Page 1 POLARIS RANGER XP 700 4X4 RANGER 6X6 SERVICE MANUAL...
Page 2: Table Of Contents
GENERAL INFORMATION MAINTENANCE ENGINE FUEL INJECTION BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...
Page 3 POLARIS RANGER XP 700 4X4 RANGER 6X6 SERVICE MANUAL...
Page 4 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION MODEL INFORMATION ..........1.2 MODEL IDENTIFICATION .
Page 5: Model Information
GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification R 0 7 R H 6 8 A G Emissions & Model Year Model Option Designation Basic Chassis Engine Designation Designation...
Page 6: Unit Serial Number (Vin) Location
GENERAL INFORMATION Unit Serial Number (VIN) Location Transmission I.D. Number Location The machine model number and serial number are important for The transmission I.D. number is located on the vehicle identification. The machine serial number (A) is right side when installed in the machine. stamped on the lower LH frame rail close to the front drive wheel.
Page 7: Vehicle Dimensions
GENERAL INFORMATION VEHICLE DIMENSIONS RANGER 4X4, 6X6 75 in. 190.50 cm RANGER 4x4 10 in. 25.4 cm 58 in. 147 cm...
Page 8: Vehicle Dimensions Ranger 4X4, 6X6
GENERAL INFORMATION Vehicle Dimensions RANGER 4X4, 6X6 120 in. 305 cm 58 in. 147 cm 27 in. 69 cm 90 in. 229 cm 113 in. 287 cm 58 in. 147 cm 76 in. 193 cm...
Page 9: General Specifications
GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: RANGER XP 4X4 MODEL NUMBER: R07RH68AD,AG,AH,AK,AL,AW ENGINE MODEL: EH068OLE Category Dimension / Capacity Length 113 in. / 287 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 76 in. / 193 cm Ground Clearance 11.5 in.
Page 10: Model: Ranger Xp 4X4
Transmission Type Polaris Automatic PVT ENGINE MODEL: EH068OLE Gear Ratio: Front / Rear High 3.34:1 / 2.89:1 Engine 8.67:1 / 7.49:1 Polaris Domestic Twin Cylinder, Platform 5.92:1 / 5.11:1 Liquid Cooled, 4-Stroke Drive Ratio - Front 3.818:1 Engine Model Number EH068OLE044 Drive Ratio - Final 3.70:1...
Page 11: Model: Ranger Xp 6X6
Transmission Type Polaris Automatic PVT ENGINE MODEL: EH068OLE Gear Ratio: Front / Rear High 3.89:1 / 3.36:1 Engine 10.08:1 / 8.71:1 Polaris Domestic Twin Cylinder, Platform 6.87:1 / 5.94:1 Liquid Cooled, 4-Stroke Drive Ratio - Front 3.818:1 Engine Model Number EH068OLE044 Drive Ratio - Mid 3.70:1...
Page 12: Paint Codes
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...
Page 13: Misc. Specifications And Charts
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: (°F + 40) ÷ 9 - 40 = °C 1.10...
Page 14: Standard Torque Specifications
GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque. 1.11...
Page 15: Sae Tap / Drill Sizes
GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes 1.12...
Page 16: 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 17 SERVICE PRODUCTS AND LUBES........2.10 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS ... 2.10 MAINTENANCE REFERENCES .
Page 18 GENERAL INFORMATION FINAL DRIVE / WHEEL AND TIRE ......... 2.27 WHEEL, HUB, AND SPINDLE TORQUE TABLE.
Page 19: Periodic Maintenance Chart
If oil level begins to rise, discontinue use and determine cause.) 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 with a could result in component failure and lead to serious injury or death.
Page 20: Pre-Ride - 25 Hour Maintenance Interval
Engine Oil Change 25 H Perform a break-in oil change at one month (Break-In Period) Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
Page 21: 50 - 100 Hour Maintenance Interval
Engine Oil Change 100 H one month Oil Filter Change 100 H Replace with oil change Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
Page 22 300 H Clean out Auxiliary Brake Inspect daily; adjust as needed Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
Page 23: General Component Locations
GENERAL INFORMATION GENERAL COMPONENT LOCATIONS RH Side (4X4) and Dash View Gas Tank Rear Gearcase Front Gearcase (Behind Radiator) Engine (under seat) Dash Components AWD / Differential Switch Instrument (if equipped) Light Cluster Switch Holder Holder Ignition Accessory Storage Switch Storage Outlet Compartment...
Page 24: Lh Side And Rear View (4X4)
GENERAL INFORMATION LH Side and Rear View (4X4) Battery Storage Rear Prop Shaft Compartment Front Prop Shaft Transmission Tail Gate Latch Air Cleaner Muffler 2" Hitch Drive Shafts...
Page 25: Lh Side And Rh Side Views (6X6)
GENERAL INFORMATION LH Side and RH Side Views (6X6) Front Gearcase (behind radiator) Engine (under seat) Rear Gearcase Transmission Mid Gearcase Battery Drive Shafts Front Prop Shaft Rear Prop Shaft...
Page 26: Service Products And Lubes
GENERAL INFORMATION SERVICE PRODUCTS AND LUBES 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. 2870585 Loctite™ Primer N, Aerosol, 25 g Part No.
Page 27: Maintenance References
Add lube to bottom of fill plug Change annually. Change more often if 3. Transmission Lubricant (PN 2873602) threads. used in severe conditions. Polaris Demand Drive Hub Drain completely. Add lube to 4. Front Gearcase Change annually*** Fluid (PN 2871654) specified quantity.
Page 28: Maintenance References, Continued
**Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) ***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special Yoke 6.
Page 29: General Vehicle Inspection And Maintenance
GENERAL INFORMATION GENERAL VEHICLE INSPECTION Shift Linkage Inspection / Adjustment AND MAINTENANCE Linkage rod adjustment is necessary when symptoms include: Pre-Ride / Daily Inspection • No All Wheel Drive light • Noise on deceleration Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
Page 30: Fuel System And Air Intake
GENERAL INFORMATION Fuel Filter Use this procedure to loosen or tighten the shift linkage cable as needed. The RANGER XP 4x4 and 6x6 EFI engines use a non- Clockwise Inside Jam Nut serviceable, high-volume, high-pressure, 60-micron internal fuel pump filter and an internal 10-micron filter located before the pump regulator.
Page 31: Throttle Freeplay Adjustment
GENERAL INFORMATION Throttle Freeplay Adjustment Air Filter Service Inspection It is recommended that the air filter be replaced annually. When riding in extremely dusty conditions replacement will be Apply the parking brake. required more often. Put the gear shift lever in the N (Neutral) position. The filter should be inspected periodically before each ride, Start the engine, and warm it up thoroughly.
Page 32: Air Intake Inspection
GENERAL INFORMATION Air Intake Inspection Check air box. If oil or water deposits are found, drain them into a suitable container. Lift the hood. NOTE: Service more frequently if vehicle is operated Inspect the foam inserts in the air baffle boxes. If the foam in wet conditions or at high throttle openings for inserts are dirty, clean the foam with a high flash point extended periods.
Page 33: Engine
GENERAL INFORMATION ENGINE Engine Oil Level The twin cylinder engine is a wet-sump engine, meaning the oil Compression and Leakdown Test is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below. NOTE: This engine does NOT have decompression components.
Page 34: Engine Oil And Filter Change
Recommended Engine Oil: dipstick. Do not overfill. (See NOTE below!) NOTE: Due to the dipstick entry angle into the Polaris Premium Synthetic OW-40 crankcase, the oil level will read higher on the (PN 2871281) (Quart) bottom side of the dipstick. Proper level indication...
Page 35: Exhaust Pipe
The exhaust pipe must be periodically purged of accumulated carbon as follows: 13. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 Synthetic Oil (PN2871281) Remove the clean out plugs located on the bottom of the muffler as shown below.
Page 36: Transmission And Gearcases
GENERAL INFORMATION If particles are still suspected to be in the muffler, back the The transmission lubricant level should be checked and changed machine onto an incline so the rear of the machine is one in accordance with the maintenance schedule. foot higher than the front.
Page 37: Front Gearcase Lubrication (4X4)
GENERAL INFORMATION To change lubricant: • The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid. Remove skid plate (if necessary). Front Gearcase Specifications Place a drain pan beneath the transmission oil drain plug area. Specified Lubricant:...
Page 38: Middle Gearcase Lubrication (6X6)
GENERAL INFORMATION To change gearcase lubricant: Remove fill plug (8 mm hex) and check the O-ring. Fill Plug 10 ft. lbs (14 Nm) Remove gearcase drain plug (B) (11 mm) located on the Fill with the recommended fluid amount (5 oz.) or to the bottom of the gearcase and drain oil.
Page 39: Rear Gearcase Lubrication (4X4)
GENERAL INFORMATION Rear Gearcase Lubrication (4x4) To check the lubricant level: The gearcase must be drained and re-filled with the proper amount of lubricant. Refer to the procedure below. REAR GEARCASE SPECIFICATIONS To change middle gearcase lubricant: Specified Lubricant: With the RANGER on a level surface, remove the fill plug ATV Angle Drive Fluid (PN 2871653) and check the lubricant level.
Page 40: Rear Gearcase Lubrication (6X6)
• Check vent hose to be sure it is routed properly and Remove fill plug. unobstructed. • The correct rear gearcase lubricant to use is Polaris ATV Angle Drive Fluid To check the lubricant level: The gearcase must be drained and re-filled with the proper amount of lubricant.
