improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this

publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any

reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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Summary of Contents for Polaris Ranger RZR SW

Page 1 Publication Printed July 2010 (PN 9922720-CD) © Copyright 2010 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 2 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.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
Page 3 GENERAL INFORMATION MAINTENANCE ENGINE ELECTRONIC FUEL INJECTION BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...
Page 5: Table Of Contents
MODEL: 2011 RANGER RZR SW ........
Page 6: Model Information
Vehicle and Engine Serial Number Location Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on a portion of the front left frame rail, close to the left front wheel (see Figure 1-1).
Page 7: Vehicle Information
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 8: General Specifications
GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2011 RANGER RZR SW MODEL NUMBER: M11VE76AA ENGINE NUMBER: 1204276 Category Dimension / Capacity Length 112 in. / 284.5 cm Width 59 in. / 150 cm Height 72.5 in. / 184 cm Wheel Base 77 in. / 196 cm Ground Clearance 13 in.
Page 9 GENERAL INFORMATION MODEL: 2011 RANGER RZR SW Drivetrain Transmission Type Polaris Automatic PVT MODEL NUMBER: M11VE76AA Drive Gear Ratio - Front Output ENGINE NUMBER: 1204276 Reverse 8.3398:1 Engine 7.1474:1 H.O. Domestic Twin Cylinder, High 2.8226:1 Platform Liquid Cooled, 4-Stroke Drive Gear Ratio - Rear Output...
Page 10: Misc. Specifications And Charts
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C...
Page 11: 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.
Page 12: Sae Tap / Drill Sizes
GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes...
Page 13: 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 14 GENERAL INFORMATION NOTES 1.10...
Page 15 MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART ......... 2.3 BREAK-IN PERIOD .
Page 16 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM ........2.26 BATTERY MAINTENANCE .
Page 17: 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 18: Pre-Ride - 25 Hour Maintenance Interval
25 H 250 (400) 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 19: 50 - 300 Hour Maintenance Interval
Inspect periodically; adjust when parts are  Toe Adjustment replaced 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 20: Maintenance Quick Reference
2 years Maintain fluid level between Check level during pre-ride Brake Fluid Polaris DOT 4 Brake Fluid “MAX and “MIN” lines on the inspection; change fluid every master cylinder reservoir two years * More often under severe use, such as operated in water or under severe loads.
Page 21: Maintenance Quick Reference, Continued
Lube Rec. Method Frequency* Add lubricant until it is visible Check level every 25 hours; Front Gearcase Polaris Demand Drive Plus at the fill hole threads change fluid yearly Polaris ATV Angle Drive Add lubricant until it is visible Check level every 25 hours;...
Page 22: Grease Lubrication Points
Item Recommended Lube Method Frequency Front Propshaft Yoke Grease before long periods Grease fittings every 500 of storage, and after A-arm Pivot Bushings Polaris Premium U-Joint Grease miles (800 km). thoroughly washing or Stabilizer Bar Bushings submerging the vehicle.
Page 23: Lubricants / Service Products
MAINTENANCE LUBRICANTS / SERVICE PRODUCTS NOTE: Each item can be purchased separately at your local Polaris dealer. Polaris Lubricants, Maintenance and Service Part No. Description Products Additives / Sealants / Thread Locking Agents / Misc. Part No. Description Loctite™ Threadlock 242 2871950 (6 ml.) (12 count)
Page 24: General Vehicle Inspection And Maintenance
MAINTENANCE GENERAL VEHICLE INSPECTION Locate the shift cable in the rear LH wheel well area. AND MAINTENANCE Clevis Pin Shift Cable Pre-Ride / Daily Inspection Mount Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. •...
Page 25: Fuel System And Air Intake
MAINTENANCE FUEL SYSTEM AND AIR INTAKE Fuel Pump / Fuel Filters The RZR 800 EFI engine uses a serviceable, high-volume, high- Fuel System pressure, fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator. WARNING Fuel Pump Asm Gasoline is extremely flammable and explosive...
Page 26: Throttle Pedal Inspection
MAINTENANCE Throttle Pedal Inspection Remove the (2) push rivets retaining the air intake box and remove the box from the frame. If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully.
Page 27: Air Filter Service
MAINTENANCE NOTE: While adjusting, lightly move the throttle NOTE: If the filter has been soaked with fuel or oil it pedal in and out. must be replaced. Re-tighten the jam nut after final adjustment is made. Seal Apply a small amount of grease to the inside of the boot and slide it over the cable adjuster to its original position.
Page 28 MAINTENANCE Air Box / Air Filter Exploded View Front Foam Seal Air Intake Duct Intake Box Foil Primary Foam Seal Intake Seal Seal Breather Filter Fitting Breather Hose Boot Clip (3) Filter Ring Air Box Can Clamps Seal Air Filter 2.14...
Page 29: Engine
MAINTENANCE ENGINE NOTE: Due to the dipstick entry angle into the crankcase, the oil level will read higher on the bottom side of the dipstick. Proper level indication is Engine Oil Level determined on the upper surface of the dipstick as it The twin cylinder engine is a wet-sump engine, meaning the oil is being removed, regardless of the level marks is contained in the bottom of the crankcase.
Page 30 MAINTENANCE Clean area around oil drain plug at bottom of engine. 11. Lubricate O-ring on new filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition. 12. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn.
Page 31: Engine Breather Hose Inspection
MAINTENANCE Engine Breather Hose Inspection Exhaust - Spark Arrestor The engine is equipped with a breather hose. Inspect the WARNING breather hose for possible kinks or wear. The hose is form fit- ted for a proper fit. Follow the breather hose from the side of Do not clean spark arrestor immediately after the the airbox to the engine valve cover.
Page 32: Transmission And Gearcases
MAINTENANCE TRANSMISSION AND GEARCASES Transmission / Gearcase Specification Chart RAIN EVEL HECK EARCASE UBRICANT APACITY ORQUE ORQUE Transmission AGL Plus 24 oz. (710 ml) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm) (Main Gearcase) Gearcase Lubricant Transmission AGL Plus 14 oz.
Page 33 MAINTENANCE Main Gearcase - Lubricant Level Check: Add the recommended fluid through the fill plug hole until it begins to flow out the level plug hole. Do not overfill. The fill plug is located on the side of the gearcase just below the shift lever bell crank.
Page 34: Front Gearcase Lubrication
The drain plug is located on the bottom of the gearcase. Front Gearcase Specifications Specified Lubricant: Polaris Demand Drive Plus (PN 2877922) Capacity: 6.75 oz. (200 ml) Fill Plug: 8-10 ft. lbs. (11-14 Nm) Drain Plug: 8-10 ft. lbs. (11-14 Nm)
Page 35: Rear Gearcase Lubrication
MAINTENANCE Rear Gearcase Lubrication Lubricant Change: The rear gearcase lubricant level should be checked and The drain plug is located on the bottom right side of the rear changed in accordance with the maintenance schedule. gearcase. • Be sure vehicle is positioned on a level surface when Remove the fill plug.
Page 36: Cooling System
Remove recovery bottle cap and add coolant using a funnel. Polaris Premium 60/40 is already premixed and ready to use. Do Fill recovery bottle to MAX level with Polaris 60/40 not dilute with water.
Page 37: Cooling System Pressure Test
MAINTENANCE Cooling System Pressure Test Carefully straighten any bent radiator fins. Refer to Chapter 3 for cooling system pressure test procedure. Remove any obstructions with compressed air or low pressure water. Cooling System Hoses CAUTION Inspect all hoses for cracks, deterioration, abrasion or leaks.
Page 38: Final Drive / Wheel And Tire
MAINTENANCE Radiator Removal FINAL DRIVE / WHEEL AND TIRE Remove the front bumper (see Chapter 5). Wheel and Hub Torque Table Remove the upper engine outlet hose and recovery hose from the top of the radiator. Item Nut Type Specification Remove the (2) upper radiator retaining bolts and the (4) Aluminum Wheels Lug Nut...
Page 39: Tire Inspection
MAINTENANCE Torque the wheel nuts and/or hub nut to the proper torque Tread specification listed in the torque table at the beginning of Depth 1/8" (3 mm) this section. If hub nut was removed, install a new cotter pin after the hub nut has been tightened.
Page 40: Electrical And Ignition System
MAINTENANCE ELECTRICAL AND IGNITION SYSTEM Battery Removal Remove the driver’s seat to access the battery. Battery Maintenance Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water.
Page 41: Battery Off Season Storage
MAINTENANCE Battery Off Season Storage Measure gap with a wire gauge. Adjust gap if necessary by carefully bending the side electrode. Refer to Chapter 10 “Electrical” for off season storage Spark Plug Gap procedures. Battery Charging (Maintenance Free) Refer to Chapter 10 “Electrical” for charging procedure. Spark Plug Service Gap - .035"...
Page 42: Steering
WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician. Use only genuine Polaris replacement parts.
Page 43: Wheel Toe Alignment Inspection
MAINTENANCE Wheel Toe Alignment Inspection Wheel Toe Adjustment Place machine on a smooth level surface and set steering If toe alignment is incorrect, measure the distance between wheel in a straight ahead position. Secure the steering vehicle center and each wheel. This will tell you which tie rod wheel in this position.
Page 44: Suspension (Fox™)
MAINTENANCE SUSPENSION (FOX™) • IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be Spring Preload Adjustment immediately apparent if done incorrectly. The front and rear shocks have a preload adjustment.
Page 45: Shock Compression Adjustment
MAINTENANCE Shock Compression Adjustment The compression damping adjustment is located on top of the shock ‘Piggyback’ reservoir of each shock. Factory Preload Setting 4.8 in. (12.2 cm) Use a flat blade screwdriver to make damping adjustments. NOTE: When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed Decrease Increase...
Page 46: 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 47: Maintenance Log
MAINTENANCE MAINTENANCE LOG Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician 2.33...
Page 48 MAINTENANCE NOTES 2.34...
Page 49 ENGINE CHAPTER 3 ENGINE ENGINE SPECIFICATIONS ..........3.2 CRANKCASE EXPLODED VIEWS .
Page 50: Engine Specifications
ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views...
Page 51 ENGINE Oil Pump / Water Pump / Engine Cover Exploded View...
Page 52 ENGINE Stator Cover / Starter / Water Pump Oil Filter / Pressure Relief / Exploded View...
Page 53 ENGINE Cylinder / Cylinder Head / Piston Exploded View ±...
Page 54 ENGINE Engine EFI Sensors / Valve Cover General Component Exploded View NOTE: See Chapter 4 for more information on the EFI System.
Page 55: 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...
Page 56: Torque Specifications
ENGINE Torque Specifications Fastener Size in. lbs. (Nm) ft. lbs. (Nm) Camshaft Phase Sensor Bolt 50 ± 5 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 57: 800 Efi Engine Service Specifications
ENGINE 800 EFI Engine Service Specifications Cylinder Head - Engine Specifications Main Component: Cylinder Head RZR800HO-11 (PN 1204276) Cam Lobe Height - Intake 1.357” (34.477 mm) Cam Lobe Height - Exhaust 1.342” (34.096 mm) 1.654"  0.00039" (42  0.010 mm) Camshaft Journal Outer Diameter - Mag 1.634"...
