking Brake Caliper Screw Clevis Clip Clip Washer Bolt Mount Bracket Cable Rear Propshaft Bolts w/Parking Brake Disc Rear Gearcase...

  • Page 286: Exploded View (6X6)

    BRAKES Exploded View (6x6) Parking Brake Clevis Lever Parking Brake Caliper Nuts Clip Bolt Mount Bracket Washers Clevis Parking Brake Disc Clip Screw Washer Middle Gearcase Cable...
  • Page 287 BRAKES Inspection Adjustment Procedure Place the vehicle in neutral on a flat level surface. Inspect the parking brake cable and brake pads on the caliper assembly located on the rear propshaft. Carefully lift the rear of the vehicle off the ground and See “Parking Brake Caliper Service”...

  • Page 288: Parking Brake Caliper Service

    BRAKES PARKING BRAKE CALIPER SERVICE Exploded View Hex Nut Pad & Holder Pad & Holder Plain Washer 18 ft. lbs. (24 Nm) Sleeve Thrust Washer Hex Head Mount Bolt Shim Pack Lever (4 Shims) Asm. Bolt 25 ft. lbs. (34 Nm) Stationary Actuator Spring Pin Compression Spring...

  • Page 289: Caliper Disassembly / Inspection

    BRAKES Loosen the two brake caliper mounting bolts (B) in equal 10. Measure the thickness of the rear caliper parking brake increments. pads. Replace assembly or pads as needed. See illustration below for proper readings. Inboard pad thickness New .304” (7.72 mm) Limit: 0.24”...

  • Page 290: New Brake Pad Installation

    BRAKES New Brake Pad Installation Caliper Installation NOTE: Parking Brake Pads can be replaced by Install the parking brake assembly into place. Tighten the ordering one of the following kits: two mounting bolts in increments for proper installation. PN 2203148 - Brake Pad and Shim Kit 18 ft.

  • Page 291: Front Brake Pads

    BRAKES FRONT BRAKE PADS Push mounting bracket inward and slip outer brake pad past edge. Then remove inner pad. Pad Removal Elevate and support front of vehicle. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.

  • Page 292: Pad Assembly / Installation

    Install the pad adjuster set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn Lubricate mounting bracket pins with a light film of (counterclockwise). Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. 1/2 Turn Adjuster Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap.

  • Page 293: Front Caliper Service

    BRAKES FRONT CALIPER SERVICE Caliper Exploded View 47 in. lbs. Apply Polaris DOT 4 Brake Fluid (5.3 Nm) to Component Apply Polaris All Purpose Grease A. Socket Set Screw B. Bleeder Screw C. Caliper Assy. D. Boot E. Square O-rings F.

  • Page 294: Caliper Disassembly

    BRAKES Remove the two caliper mounting bolts and remove the Remove mounting bracket, pin assembly and dust boot. caliper assembly from the front strut. NOTE: Image shown with brake line attached. Be sure to remove prior to this step. Remove Thoroughly clean the brake caliper before disassembly and prepare a clean work area to disassemble the caliper.
  • Page 295 Caliper Piston Bore I.D.: Std: 1.373” (34.87 mm) Service Limit: 1.375” (34.93 mm) 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.

  • Page 296: Caliper Installation

    BRAKES Lubricate the mounting bracket pins with Polaris Premium Install brake line and torque the banjo bolt to the proper All Season Grease (PN 2871423), and install the rubber torque specification. dust seal boots. 15 ft. lbs. (20 Nm) Install the pad adjustment screw and turn until stationary Compress the mounting bracket and make sure the dust seal pad contacts disc, then back off 1/2 turn.

  • Page 297: Front Brake Disc

    BRAKES FRONT BRAKE DISC Disc Replacement Remove front brake caliper (see “Front Caliper Service”). Disc Inspection Remove dust cap, cotter pin, castle nut and washers. Visually inspect disc for scoring, scratches, or gouges. Remove the wheel hub assembly from the vehicle and Replace the disc if any deep scratches are evident.