Page 41: Cooling System
Overheating of engine could occur if air is not fully purged from system. NOTE: If overheating is evident, allow system to Polaris Premium 60/40 is already premixed and ready to use. Do cool completely and check coolant level in the not dilute with water.
Page 42: Radiator Coolant Level Inspection
NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or Polaris 60/40 Anti-Freeze / Coolant repair. However, if the recovery bottle has run dry, or if overheating is evident, the level in the radiator (PN 2871323) should be inspected and coolant added if necessary.
Page 43: Radiator
GENERAL INFORMATION Radiator Remove the outlet radiator hose, inlet radiator hose, surge tank hose, and overflow hose from the radiator. Check radiator (A) air passages for restrictions or damage. Remove the radiator. Inlet Radiator Hose Outlet Radiator Hose Carefully straighten any bent radiator fins. Surge Tank Hose Remove any obstructions with compressed air or low Plug...
Page 44: Cv Shaft Boot Inspection
If the rubber boot exhibits any of these symptoms, replace the boot. Refer to Chapter 7 for CV boot replacement, or have you Polaris dealer If wheels are improperly installed it could affect replace the boot.
Page 45: Tire Pressure
GENERAL INFORMATION Tire Pressure NOTE: Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. Charge battery for 3-5 hours at a current CAUTION equivalent of 1/10 of the battery’s rated amp/hour capacity.
Page 46: Battery Installation
NOTE: Battery charge can be maintained by using a picture below for proper spark plug type and gap. Adjust Polaris battery tender charger or by charging about gap if necessary by bending the side electrode carefully. once a month to make up for normal self-discharge.
Page 47: Engine To Frame Ground
WARNING Recommended Spark Plug: Champion RC7YC3 Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be Spark Plug Torque: performed by an authorized Polaris MSD- 18 Ft. Lbs. (24 Nm) certified technician when replacing worn or damaged steering parts.
Page 48: Wheel Toe Alignment Inspection
GENERAL INFORMATION Wheel Toe Alignment Inspection Toe Adjustment Place machine on a smooth level surface. If toe alignment is incorrect, measure the distance between Set steering wheel in a straight ahead position and secure vehicle center and each wheel. This will tell you which tie rod the steering wheel in this position.
Page 49: Front Suspension
GENERAL INFORMATION Front Suspension Rear Suspension • Compress and release front suspension. Damping should be smooth throughout the range of travel. • Check all front suspension components and fasteners for wear or damage. • Inspect front strut cartridges for leakage. Bolt Torque 15 ft.
Page 50: Rear Suspension Adjustment (4X4)
• Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir. Inside Mounting Holes • Use Polaris DOT 3 or DOT 4 Brake Fluid. • Check brake system for fluid leaks. • Check brake for excessive travel or spongy feel.
Page 51: Parking Brake Pad Inspection
GENERAL INFORMATION Parking Brake Pad Inspection Measure the thickness of the rear caliper parking brake pads. Replace assembly as needed. See illustration below for proper readings. Inboard Pad Thickness New .304” (7.72 mm) Limit: 0.24” (6.1 mm) Inboard Outboard Outboard Pad Thickness New 0.360”...
Page 52 ENGINE CHAPTER 3 ENGINE ENGINE SPECIFICATIONS ..........3.2 CRANKCASE EXPLODED VIEWS .
Page 53: Engine Specifications
ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views A. Journal Bearings B. Camshaft C. Thrust Plate D. Balance Shaft E. Woodruff Key F. Flange Seal G. Crankshaft H. Oil Pickup I. Journal Bearings J. Baffle K. Oil Plug L. Washer M. O-ring N.
Page 54 (6.8 ± .68 Nm) Apply corrosion resistant grease to stator grommet area. 96 ± 3 in.lbs. (10.85 ± 0.35 Nm) Oil Pump Bolt Tighten Sequence Mag Cover Bolt Tighten Sequence Apply Polaris OW-40 oil to component Apply White Lithium Grease...
Page 55 Stator Cover / Starter / Water Pump Exploded View Apply Polaris Water Pump Cover Starter Grease Bolt Tighten Sequence Apply Polaris 0W-40 oil to seal Loctite™ Pipe Sealant (PN 2871956) No Grease or Oil 84 ± 8 ft.lbs. (9.5 ± 0.9 Nm) 96 ±...
Page 56 ENGINE Oil Filter / Pressure Relief / Dipstick Assembly Exploded View A. Clamp B. Oil Fill Tube C. Dipstick D. O-ring E. Hex Plug F. Oil Filter Nipple G. Oil Filter H. Dowel I. Galley Plug Asm. J. Screw K. Relief Spring 50 ±...
Page 57 A. Head Bolts B. Rocker Arms C. Head Assembly D. Gasket Circlip UP for Install E. Pushrods F. Bushing G. Expansion Plug H. Cylinder I. Piston Assembly J. Circlip K. Gasket L. Hydraulic Lifter Apply Polaris 0W-40 Oil Apply Moly Lube Grease...
Page 58 ENGINE Engine Sensors / Valve Cover / General Component Exploded View 84 ± 8 in. lbs. (9.5 ± 0.9 Nm) A. Screws 20 ± 5 in. lbs. B. Rocker Cover (2.5 ± 0.55 Nm) C. Breather D. O-ring Seal 18 ± 2 ft. lbs. E.
Page 59: Fuel Injection
ENGINE EFI Harness / Fuel Injection Exploded View A. Fuel Injector B. Fuel Rail C. EFI Harness 18 ± 2 ft. lbs. (24.5 ± 2.7 Nm) NOTE: See Chapter 4 for more information on the EFI system.
Page 60: Engine Fastener Torque Patterns
ENGINE Engine Fastener Torque Patterns Crankcase Bolt Tighten Sequence 22 ± 2 ft. lbs. (30 ± 3 Nm) Cylinder Head Bolt Tighten Sequence Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, then °...
Page 61: Torque Specifications
ENGINE Torque Specifications Engine Torque Specifications Fastener Size in. lbs. (Nm) ft. lbs. (Nm) Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 115 ± 12 (13 ± 1.35) 9.5 ± 1 (13 ± 1.35) Throttle Body Adaptor Bolts 8 mm 216 ±...
Page 62: 700 Efi Engine Service Specifications
ENGINE 700 EFI Engine Service Specifications Cylinder Head - Engine Specifications Main Component: Cylinder Head EH068OLE Cam Lobe Height - Intake / Exhaust 1.3334" (33.8674 mm) 1.654" ± 0.00039" (42 ± 0.010 mm) Camshaft Journal Outer Diameter - Mag 1.634"± 0.00039" (41.50 ± 0.010 mm) Camshaft Journal Outer Diameter - Center 1.614"...
Page 63 ENGINE Cylinder / Piston - Engine Specifications Main Components: Cylinder / Piston / Connecting Rod EH068OLE Cylinder - Surface warp limit 0.004" (0.10 mm) (mating with cylinder head) Cylinder Bore - Standard 3.1495" (80 mm) Cylinder Cylinder Taper Limit 0.00031" (0.008 mm) Cylinder Out of Round Limit 0.00030"...
Page 64: Special Tools
System Capacity 3.25 Quarts (2.13L) • Gear Train Components Radiator Cap Pressure Relief 13 PSI Following Components Require Engine Removal for service: Polaris Premium Antifreeze • Counterbalance Shaft or Bearings 2871534 - Quart • Connecting Rod 2871323 - Gallon • Crankshaft •...
Page 65: Cooling System Pressure Test
The cooling system is under heat dissipation, resulting in possible engine damage. Polaris pressure and serious burns may result. Premium 60/40 Antifreeze/Coolant is recommended for use in Allow the engine and cooling system to cool all cooling systems and comes pre-mixed, ready to use.
Page 66: Cooling System Exploded View
ENGINE Cooling System Exploded View Radiator Inlet Hose Engine Outlet Hose Engine Inlet Hose Radiator Outlet Hose Radiator Cap Surge Tank Radiator Shroud Drain Plug Cooling System Bleeding Procedure PROCEDURE 1: Park machine on a flat surface. Place the vehicle in Neutral WARNING and set the parking brake.
Page 67 Squeeze the coolant lines by hand to help purge the system of air. Be sure the engine has cooled and there is no Add Polaris Premium Antifreeze to the radiator if the level pressure built up in the cooling system before goes down.
Page 68: Valve Cover Removal - 6X6 Models (Engine Installed)
ENGINE Valve Cover Removal - 6x6 Models Remove the heat shield shown below and loosen the exhaust mounts. (Engine Installed) The RANGER 6x6 models have a different engine mounting system that makes it more difficult to access and remove the Loosen Remove engine valve cover.
Page 69: Engine Removal
ENGINE Engine Removal 12. Disconnect the air intake hose (D) from the air box and remove the air intake hose. WARNING Always wear safety glasses and proper shop clothing when performing the procedures in this manual. Failing to do so may lead to possible injury or death.
Page 70: Engine Installation Notes
ENGINE 16. Remove the crank position sensor (I) located on the mag NOTE: Use caution when lifting the engine out of frame. Use an engine lift or other means if the engine cover. is too heavy to be lifted manually. 17.