Page 58 ENGINE Cylinder / Piston - Engine Specifications Main Components: Cylinder / Piston / Connecting Rod RZR800HO-11 (PN 1204276) 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"...
Page 59: Special Tools
ENGINE Special Tools Part Number Tool Description PU-50105 OIL FILTER WRENCH PU-45257 VALVE SPRING COMPRESSOR PU-45652 VALVE PRESSURE HOSE 2871043 FLYWHEEL PULLER 2870390 PISTON SUPPORT BLOCK PU-45497-1 CAM GEAR SPRING INSTALLATION KIT PU-45497-2 CAM GEAR TOOTH ALIGNMENT TOOL PU-45498 CAM SPANNER WRENCH PU-45838 GEAR HOLDER PA-44995...
Page 60: Engine Cooling System
CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce Pressure Cap heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.
Page 61: Cooling System Exploded View
ENGINE Cooling System Exploded View Bypass Hose (To Cylinder Head) Engine Outlet Hose (Thermostat Housing) Radiator Inlet Hose To Lower Fitting on Filler Neck Engine Inlet Hose (Water Pump Cover) Fan Motor Shroud Pressure Cap Filler Neck Recovery Bottle Radiator Outlet Hose Radiator To Top Fitting on Filler Neck...
Page 62: Cooling System Bleeding Procedure
ENGINE Cooling System Bleeding Procedure Remove pressure cap and top off coolant. Remove recovery bottle cap and fill bottle to the full line. WARNING Recovery Bottle Always wear safety glasses and proper shop clothing when performing the procedures in this Pressure Cap manual.
Page 63: General Engine Service
ENGINE GENERAL ENGINE SERVICE 10. Add Polaris Premium Antifreeze to the radiator filler neck if the level goes down. If no bubbles are seen at the filler neck, the system should be purged of air Engine Lubrication Specifications WARNING Be sure to install the pressure cap before shutting off the engine.
Page 64: Oil Flow Chart
ENGINE Oil Flow Chart This chart describes the flow of oil through the 800 EFI engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.
Page 65: Engine Removal
Remove the (2) screws from the rear of the center console. Because of its design configuration and fastener torque requirements, Polaris recommends removing the engine, transmission and rear gearcase as one assembly. Use the following procedure when engine removal is required.
Page 66 ENGINE 14. Loosen the hose clamp attaching the outlet duct to the PVT 18. Remove the (6) fasteners retaining the upper bolt-in frame cover. Leave the duct attached to the upper frame support. brace and remove it from the vehicle with the ignition coil and PVT duct attached.
Page 67 ENGINE 22. Loosen the hose clamp between the throttle body and intake 25. Remove the airbox and throttle body from the vehicle as an adaptor. assembly. Take care in not allowing the throttle cable to bend excessively or kink. Carefully place the assembly on Loosen the floor next to the vehicle.
Page 68 ENGINE NOTE: If the upper jam nut is moved, shift cable 27. Disconnect the fuel line from the fuel injector rail by adjustment will required during engine slightly squeezing the lock tabs and gently pushing the connector lock out. To separate the lines, pull the fuel line installation (see Chapter 2 “Shift Cable Inspection / from the tank strait down.
Page 69 ENGINE 33. Disconnect the transmission speed sensor harness. 36. Remove the through-bolt that attaches the upper A-arm to the rear hub on both sides of the vehicle. Speed Sensor Connector 34. Disconnect the cam phase sensor connector. 37. Pivot the A-arms upward and rear hub carriers downward and remove the drive shafts from the hub carriers.
Page 70 ENGINE 39. Disconnect the engine coolant temperature (ECT) sensor 45. Remove RH engine mount fastener. harness and the bypass coolant hose. Connector Coolant Bypass 46. Remove the (2) lower bolts that retain the LH transmission 40. Loosen the hose clamp and remove the lower coolant hose mount to the frame.
Page 71 ENGINE 48. Using an engine hoist, hook a chain between the engine / 50. Remove propshaft from the transmission output shaft. transmission mounting plate and the transmission / rear 51. Then move assembly towards the front of the vehicle while gearcase mounting plate.
Page 72: Engine / Transmission Separation
ENGINE Engine / Transmission Separation Tilt the assembly up and remove the remaining (2) nuts that retain the transmission to the engine. Once the engine / transmission / rear gearcase assembly has been removed from the vehicle, the engine and transmission will need to be separated to allow engine servicing.
Page 73: Engine Disassembly And Inspection
ENGINE ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Head Bolts Valves Rocker Arms Retainer Locks (keepers) Push Rods Spring Retainers Springs Valve Seals (2) Valve Spring Seats (2) Coolant Bleeder Cylinder Head Hydraulic Lifters 3.25...
Page 74: Rocker Arms / Push Rods
ENGINE Rocker Arms If the push rod (A) is visibly bent, it should be replaced. Remove the valve cover. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. Cylinder Head Removal NOTE: The cargo box assembly and the upper frame bolt-in brace must be removed to allow enough clearance to remove all the cylinder head bolts.
Page 75: Cylinder Head Inspection / Cylinder Head 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 76: 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 77: Valve Inspection
ENGINE Valve Inspection = In. / mm. Remove all carbon from valves with a soft wire wheel or brush. Check valve face for runout, pitting, and burnt spots. To Valve Stem Diameter: Intake: 0.2356"  0.00039" check for bent valve stems, mount valve in a drill or use “V” (5.985 ...
Page 78: Combustion Chamber
Combustion Area Install pilot into valve guide. Valve Seat Reconditioning Apply cutting oil to valve seat and cutter. NOTE: Polaris recommends that the work be done  by a local machine shop that specializes in this area. Place 46 cutter on the pilot and make a light cut.
Page 79 ENGINE Inspect the cut area of the seat: NOTE: When using an interference angle, 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 80: Cylinder Head Reassembly
ENGINE Cylinder Head Reassembly Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the NOTE: Assemble the valves one at a time to valve. maintain proper order. NOTE: Lapping is not required with an interference Apply engine oil to valve guides and seats.
Page 81: 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 82: 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 Remove the circlip. Mark the piston with a white pen to has a locating tab on the end which fits into a notch (B) in the ensure proper orientation (if reused) during assembly.
Page 83: Cylinder Inspection
ENGINE Cylinder Inspection Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure in two Remove gasket material from cylinder sealing surfaces. different directions, front to back and side to side, on three different levels (1/2, down from top, in the middle, and 1/ Inspect the top of the cylinder (B) for warp using a straight 2, up from bottom).
Page 84: 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 85: Piston-To-Cylinder Clearance
ENGINE Piston-to-Cylinder Clearance Measure piston pin O.D. Replace piston and/or piston pin if out of specification. 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 86: 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 87: 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 88 ENGINE Remove the nut (C), washer (D) and water pump impeller Remove the starter bendix (G), wire holddown plate (H), (E). Remove part of the water pump seal behind the and the woodruff key (I) from the crankshaft. The stator impeller.
Page 89 ENGINE Use a white pen to accent the timing marks on the following gears: camshaft gear (K), crankshaft gear (M), or CAUTION 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 90 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 Inspect Teeth & Tabs gear hole.
Page 91 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 92 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 93 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 94 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 95: Camshaft Inspection
ENGINE Camshaft Inspection 39. Remove and clean oil pick up (V) and oil baffle weldment (W). Thoroughly clean the cam shaft. Visually inspect each cam lobe for wear, chafing or damage. Measure height of each cam lobe using a micrometer. Compare to specification.
Page 96: Engine Reassembly
ENGINE ENGINE REASSEMBLY Measure camshaft journal outside diameters (O.D.). Crankcase Reassembly CAUTION After any reassembly or rebuild, the engine must be primed using the Oil Priming Adapter (PU-45778) and a 3/4-full oil filter before initial start-up (see “Oil Pump Priming”). NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris.
Page 97 ENGINE NOTE: Always install new balance shaft bearings. Assemble the crankcase halves. Apply LocTite™ 242 (PN 2871949) to the threads and pipe sealant to the bolt flanges. Apply assembly lube to cam journals and balance shaft Torque bolts to specification following torque pattern at bearing surfaces of the MAG case halve.
Page 98 ENGINE 10. Lubricate connecting rods with PS-4 PLUS synthetic 13. Install piston assemblies into cylinder aligning the piston engine oil. pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons. 11.
Page 99 ENGINE NOTE: While installing in piston circlips, cover all 17. Assemble rotors as marked when disassembled. Use a engine passages. The clip could fall into the engine cleaner to remove the marks previously made on the rotors. during installation. Line Up Marks 18.
Page 100 ENGINE 20. Install oil pump housing bolts (H). The new bolts contain 22. Before installing the crankshaft gear (I), heat the crankshaft    patch lock, so Loctite is not needed on the new bolts. gear to 250 F (121 C) on a hot plate (J).
Page 101 ENGINE 25. Install counter balance shaft gear (J) with new key, aligning NOTE: Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve timing marks with crankshaft gear (I). Install washer and bolt. Use the Gear Holder (PU-45838). Torque to train is assembled.
Page 102 ENGINE NOTE: Install the crankshaft seal (P) with the seal lip 28. Before installing the gear / stator housing, replace the seals facing out (towards the crankcase). in the cover. Install a new water pump seal (N) into the gear / stator housing.
Page 103 ENGINE 32. Before installing the gear/stator housing cover, install the Water Pump Seal Saver (PA-45401) onto the water pump shaft. PA-45401 35. Install the gear/stator housing gasket onto the crankcase. Gear / Stator Housing Gasket 33. Install a NEW gasket to the gear/stator housing cover and crankcase.
Page 104 ENGINE NOTE: Before assembly, clean the bolts and bolt 39. Install water pump cover (R) with new O-ring seal. Torque holes with Primer N (PN 2874275) to remove any bolts to specification in proper sequence (see Page 3.4). debris. This will ensure proper sealing when Install the O-ring dry installing bolts.
Page 105: Flywheel / Stator Installation
ENGINE Flywheel / Stator Installation NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any Flywheel Nut Torque debris. This will ensure proper sealing when 65 ± 7 ft. lbs. (88 ± 9.50 Nm) installing bolts.
Page 106 ENGINE Install cylinder head on cylinder. Lubricate push rods (D) and install into lifters. Lubricate threads and top of washers underside of bolt head with engine oil. Install head bolts (C) and torque to specification in sequence. Lubricate rockers (E) with engine oil. Verify pushrods are engaged in lifters.
Page 107: Oil Pump Priming
ENGINE Install breather reed (G) into rocker cover (H). Lightly 11. Install thermostat (J), new O-ring, and thermostat housing. apply black RTV sealant to the outer edges of the breather Torque to specification. reed. The reed has a tab and will assemble one-way only. 17 ±...