  • Page 298: Rear Brake Pads (6X6)

    BRAKES REAR BRAKE PADS (6X6) Pad Inspection Push caliper piston into caliper bore slowly with pads Pad Removal installed. Elevate and support rear of machine. NOTE: Brake fluid will forced through compensating port into master cylinder fluid CAUTION reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required.

  • Page 299: Pad Installation

    BRAKES Pad Installation REAR BRAKE PADS (4X4 CREW) Install new pads in caliper body. Pad Removal Elevate and support rear of vehicle. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. Remove the wheel nuts, washers and rear wheel.
  • Page 300 Push mounting bracket inward and slip outer brake pad past edge. Then remove inner pad. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Pad Inspection Compress mounting bracket and make sure dust boots are fully seated.

  • Page 301: Brake Burnishing Procedure

    BRAKES Install the adjustment set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). 1/2 Turn Adjuster Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap. Master Cylinder Fluid Up to MAX line inside reservoir Install wheel and torque wheel nuts to specification (see “Chapter 2 - Maintenance”).

  • Page 302: Rear Caliper Service (6X6)

    BRAKES REAR CALIPER SERVICE (6X6) Rear Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Component Apply Polaris All Purpose Grease A. Socket Set Screw 47 in. lbs. B. Bleeder Screw (5.3 Nm) C. Caliper Assy. D. Boot E. Square O-rings F.
  • Page 303 BRAKES Caliper Disassembly Caliper Inspection Remove brake pad adjuster screw (A). 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. Push upper pad retainer pin inward and slip brake pads past edge, if pads are still installed.
  • Page 304 (PN 2872189). Install piston (B) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance. Lubricate the mounting bracket pins with Polaris Premium All Season Grease, and install the rubber dust seal boots. Polaris Premium All Season Grease...

  • Page 305: Rear Caliper Service (4X4 Crew)

    BRAKES REAR CALIPER SERVICE (4X4 CREW) Rear Caliper Exploded View 47 in. lbs. Apply Polaris DOT 4 Brake Fluid (5.3 Nm) to Component Apply Polaris All Purpose Grease A. Socket Set Screw B. Bleeder Screw C. Caliper Assy. D. Boot E.

  • Page 306: Caliper Disassembly

    BRAKES Remove the two caliper mounting bolts and remove the Remove mounting bracket, pin assembly and dust boot. caliper assembly from the rear hub. Remove Thoroughly clean the brake caliper before disassembly and prepare a clean work area to disassemble the caliper. Use low pressure compressed air to remove the pistons Caliper Disassembly from the caliper.
  • Page 307 Caliper Piston Bore I.D.: Std: 1.192” (30.28 mm) Service Limit: 1.194” (34.33 mm) 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.

  • Page 308: Caliper Installation

    BRAKES Lubricate the mounting bracket pins with Polaris Premium Install brake line and tighten securely with a line wrench. All Season Grease (PN 2871423), and install the rubber Torque the banjo bolt brake line(s) to the proper torque dust seal boots.

  • Page 309: Rear Brake Disc

    BRAKES REAR BRAKE DISC Remove the wheel hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub. Disc Inspection (4) Bolts Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. Use a 0-1"micrometer and measure disc thickness at 8 Dust different points around perimeter of disc.

  • Page 310: Troubleshooting

    BRAKES TROUBLESHOOTING Brakes Squeal / Poor Brake Performance • Air in system • Water in system (brake fluid contaminated) • Caliper/disc misaligned • Caliper dirty or damaged • Brake line damaged or lining ruptured • Worn disc and/or friction pads •...
  • Page 311 BRAKES NOTES 9.34...
  • Page 312 ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION ..........10.3 SPECIAL TOOLS .
  • Page 313 ELECTRICAL STARTER SYSTEM ........... 10.29 TROUBLESHOOTING .