Page 71: Cylinder Hone Selection And Honing Procedure
Engine Break-In Period Using a common spring loaded glaze breaker The break-in period for a Polaris RANGER engine is defined as for honing is not advised for nicasil cylinders. the first ten hours of operation, or the time it takes to use two full Polaris recommends using a rigid hone or arbor tanks of gasoline.
Page 72: Cleaning The Cylinder After Honing
Insert a 1/8 NPT oil pressure gauge adaptor into the crankcase and attach the gauge. Start engine and allow it to reach operating temperature, monitoring gauge indicator. NOTE: Use only Polaris Premium 0W-40 Synthetic Engine Lubricant. Oil Pressure at 5500 RPM (Engine Hot): Standard: 39 PSI...
Page 73: Oil Flow Chart
ENGINE Oil Flow Chart This chart describes the flow of oil through the 700 engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.
Page 74: Engine Disassembly And Inspection
ENGINE ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Rocker Arms Retainer Locks (keepers) Push Rods Spring Retainers Springs Valve Seals Valve Spring Seats Cylinder Head Hydraulic Lifters Valves 3.23...
Page 75: Rocker Arms / Push Rods
ENGINE Rocker Arms If the push rod (A) is visibly bent, it should be replaced. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. Cylinder Head Removal Inspect the wear pad at the valve end of the rocker arm for Loosen the six cylinder head bolts evenly 1/8 turn each in indications of scuffing or abnormal wear.
Page 76: Cylinder Head Inspection
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 77: 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 78: Valve Inspection
ENGINE Valve Inspection Remove all carbon from valves with a soft wire wheel or = In. / mm. brush. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” Valve Stem Diameter: blocks and a dial indicator.
Page 79: Combustion Chamber
Install pilot into valve guide. Valve Seat Reconditioning NOTE: Polaris recommends that the work be done Apply cutting oil to valve seat and cutter. by a local machine shop that specializes in this area.
Page 80 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 81: Cylinder Head Reassembly
ENGINE Cylinder Head Reassembly Clean all filings from the area with hot soapy water, rinse, and dry with compressed air. NOTE: Assemble the valves one at a time to maintain proper order. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the Apply engine oil to valve guides and seats.
Page 82: Valve Sealing Test
ENGINE Valve Sealing Test Valve Lifter Removal / Inspection Clean and dry the combustion chamber area (A). Remove the valve lifter's 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 83: Piston Removal
ENGINE Piston Removal The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. The top rail has Remove circlip (A). Mark the piston with a white pen to a locating tab on the end which fits into a notch (B) in the upper ensure proper orientation (if reused) during assembly.
Page 84: Cylinder Inspection
ENGINE Cylinder Inspection Inspect cylinder for wear, scratches, or damage. Remove all gasket material from the cylinder sealing surfaces. Inspect the top of the cylinder (B) for warp using a straight edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge.
Page 85: Piston-To-Cylinder Clearance
ENGINE Piston-to-Cylinder Clearance Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.
Page 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 nylok nut (C), washer (D), and water pump Remove the starter bendix (G), wire holddown plate (H), impeller (E). Remove part of the water pump seal behind and the woodruff key (I) from the crankshaft. The stator the impeller.
Page 89 ENGINE Use a white pen to accent the timing marks on the following CAUTION gears: camshaft gear (K), crankshaft gear (M), or counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears. Wear safety glasses at all times. Use caution when working with the top gear.
Page 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 gear hole Inspect Teeth & Tabs and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring.
Page 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 40. Remove balance shaft and crankshaft. 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. 41. Remove and inspect crankshaft main journal bearings for abnormal wear.
Page 96: Engine Reassembly
ENGINE Measure ID of camshaft journal bores. Install oil pick up (A), if removed. Torque to specification. = In. / mm. Camshaft Journal Bore I.D.: (Mag): 1.656" ± 0.00039" (42.07± 0.010 mm) (Ctr.) 1.637" ± 0.00039" (41.58 ± 0.010 mm) (PTO) 1.617"...
Page 97 ENGINE Apply assembly lube to cam journals and balance shaft Assemble the crankcase halves. Apply LocTite™ 242 (PN bearing surfaces of the MAG case halve. Install camshaft 2871949) to the threads and pipe sealant to the bolt flanges. and balance shaft. Torque bolts to specification following torque pattern at beginning of this chapter.
Page 98 ENGINE 10. Lubricate connecting rods with 0W-40 engine oil. 13. Install piston assemblies into cylinder aligning the piston pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons. 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 NOTE: Cam Spanner Wrench (PU-45498) is only 25. Install counter balance shaft gear (J) with new key, aligning 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 28. Before installing the gear / stator housing, replace the seals NOTE: Install the crankshaft seal (P) with the seal lip 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 he 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 2870585) to remove any bolts to specification in proper sequence (See front of this debris. This will ensure proper sealing when chapter).
Page 105: Flywheel / Stator Installation
ENGINE Flywheel / Stator Installation NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any Flywheel Nut Torque debris. This will ensure proper sealing when installing bolts. 65 ± 7 ft.lbs. (88 ± 9.50 Nm) Install stator housing with new o-rings.
Page 106 ENGINE Install cylinder head on cylinder. Lubricate rockers (E) with engine oil. Lubricate threads and top of washers underside of bolt head with engine oil. Install head bolts (C) and torque to specification. Verify pushrods are engaged in lifters. Install rockers. Be sure that tab of fulcrum (F) is seated in head stand-off.
Page 107 ENGINE 11. Install thermostat (J), new O-ring, and thermostat housing. Torque to specification. 17 ± 2 ft. lbs. Breather Bolt Toque: (23 ± 3 Nm) ± ± 5 in. lbs. (2.5 0.55 Nm) NOTE: When applying RTV, do not get any RTV inside the reed assembly.
Page 108: Oil Pump Priming
Remove primer plug from the engine. Install Oil System Priming Adapter (PU-45778) into the oil plug hole. Push 3-5 oz. (approx.) of Polaris 0W-40 into the adapter or until resistance is felt. Remove the adapter. Apply sealant to the plug threads. Install the plug and torque to specification.
Page 109: 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 110: 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 111 FUEL INJECTION CHAPTER 4 FUEL INJECTION GENERAL INFORMATION ..........4.2 SPECIAL TOOLS .
Page 112: General Information
FUEL INJECTION GENERAL INFORMATION Fuel Pressure Gauge Kit - PU43506-A IMPORTANT: The EFI fuel system remains under high WARNING pressure, even when the engine is not running. Before attempting to service any part of the fuel system, the pressure must be relieved. The pressure Gasoline is extremely flammable and explosive adapter has an integrated relief valve.
Page 113 SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. This module kit is used on all 8 pin connector-based Polaris EFI systems. This kit is available to Polaris dealers through our tool supplier, SPX (1-800-328-6657). Throttle Body Adjustment Screwdriver PU-47315 This tool has a special ‘D’...
Page 114: Service Notes
• 80% of all EFI problems are caused by wiring harness connections. • For the purpose of troubleshooting difficult running issues, a known-good ECU from another Polaris RANGER XP EFI of the same model may be used without damaging system or engine components.
Page 115: Efi System Exploded View
FUEL INJECTION EFI System Exploded View 1. Electronic Control Unit (ECU) 2. Intake Air Temperature / Barometric Air Pressure Sensor (T-BAP) 3. Crankshaft Position Sensor (CPS) 4. Fuel Injectors 5. Fuel Filter 6. Fuel Pump / Regulator / Gauge Sender Asm. (Located in tank as an assembly) 7.
Page 116: Efi System Component Locations
FUEL INJECTION EFI System Component Locations Fuel Injectors / Fuel Rail Attached to the fuel rail located in the intake track of the Electronic Control Unit (ECU) cylinder head. Located under the seat on the driver’s side. Fuel Pump / Regulator / Gauge Sender Assembly Located in fuel tank as an assembly.
Page 117 FUEL INJECTION Throttle Position Sensor (TPS) Located on the right-hand side of the throttle body. Engine Coolant Temperature Sensor (ECT) Located in the cylinder head.
Page 118: Fuel Tank
FUEL INJECTION FUEL TANK Exploded View Fuel Flow...
Page 119: Fuel Lines - Quick Connect
FUEL INJECTION Fuel Lines - Quick Connect EFI Operation Overview RANGER EFI models use quick connect fuel lines. Refer to the The EFI system is designed to provide peak engine performance steps below for fuel line removal. with optimum fuel efficiency and lowest possible emissions. The ignition and injection functions are electronically Place a shop towel around the fuel line to catch any controlled, monitored and continually corrected during...
Page 120: Initial Priming / Starting Procedure
FUEL INJECTION Initial Priming / Starting Procedure ELECTRONIC CONTROL UNIT (ECU) NOTE: The Injection system must be purged of all Operation Overview air prior to the initial start up, and / or any time the system has been disassembled. The ECU is the brain or central processing computer of the entire EFI fuel/ignition management system.
Page 121: Ecu Service
For the purpose of troubleshooting, a known-good ECU from fuel pump, which pressurizes the system for start-up. another Polaris RANGER XP EFI of the same model may be used without system or engine component damage. The ECU switches off the pump preventing the continued...
Page 122: Fuel Pump Test
ECU of the same model. NOTE: If the pump still does not operate, replace the pump/tank assembly. Connect the pressure hose of the Polaris pressure tester (PN PU-43506) to the test valve on the fuel rail. Route the Fuel Pump / Tank Assembly Replacement clear hose into a portable gasoline container or the equipment fuel tank.