Page 108: Engine Installation
Remove primer plug from the engine. Install Oil System Priming Adapter (PU-45778) into the oil plug hole. Push 40 ft. lbs. 3-5 oz. (approx.) of Polaris PS-4 PLUS engine oil into the (54 Nm) adapter or until resistance is felt. Remove the adapter.
Page 109: Engine Break-In Period
• Replace exhaust gaskets. Seal connections with high - Oil Pressure Specification - temp silicone sealant. Check to be sure all exhaust 27-35 psi @ 6000 RPM, Polaris PS-4 PLUS springs are in good condition. Synthetic, Engine at operating temperature.
Page 110: 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 111: 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 112 ENGINE NOTES 3.64...
Page 113 ELECTRONIC FUEL INJECTION CHAPTER 4 ELECTRONIC FUEL INJECTION GENERAL INFORMATION ..........4.2 SPECIAL TOOLS .
Page 114: General Information
ELECTRONIC FUEL INJECTION GENERAL INFORMATION Throttle Position Sensor (TPS) Tester - 2201519-A This tester allows the use of a digital multi-meter to test TPS WARNING function as well as perform the TPS adjustment procedure. NOTE: This TPS Tester replaces the existing tester Gasoline is extremely flammable and explosive (PU-47082), which included the 4010264 regulator.
Page 115 PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. This module kit is used on all 8 pin connector-based Polaris EFI systems. This kit is available to Polaris dealers through our tool supplier SPX at (1-800-328- 6657) or http://polaris.spx.com Adaptor shown is included with kit.
Page 116: Service Notes
• Never use a battery boost-pack to start the engine. IMPORTANT: For the most recent information on • Do not charge battery with key switch "on." Digital Wrench™ software and update downloads please visit the website: www.polaris.diagsys.com • Always disconnect negative (-) battery cable lead before charging battery. •...
Page 117: Efi System Exploded View
ELECTRONIC FUEL INJECTION EFI System Exploded View 1. Electronic Control Unit (ECU) 13. Spark Plug Wires 2. Temperature / Manifold Absolute Pressure Sensor (T-MAP) 14. IAC Motor (Idle Air Control Motor) 3. Crankshaft Position Sensor (CPS) 15. Camshaft Phase Sensor 4.
Page 118: Efi System Component Locations
ELECTRONIC FUEL INJECTION EFI System Component Locations Crankshaft Position Sensor (CPS) - Located in the magneto cover between the engine and Electronic Control Unit (ECU) transmission, just in front of the rear gear case. - Located behind the driver’s seat. Fuel Injectors / Fuel Rail - Attached to the fuel rail located in the intake track of the cylinder head.
Page 119 ELECTRONIC FUEL INJECTION Fuel Pump / Regulator / Fuel Gauge Sender Assembly Throttle Position Sensor (TPS) - Located under the passenger seat. - Located on the right-hand side of the throttle body. Fuel Pump Assembly Idle Air Control Motor (IAC) - Located on the right-hand / top side of the throttle body Located in Fuel Tank above the TPS sensor.
Page 120 ELECTRONIC FUEL INJECTION 10. Engine Coolant Temperature Sensor (ECT) - Located in the cylinder head next to the thermostat housing. The sensor can be accessed with the driver and passenger seats and rear service panel removed. 11. Ignition Coil - Located behind the driver’s seat and rear service panel just above the PVT cover.
Page 121: Fuel Tank
ELECTRONIC FUEL INJECTION FUEL TANK Exploded View Fuel Flow Fuel Injectors Fuel Rail Fuel Tank Pressure Regulator Fuel Pump Assembly Fuel Filters Quick Connect Fuel Line...
Page 122: Fuel Lines - Quick Connect
ELECTRONIC FUEL INJECTION Fuel Lines - Quick Connect ELECTRONIC FUEL INJECTION RANGER EFI models use quick connect fuel lines. Refer to the Principal Components steps below for fuel line removal. The Electronic Fuel Injection (EFI) system is a complete engine Place a shop towel around the fuel line to catch any fuel and ignition management design.
Page 123: Initial Priming / Starting Procedure
ELECTRONIC FUEL INJECTION ELECTRONIC CONTROL UNIT (ECU) The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for intake air temperature, manifold absolute pressure (load), Operation Overview engine temperature, speed (RPM), camshaft position and The ECU is the brain or central processing computer of the throttle position.
Page 124: Ecu Service / Replacement
For the purpose of troubleshooting, a known-good ECU from relayed to the ECU. These signals, comprised of separate air another Polaris RANGER RZR EFI of the same model may be temperature and manifold absolute pressure readings, are used without system or engine component damage.
Page 125: Crankshaft Position Sensor (Cps)
ELECTRONIC FUEL INJECTION Install the sensor by inserting it with a twisting motion to A ferromagnetic 60-tooth ring gear with two consecutive teeth properly seat the grommet. missing is mounted on the flywheel. The inductive speed sensor is mounted 1.0  0.26 mm (0.059  0.010 in.) away from the ring gear.
Page 126: Cps Replacement
ELECTRONIC FUEL INJECTION Measure between the pin terminal leading from the Black Remove the exhaust pipe between the elbow pipe and the wire and ground. A resistance value of 0 - 0.5 ± 10% exhaust silencer. Remove the exhaust silencer. should be obtained.
Page 127 ELECTRONIC FUEL INJECTION Remove the bolt from the bracket at the front of the rear 11. Torque the CPS retaining bolt to specification. gearcase. CPS Retaining Bolt Torque: 25 in. lbs. (2.8 Nm) Installation IMPORTANT: When reinstalling the transmission to rear gearcase mount bracket, it is extremely important to torque all (7) fasteners to specification.
Page 128 ELECTRONIC FUEL INJECTION Bottom Transmission Bolt Reinstall mounting bracket and hand tighten the (7) bolts. Torque ALL mounting bracket bolts to specification. Mount Bracket Bolt Torque: 23-27 ft. lbs. (31-37 Nm) Using special tool (PA-48873), torque the (3) bolts that retain the front portion of the mounting bracket to the transmission.
Page 129: Fuel Injectors
ELECTRONIC FUEL INJECTION FUEL INJECTORS Middle Rear Gearcase Bolt Operation Overview NOTE: All EFI units utilize quick connect fuel lines. The fuel injectors mount into the cylinder head, and the fuel rail attaches to them at the top end. O-rings on both ends of the injector prevent external fuel leaks and also insulate it from heat and vibration.
Page 130: Fuel Injector Service / Test
ELECTRONIC FUEL INJECTION Fuel Injector Service Fuel Injector Test NOTE: The harness connector and locking spring is Injector problems typically fall into three general categories- electrical, dirty / clogged, or leakage. An electrical problem bonded to the fuel injectors with an epoxy. DO NOT attempt to disconnect the connector from the fuel usually causes one or both of the injectors to stop functioning.
Page 131: Fuel Injector Replacement
ELECTRONIC FUEL INJECTION Fuel Injector Replacement Separate the fuel injector from the vehicle harness as shown in the illustration below. Be sure the engine has cooled enough to work on. Fuel Disconnect Here Injector Remove the seats and rear service panel (see chapter 5). Harness Remove the rear cargo box (see chapter 5).
Page 132: Fuel Pump
ELECTRONIC FUEL INJECTION FUEL PUMP The ECU switches off the pump preventing the continued delivery of fuel in these instances: Operation Overview • If the key switch is not promptly turned to the "start" position. An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank.
Page 133: Fuel Pump Test
ELECTRONIC FUEL INJECTION Fuel Pump Test Normal Fuel Pressure: 45 ± 2 psi. If a fuel delivery problem is suspected, make certain the fuel pump filters are not plugged, that the pump is being activated through the ECU, all electrical connections are properly NOTE: If the fuel pressure is out of specification, secured, the fuses are good, and a minimum of 7.0 volts is being replace the fuel pump assembly.
Page 134: Fuel Pump Replacement
ELECTRONIC FUEL INJECTION Fuel Pump Replacement Be sure the top of the fuel tank is clean. If it requires cleaning, hand wash the top of the tank to ensure no debris will enter the fuel system when the fuel pump is removed. WARNING Clean this area Always wear safety goggles when working with...
Page 135 ELECTRONIC FUEL INJECTION Carefully lift the fuel pump out of the fuel tank. As the fuel 12. Install new PFA gasket onto fuel pump assembly using care pump assembly is being removed, be aware of float arm and not to damage gasket or bend float arm. pump pre-filter.
Page 136 ELECTRONIC FUEL INJECTION 13. Install fuel pump into fuel tank, hold float arm to the pump 17. Torque PFA nut to specification using the Fuel Pump body and tilt assembly to ensure float arm does not get Service Tool (PU-50326) and a calibrated torque wrench. caught or bent during installation.
Page 137: Fuel Tank Removal
ELECTRONIC FUEL INJECTION Fuel Tank Removal Disconnect the fuel pump electrical harness. IMPORTANT: Syphon as much fuel from the tank as possible before attempting to remove it from the Disconnect Here vehicle. WARNING Always wear safety goggles when working with high pressure or flammable fluids.
Page 138 ELECTRONIC FUEL INJECTION Remove the push rivets and screws retaining the RH rocker 11. Remove the (3) shift lever support bracket bolts by and panel and remove panel from the vehicle (see Chapter 5). place bracket out of the way of the fuel tank, but do not remove or cut the plastic wire harness retainer.
Page 139: Fuel Tank Installation
ELECTRONIC FUEL INJECTION IDLE AIR CONTROL (IAC) 13. Lift the rear of the fuel tank up first and carefully pull it up and out from the vehicle. Operation Overview The Idle Air Control (IAC) is used to stabilize the idle quality of the engine at cold start-up and after warm-up operations.
Page 140: Iac Replacement
ELECTRONIC FUEL INJECTION IAC Replacement THROTTLE POSITION SENSOR (TPS) Remove the seats, rear main service panel and the rear Operation Overview cargo box. (See chapter 5) The throttle position sensor (TPS) is used to indicate throttle Loosen the hose clamps retaining the throttle body. plate angle to the ECU.
Page 141: Tps Resistance Tests
ELECTRONIC FUEL INJECTION TPS Resistance Tests Set-up the TPS Tester Wire Harness (PU-47466) and TPS Tester Regulator (547927) according to the instructions that The TPS is a non-serviceable item. If it is faulty, it must be accompanied the tester. Make sure the 9 Volt battery is new. replaced.
Page 142: Tps Replacement
ELECTRONIC FUEL INJECTION Verify TPS Tester Reference Voltage TPS Replacement A 5 volt reference voltage from the TPS Tester harness is NOTE: The correct position of the TPS angle on the required for the TPS test to be accurate. Refer to the instructions throttle body is established and set at the factory.
Page 143 ELECTRONIC FUEL INJECTION Set your voltmeter to read DC Volts. Insert the red and 11. Retighten the TPS mounting screws and torque to black voltmeter probes into the test ports as shown. specification. TPS Mounting Screws: 17.7 in. lbs. (2 Nm) 12.