  • Page 314: General Information

    ELECTRICAL GENERAL INFORMATION Under-Hood Components The following components can be accessed under the hood. Special Tools • Voltage Regulator Part Number Tool Description • Battery PV-43568 Fluke™ 77 Digital Multimeter • Battery Cables 2870630 Timing Light • Terminal Block 2870836 Battery Hydrometer •...

  • Page 315: Switches / Controls

    ELECTRICAL SWITCHES / CONTROLS Inspect the switch connections and test the switch for continuity at the appropriate pin terminals as shown in the following illustration. Headlight Switch Lift the front hood. The wires are located on the back side of the instrument panel.

  • Page 316: Brake Light Switch

    ELECTRICAL Differential Solenoid Circuit Operation If the rear carrier fails to switch from operational modes: The rear differential solenoid relay is located under the hood. • Check the connector located under the left rear fender. Look for loose wires or bad connections. Power is present at the AWD / 2WD / Turf Switch when the •...

  • Page 317: Parking Brake Switch

    ELECTRICAL Parking Brake Switch Testing The Parking Brake Switch Disconnect the harness connector at the parking brake The parking brake switch is located within the parking brake switch (Orange/Red and Red/White wires). lever. Follow the parking brake lever under the dash to locate the internally mounted switch.

  • Page 318: Instrument Cluster

    ELECTRICAL INSTRUMENT CLUSTER Rider Information Display The rider information display is located in the instrument Overview cluster. All segments will light up for 2.5 seconds at start-up. The RANGER instrument cluster senses vehicle speed from the NOTE: If the instrument cluster fails to illuminate, a right front wheel.

  • Page 319: Standard Display Modes

    ELECTRICAL Standard Display Modes Clock Screen Use the yellow mode button located under the speedometer to toggle through the mode options. Odometer Mode The odometer records the miles 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.
  • Page 320 ELECTRICAL AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil. NOTE: A 10 - 20% variance from these readings is within normal parameters. Programmable Service Interval Gear Circuit Diagnostic Screen When the hours of engine operation equal the programmed This screen displays the resistance value (in ohms) being read at service interval setting, the wrench icon will flash for 5 seconds the gear switch input of the gauge.

  • Page 321: Viewing Diagnostic Codes

    ELECTRICAL To enable or disable the service interval: Enter the diagnostic mode. Toggle to the service interval screen. 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: Enter the diagnostic mode.

  • Page 322: Instrument Cluster Installation

    ELECTRICAL Any blink code numbers stored in the EFI module will Push the instrument cluster out from the back side of the display, one at a time, on the screen. dash panel, while securely holding the panel and rubber Example below shows a Blink Code of “42”. mount.

  • Page 323: Instrument Cluster Troubleshooting Tests

    ELECTRICAL INSTRUMENT CLUSTER TROUBLESHOOTING TESTS Test 1 - No All Wheel Drive 10.12...

  • Page 324: Test 2 - No Display

    ELECTRICAL TEST 2 - No Display TEST 3 - Wheel Speed Sensor 10.13...

  • Page 325: Test 4 - No Awd Hub Safety Limiter

    ELECTRICAL TEST 4 - No AWD Hub Safety Limiter 10.14...

  • Page 326: Test 5 - Fuel Gauge Display Not Working

    ELECTRICAL TEST 5 - Fuel Gauge Display Not Working TEST 6 - Shift Indicator Not Working (Transmission Switch) 10.15...

  • Page 327: All Wheel Drive (Awd) Coil

    ELECTRICAL ALL WHEEL DRIVE (AWD) COIL GEAR POSITION INDICATOR SWITCH Operation Overview Test Diagram • When the AWD switch is “ON”, 12 VDC power is NOTE: Also see “INSTRUMENT CLUSTER present at the hub coil. TROUBLESHOOTING” for switch circuit. TRANSMISSION SWITCH •...