Page 123 FUEL INJECTION Disconnect the negative battery cable. Remove the RH rear fender and fuel cap. Remove the seat. Disconnect the fuel line from the fuel pump. Remove the two inner bolts that hold the fuel tank to the frame. Disconnect the fuel pump electrical harness. Remove the two outer lower bolts that hold the fuel tank to the frame.
Page 124: Fuel Pressure Regulator
FUEL INJECTION Fuel Pressure Regulator Test Reinstall the fuel cap and carefully pull the fuel tank out the RH side of the frame. Refer to the “FUEL PUMP TEST” procedure. See “Fuel Pump Test” on page 4.12. Fuel Pressure Regulator Replacement The regulator is a sealed, non-serviceable assembly.
Page 125: Fuel Injector Service
FUEL INJECTION Fuel Injector Service Remove the fuel rail mounting screw and carefully loosen / pull the rail away from the injectors. Injector problems typically fall into three general categories- Reverse the procedures to install the new injector(s) and electrical, dirty / clogged, or leakage. An electrical problem reassemble.
Page 126: Cps Test
FUEL INJECTION CPS Test TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP) The crankshaft position sensor is a sealed, non-serviceable assembly. If fault code diagnosis indicates a problem within this area, test and correct as follows: Operation Overview Disconnect main harness connector from ECU. Mounted on the throttle body intake, the temperature and Connect an ohmmeter between the pin terminals.
Page 127: Throttle Position Sensor (Tps)
FUEL INJECTION THROTTLE POSITION SENSOR (TPS) • Harness Test: Insert black voltmeter probe into the “Bk” test port. Operation Overview • Connect the red meter probe into the “R” port and verify the voltage is 4.99-5.01 Vdc. If this reading is The throttle position sensor (TPS) is used to indicate throttle low, verify the 9 volt battery is good or try a new 9 volt plate angle to the ECU.
Page 128: Tps Initialization
FUEL INJECTION If voltage varies with throttle movement, continue on to • With engine off, back out air flow screw until it no step 3 and measure the idle air flow reading. If the sensor longer is in contact with throttle plate cam. The throttle does not function correctly, replace it.
Page 129: Tps Replacement
FUEL INJECTION STEP 2 Disconnect sensor (A) from the harness. Establishing correct flow: Now that the zero offset voltage has been set, you can now set the throttle body to the correct air flow value. With voltmeter still attached to the TPS Test Adapter Harness (PU-47082), turn the air flow adjustment screw until the voltmeter reads .710 ±...
Page 130: Ect Sensor Test
‘HOT’ should indicate on the instrument cluster. This indicates all other components are working properly. Refer to Chapter 10 for ECT testing. Polaris dealers can also test the sensor by using the Digital Wrench™ Diagnostic Software (dealer only). Refer to the Digital Wrench™ User Guide for more information.
Page 131: General Troubleshooting
FUEL INJECTION GENERAL TROUBLESHOOTING Any “blink codes” stored in the ECU will display a numerical “blink code”, one at a time, in numerical order, Diagnostic “Blink Codes” on the instrument cluster display. The word “End” will display after all of the codes have been NOTE: The EFI diagnostic mode is intended to displayed or if no codes are present.
Page 132: Efi Troubleshooting
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 133: Body / Steering / Suspension
BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS..........5.2 SPECIAL TOOLS .
Page 134: Torque Specifications
BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS SPECIAL TOOLS ITEM TORQUE VALUE TOOL DESCRIPTION PART NUMBER ft.lbs. (Nm) Strut and Ball Joint Tool Set 2870871 Front A-Arm Attaching Bolt 30 ft. lbs. (41 Nm) Shock Spanner Wrench 2870872 Front A-Arm Ball Joint Stud Nut 30 ft.
Page 135: Body Component Removal
BODY / STEERING / SUSPENSION BODY COMPONENT REMOVAL Removal Procedures TO REMOVE: PERFORM THESE STEPS: SEAT Pull up on front of seat and then pull forward 1. Remove the gear selector handle 2. Then remove the 4 screws that attach the hood to the dash DASH 3.
Page 136: Lower Body Components
BODY / STEERING / SUSPENSION Lower Body Components...
Page 137: Hood / Dash Components
BODY / STEERING / SUSPENSION Hood / Dash Components T-27 4-5 ft. lbs. Glove Box Assembly (5-6 Nm) 8-10 in. lbs. T-30 (0.9-1.0 Nm) Hinges 4-5 ft. lbs. Cup Holder (5-6 Nm) T-27 Hood 4-5 ft. lbs. (5-6 Nm) T-27 Torx Grille Headlights Hood Latch Strap...
Page 138: Dash Instruments And Controls
BODY / STEERING / SUSPENSION Dash Instruments and Controls A. Speedometer B. Headlight Switch C. 2WD/AWD Switch D. 12 Volt Accessory Receptacle E. Speedometer “Mode” Button F. Key Switch G. Speedometer Mount Plate...
Page 139: Cab Frame
BODY / STEERING / SUSPENSION CAB FRAME Assembly / Removal Assemble the two rear cab frames at the coupler joint and secure with two 3/8" screws and nuts. Assemble the front frame in same manner. Tighten all 3/8" screws to 25-28 ft. lbs. (34-38 Nm). Assemble the center cross bracket to the rear cab frame and secure with two 5/16 hex bolts and nuts.
Page 140: Chassis / Main Frame (4X4)
BODY / STEERING / SUSPENSION CHASSIS / MAIN FRAME (4X4) Exploded View Seat Base Frame Extension RH Floor Support 45 ft. lbs. (61 Nm) Main Frame Front Cab Support 28-32 ft. lbs. (38-43 Nm) Bumper Grills 13-15 ft. lbs. (17-20 Nm) LH Floor Support T-27 28-32 ft.
Page 141: Chassis / Main Frame (6X6)
BODY / STEERING / SUSPENSION CHASSIS / MAIN FRAME (6X6) Exploded View Seat Base Frame Extension Front Cab Support RH Floor Support 45 ft. lbs. (61 Nm) Main Frame 28-32 ft. lbs. (38-43 Nm) Bumper Grills 13-15 ft. lbs. (17-20 Nm) LH Floor Support T-27 28-32 ft.
Page 142: Seat / Head Rest
BODY / STEERING / SUSPENSION SEAT / HEAD REST Seat Base / Seat Back / Head Rest Assembly After attaching the frame to the vehicle, install the two headrests onto the frame using T-27 nuts. Install the bolts loosely, then tighten to 4-6 ft.
Page 143: Steering Assembly
BODY / STEERING / SUSPENSION STEERING ASSEMBLY Exploded View 25-30 ft. lbs. (34-41 Nm) Rod End & Jam Nut Steering Wheel Bushing Wave Washers Screw & Lock Washer 15-22 ft. lbs. (20-30 Nm) Screw & Nut Upper Steering Shaft Tie Rod Bolt Lower Steering Shaft 30 ft.
Page 144: Steering And Suspension
BODY / STEERING / SUSPENSION STEERING AND SUSPENSION Exploded View NOTE: To avoid damage to the tie rod ends and Always use new other steering components, be sure to install tie Always use new bolts cotter pins upon rod end bolts in the proper direction. The stee- upon reassembly reassembly.
Page 145: Front A-Arm
BODY / STEERING / SUSPENSION FRONT A-ARM Attach A-arm to hub strut assembly. Tighten ball joint nut to 25 ft. lbs. (35 Nm). If cotter pin holes are not aligned, Replacement tighten nut slightly to align. Install a new cotter pin with open ends toward rear of machine.
Page 146: Front Strut
BODY / STEERING / SUSPENSION FRONT STRUT Exploded View Pivot Ball Spring 15 ft. lbs. Retainer (21 Nm) Spacer Rubber Bottom Pivot Ball Washer Spacer Front Strut Clamp Washer 18 ft. lbs. (24 Nm) Spring Bolt 18 ft. lbs. Strut Bumper (24 Nm) Wheel Speed Sensor (Hall Effect Sensor)
Page 147: Front Strut Cartridge Replacement
BODY / STEERING / SUSPENSION Front Strut Cartridge Replacement Remove cotter pin (A) from ball joint castlenut. Remove castle nut (B) and separate A-arm (C) from ball Refer to Illustration on Page 5.14. joint stud. Hold strut rod and remove top nut. Remove screws (D) and ball joint retaining plate (E).
Page 148: Mid Axle A-Arm (6X6)
BODY / STEERING / SUSPENSION Apply Loctite™ 242 (PN 2871949) to threads of retaining WARNING plate screws or install new screws with pre-applied locking agent. Torque screws to 8 ft. lbs. (11 Nm). The locking features on the existing bolts were 10.
Page 149: Rear A-Arm (4X4)
BODY / STEERING / SUSPENSION REAR A-ARM (4X4) Remove the hub and brake disc assembly by sliding it off of the axle. Replacement NOTE: Use the exploded view on the next page as reference during the procedure. Elevate and safely support vehicle with weight removed from the rear wheel(s).
Page 150 BODY / STEERING / SUSPENSION 11. Remove the bottom stabilizer bar nut. 14. Install new A-arm assembly onto vehicle frame. Torque new bolts to 30 ft. lbs. (41 Nm). WARNING Stabilizer Bar The locking features on the existing bolts were destroyed during removal.