Page 144: Camshaft Phase Sensor
ELECTRONIC FUEL INJECTION CAMSHAFT PHASE SENSOR Cam Phase Sensor Replacement Disconnect vehicle harness from the sensor. Operation Overview Remove the retaining bolt and remove the sensor from the Mounted on the engine crankcase, the Cam Phase Sensor engine. provides camshaft position information to the ECU to be used along with the crankshaft position data to allow for sequential Use a light coating of engine oil to lubricate the O-ring upon fuel injection.
Page 145: Engine Coolant Temperature Sensor (Ect)
ELECTRONIC FUEL INJECTION ENGINE COOLANT TEMPERATURE Refer to Chapter 10 for additional ECT sensor information. Polaris dealers can test the sensor by using the Digital Wrench™ SENSOR (ECT) Diagnostic Software (dealer only). Operation Overview ECT Sensor Resistance Readings Mounted on the cylinder head, the engine temperature sensor Temperature F (C)
Page 146: Ignition Coil
ELECTRONIC FUEL INJECTION IGNITION COIL Ignition Coil Tests The ignition coil can be tested by using an ohm meter. Use the Operation Overview following illustration and specification table to test the ignition The ignition coil is used to provide high voltage to fire the spark coil.
Page 147: Efi Diagnostics
ELECTRONIC FUEL INJECTION EFI DIAGNOSTICS A set of three numbers will appear in the information area. • The first number (located far left) can range from 0 to 9. Instrument Cluster Trouble Code Display This number represents the total number of trouble code present (example: 2 means there are 3 codes present).
Page 148 ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE Digital Wrench™ Component Condition P-Code P0563 Voltage Too High C1063 System Power (Battery Potential / Power Input) P0562 Voltage Too Low C1064 Engine Speed (This is applicable when the EPS module gets the Received Engine Speed Has Error C1066 engine speed from the ECM)
Page 149 ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE Digital Wrench™ Component Condition P-Code Steering Torque Full Failure Condition Exists 520224 C1053 Greater than 110 (230 C1054 ° C ° F EPS Inverter Temperature 520225 Greater than 120 (248 C1055 ° C °...
Page 150: 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, •...
Page 151: Digital Wrench™ Operation
IMPORTANT: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench™ Diagnostic Kit to install the Polaris Digital Wrench™ diagnostic software on your computer. The Digital Wrench™ diagnostic software allows the technician to perform the following tests and observations: •...
Page 152: Digital Wrench™ - Diagnostic Connector
Remove the protective cap from the Digital Wrench™ In this case, the version number is 3.1 with a 03/13/09 connector. update. Proceed to http://polaris.diagsys.com to see if a newer update is available. Connect the Vehicle Interface Cable to the Digital Wrench™...
Page 153: Digital Wrench™ Updates
If the update file date listed is newer than your current version and update (see “Digital Wrench™ Version and Updates are released for Digital Wrench™ via the Internet at: Update ID”), download the file. http://polaris.diagsys.com. The Digital Wrench™ website can also accessed through...
Page 154: Digital Wrench™ Feature Map
ELECTRONIC FUEL INJECTION Digital Wrench™ Feature Map 4.42...
Page 155: Engine Controller Reprogramming (Reflash)
Reflash Authorization site. The Request Code is automatically generated by Digital Wrench™ Proceed to http://polaris.diagsys.com for specific during the reprogramming process. The Reflash Authorization information and FAQs on how to troubleshoot site is located under the “Service and Warranty”...
Page 156 ELECTRONIC FUEL INJECTION Connect the SmartLink Module cables to the PC and Select “Engine Controller Reprogramming”. vehicle. See “Digital Wrench™ - Diagnostic Connector” on page 4.40. Select the file you want to load into the ECU then click the “Continue” icon to proceed to the Integrity Check. Open the Digital Wrench™...
Page 157 ELECTRONIC FUEL INJECTION Copy (CTRL+C) the Request Code that will be required on 12. Select the same file type from the list that you selected the dealer website in the next step. DO NOT CLOSE previously while in Digital Wrench™. Enter the VIN along Digital Wrench™...
Page 158 ELECTRONIC FUEL INJECTION 15. At this point the reflash process will begin. Do not touch the vehicle or PC during the process. 16. Once the ECU reprogramming procedure is complete, click the ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle.
Page 159 BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS..........5.2 SPECIAL TOOLS .
Page 160: Torque Specifications
BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS SPECIAL TOOLS ITEM TORQUE VALUE TOOL DESCRIPTION PART NUMBER Front LH/RH Upper / Lower Gas Shock Recharging Kit 2200421 40 ft. lbs. (54 Nm) A-Arm Bolt Shock Shaft Seal Protector 2201640 Rear LH/RH Upper / Lower .625"...
Page 161: Cab Frame
BODY / STEERING / SUSPENSION CAB FRAME Assembly / Removal NOTE: Finger tighten all components until cab frame is completely assembled on vehicle, then tighten to specifications listed. Assemble the rear cab frame and the front cab frame at the coupler joints and secure with four (3/8-16 x 1 1/4) screws and (3/8-16 Nyloc) nuts.
Page 162: Body Exploded Views
BODY / STEERING / SUSPENSION BODY EXPLODED VIEWS Hood / Front Body Work 1/4 Turn Latch Washer Grommet T25 Screws T27 Screws Push Rivet T27 Screws Push Rivets T27 Screws...
Page 163: Front Bumper
BODY / STEERING / SUSPENSION Front Bumper Screws O-Ring Bulb Screw Headlight Screw Rear Bumper LH Tail Light RH Tail Light Screw Speed Screws Nuts Rear Bumper Screws...
Page 164: Seat Assembly
BODY / STEERING / SUSPENSION Seat Assembly Seat Hoop Tube 48 in. lbs. (5.4 Nm) Latch Body Nuts Lever Seat Base Asm. Spring Plate 41-57 in. lbs. 41-57 in. lbs. Grommets (4.6-6.4 Nm) (4.6-6.4 Nm) Seat Belts / Mounting Driver 3 Point Seat Seat Belt...
Page 165: Floor / Rocker Panels
BODY / STEERING / SUSPENSION Floor / Rocker Panels Self-Tapping Screw LH Rocker Rear Support Bracket Push Rivets Self-Tapping Screws Console Cover Screws Front Support Bracket Rear Support Bracket Self-Tapping Screws Screw Screw Screws Push Rivets U-Type Upper Floor Nuts Torx Screws Plastic Dart...
Page 166: Rear Cargo Box / Fenders
BODY / STEERING / SUSPENSION Rear Cargo Box / Fenders Torx Screws 1/4 turn Latch Screw Push Rivets Cargo Box Support...
Page 167: Chassis / Main Frame
BODY / STEERING / SUSPENSION Chassis / Main Frame Bolt-In Brace 15 ft. lbs. (20 Nm) Rear Bumper Support Main Frame 15 ft. lbs. 17 ft. lbs. (20 Nm) (23 Nm) Skid Plate Washer 6-8 ft. lbs. (8-11 Nm)
Page 168: Body Component Removal
BODY / STEERING / SUSPENSION BODY COMPONENT REMOVAL Front Bumper Remove the (4) push rivets from the sides of the front Seats bumper. To remove any of the seats, lift upward on the latch lever located behind the seat bottom. Latch Lever Push...
Page 169: Hood And Front Body Work
BODY / STEERING / SUSPENSION Hood and Front Body Work Hood Removal To remove the hood, turn both latches to disengage the rear portion of the hood. Remove the (2) Torx screws and (2) push rivets that retain the front and rear portions of the dash assembly. Push Rivets Tilt the hood back to disengage the front tabs and remove...
Page 170: Rear Fender, Flair And Tie Down Removal
BODY / STEERING / SUSPENSION Rear Fender, Flair and Tie Down Removal Cargo Box Assembly Removal Remove the rear bumper (see “BODY COMPONENT Remove the seats and rear panel or cover (see “Seats” and REMOVAL - Rear Bumper”). “Rear Service Panel”). Remove the push rivets that retain the rear portion of the Remove the (4) Torx screws retaining the lower portion of rocker panels to the rear fenders.
Page 171: Rocker Panels, Console And Floor
BODY / STEERING / SUSPENSION Rocker Panels, Console and Floor Rocker Panel Removal Remove the push rivets and Torx screws retaining the rocker panel and remove panel from the vehicle. Push Rivets Screws Console and Lower Floor Removal Remove both seats and rocker panels (see “Rocker Panel Removal”).
Page 172: Steering Assembly
BODY / STEERING / SUSPENSION STEERING ASSEMBLY Exploded View Spacer Thick Steering Wheel Washers Thin 25-31 ft. lbs. Washer Thin (34-42 Nm) Washer Thick Washer Thin Washer Steering Shaft Pivot Tube Spacer Bearing Bushing 7 ft. lbs. 42.5 ft. lbs. (10 Nm) (58 Nm) 23 ft.
Page 173: Steering Wheel Removal
BODY / STEERING / SUSPENSION Steering Wheel Removal Refer to steps 11-13 of the “Steering Shaft Bearing Replacement” procedure for installation. Remove the steering wheel cap. Loosen the nut and back it half way off the steering shaft. Steering Shaft Bearing Replacement With a glove on your hand, place it under the steering Perform the “Steering Shaft Removal”...
Page 174: Front A-Arms
BODY / STEERING / SUSPENSION FRONT A-ARMS 11. Reinstall the steering shaft assembly in the vehicle. Install the lower portion of the steering shaft onto the steering gear box assembly (see Figure 5-16). Torque the lower pinch Removal / Replacement bolt to 30 ft.
Page 175: Exploded View
BODY / STEERING / SUSPENSION Exploded View 18. If not replacing the A-arm, thoroughly clean the A-arm and pivot tube. 19. Install new ball joint into A-arm. Refer to “Ball Joint Replacement” section. Upper Fastener Bushings 20. Insert new A-arm bushings and pivot tube into new A-arm. Pivot 21.
Page 176: Ball Joint Service
BODY / STEERING / SUSPENSION BALL JOINT SERVICE Use a press and correct size driver to remove the ball joint from the A-arm. Removal Correct Driver Placement IMPORTANT: Do not reuse a ball joint if it has been removed for any reason. If removed, it must be replaced.
Page 177: Installation
BODY / STEERING / SUSPENSION Installation REAR A-ARMS Place the A-arm in the correct position for ball joint Removal installation. Face the A-arm end flat on top of the driver. Carefully drive the ball joint into place until the ball joint The following procedure details upper and lower A-arm is properly seated.
Page 178 BODY / STEERING / SUSPENSION Remove the fastener (H) attaching the lower A-arm to the WARNING bearing carrier (see previous illustration). Remove the (2) fasteners (J) attaching the lower A-arm to The locking agent on the existing bolts was the frame and remove the lower A-arm from the vehicle destroyed during removal.
Page 179: Installation
BODY / STEERING / SUSPENSION Installation Exploded View Install lower A-arm assembly onto vehicle frame. Torque Upper Fastener new fasteners to specification. Attach lower A-arm to bearing carrier. Torque new fastener to specification. Pivot Tube Route brake line on top of the lower A-arm and between lower shock mounting tabs.