  • Page 328: Headlights

    ELECTRICAL HEADLIGHTS Adjust the beam to desired position. Repeat the procedure to adjust the other headlight. Headlight Adjustment WARNING The headlight beam is adjustable. Due to the nature of light utility vehicles and Place the vehicle on a level surface with the headlight where they are operated, headlight lenses approximately 25 ft.

  • Page 329: Headlight Housing Installation

    ELECTRICAL TAIL LIGHT / BRAKE LIGHT Remove the O-ring (A) from the headlight brackets (both sides). Lamp Replacement Before replacing the tail light, use a digital multi-meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present.

  • Page 330: Cooling System

    ELECTRICAL COOLING SYSTEM Cooling System Break-Out Diagram 10.19...

  • Page 331: Coolant Temperature Sensor

    ELECTRICAL Fan Control Circuit Operation EFI DIAGNOSTICS Power is supplied to the fan via the Orange/Black wire when the EFI Component Testing relay is ON. The ground path for the fan motor is through the Brown harness wire. Refer to “RELAYS” later in this chapter All EFI component information and diagnostic testing for more information on fan functions.

  • Page 332: Relays

    ELECTRICAL RELAYS REAR DIFF SOLENOID RELAY Operation OLOR UNCTION Key-On battery power supply, switched on The relays, located under the hood, assist with component Red / White by key switch, enables power to relay. operation like the fan, fuel pump, and rear differential. Brown Ground path for relay.

  • Page 333: Fuses / Circuit Breaker

    ELECTRICAL FUSES / CIRCUIT BREAKER Operation The fuse panel, located under the hood, provides component protection for components such as the Instrument Cluster, ECU, EFI system, Chassis Power and Accessories. A 15-amp circuit breaker protects the fan motor circuit. 10.22...

  • Page 334: Charging System

    ELECTRICAL CHARGING SYSTEM Charging System “Break Even” Test Current Draw - Key Off CAUTION 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 Do not connect or disconnect the battery cable damage to electrical components.

  • Page 335: Charging System Alternator Tests

    ELECTRICAL Charging System Alternator Tests TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM Three tests can be performed using a multi-meter to determine the condition of the stator (alternator). Set the selector dial to measure AC Voltage. Start the engine and let it idle.

  • Page 336: Charging System Testing Flow Chart

    ELECTRICAL 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.: Remove the battery and properly ser- Using a multitester set on D.C. volts, mea- vice.

  • Page 337: Battery Service

    ELECTRICAL BATTERY SERVICE Battery Activation Battery Terminals / Bolts CONVENTIONAL BATTERY Use Polaris corrosion resistant Nyogel™ grease (PN 2871329) Removable on battery terminal bolts. Caps Top View Electrolyte Level Indicator Apply Side View Nyogel™ WARNING Battery Terminal Block The terminal block is located under the front hood next to the Battery electrolyte is poisonous.

  • Page 338: Battery Inspection

    ELECTRICAL To ensure maximum service life and performance from a new Inspect the battery fluid level. When the battery fluid nears the battery, perform the following steps. NOTE: Do not service the lower level, remove the battery and fill with distilled water only battery unless it will be put into regular service within 30 days.

  • Page 339: Off Season Storage

    ELECTRICAL Specific Gravity Test A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still may not have the storage A tool such as a Battery Hydrometer (PN 2870836) can be used capacity necessary to properly function in the electrical system.

  • Page 340: Troubleshooting

    ELECTRICAL STARTER SYSTEM Voltage Drop Test The Voltage Drop Test is used to test for bad connections. When Troubleshooting performing the test, you are testing the amount of voltage drop through the connection. A poor or corroded connection will Starter Motor Does Not Run appear as a high voltage reading.

  • Page 341: Brush Inspection / Replacement

    ELECTRICAL NOTE: Note the alignment marks on both ends of Measure resistance between insulated brush and starter the starter motor casing. These marks must align housing. Reading should be infinite (OL). Inspect during reassembly. insulation on brush wires for damage and repair or replace as necessary.