Page 151: Rear Stabilizer Bar (4X4)
BODY / STEERING / SUSPENSION REAR STABILIZER BAR (4X4) Remove the two bolts that secure the stabilizer bar to the main frame, each side. Removal / Installation Elevate and safely support vehicle with weight removed from the rear wheel(s). Remove the rear wheel to gain access to the stabilizer bar, each side.
Page 152: Swing Arm (6X6)
BODY / STEERING / SUSPENSION SWING ARM (6X6) Removal Support machine on a level surface. Remove rear wheels. NOTE: The rear axle may be removed to ease the removal of the swing arm. Refer to Chapter 7, “REAR AXLE HOUSING REMOVAL/INSPECTION”. Support swing arm, remove rear axle shocks.
Page 153: Rear Drive Axle And Swingarm Exploded View (6X6)
BODY / STEERING / SUSPENSION REAR DRIVE AXLE AND SWINGARM EXPLODED VIEW (6X6) Retaining Ring Axle Tube Wheel Screw & Washer Bearing 60 ft. lbs. (81 Nm) Vehicle Frame Screw & Washer 60 ft. lbs. (81 Nm) Swing Arm Axle Wheel Bearing 150 ft.
Page 154: Rear Cargo Box
BODY / STEERING / SUSPENSION REAR CARGO BOX Cargo Box - Panels 8-10 in. lbs. (0.9-1.0 Nm) Taillight T-20 8-10 in. lbs. (0.9-1.0 Nm) T-30 Tailgate Support T-27 4-6 ft. lbs. (5-8 Nm) T-20 T-30 8-10 in. lbs. (0.9-1.0 Nm) Seal Foam T-20 8-10 in.
Page 155: Cargo Box - Tailgate / Box Support
BODY / STEERING / SUSPENSION Cargo Box - Tailgate / Box Support Tailgate Cap Tailgate Latch 20-25 in. lbs. Cable T-20 (2-3 Nm) T-20 8-10 in. lbs. Outer Panel (0.9-1.0 Nm) Inner Panel Tailgate Tube Box Support Box Latch Assembly Hinge Pin Shock Pins Bolt...
Page 156: Box Removal
BODY / STEERING / SUSPENSION Box Removal Lift the cargo box into the dump position. Slide Hinge Pin Out Disconnect the rear wire harness attached to the tail lights. Remove the upper clip and pin attaching the shock to the cargo box.
Page 157: Storage Box
BODY / STEERING / SUSPENSION STORAGE BOX DECAL REPLACEMENT Plastic polyethylene material must be “flame treated” prior to Removal installing a decal to ensure good adhesion. The flame treating procedure can often be used to reduce or eliminate the whitish Remove the two bottom T-27 torx screws.
Page 158: Clutching
CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES ......... . 6.2 TORQUE SPECIFICATIONS.
Page 159: 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 a Polaris ATV, the TORQUE SPECIFICATIONS PVT system is matched first to the engine power curve; then to average riding conditions and the vehicle’s intended usage.
Page 160: Driven Clutch Operation
CLUTCHING Driven Clutch Operation Maintenance / Inspection Under normal operation the PVT system will provide years of Driven clutches primarily sense torque, opening and closing trouble free operation. Periodic inspection and maintenance is according to the forces applied to it from the drive belt and the required to keep the system operating at peak performance.
Page 161: Overheating / Diagnosis
10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. For inspection of clutch components, please contact your Polaris dealer. Shift Clutch malfunction. transmission to Low during loading of the vehicle to prevent belt burning.
Page 162: Pvt System Service
CLUTCHING PVT SYSTEM SERVICE PVT Sealing, Guard, and Ducting Components SEALING AND DUCTING COMPONENTS Clutch Outlet Duct Inner Cover Clamps Inner Cover Seal Retainer Outer Cover Seal Cover Bolts PVT Outer Cover Disassembly Install the Drive Clutch Holder (PN 9314177) (A). Some fasteners and procedures will vary.
Page 163: Assembly
CLUTCHING Assembly Use the Driven Clutch Puller (PN 2870913), (C) if necessary. Inspect PVT inner cover-to engine seal. Replace if cracked or damaged. Apply RTV Silicone Here Driven Clutch Puller (PN 2870913) 10. Remove driven clutch offset spacers from the transmission input shaft.
Page 164: Drive Belt
CLUTCHING DRIVE BELT Clean splines inside driven clutch and on the transmission input shaft. Belt Deflection (Tension) Apply a light film of grease to the splines on the shaft. 10. Install the driven clutch, washer, lock washer, and retaining Straight Edge bolt.
Page 165: Belt Inspection
CLUTCHING NOTE: Belt is normally positioned so that part Measure belt width and replace if worn severely. numbers are easily read. Generally, belt should be replaced if clutches can no longer be adjusted to provide proper belt deflection. • The top edges have been trimmed on some drive belts. It will be necessary to project the side profiles and measure from corner to corner.
Page 166: Belt Installation
CLUTCHING CLUTCH ALIGNMENT / OFFSET NOTE: If a new belt is installed, check belt deflection. Clutch Alignment Clutch Alignment Tool Belt Installation Loop belt over the drive clutch and over top of the driven (PN PA-47346) sheave. 1/8” +0/ - 1/16 3.2 mm +0 / -1.6 mm Remove belt and install the Clutch Alignment Tool as While pushing down on top of belt, turn the back or...
Page 167: Clutch Offset
CLUTCHING NOTE: On some models, minor adjustments can be made by adding shims between the frame and front lower left engine mount to increase the distance at point “A”. If a shim is present, it can be removed to decrease the distance at point “A”. Shim Kit PN: 2200126 Clutch Offset IMPORTANT: Inspect clutch alignment and center...
Page 168: 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. To control the rate at which the drive belt moves upward in the drive clutch sheaves.
Page 169: Shift Weights
CLUTCHING Shift Weights Shown below are the shift weights which have been designed for, or which may be used in 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 170: Exploded View
Clutch Inspection All PVT system maintenance repairs must be performed only by WARNING an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual. Because of the...
Page 171: Clutch Disassembly
CLUTCHING Button To Tower Clearance Inspection Inspect cover bushing (A). The outer cover bushing is manufactured with a Teflon™ coating. Bushing wear is Inspect for any clearance between spider button to tower. determined by the amount of Teflon™ remaining on the If clearance exists, replace all buttons and inspect surface bushing.
Page 172: Spider Removal
CLUTCHING Spider Removal Roller, Pin, and Thrust Washer Inspection Install clutch in holding fixture and loosen the spider Inspect all rollers, bushings and roller pins by pulling a flat (counterclockwise) using spider removal tool. metal rod across the roller. Turn roller with your finger. If you notice resistance, galling, or flat spots, replace rollers, pins and thrust washers in sets of three.
Page 173: Bushing Service
CLUTCHING Bushing Service Insert the Number Two Adapter (#10) (PN 5020633) into the bushing from belt side as shown. With towers pointing *Clutch Bushing Replacement Tool Kit (PN 2871226) toward vise, slide sheave and bushing onto puller rod. Stamp Qty. Part Description Part # Install the nut removed in Step 2 onto end of puller rod and...
Page 174: Clutch Cover - Bushing Removal
CLUTCHING Install nut on puller rod and hand tighten. Turn barrel to Install nut onto puller rod and hand tighten. Turn puller apply additional tension if needed. barrel to increase tension as needed. Turn sheave and barrel together counterclockwise until Turn clutch cover counterclockwise on puller rod until bushing is seated.
Page 175: Clutch Assembly
CLUTCHING Turn clutch cover and barrel together counterclockwise on Compress spider buttons for each tower and install spider, puller rod until bushing is seated. making sure that “X”, or the marks that were made earlier, on spider aligns with “X”, or the marks that were made earlier, in moveable sheave.
Page 176: Driven Clutch Service
CLUTCHING DRIVEN CLUTCH SERVICE Exploded View DRIVEN CLUTCH Compression Spring Spring Retainer Secondary Stationary Sheave Retaining Ring Inner Spring Retainer Moveable Inner Sheave Clutch Disassembly / Inspection With the snap ring (A) removed and spring pressure relieved, remove the outer retainer (B), spring (C), and inner retainer (D).
Page 177 CLUTCHING Separate the two clutch sheaves. Check the rollers in the stationary sheave for wear. If the rollers are worn, a new driven clutch assembly may be needed. Check Rollers for Wear Inspect the helix and inner spring retainer on the moveable sheave.
Page 178: Clutch Assembly
CLUTCHING Clutch Assembly Install spring into inner retainer. Install moveable inner spring retainer if removed. Do not Install outer retainer on top of spring. apply oil or grease to the bearings. Compress the outer retainer and install the snap ring. Align the “X”...
Page 179: 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 180 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 181: Final Drive
FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIAL TOOLS ............7.3 TORQUE SPECIFICATIONS.
Page 182 FINAL DRIVE REAR HUB / BEARING CARRIER (4X4) ........7.36 HUB INSPECTION .
Page 183: Special Tools
FINAL DRIVE SPECIAL TOOLS FRONT HUB Hub Removal / Inspection PART NUMBER TOOL DESCRIPTION Elevate front end and safely support machine under Roller Pin Removal Tool 2872608 footrest / frame area. CV Boot Clamp Pliers 8700226 CAUTION TORQUE SPECIFICATIONS Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this Wheel, Hub, and Spindle Torque Table service procedure.