Page 180: Rear Stabilizer Bar
BODY / STEERING / SUSPENSION REAR STABILIZER BAR Removal / Installation Remove the stabilizer bar from the bracket (bracket can remain attached to the frame). Remove the exhaust pipe and exhaust silencer from the vehicle. Leave bracket attached to frame. Remove Fasteners Inspect the stabilizer bar for straightness.
Page 181: Decal Replacement
BODY / STEERING / SUSPENSION DECAL REPLACEMENT WARNING The following procedure involves the use of an open flame. Perform this procedure in a well ventilated area, away from gasoline or other flammable materials. Be sure the area to be flame treated is clean and free of gasoline or flammable residue.
Page 182: Shocks / Springs / Fasteners
BODY / STEERING / SUSPENSION SHOCKS / SPRINGS / FASTENERS Shock Replacement Using a spring compressor, compress the shock spring far Exploded View enough to remove the spring retainer. Shock Spring Compressor Tool 2870623 Remove the spring and adjusting cam from the existing shock and install components onto the new shock.
Page 183: Fox™ Shock Exploded Views
BODY / STEERING / SUSPENSION FOX™ SHOCK EXPLODED VIEWS FOX™ 2.0 ‘Piggyback’ Shock 18 ft. lbs. (24 Nm) ® Loctite 638™ / Primer N™ ® 100 ft. lbs. (136 Nm) Loctite 638™ / Primer N™ 50 ft. lbs. (68 Nm) Preload Ring 10 ft.
Page 184: Fox™ Shock Service
BODY / STEERING / SUSPENSION FOX™ SHOCK SERVICE General Service Information Recommended Service Intervals FOX™ Racing Shocks will perform the best if serviced at regular intervals: • Every ride - Wash and dry the vehicle and suspension • Every 100 hours - Visually inspect shock seals •...
Page 185 BODY / STEERING / SUSPENSION FOX™ Shock Rebuild Information Special Tools Required: Body Holding Tool (PN 2871071) When performing maintenance on FOX™ shocks, use the Gas Shock Recharging Kit (PN 2200421), as it contains the Charging Needle (PN 7052069-A) necessary valves, pressure gauge, and fittings to deflate and Gas Shock Recharging Kit (PN 2200421) pressurize shocks.
Page 186 BODY / STEERING / SUSPENSION FOX™ Shock Disassembly Figure 2 NOTE: Read through all of these instructions first to familiarize yourself with the rebuild procedure. Make sure you have a clean work area, and all of the necessary tools are available. Always use proper safety equipment when...
Page 187 BODY / STEERING / SUSPENSION 12. Clamp the body cap of the shock securely in vise with shaft 17. Align the slot of the IFP Depth Setting Tool with the end side up. of the IFP (Internal Floating Piston). Engage the IFP by rotating the tool 90 degrees (Fig.
Page 188 BODY / STEERING / SUSPENSION Figure 9 Figure 7 Thoroughly clean the bearing housing, and piston assembly 24. Slide bearing assembly off of shaft. Use extreme caution with solvent. Dry with compressed air in a well ventilated not to scratch inside of the bearing assembly when passing area.
Page 189 Shock oil will come up through the IFP bleed hole. FOX™ Shock Reassembly Polaris Gas Shock Oil - 5 wt. Clamp shaft eyelet securely in vise, and place seal bullet PN 2870995 - qt. tool on end of shaft.
Page 190 BODY / STEERING / SUSPENSION 12. Fill shock body to the bottom of bearing threads with oil. 20. Add oil to the body tube until the surface of the oil is to the top of the threads inside the body tube. 13.
Page 191 BODY / STEERING / SUSPENSION 34. Continue charging with gas as you pull the reservoir away Figure 17 from the FOX™ Nitrogen Safety Needle using a smooth, straight motion. Keep the reservoir as straight as possible to prevent the safety needle from bending. As the safety needle is pulled free from the FOX™...
Page 192 BODY / STEERING / SUSPENSION NOTES 5.34...
Page 193 CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES ......... . 6.2 TORQUE SPECIFICATIONS.
Page 194: Special Tools And Supplies
The internal components of the drive clutch and driven clutch control engagement (initial vehicle movement), clutch upshift and backshift. During the development of the Polaris vehicle, the PVT system is matched first to the engine power curve; then TORQUE SPECIFICATIONS to average riding conditions and the vehicle’s intended usage.
Page 195: 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 196: Overheating / Diagnosis
10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD certified Clutch malfunction. technician.
Page 197: Pvt System Service
CLUTCHING PVT SYSTEM SERVICE PVT Covers and Ducting Components Clutch Push Clamps Inlet Duct Rivets Boot Clutch Boot Outlet Duct Cover Screws Clamp Clamps Bolt & Washer Inner Clutch Cover Retainer Outer Screws Outer Cover Seal Clutch Cover PVT Disassembly Some fasteners and procedures will vary.
Page 198: Pvt Assembly
CLUTCHING PVT Assembly Remove the driven clutch retaining bolt and driven clutch. Remove driven clutch offset spacers from the transmission Inspect inner clutch cover. Replace if cracked or damaged. input shaft. Inspect the seal on the transmission input shaft. Replace if Keep Spacers In Order (Note Thickness) damaged.
Page 199: Clutch Offset Procedure
CLUTCHING Clutch Offset Procedure 11. Clean end of taper on crankshaft and the taper bore inside drive clutch. If the vehicle exhibits drive clutch drag or hard shifting while at 12. Install drive clutch and torque retaining bolt to idle speed, a clutch offset adjustment is required. Washers specification.
Page 200: Brakes
CLUTCHING Reinstall the driven clutch and drive belt. Torque the driven Install the outer clutch cover and torque the cover screws clutch retaining bolt to 17 ft. lbs. (23.5 Nm). Be sure to to 45-50 in. lbs. (5-5.6 Nm). rotate the driven clutch counterclockwise several times to Install the clutch cover outlet duct and tighten the clamps.
Page 201: Drive Belt
CLUTCHING DRIVE BELT Belt Inspection Inspect belt for hour glassing (extreme circular wear in at Belt Removal least one spot and on both sides of the belt). Hour glassing Remove outer clutch cover as described in the “PVT occurs when the drive train does not move and the drive Disassembly”...
Page 202: 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 203: Shift Weights
CLUTCHING Primary Clutch Springs 7043594 Black .177" 2.80" 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 204: Clutch Disassembly
CLUTCHING Clutch Disassembly Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or Using a permanent marker, mark the cover, spider, and damaged. moveable and stationary sheaves for reference, as the cast Inspect Shaft in X's may not have been in alignment before disassembly.
Page 205: Roller, Pin, And Thrust Washer Inspection
CLUTCHING Roller, Pin, and Thrust Washer Inspection NOTE: It is important that the same number and thickness of washers are reinstalled beneath the Inspect all rollers, bushings and roller pins by pulling a flat spider during assembly. Be sure to note the number metal rod across the roller.
Page 206: Button To Tower Clearance Inspection
CLUTCHING Button To Tower Clearance Inspection Remove shift weight bolts and weights. Inspect the contact surface of the weight. The surface should be smooth and Inspect for any clearance between spider button to tower. free of dents or gall marks. Inspect the weight pivot bore If clearance exists, replace all buttons and inspect surface and pivot bolts for wear or galling.
Page 207: Clutch Inspection
CLUTCHING Clutch Inspection Inspect surface of shaft for pitting, grooves, or damage. Measure outside diameter compare NOTE: Remove cover, spring, and spider following specifications. Replace the drive clutch assembly if shaft is instructions for drive clutch removal, then proceed worn or damaged. as follows: Remove the moveable sheave spacer sleeve (1) and the thrust washer (2).
Page 208: Moveable Sheave Bushing Inspection
CLUTCHING Moveable Sheave Bushing Inspection Bushing Service IMPORTANT: Special Tools Required Inspect the Teflon coating (arrow) on the moveable sheave bushing. Inspect both sheaves for signs of wear, grooving or EBS Clutch Bushing Tool Kit - 2201379 cracking. De-glaze sheave surfaces with a 3M Scotch-Brite Pad if needed.
Page 209 CLUTCHING NOTE: Use Bushing Tool PA-47336. CAUTION Install nut (C) onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Using Clutch components will be hot! In order to avoid a hand held propane torch, apply heat around outside of serious burns, wear insulated gloves during the bushing until tiny smoke tailings appear.
Page 210: Clutch Assembly
CLUTCHING Cover Bushing Removal Clutch Assembly Install main adapter (Item 8) on puller. NOTE: It is important that the same number and thickness of washers are reinstalled beneath the Removal Tool Nut (C) spider during assembly. The Teflon bushings are self-lubricating.
Page 211 CLUTCHING Torque spider to specification using the holding fixture and spider tool. Torque with smooth motion to avoid damage to the stationary sheave. Spider Torque: 200 ft. lbs. (271 Nm) CAUTION Be sure the spider spacer washers are fully seated in the recessed area in the spider. Any misalignment will alter clutch balance.
Page 212: Driven Clutch Service
CLUTCHING DRIVEN CLUTCH SERVICE Exploded View Compression Spring Spacer Outer Stationary Spring Retainer Secondary Sheave Inner Retaining Spring Retainer Ring Moveable Secondary 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 213 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), spacer (D), and inner spring retainer (E). Inspect for Abnormal Wear Check the rollers in the stationary sheave for wear.
Page 214: 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 215: 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 216 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 217 FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIAL TOOLS ............7.2 TORQUE SPECIFICATIONS.
Page 218: Special Tools
FINAL DRIVE SPECIAL TOOLS FRONT BEARING CARRIER Bearing Carrier Inspection / Removal PART NUMBER TOOL DESCRIPTION Elevate front of vehicle and safely support machine under Roll Pin Removal Tool 2872608 the frame area. CV Boot Clamp Pliers 8700226 (earless type) CAUTION Axle Boot Clamp Tool PU-48951...
Page 219: Bearing Replacement
FINAL DRIVE Bearing Replacement Remove the two front brake caliper mounting bolts and remove the caliper from the brake disc (see Chapter 9). Bearing Removal CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. Remove the outer snap ring.
Page 220: Bearing Carrier Installation
FINAL DRIVE Bearing Installation Install pinch bolts and torque to specification. Thoroughly clean the front bearing carrier housing and the outer race on the new bearing. Be sure that all oil residue has been removed from each surface. Support the bottom of the bearing carrier housing. 22.5 ft.
Page 221: Front Drive Shaft
FINAL DRIVE NOTE: Refer to the photos below to ensure proper 10. Install wheel and (4) wheel nuts. Torque wheel nuts to placement of the tie rod end. specification. 42.5 ft. lbs. 58 (Nm) Wheel Nuts: Steel Wheels: 35 ft. lbs. (47 Nm) Aluminum Wheels: 30 ft.
Page 222: Drive Shaft / Cv Joint Handling Tips
FINAL DRIVE Drive Shaft / CV Joint Handling Tips Remove the front wheel hub assembly. Remove the upper ball joint pinch bolt. Care should be exercised during drive shaft removal or when servicing CV joints. Drive shaft components are precision parts. Pinch Cleanliness and following these instructions is very important to Bolt...