  • Page 342: Armature Testing

    ELECTRICAL Brush Replacement Measure the resistance between each commutator segment and the armature shaft. The reading should be infinite (no Remove terminal nut with lock washer, flat washer, large continuity). phenolic washer, the small phenolic spacers, and sealing O-ring. Inspect O-ring and replace if damaged. Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate.

  • Page 343: Starter Drive

    ELECTRICAL NOTE: It is important to tighten the bottom starter Install O-ring, two small phenolic spacers, large phenolic bolt first (circle), as the bottom hole acts as a pilot washer, flat washer, lock washer, and terminal nut. hole to properly align the starter drive (bendix) with While holding brush springs away from brushes, push the flywheel.

  • Page 344: Starter Solenoid Bench Test

    ELECTRICAL 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.

  • Page 345: Starter Exploded View

    ELECTRICAL Starter Exploded View 10. Gear Assembly Indicates Do not reuse. 1. Rubber Ring* Replace with new parts. 11. Through Bolt 2. Brush Spring 12. Cover 3. Thrust Washer 13. Stopper 4. Gear Assembly 14. Snap Ring 5. O-Ring* 15. Washer 6.

  • Page 346: Starting System Testing Flow Chart

    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 Remove battery and properly service. Install red lead on the battery positive. Reading should fully charged shop battery to continue test.

  • Page 347: Electric Box Lift Actuator

    ELECTRICAL ELECTRIC BOX LIFT ACTUATOR DIAGNOSIS (if equipped) 1. Disconnect the wiring harness to the Disconnect Harness box lift actuator. 2. Connect a multimeter across the box lift actuator harness connection. 3. Actuate the box lift switch in both directions. Verify that there is 12 Volts reaching the box lift actuator.

  • Page 348: Electrical Break-Out Diagrams

    ELECTRICAL ELECTRICAL BREAK-OUT DIAGRAMS Starting Circuit Key-On Power Circuit 10.37...

  • Page 349: Transmission Switch Circuit

    ELECTRICAL Transmission Switch Circuit AWD Circuit 10.38...

  • Page 350: Speed Sensor Circuit

    ELECTRICAL Speed Sensor Circuit Charging System Circuit 10.39...

  • Page 351: Cooling Fan Circuit

    ELECTRICAL Cooling Fan Circuit Fuel Display / Fuel Pump Circuit 10.40...
  • Page 352 Air Filter Service ......2.12 Cab Frame, Assembly / Removal (4x4 CREW) ..5.9 Air Intake Inspection .
  • Page 353 Engine, Oil Pressure Test ......3.20 Engine, Oil Pump Disassembly ....3.41 EFI Circuit Diagrams .
  • Page 354 Fuel Sender Test ......4.12 10.20 Parking Brake Caliper, Removal ....9.11 Fuel System .
  • Page 355 Special Tools, Clutching ......6.2 Switch, Headlight ......10.4 Special Tools, EFI .
  • Page 356 PN 9921885 Printed in USA...
  • Page 357 WIRE DIAGRAM 2009 RANGER 700 4X4 CREW (CHASSIS/BOX) PAGE 1 OF 2 WD-1...
  • Page 358 WIRE DIAGRAM 2009 RANGER 700 4X4 CREW (CHASSIS/BOX) PAGE 2 OF 2 WD-2...
  • Page 359 WIRE DIAGRAM 2009 RANGER 700 6X6 (CHASSIS) PAGE 1 OF 2 WD-3...
  • Page 360 WIRE DIAGRAM 2009 RANGER 700 6X6 (CHASSIS) PAGE 2 OF 2 WD-4...
  • Page 361 WIRE DIAGRAM 2009 RANGER 700 4X4 CREW / 6X6 (DASH) WD-5...
  • Page 362 WIRE DIAGRAM 2009 RANGER 700 4X4 CREW / 6X6 (BREAKOUTS) WD-6...

This manual is also suitable for:

2009 ranger 700 4x4 crew2009 ranger 700 6x6

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