Page 184: Hubstrut Bearing Replacement
FINAL DRIVE Remove hub cap, cotter pin, front spindle nut, and washer. Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. Rotate each bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion.
Page 185: Hub Installation
FINAL DRIVE Hub Installation 10. Install brake caliper using new bolts. Tighten bolts to specified torque. Inspect the hubstrut bearing surface for wear or damage. Apply grease to drive axle spindle. Install spindle through the backside of the hubstrut. Install the hub onto the spindle.
Page 186: Front Hub Exploded View
FINAL DRIVE Front Hub Exploded View Disc Brake Stud Front Hub Tire 18 ft. lbs. (24 Nm) Use new bolts with pre-applied locking agent. Wheel Nut (Spec on page 7.3) Dust Cover Washer Slotted Nut Cotter Pin 70 ft. lbs. (95 Nm)
Page 187: Drive Shaft / Propshaft
FINAL DRIVE DRIVE SHAFT / PROPSHAFT Exploded View RANGER Front Driveshaft 30g Grease Packet CV Joint 30g Grease Packet Plunging Joint Inner Clamps Circlip Clamp Boots Clamp RANGER Front Propshaft Joint Kit Grease Zerk O-ring Shaft Yoke Front Yoke RANGER 4X4 & 6X6 Rear Propshaft Spring Pin O-ring O-ring...
Page 188: Driveshaft / Cv Joint Handling Tips
FINAL DRIVE DRIVESHAFT / CV JOINT Check bearings for side play by grasping tire / wheel firmly and checking for movement. It should rotate smoothly HANDLING TIPS without binding or rough spots. Care should be exercised during driveshaft removal or when servicing CV joints.
Page 189: Cv Joint / Boot Replacement
FINAL DRIVE CV Joint / Boot Replacement Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint. Remove wheel, brake caliper and wheel hub. Refer to “Front Hub Removal” for procedure. Remove cotter pin and castle nut from A-arm ball joint. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly.
Page 190 FINAL DRIVE Remove the large end of the boot from the CV joint, slide FRONT DRIVE SHAFT the boot back and separate the wheel spindle and CV joint assembly from the axle shaft by pulling the shaft sharply outward, away from the CV joint. It may be necessary to tap the CV joint assembly outward with a soft faced hammer.
Page 191: Installation
FINAL DRIVE Installation FRONT PROPSHAFT REMOVAL Install new spring ring on drive shaft. Apply an anti-seize compound to splines. Align splines of drive shaft with Elevate front end and safely support machine under front gearcase and install by lightly tapping on drive shaft footrest / frame area.
Page 192: Propshaft U-Joint Service
FINAL DRIVE NOTE: Remove the drive shaft floor cover to help Support inner yoke as shown and drive outer yoke down align the roll pin removal tool to the roll pin for (bearing cap out) with a soft face hammer. removal.
Page 193: Assembly
FINAL DRIVE Assembly Install outer yoke, aligning marks made before disassembly. Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislodge needle bearings upon installation of cross joint. Tighten vise to force bearing caps in.
Page 194: Front Gearcase Centralized Hilliard
FINAL DRIVE FRONT GEARCASE CAUTION CENTRALIZED HILLIARD If the rear wheels are spinning, release the AWD Operation throttle before turning the AWD switch on. If AWD is engaged while the wheels are Engaging Front Gearcase: The AWD switch may be turned on spinning, severe drive shaft and clutch or off while the vehicle is moving.
Page 195: Centralized Hilliard Exploded View
FINAL DRIVE Centralized Hilliard Exploded View 17 ft. lbs. (23 Nm) 17 ft. lbs. (23 Nm) 10 ft. lbs. (14 Nm) 8-30 ft. lbs. (11-41 Nm) ESCRIPTION ESCRIPTION Set Screw Seal Kit (Includes O-Rings and Seals) Cover Plate Asm. Screw Thrust Button Input Cover Thrust Plate...
Page 196: Awd Diagnosis
FINAL DRIVE AWD Diagnosis Possible Symptom: AWD Will Not Engage. Wear Ring on Armature Plate Check the gearcase coil resistance. To test the gearcase coil resistance. Test between the Grey & Brown / White wires. The gearcase coils should measure between 22.8 ohms and 25.2 ohms.
Page 197: Gearcase Removal
FINAL DRIVE Inspect the rollers for nics and scratches. The rollers must The front gearcase and drive shafts can be accessed from slide up and down and in and out freely within the roll cage both sides of the vehicle and limited access from the top. sliding surfaces.
Page 198: Gearcase Disassembly / Inspection
FINAL DRIVE Gearcase Disassembly / Inspection Remove the roll cage assembly, rollers, and H-springs. Drain and properly dispose of used oil. Remove any metal particles from the drain plug magnet. Remove bolts and output shaft cover. Thoroughly clean all parts. Inspect the rollers (A) for nicks and scratches.
Page 199 FINAL DRIVE 10. Use a flat head screwdriver to remove the retaining ring 13. Remove the output hub (G) from the cover. remove the from the output cover. thrust bearing (F) from the output hub (G). Inspect the thrust bearing (F) and the dowel (H). Retaining Ring 11.
Page 200: Gearcase Reassembly / Inspection
FINAL DRIVE 16. Remove the other output hub (K) from the main gearcase. 19. Install new seals into the gearcase housing and use new O- Inspect the inner bearing (L) for wear. If there is excessive rings for the gearcase input and output covers. wear, replace bearing as needed.
Page 201 FINAL DRIVE Install the output hub (A) into the gearcase housing. The Install the retaining ring (F) into the output cover. Be sure output hub should spin freely. the retaining ring is properly seated into the cover. Install the other output hub (B) and thrust bearing (C) into Install the ring gear (G) onto the output hub on the output the output cover.
Page 202: Backlash Pad (Thrust Pad) Adjustment
FINAL DRIVE Backlash Pad (Thrust Pad) Adjustment 11. Install the output cover assembly onto the main gearcase. Lay the gearcase on the side with the output cover facing The backlash screw is loctited into place. Use a heat gun to lightly heat up the loctite on the screw (A).
Page 203: Gearcase Installation
FINAL DRIVE MID DRIVE HUB / BEARING CARRIER If a tight spot is felt during rotation, loosen the backlash screw another 1/8 turn. Perform the previous step again. (6X6) Repeat this procedure until the pinion shaft rotates smoothly 4 times (1 revolution of ring gear). Removal Lock the emergency parking brake.
Page 204: Hub Disassembly
FINAL DRIVE NOTE: Drive bearing out evenly by tapping on outer Remove the upper and lower control arm bolts. race only. Once bearing is at bottom of casting, Upper Bolt support casting on outer edges so bearing can be removed. Lower Bolt Remove the bearing carrier from the A-arm assembly.
Page 205: Hub Installation
FINAL DRIVE Hub Installation Start bearing (B) in housing (A). Install hub carrier to lower A-arm. Hand tighten lower A- arm bolt. Slide mid drive shaft through the hub carrier. Press bearing into place until outer race bottoms on housing. CAUTION Install upper A-arm bolt and torque both upper and lower Use an arbor and press only on the outer race,...
Page 206: Mid Drive Exploded View
FINAL DRIVE Install the castle nut (C), wheel, and wheel nuts. Remove jackstand and torque mid hub nut to 110 ft. lbs. (149 Nm) and wheel nuts to 35 ft. lbs. (47 Nm). Mid Hub Nut Torque: 110 ft. lbs. (149 Nm) Mid Wheel Nut Torque 35 ft.
Page 207: Mid Drive Shaft (6X6)
FINAL DRIVE MID DRIVE SHAFT (6X6) Installation Apply Anti-Seize compound onto the mid gearcase output Removal shaft splines. Slide mid drive shaft (A) onto the mid gearcase output shaft (B). Repeat Steps 1-7 in the “Mid Drive Hub / Bearing Carrier Removal”...
Page 208: Mid Prop Shaft (6X6)
FINAL DRIVE Install the castle nut (C), wheel, and wheel nuts. Install a new cotter pin. Tighten nut slightly to align holes if required. Install hub cap. MID PROP SHAFT (6X6) Removal Use the Roll Pin Removal Tool (PN 2872608), to remove the roll pin from prop shaft at rear of transmission.
Page 209: Gearcase Disassembly
FINAL DRIVE Gearcase Disassembly NOTE: To ease the removal of the middle axle gearcase, remove the box from the frame. Refer to Drain the oil from the mid drive gearcase. Properly dispose the Box Removal Procedure in Chapter 5. of the oil. Remove the vent line clamp and vent line (A) from the top Remove the output cover bolts (A) and the output cover (B).
Page 210 FINAL DRIVE Remove the output shaft and ring gear assembly (E) from Remove the input cover bolts (I). Remove the input cover the gearcase. Inspect the ring gear for abnormal wear, (H) and pinion gear assembly from the gearcase. broken, or chipped teeth. Inspect and spin the bearings (F), the bearings should rotate smoothly.
Page 211 FINAL DRIVE Inspect the pinion gear (K) and 26T output gear (L) for nics 12. Carefully pull the output thru shaft (Q) through the or uneven wear. Inspect the bearing (M), the bearing should gearcase. spin smoothly. Replace the parts as needed. 10.
Page 212: Gearcase Assembly
FINAL DRIVE Install the 26T input gear (D), shim (E), and a new retaining ring (F) onto the output shaft. 15. Replace all O-ring, seals, and worn components. Replace Assemble the pinion shaft assembly (if previously the seals as shown in the photo. disassembled).