Page 223 FINAL DRIVE Make sure the circlip remains on the shaft and not left in 11. Slide the joint onto the drive shaft splines and align the the joint. Discard the circlip as it will be replaced. circlip with the lead-in chamfer on the inner race. Circlip 12.
Page 224: Inner Plunging Joint / Boot Replacement
FINAL DRIVE Inner Plunging Joint / Boot Replacement 12. Grease the joint with the special joint grease provided in the boot replacement kit. Fill the cavity behind the balls and the Remove the front drive shaft from the vehicle (see splined hole in the joint’s inner race.
Page 225: Drive Shaft Installation
FINAL DRIVE Drive Shaft Installation 21. Position the boot lip in its groove. Install and secure the boot with the large clamp using the “earless” clamp pliers. Install new spring ring on drive shaft. Apply an anti-seize compound to splines. CV Boot Clamp Pliers Earless Type: 8700226 Spring Ring...
Page 226 FINAL DRIVE Install the upper pinch bolt and torque to specification. 22.5 ft. lbs. 30.5 (Nm) Wheel Hub Castle Nut: 80 ft. lbs. (108 Nm) Install brake caliper mounting bolts and torque to specification. Front Caliper Mounting Bolts: 31-34 ft. lbs. (42-46 Nm) CAUTION New bolts have a pre-applied locking agent Pinch Bolts:...
Page 227: Propshaft Service
FINAL DRIVE PROPSHAFT SERVICE Remove the fasteners retaining the plastic skid plate and remove the skid plate from the vehicle. Removal / Installation Locate the propshaft roll pin and use the Roll Pin Removal Tool (PN 2872608) to remove the roll pin. NOTE: Front wheel can be removed to gain better access to the propshaft roll pin.
Page 228: 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 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 229 FINAL DRIVE Using a suitable arbor, fully seat the bearing cap in one side. Continually check for free movement of bearing cross as bearing caps are assembled. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. Install outer yoke, aligning marks made at disassembly and repeat Steps 1-3 to install bearing caps on outer yoke.
Page 230: Front Gearcase / Centralized Hilliard
FINAL DRIVE FRONT GEARCASE / CENTRALIZED HILLIARD Centralized Hilliard Exploded View 7.14...
Page 231: 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 232: Awd Diagnosis
FINAL DRIVE AWD Diagnosis Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil Symptom: AWD Will Not Engage should be seated below the U-shaped insert. The U-shaped insert controls the pole gap.
Page 233: Gearcase Removal
FINAL DRIVE Gearcase Removal Remove the gearcase from the front LH wheel well area and slide it between the upper and lower A-arm. Stop engine and place gear selector in Park. Refer to “FRONT DRIVE SHAFT - Drive Shaft Removal” and remove both front drive shafts from the front gearcase.
Page 234 FINAL DRIVE Remove the LH output hub assembly from the clutch Remove the RH output hub assembly from the gearcase housing. housing. Carefully remove the armature plate, torsion spring retainer Remove pinion seal. The pinion seal must be replaced every and torsion spring from the ring gear.
Page 235 FINAL DRIVE 10. Inspect the coil located in the cover plate assembly. Refer 13. Thoroughly clean all parts and inspect the rollers (A) for to “AWD Diagnosis” for detailed inspection process. nicks and scratches. The rollers must slide up and down and Replace the cover plate seal and O-ring.
Page 236: Gearcase Assembly / Inspection
FINAL DRIVE NOTE: Install the roll cage so that the ring gear 16. Inspect both output hub assemblies. Inspect the bearings grooves line up with the roll cage slots (see below). and replace if needed. Thrust Bearing Bearing Align during installation Roller Surface...
Page 237 FINAL DRIVE Install the torsion spring by wrapping each leg of the spring 12. Be sure the armature plate tabs are fully engaged into the around the dowel pin on the ring gear. roll cage assembly and are resting on the cut-grooves of the ring gear.
Page 238: Gearcase Installation
FINAL DRIVE NOTE: Rotate the input shaft while setting the Gearcase Installation gearcase housing in place. Install the gearcase back into the vehicle through the LH wheel well area, between the upper and lower A-arms. 16. While holding the gearcase together, flip it over and install the cover plate screws.
Page 239: Rear Bearing Carrier
Add the proper lubricant to the front gearcase. Refer to nut. Remove the nut, and (2) cone washers from the rear Chapter 2 for fluid fill and change information. wheel hub assembly. Polaris Demand Drive Plus (PN 2877922) Front Housing Capacity 6.75 fl. oz. (200 ml)
Page 240: Bearing Replacement
FINAL DRIVE NOTE: Due to extremely close tolerances and Remove the rear wheel hub assembly. minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race.
Page 241: Bearing Carrier Bushing Replacement
FINAL DRIVE Bearing Carrier Installation Bearing Installation Install drive shaft axle through the backside of the bearing Thoroughly clean the rear bearing carrier housing and the carrier. Be sure bushings and pivot tubes are installed. outer race on the new bearing. Be sure that all oil residue has been removed from each surface.
Page 242 FINAL DRIVE Install rear wheel hub assembly, cone washers, and hand Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a tighten the castle nut. Install washers with domed side out. NEW cotter pin. Tighten nut slightly if necessary to align cotter pin holes.
Page 243: Rear Drive Shaft
FINAL DRIVE REAR DRIVE SHAFT Remove the rear wheel hub assembly. Drive Shaft Removal Elevate rear of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.
Page 244: Outer Cv Joint / Boot Replacement
FINAL DRIVE NOTE: Take care when removing prevent Place the drive shaft in a soft-jawed vise. Using a soft-faced damaging the seal. hammer, or brass drift, strike the inner race of the joint to drive the joint off the drive shaft. Be sure to tap evenly around the joint to avoid binding.
Page 245 FINAL DRIVE IMPORTANT: If the grease in the joint is obviously NOTE: The amount of grease that’s provided is pre- contaminated with water and/or dirt, the joint should measured, so use all the grease. be replaced. Boot Replacement Grease Requirement: Grease Only Service Kits PN 1350059 (20g) / PN 1350046 (30g) / PN 1350047 (50g) Outer CV Joint Capacity: 90g...
Page 246: Inner Plunging Joint / Boot Replacement
FINAL DRIVE 18. Install and tighten the large clamp using the Axle Boot 20. Install and tighten the small clamp on the boot using the Clamp Tool (PU-48951). Axle Boot Clamp Tool (PU-48951). Axle Boot Clamp Tool Axle Boot Clamp Tool PU-48951 PU-48951 19.
Page 247 FINAL DRIVE Remove the large end of the boot from the plunging joint Remove the boot from the shaft. and slide the boot down the shaft. CAUTION Complete disassembly of the plunging joint is NOT recommended. The internal components are a precision fit and develop their own characteristic wear patterns.
Page 248 FINAL DRIVE NOTE: The amount of grease that’s provided is pre- 20. Install and tighten the small clamp using the Axle Boot measured, so use all the grease. Clamp Tool (PU-48951). Boot Replacement Grease Requirement: Grease Only Service Kits PN 1350059 (20g) / PN 1350046 (30g) / PN 1350047 (50g) Inner Plunging Joint Capacity: 90g 14.
Page 249: Drive Shaft Exploded View
FINAL DRIVE Drive Shaft Exploded View Drive Shaft Installation Install new spring ring on drive shaft. Apply anti-seize REAR SHAFT compound to splines. Spring Ring Spring Ring Plunging Joint Spring Ring Apply Large Clamp Anti-Seize Grease Pack Gear Side Align splines of drive shaft with rear gearcase and reinstall Boot Kit the drive shaft.
Page 250 FINAL DRIVE Lift bearing carrier into place and install the bolt attaching the bearing carrier to the upper A-arm. Torque fastener to specification. Rear Caliper Mounting Bolts: 18 ft. lbs. (24 Nm) CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal.
Page 251: Rear Gearcase
FINAL DRIVE REAR GEARCASE Shift Yoke Clutch Gear General Operation The rear gearcase has three traction operational modes: AWD, Differential Lock, and Differential Unlock. Locking the rear differential is beneficial in low traction and rough terrain conditions. Unlocking the rear differential makes maneuvering easier and minimizes damage to turf and sensitive terrains.
Page 252: Gearcase Removal
FINAL DRIVE Gearcase Removal When the clutch gear is unlocked the rear drive shafts are dependent on the differential allowing tighter turns. When it’s Drain the fluid from the rear gearcase and remove the rear locked it becomes a solid rear axle increasing traction. drive shafts from each side of the rear gearcase.
Page 253: Gearcase Disassembly
FINAL DRIVE Gearcase Disassembly Disconnect the differential solenoid 2-wire harness. IMPORTANT: The pinion gear assembly is NOT Remove the fasteners and bracket that secure the rear intended to be disassembled from the case, as it gearcase to the transmission. requires special OEM tooling in order to properly reassemble.
Page 254 FINAL DRIVE Remove the differential assembly from the housing. Remove the shim(s) from the differential assembly. Be sure to keep the shims together for reassembly. Inspect the ring gear and differential gears for chipped, worn, or broken teeth. Remove the bearing from the lower portion of the differential assembly.
Page 255 FINAL DRIVE Inspect each differential bearing and race for signs of wear 12. Inspect the pinion shaft by rotating the assembly in the or damage. If bearing replacement is required, use standard gearcase housing while checking for any looseness or bearing puller tools to remove the bearing races.
Page 256 FINAL DRIVE 15. Remove the clutch gear from the gearcase. 18. Carefully remove the shift yoke assembly from the gearcase cover. 16. Inspect the shift lever (A), shift lever spring (B), shift return springs (C), and shift yoke (D) for excessive wear or 19.
Page 257: Differential Disassembly
FINAL DRIVE Differential Disassembly Use a scribe to mark the ring gear and differential case. Remove the (8) bolts that secure the ring gear to the Use a scribe to mark the differential cover and case. differential and allow the ring gear to slide down and off. Remove the (10) screws retaining the differential cover.
Page 258: Differential Assembly
FINAL DRIVE Inspect the gears, thrust washers and differential case for Install the side differential gears and thrust washers and excessive wear or damage. Replace components if needed. slide the cross pin into position with the hole side facing the hole in the differential case.
Page 259: Gearcase Assembly
If previously removed; assembly the shift lever (A), shift NOTE: Grease all seals and O-rings with Polaris All lever spring (B), shift return springs (C), shift yoke (D), and Season Grease (PN 2871322) upon assembly.
Page 260 FINAL DRIVE Carefully install the shift yoke assembly into the gearcase. 11. Install the differential assembly into the gearcase housing and install a new lightly greased O-ring onto the cover. O-Ring Install the shift yoke assembly with the shift return springs (C), facing down in the housing.
Page 261: Gearcase Installation
Refer to the “Installation” procedure listed on page 4.14. Special Tool PA-48873 Add Polaris ATV Angle Drive Fluid to rear gearcase. Refer to maintenance information in Chapter 2 for more details. Torque drain and fill plugs to specification. Rear Gearcase Capacity: 22 fl.
Page 262: Gearcase Exploded View
FINAL DRIVE Gearcase Exploded View 70-80 ft. lbs. (95-108 Nm) 130-155 in. lbs. (15-18 Nm) 30-40 ft. lbs. (41-54 Nm) 23-27 ft. lbs. (31-37 Nm) 40 ft. lbs. (54 Nm) 23-27 ft. lbs. 30-45 in. lbs. (31-37 Nm) (3-5 Nm) ESCRIPTION ESCRIPTION Screw...
Page 263: Wheel Hubs
FINAL DRIVE WHEEL HUBS Front Hub Exploded View Sealed Ball Bearing Bolts Wheel Hub Cone Bearing Washers Front Tire Cotter Pin Carrier Retaining Wheel Nuts Ring 35 ft. lbs. (47 Nm) Brake Disc Studs Castle Nut 80 ft. lbs. (108 Nm) Front Rim (Steel) Rear Hub Exploded View...
Page 264 FINAL DRIVE NOTES 7.48...
Page 265 TRANSMISSION CHAPTER 8 TRANSMISSION TORQUE VALUES / SPECIFICATIONS ........8.2 SHIFT LEVER .
Page 266: Torque Values / Specifications
TRANSMISSION TORQUE VALUES / SPECIFICATIONS SHIFT LEVER Removal Maintain and check/change these items in accordance with the maintenance schedule in Chapter 2 or during service repairs. Pry the shift lever cover using a suitable tool and remove the screw. Pull knob off the shifter. ITEM TORQUE VALUE Transmission Fill Plugs...
Page 267: Shift Cable Inspection / Adjustment
TRANSMISSION Shift Cable Inspection / Adjustment Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH (H) Shift cable adjustment may be necessary if symptoms include: gear and PARK (P). •...
Page 268: Transmission Service
TRANSMISSION TRANSMISSION SERVICE Remove the (7) fasteners retaining the transmission to rear gearcase mount bracket. Transmission Removal / Service Notes The engine, transmission and rear differential are bolted together as a unit. Removal of the transmission is not possible without removing the engine and differential. The shift housing cannot be removed without first disassembling the transfer case.
Page 269 TRANSMISSION After removing the cover, remove the intermediate shaft 10. Remove the intermediate pinion shaft assembly from the bearing cup and shims from the cover. Bearing cup is a slip- housing. Check bearings and gear teeth for wear or damage fit.
Page 270 TRANSMISSION 13. Remove the front output pinion shaft assembly. The shaft 15. Remove the lower snap ring from under the gear. can be disassembled as shown using a press and standard bearing removal tools. 16. Remove the intermediate shaft seal using a seal puller or other suitable method.
Page 271: Transfer Case Reassembly
TRANSMISSION Transfer Case Reassembly Install the shims, bearing cup and alignment dowels into the retaining bracket. Install the intermediate shaft seal (circled) flush or slightly below the case. Install circlips and gear onto the input intermediate shaft as shown. Install a new output shaft seal flush with the case. Install the output pinion shaft assembly and bearing cup/bracket assembly as shown.
Page 272 TRANSMISSION Reinstall the intermediate pinion shaft assembly and Install the transfer case cover. Align the dowels (#1 & #7) bearing cup. and insert the cover screws (note position of the longest screw #4). Torque the screws evenly to specification in sequence as shown.
Page 273: Transmission Shift Housing Disassembly
TRANSMISSION Transmission Shift Housing Disassembly Place the transmission shift housing onto a flat surface as shown. Lift the transmission case half straight up and IMPORTANT: Shift housing repairs are not possible remove. without performing transfer case disassembly. Read and understand all instructions before beginning disassembly.
Page 274 TRANSMISSION Remove the (5) screws retaining the park flange. Inspect the Remove the input shaft seal and clutch intermediate shaft park flange for wear or damage. Replace if needed. seal using a seal puller or punch. Remove the (2) screws that attach the gear position sensor to the shift housing.
Page 275 TRANSMISSION 10. Remove the spacer, contact pins, springs, drum gear and 13. Pull back fully on gear selector arm to bring shift collar up washer from the shift housing. Replace any worn or and disengage the shift collar from the clutch yoke. Lifting damaged components.
Page 276 TRANSMISSION 19. Remove the clutch shaft assembly from the housing. The 22. Locate the retaining ring on the shifter assembly and move forward gear assembly and bearings will remain on the the retaining ring out of the groove to allow the shifter shaft upon removal.
Page 277: Transmission Shift Housing Reassembly
TRANSMISSION Transmission Shift Housing Reassembly 26. Remove the screw from the end of the shift cable lever and remove the shifter assembly from the housing. Install a new shift cable lever seal and press it flush with the case. Apply lubricant to the seal lip. Lubricate the shaft of the shifter assembly and install the assembly into the housing with a new retaining ring and washer.
Page 278 TRANSMISSION Install the input shaft assembly into the transmission housing. Pivot Pin Set Screw: 100-125 in. lbs. (11-14 Nm) Assemble the clutch shaft with new needle bearings. Press a new ball bearing onto the end of the shaft and install a new retaining ring.
Page 279 TRANSMISSION 10. Install the shift collar onto the clutch shaft. Pull back fully 12. With the transmission in neutral, lubricate and install the on gear selector arm to bring the shift yoke arms up and thrust washer, drum gear, plate, springs, contact pins and engage the shift shoes onto the center groove of the shift the gear position sensor/O-ring assembly.
Page 280 TRANSMISSION 14. Install the reverse idler lower washer, needle bearing, gear, 17. Install the reverse clutch assembly onto the park flange. upper washer and retaining ring onto the idler shaft. Note the orientation of the needle bearing. 15. Install a new shaft bearing (if required). 18.
Page 281 TRANSMISSION 20. Place the transmission shift housing onto a flat surface as 22. Install the (2) shift housing case screws to the backside as shown. Apply a bead of crankcase sealant onto the mating shown. Torque to specification. surfaces. Align the dowels and install the transmission case NOTE: Shift cable bracket installation is required.
Page 282: 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 283: Transmission Exploded View
TRANSMISSION TRANSMISSION EXPLODED VIEW Shift Housing / Transfer Case Exploded View 8.19...
Page 284 TRANSMISSION NOTES 8.20...
Page 285 BRAKES CHAPTER 9 BRAKES GENERAL SPECIFICATIONS..........9.2 TORQUE SPECIFICATIONS.
Page 286 BRAKES GENERAL SPECIFICATIONS FRONT BRAKE SYSTEM Item Standard Service Limit Front Brake Pad Thickness .297 ± .007" (7.54 ± .178 mm) .180" (4.6 mm) Front Brake Disc Thickness .188" (4.78 mm) .170" (4.32 mm) Front Brake Disc Runout .010" (.254 mm) REAR BRAKE SYSTEM Item Standard...
Page 287: 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 288: 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 289: Brake System Exploded View
BRAKES BRAKE SYSTEM EXPLODED VIEW RZR SW Cross LH Front LH Rear Line Fitting Brake Line Brake Switch Master Cylinder Front Calipers Rear Calipers MC Rear Brake Line RH Rear Line Master Cylinder Side View RH Front 15 ft. lbs. Caliper Banjo Style Fittings: Brake Line (20 Nm)
Page 290: Master Cylinder
BRAKES MASTER CYLINDER NOTE: Make note of front and rear brake line locations to master cylinder. Removal Loosen the brake line banjo bolts (C) and allow fluid to drain. Locate the master cylinder above the left front tire in the wheel well area.
Page 291: Brake Bleeding / Fluid Change
13. Check brake system for fluid leaks. Mity Vac™ (PN 2870975) Add brake fluid to the indicated MAX level of reservoir. Polaris DOT 4 Brake Fluid (PN 2872189) Begin bleeding procedure with the caliper that is farthest from the master cylinder. Install a box end wrench on caliper bleeder screw.
Page 292: Front Brake Pads
BRAKES FRONT BRAKE PADS Push the mounting bracket inward and the slip outer brake pad out between the bracket and caliper body. 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 293: Pad Assembly / Installation
Maintain at least 1/2, (12.7 mm) of brake fluid in the Lubricate mounting bracket pins with a light film of reservoir to prevent air from entering the brake system. Polaris Premium All Season Grease (PN 2871423), and Install the adjustment set screw and turn clockwise until install rubber dust boots.
Page 294: Front Caliper Service
BRAKES FRONT CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Components 47 in. lbs. (5.3 Nm) Apply Polaris All Purpose Grease A. Socket Set Screw B. Bleeder Screw C. Caliper Assy. D. Boots E. Square O-rings F.
Page 295: Caliper Disassembly
BRAKES Loosen brake pad adjustment set screw 2-3 turns to allow Thoroughly clean the caliper before disassembly and brake pad removal after the caliper is removed. prepare a clean work area for disassembly. Use a commercially available caliper piston pliers to extract the pistons from the caliper.
Page 296: Caliper Inspection
Front 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 297: Caliper Installation
BRAKES Lubricate the mounting bracket pins with Polaris Premium Torque the banjo bolt to the proper torque specification. All Season Grease (PN 2871423), and install the rubber dust seal boots. Apply Grease to Each Bracket Pin 15 ft. lbs. (20 Nm)
Page 298: Front Brake Disc
BRAKES FRONT BRAKE DISC Brake Disc Thickness Disc Runout New .188” (4.78 mm) Service Limit .170” (4.32 mm) Mount dial indicator as shown to measure disc runout. Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specification. Brake Disc Thickness Variance Service Limit: .002”...
Page 299: Rear Brake Pads
BRAKES REAR BRAKE PADS CAUTION Pad Removal Always use new brake disc mounting bolts. The Elevate and support rear of vehicle. bolts have a pre-applied locking agent which is destroyed upon removal. CAUTION Install wheel hub assembly, washers, and castle nut. Torque castle nut to 80 ft.
Page 300: Pad Inspection
Pad Assembly / Installation Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Remove the inner brake pad. Compress mounting bracket and make sure dust boots are fully seated.
Page 301: Brake Burnishing Procedure
BRAKES Install caliper and torque mounting bolts to specification. 18 ft. lbs. (24 Nm) Rear Caliper Mount Bolt Torque: 18 ft. lbs. (24 Nm) Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system.
Page 302: Rear Caliper Service
BRAKES REAR CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Component 47 in. lbs. Apply Polaris All Purpose (5.3 Nm) Grease A. Brake Pad B. Mount Bracket C. Piston D. Caliper Assy. E. Square Ring (thick) F.
Page 303: Caliper Disassembly
BRAKES Caliper Disassembly Caliper Inspection Remove brake pad adjustment set screw (K). Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage Push upper pad retainer pin inward and slip brake pads past is evident or if worn beyond service limit.
Page 304: Caliper Assembly
18 ft. lbs. (24 Nm) Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance.