Page 213 Install the output shaft and ring gear into the gearcase. Be sure the 10T input pinion gear and the output pinion gear mesh smoothly. Apply Polaris Crankcase Sealant (PN 2871557) to the inside surface of the input cover (J). Install the shims (M) into the output cover (N). Install the...
Page 214: Gearcase Installation
12. Remove the fill plug (P) and fill the mid gearcase with 6.75 Install the mid drive shafts (D) onto the mid gearcase (B). oz. (200 ml) of Polaris ATV Angle Drive Fluid (PN 2871653). Torque the fill plug to 14 ft. lbs. (19 Nm).
Page 215 FINAL DRIVE Mid Gearcase Exploded 18-23 ft. lbs. (24-31 Nm) 30 ft. lbs. (41 Nm) 18-23 ft. lbs. (24-31 Nm) ESCRIPTION ESCRIPTION Screw (5/16-18 x 1.0) Washer, Thrust Plug, Square Socket Bearing, Plain Flanged Seal, Dual Lip Gearcase Tube, Vent 1/4” Hose Bushing Cover, Output Pinion, 10T...
Page 216: Rear Drive (4X4)
FINAL DRIVE REAR DRIVE (4X4) Exploded View 30 ft. lbs. Rear Gearcase (41 Nm) Coil A-arm bolts Shaft Bushings Shock Upper A-arm Bushings Rear Drive Axle 30 ft. lbs. (41 Nm) Caliper 18 ft. lbs. A-arm bolts (24 Nm) Nuts Bearing Lower A-arm Bushings...
Page 217: Hub Disassembly
FINAL DRIVE Remove the two brake caliper attaching bolts. Remove the upper and lower control arm bolts from the rear CAUTION: Do not hang the caliper by the brake line. Use hub / bearing carrier. wire to hang the caliper to prevent possible damage to the brake line.
Page 218: Hub Assembly
FINAL DRIVE Inspect the bearing. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race.
Page 219: Rear Drive Shaft (4X4)
FINAL DRIVE REAR DRIVE SHAFT (4X4) Torque the top and bottom A-arm bolts as shown in the photo. Removal Repeat all of the steps in the “Rear Hub / Bearing Carrier, Hub Removal” section. Remove upper carrier bolt. Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft.
Page 220: Cv Joint / Boot Replacement
FINAL DRIVE CV Joint / Boot Replacement NOTE: When replacing a damaged boot, check the grease for contamination by rubbing it between two Remove clamps from rubber boot(s) using the CV Boot fingers. A gritty feeling indicates contamination. If Clamp Pliers (PN 8700226) (A). the grease is not contaminated, the boot can be replaced without cleaning the CV joint.
Page 221 FINAL DRIVE Refit CV joint on the shaft by tapping with a plastic hammer 11. While pulling out on the CV shaft, fully extend the CV joint on the joint housing. Take care not to damage threads on and slide a straight O-ring pick or a small slotted screw the outboard CV joint.
Page 222: Installation
FINAL DRIVE Installation Lift bearing carrier into place and install the bolt into the upper control arm. Torque bolt to 30 ft. lbs. (41 Nm). Slide the rear drive axle into the bearing carrier hub. 30 ft. lbs. (41 Nm) Install hub, domed washer (domed side out) and nut.
Page 223: Rear Propshaft (4X4)
FINAL DRIVE REAR PROPSHAFT (4X4) Slide the propshaft off the transmission shaft and rear gearcase input shaft. Orientate the shaft so that it’s parallel Removal with the frame supports as shown below. Remove the pin clips from upper and lower cargo box shock pins and remove shock.
Page 224: Rear Gearcase (4X4)
FINAL DRIVE REAR GEARCASE (4X4) When the clutch gear is unlocked the rear axle becomes a differential. When it’s locked it becomes a solid rear axle increasing traction. (See images below) General Operation Clutch Gear Shift Yoke The RANGER rear gearcase has three traction operational modes: AWD, Differential Lock, and Differential Unlock.
Page 225: Operation Modes
FINAL DRIVE Operation Modes Differential Unlocked Differential Locked Rear wheels can rotate at different Both rear wheels rotate at same speed. speeds. (Allow for sharper turning) AWD Mode Rear Wheels rotate as same speed. Front Wheels rotate as same speed when AWD activated. 7.45...
Page 226: Differential Removal
FINAL DRIVE Differential Removal Differential Disassembly IMPORTANT: The pinion gear assembly is NOT Follow “Rear Drive Shaft Removal” procedure to remove the drive axles from each side of the rear differential. intended to be disassembled from the case, as it requires special OEM tooling in order to properly Disconnect the differential solenoid 2 wire harness.
Page 227 FINAL DRIVE Remove the differential assembly (C) from the housing. Remove the differential lock solenoid (F) from the carrier Inspect the bevel gear teeth for chipped, worn, or broken housing by turning the solenoid counterclockwise. teeth. Inspect the tip of the solenoid (F) for wear. If the tip of the solenoid is flat the solenoid may need to be replaced.
Page 228 FINAL DRIVE Inspect the shift yoke (H), shift lever (J), and shift lever 12. Thread the bolt into the shift yoke pivot shaft (L). return spring (K). 13. Carefully pull the shift yoke pivot shaft (L) out of the carrier cover.
Page 229: Differential Assembly
Replace all O-rings, seals, and worn components. Replace the O-ring and oil seal on the carrier housing. NOTE: Grease all seals and O-rings with Polaris All Season Grease (PN 2871322) upon assembly. Install the spring lever and shift yoke into the carrier cover, if previously removed.
Page 230 FINAL DRIVE Assemble the shift yoke (D), shift lever (G), spring lever Install the new lightly greased O-ring (K) onto the carrier (F), and return spring (E). cover. Carrier Cover Use the bolt that was used to remove the shift yoke pivot Install the carrier cover bolts.
Page 231: Differential Installation
Slide the rear propshaft onto the rear differential input shaft. Reverse the removal procedure for the rest of the installation. Add Polaris ATV Angle Drive Fluid (PN 2871653) to rear carrier. Refer to maintenance information in Chapter 2 for more details. Torque drain plug to 30-45 in.lbs. (3-5 Nm).
Page 232: Differential Exploded View
FINAL DRIVE Differential Exploded View 30-45 in. lbs. 40 ft. lbs. (3-5 Nm) (54 Nm) 25-35 ft. lbs. (34-48 Nm) 15 16 25-35 ft. lbs. (34-48 Nm) 30-40 ft. lbs. (41-52 Nm) ESCRIPTION ESCRIPTION Pinion Oil Seal Flanged Hex Nut Pinion Nut Flanged Hex Bolt Pinion Bearing Cone...
Page 233: Rear Axle / Gearcase Service (6X6)
FINAL DRIVE REAR AXLE / GEARCASE SERVICE Remove the bottom shock bolts and shocks (both sides). (6X6) Rear Axle Removal Jack up vehicle and support on frame and swing arm. CAUTION Serious injury could occur if machine tips or falls. Remove rear wheels.
Page 234: Axle Tube Removal
FINAL DRIVE Axle Tube Removal 10. Loosen the four U-bolts. Loosen each U-bolt nut a few turns at a time, this will reduce stress on all of the U-bolts during Place the rear axle assembly on a clean surface. U-bolt removal. Remove the bolts that secure the rear gearcase to the axle tubes and remove the rear gearcase skid plate Loosen U-bolts...
Page 235: Axle Tube Bearing Replacement
FINAL DRIVE Axle Tube Bearing Replacement Gearcase Disassembly / Inspection Remove the retaining ring from the axle tube. Drain and properly dispose of used oil. Remove the differential housing cover bolts and the gearcase housing cover. Remove the bearings from the axle tube with a bearing puller.
Page 236: Gearcase Assembly
FINAL DRIVE Remove the wave spring from the differential assembly. Inspect the pinion shaft bushing for wear. Wave Spring Remove the four bolts that secure the pinion gear cover to the differential. Remove the pinion gear cover and O-ring. Gearcase Assembly Pinion Gear Cover Replace all O-rings, seals, and worn components.
Page 237: Gearcase / Axle Installation
FINAL DRIVE Replace the pinion shaft cover O-ring and install the cover. NOTE: The O-ring is a smaller diameter than the gearcase. Use two hands to work the O-ring onto the Install the four pinion shaft cover bolts and torque the bolts to 26 ft.
Page 238 FINAL DRIVE NOTE: The two top gearcase / axle tube bolts (B) on Install the four U-bolts. Align the U-bolts with the white the left side are installed into the frame later in this marks previously made on the axle tube for proper rear axle assembly procedure.
Page 239 FINAL DRIVE Torque the U-bolts nuts to 40 ft. lbs. (54 Nm). 13. Install the brake caliper. Torque the bolts to 18 ft. lbs. (24.8 Nm). U-Bolt Nut Torque: 40 ft. lbs. (54 Nm) Brake Caliper Torque: 18 ft. lbs. (24.8 Nm) 10.
Page 240: Gearcase Exploded View
FINAL DRIVE Gearcase Exploded View 26 ft. lbs. (35 Nm) 30 ft. lbs. (41 Nm) ESCRIPTION ESCRIPTION Seal, Triple Lip O-Ring Screw (5/16-18 x 1.0) Spring, Wave Cover, Input Bearing, Ball O-Ring Shaft, Output Bearing, Ball Gear, Ring 37T Pinion, 10T Bearing, Ball Bearing, Plain Shim...