Page 305: Rear Brake Disc
BRAKES REAR BRAKE DISC Disc Replacement Remove rear brake caliper (see “REAR CALIPER Disc Inspection SERVICE”). Visually inspect disc for scoring, scratches, or gouges. Remove wheel hub cotter pin, castle nut and washers. Replace the disc if any deep scratches are evident. Remove the hub assembly from the vehicle and remove the Use a 0-1”...
Page 306: Troubleshooting
BRAKES TROUBLESHOOTING Brakes Squeal / Poor Brake Performance • Air in system • Water in system (brake fluid contaminated) • Caliper or disc misaligned • Caliper dirty or damaged • Brake line damaged or lining ruptured • Worn disc and/or friction pads •...
Page 307 ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION ..........10.3 SPECIAL TOOLS .
Page 308 ELECTRICAL CHARGING SYSTEM ..........10.22 CURRENT DRAW - KEY OFF .
Page 309: General Information
ELECTRICAL GENERAL INFORMATION Under-Dash Components The following switches and components can be accessed Special Tools underneath the instrument / dash panel: • Speedometer Part Number Tool Description • Speedometer Mode Switch PV-43568 Fluke™ 77 Digital Multimeter • Digital Wrench Diagnostic Connector PV-43526 Connector Test Kit •...
Page 310: Headlamp Switch
ELECTRICAL Headlamp Switch Ignition Key Switch Disconnect the headlamp switch harness by depressing the Disconnect the key switch harness by lifting the connector connector locks and pulling on the connector. Do not pull lock and pulling on the connector. Do not pull on the on the wiring.
Page 311: Awd / 2Wd / Turf Switch
ELECTRICAL AWD / 2WD / TURF Switch Blackout Switch Disconnect the AWD / 2WD / TURF switch harness by Disconnect the blackout switch harness by depressing the depressing the connector locks and pulling on the connector locks and pulling on the connector. Do not pull connector.
Page 312: I.r. Light Switch
ELECTRICAL I.R. Light Switch Winch Switch Disconnect the I.R. light switch harness by depressing the Disconnect the winch switch harness by depressing the connector locks and pulling on the connector. Do not pull connector locks and pulling on the connector. Do not pull on the wiring.
Page 313: Transmission (Gear Position) Switch
ELECTRICAL Transmission (Gear Position) Switch VEHICLE SPEED SENSOR Disconnect the transmission switch harness by lifting the Speed Sensor Location connector lock and pulling on the connector. Do not pull The speed sensor is located in the transmission transfer case on the wiring. cover and can be accessed through the rear LH wheel well area.
Page 314: Rear Differential Solenoid
ELECTRICAL REAR DIFFERENTIAL SOLENOID Differential Solenoid Overview The differential solenoid is located on the rear gear case. The solenoid actuates an engagement dog, which locks and unlocks the rear differential. Refer to Chapter 7 for more information on the rear differential mechanical operation. Differential Solenoid Circuit Operation The Rear Diff Solenoid Relay is attached to the rear plastic LH panel divider behind the driver’s seat.
Page 315: Instrument Cluster
ELECTRICAL INSTRUMENT CLUSTER Overview The instrument cluster displays critical vehicle information to the user. Reference the following page for display functions and descriptions. NOTE: Some features are not applicable to all models. IMPORTANT: The use of a high pressure washer may damage the instrument cluster. Wash the vehicle by hand or with a garden hose using mild soap.
Page 316: Rider Information Display
ELECTRICAL Rider Information Display 12. Neutral Gear Indicator - LED icon illuminates when gear selector is in the neutral (N) position. The rider information display is located in the instrument cluster. All segments will light up for 1 second at start-up. 13.
Page 317 ELECTRICAL Trip Meter Engine Hours The trip meter records the miles traveled by the vehicle on each Engine hours are logged anytime the engine is running. Total trip. To reset the trip meter: hours can not be reset. Toggle the MODE button to TRIP 1. Programmed Service Interval To reset to 0, push and hold the MODE button until the distance display changes to 0.
Page 318 ELECTRICAL Clock Units of Measurement Standard Display Metric Display Distance Miles (MPH) Kilometers (KM/H) Time 12-Hour Clock 24-Hour Clock Temperature Fahrenheit Celsius To change between Standard and Metric units of measurement, follow these steps: Turn the key to the OFF position. Press and hold the MODE button while turning the key to the ON position.
Page 319: Diagnostic Mode
ELECTRICAL Diagnostic Mode Under / Over Voltage This warning usually indicates that the vehicle is operating at an The diagnostic mode is accessible only when the check engine RPM too low to keep the battery charged. It may also occur MIL has been activated.
Page 320: Instrument Cluster Pinouts
ELECTRICAL Use the trouble code reference table in the EFI Chapter for Push the instrument cluster out from the back side of the a description of each code. dash while securely holding the dash and rubber mount. Push Instrument If more than one code exists, press the MODE button to Dash Panel Cluster Outward advance to the next trouble code.
Page 321: All Wheel Drive Coil
ELECTRICAL ALL WHEEL DRIVE COIL HEAD LIGHTS Operation Overview Headlight Adjustment • When the AWD switch is “ON”, 12 VDC power is The headlight beam is adjustable. present at the hub coil. Place the vehicle on a level surface with the headlight approximately 25 ft.
Page 322: Headlamp Bulb Replacement
ELECTRICAL Headlamp Housing Removal Adjust the beam to desired position. Repeat the procedure to adjust the other headlight. Disconnect the wire harness from the headlamp bulb. Be WARNING sure to pull on the connector, not on the wiring. Remove the O-rings (A) from the headlamp brackets on Due to the nature of light utility vehicles and both sides of the headlamp.
Page 323: Tail / Brake Lights
ELECTRICAL TAIL / BRAKE LIGHTS Bulb Replacement Before replacing the bulb(s), use a digital multi-meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present. If a tail light or brake light does not work the bulb may need to be replaced.
Page 324: Cooling System Schematic
ELECTRICAL COOLING SYSTEM SCHEMATIC Cooling System Break-Out Diagram 10.18...
Page 325: Fan Control Circuit Operation / Testing
ELECTRICAL Fan Control Circuit Operation / Testing 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 326: Fuse Box: Fuses / Relays / Circuit Breaker
ELECTRICAL FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKER Overview / Operation Located in the fuse box under the dash, the fuses provide overload protection for wiring and components such as the instrument cluster, ECU, EFI system, chassis power, lights and accessories. The relays assist with component operation like the cooling fan, fuel pump and EFI system.
Page 327: Relay Operation
ELECTRICAL Relay Operation FAN RELAY provides power to the following system: • Fan Motor Located in the fuse box under the dash, the relays assist with component operation like the cooling fan, fuel pump and EFI FAN RELAY system. OLOR UNCTION NOTE: The Rear Diff Solenoid Relay is mounted separately, attached to the rear plastic LH panel...
Page 328: Charging System
ELECTRICAL CHARGING SYSTEM BLACKOUT RELAY provides power to the following system: Alternator Output • Rear Differential Solenoid AMPS VOLTS BLACKOUT RELAY 2500 13.2 Vdc OLOR UNCTION Current Draw - Key Off Ground input from Blackout Switch to White enable (open) relay CAUTION BUS Bar - 10-Amp fuse protected 12 Red / Yellow...
Page 329: Charging System Alternator Tests
ELECTRICAL NOTE: If there are any significant variations in ohm WARNING readings between the three legs it is an indication that one of the stator legs may be weak or failed. Never start the engine with an ammeter TEST 2: Resistance Value of Each Stator Leg to Ground connected in series.
Page 330: Regulator / Rectifier Test
ELECTRICAL Regulator / Rectifier Test • Remove the regulator / rectifier from the vehicle. NOTE: Unit must be cool for accurate testing. • Use DIODE CHECK function on the Fluke 77 DMM • Perform all tests described in test table below. Test results describe a properly functioning component. NOTE: If the temperature of the regulator / rectifier exceeds 194 °F (90°C), the unit will turn itself off to cool down.
Page 331: 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 332: Battery Service
Serious burns can result from contact with the skin, NOTE: Battery charge can be maintained by using a eyes, or clothing. Polaris battery tender charger or by charging once a month to make up for normal self-discharge. Battery ANTIDOTE: tenders can be left connected during the storage External: Flush with water.
Page 333: Ocv - Open Circuit Voltage Test
Authorized Polaris dealers/distributors are required to use the efficiency and service life of the battery. conductance analyzer when testing 12V Polaris batteries.
Page 334: Charging Procedure
ELECTRICAL Charging Procedure STARTING SYSTEM If battery voltage is 12.6 Vdc or less, the battery may need Troubleshooting recharging. When using an automatic charger, refer to the charger manufacturer’s instructions for recharging. Starter Motor Does Not Run • Battery discharged Do not exceed 9 amps when charging the battery.
Page 335: Voltage Drop Test
ELECTRICAL Voltage Drop Test NOTE: Note the alignment marks on both ends of the starter motor casing. These marks must align The Voltage Drop Test is used to test for bad connections. When during reassembly. performing the test, you are testing the amount of voltage drop through the connection.
Page 336: Armature Testing
ELECTRICAL Brush Replacement Measure resistance between insulated brush and starter housing. Reading should be infinite (OL). Inspect Remove terminal nut with lock washer, flat washer, large insulation on brush wires for damage and repair or replace phenolic washer, the small phenolic spacers, and sealing as necessary.
Page 337: Starter Reassembly / Installation
ELECTRICAL Measure the resistance between each commutator segment Install O-ring, two small phenolic spacers, large phenolic and the armature shaft. The reading should be infinite (no washer, flat washer, lock washer, and terminal nut. continuity). While holding brush springs away from brushes, push brushes back and hold in place.
Page 338: Starter Solenoid Bench Test
ELECTRICAL NOTE: It is important to tighten the bottom starter Remove the retaining ring, thrust washer, spring retainers bolt first (circle), as the bottom hole acts as a pilot and clutch return spring. Screw the overrun clutch off the hole to properly align the starter drive (bendix) with end of the pinion shaft.
Page 339: Starter Exploded View
ELECTRICAL Starter Exploded View Indicates Do not reuse. 10. Gear Assembly 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 340: 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 341 Clutch Offset Procedure ......6.7 Combustion Chamber ......3.30 Air Filter Service .
Page 342 Electrical, Cooling System Breakout Diagram ..10.20 Engine, Troubleshooting ......3.62 Electronic Control Unit (ECU) ....4.11 Engine, Valve Inspection .
Page 343: Body / Steering / Suspension
PVT, Drive Clutch Cover Bushing ....6.17 PVT, Drive Clutch Disassembly ....6.12 Idle Air Control (IAC) .
Page 344 Special Tools, EFI .......4.2 Switch, Blackout ......10.5 Special Tools, Electrical .

Polaris Ranger RZR SW Service Manual

General Information Chapter 1 1

Maintenance Chapter 2 Maintenance

Chapter 3 Engine

Chapter 4 Electronic Fuel Injection

Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

Clutching Chapter 6 Clutching

Chapter 7 Final Drive

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Polaris Ranger RZR SW