Page 241 TRANSMISSION CHAPTER 8 TRANSMISSION TORQUE SPECIFICATIONS..........8.2 SHIFT LEVER .
Page 242: Torque Specifications
TRANSMISSION TORQUE SPECIFICATIONS Remove the shift lever cover and then remove the screw. Pull off the shifter knob. Shift Lever ITEM TORQUE VALUE 10-14 ft. lbs. Transmission Fill Plug (14-19 Nm) 10-14 ft. lbs. Transmission Drain Plug (14-19 Nm) 27-34 ft. lbs. Transmission Case Bolts (37-46 Nm) 12-18 ft.
Page 243: Adjustment
TRANSMISSION Adjustment TRANSMISSION SERVICE Place gear selector in neutral. Make sure the transmission Transmission Removal bell crank is engaged in the neutral position detents. Remove the PVT system from the left side of the transmission. Drive roll pin from rear driveshaft yoke. NOTE: On the 4x4 &...
Page 244 TRANSMISSION Disconnect the transmission switch. Remove the mounting bolts from the transmission mounting on both sides of the transmission. General Transmission Mounting Transmission Switch Remove the cotter pin from the shift linkage rod. Remove the shift linkage rod and a washer from the bellcrank. Remove the four bottom transmission to frame bolts.
Page 245: Transmission Disassembly
TRANSMISSION Transmission Disassembly Mark the detent gear with a white pen. Remove the detent gear from the case. NOTE: The following disassembly procedure shows the 4x4 transmission disassembly. Follow the same NOTE: It may be helpful to place a mark just above procedure for the 6x6 transmission disassembly.
Page 246 TRANSMISSION NOTE: You may have to tap the shift drum from the Note the transmission gear position and mark the two shift backside of the case to aid in removal. gears before removing them to aid with reassembly. Remove the shift gears from the case. NOTE: Depending on what gear the transmission is 12.
Page 247 TRANSMISSION 14. Remove the shift forks from the assembly. Note the correct 17. Remove the bearing from the input shaft with a puller. position of each fork. Shift Fork 18. Remove the snap ring and washer from the reverse shaft. NOTE: The picture above depicts a transmission with a “park dog”...
Page 248 TRANSMISSION 21. Remove the rest of the bearings from the shafts. 24. Remove the gear, split bearing, and washer from the reverse shaft. 22. Use a press to remove the gear from the shaft. 25. Slide off the shift dogs and wave springs. 23.
Page 249 TRANSMISSION 27. Remove bearing and the helical gear. 30. Remove the front housing cover, shim, thrust button, and thrust button shim. 28. Remove the pinion shaft retainer plate and the pinion shaft. 31. Remove the shafts as an assembly. 29. Remove the front housing cover screws. 32.
Page 250: Transmission Assembly
Before installing the cover make sure the sealing surfaces are clean and dry, and shafts are fully seated in the IMPORTANT: New seals should be installed after the transmission case. Apply Polaris Crankcase Sealant to the transmission is completely assembled. mating surfaces.
Page 251 TRANSMISSION Apply Loctite™ 262 (Red) (PN 2871951) to screw threads 11. Slide the reverse shaft assembly through the silent chain. and torque screws to 6-12 ft. lbs. (8-16 Nm). 12. Install a new needle bearing, the low gear, the thrust washer and the snap ring.
Page 252 TRANSMISSION 16. Carefully install the shaft assembly and gear cluster as a 20. Lift the shift rail slightly and rotate the rail/fork assembly unit into their respective bearing case recesses. Tap with a so it meshes with the tracks on the shift drum. Be sure the soft face hammer to seat shaft assemblies.
Page 253 TRANSMISSION 25. Install drain plug with a new sealing washer. Torque drain 28. Install the lockout disc with the raised edge facing outward. plug to 10-14 ft. lbs. (14-19 Nm). Use the white mars that was previously applied for reference. Transmission Lockout Disc Drain Plug...
Page 254: Transmission Installation
12-18 ft. lbs. (16-24 Nm) Transmission Mounting Bolts Torque 25 ft. lbs. (34.5 Nm) 34. Install transmission and add Polaris AGL Gearcase Lubricant (PN 2872602). NOTE: Be sure to tighten the lower transmission bolts first, this ensures that the transmission is tight against the lower frame and helps to properly align the transmission.
Page 255: 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 256: Transmission Exploded View
7-9 ft. lbs. (37-46 Nm) (10-12 Nm) 12-18 ft. lbs. (16-24 Nm) 15-19 ft. lbs. (20-26 Nm) 10-14 ft. lbs. (14-19 Nm) FOR REASSEMBLY Apply White Lithium Based Grease. Apply Polaris Crankcase Sealant. Apply Loctite 262 to the bolt threads. 8.16...
Page 257 TRANSMISSION Exploded View (4x4, 6x6), Cont. Ref. Qty. Description Ref. Qty. Description Asm., 4x4 Transmission 22T Sprocket 19T Sprocket Shift Drum Bellcrank Silent Chain Cover Screws Front Main Output Shaft Sector Cover Gear Set - 10T / 31T O-ring Ball Bearing Detent Pawl Spacer Compression Spring...
Page 258 BRAKES CHAPTER 9 BRAKES GENERAL SPECIFICATIONS / TORQUE SPECIFICATIONS / SPECIAL TOOLS ..9.2 BRAKE SYSTEM SERVICE NOTES......... 9.3 BRAKE NOISE TROUBLESHOOTING .
Page 259: General Specifications / Torque Specifications / Special Tools
BRAKES GENERAL SPECIFICATIONS FRONT BRAKE SYSTEM Item Standard Service Limit Front Brake Pad Thickness .298 ± .007" / 7.56 ± .178 mm .180" (4.6 mm) Front Brake Disc Thickness .150 -.165" ( 3.810 - 4.19mm) .140" (3.56mm) Front Brake Disc Runout .010"...
Page 260: Brake System Service Notes
BRAKES BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight, low maintenance, and perform well in the conditions ATVs 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 261: Hydraulic Brake System Operation
When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (P/N 2872189). Polaris brake fluid is sold in 12 oz. bottles. WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid.
Page 262: Brake System Exploded View
BRAKES BRAKE SYSTEM EXPLODED VIEW Caliper Banjo Style Fittings: 15 ft. lbs. (20 Nm). All Caliper Bleed Screws: 30-60 in. lbs. (3.4-6.8 Nm) All Flare Style Fittings: 12-15 ft. lbs. (16-20 Nm) LH Front Brake Line LH Rear Line Master Cylinder LH Front Caliper Brake Switch MC Rear...
Page 263: Master Cylinder
BRAKES MASTER CYLINDER FOOT BRAKE PEDAL Removal Pedal Removal Open the hood. Locate the master cylinder. Open the hood. Locate the master cylinder. Remove the nut and bolt (A) from the brake pedal. Remove the nut, bushing, tube, and bolt from the brake pedal.
Page 264: Brake Bleeding / Fluid Change
Add brake fluid to the indicated MAX level of reservoir. 13. Field test machine at low speed before putting into service. Check for proper braking action and pedal reserve. With Polaris DOT 4 Brake Fluid pedal firmly applied, pedal reserve should be no less than (P/N 2872189) 1/2"(1.3 cm).
Page 265: Parking Brake
BRAKES PARKING BRAKE Exploded View Park Brake Handle / Lever Mount Cotter Pin Washer Spring Washer Handle Spring Bushings Pin Clip Park Brake Sensor Switch Grommet Latch Park Brake Lever Washer Brake Release Park Brake Assembly Bolt Parking Brake Assembly Washer Clip Pin Clip Pin...
Page 266 BRAKES Inspection After 2 to 3 clicks the wheels should not rotate when turning by hand. After 10 full clicks of lever travel, the vehicle Inspect the springs and bushings on the parking brake lever should not roll while parked. assembly.
Page 267: Parking Brake Caliper Service
BRAKES PARKING BRAKE CALIPER SERVICE Exploded View Hex Nut Pad & Holder Pad & Holder Plain Washer 18 ft. lbs. (24 Nm) Sleeve Thrust Washer Hex Head Mount Bolt Shim Pack Lever (4 Shims) Asm. Bolt 25 ft. lbs. (34 Nm) Stationary Actuator Spring Pin Compression Spring...
Page 268: Caliper Disassembly / Inspection
BRAKES Loosen the two brake caliper mount bolts (B) in equal Slide the brake pads and springs from the assembly. increments. NOTE: Retain the lever and ball bearings for 4x4 Model Shown reassembly. Inspect the brake pads linings for excessive wear. Replace as needed.
Page 269: New Brake Pad Installation
BRAKES New Brake Pad Installation Caliper Installation NOTE: Parking Brake Pads can be replaced by Install the park brake assembly into place. Tighten the two ordering one of the following kits: mounting bolts in increments for proper installation. PN 2203148 - Brake Pad and Shim Kit 18 ft.
Page 270: Front Brake Pads
BRAKES FRONT BRAKE PADS Push caliper piston into caliper bore slowly using a C- clamp or locking pliers with pads installed. Pad Removal / Disassembly Elevate and support front of machine. CAUTION Use care when supporting vehicle so that it does not tip or fall.
Page 271 (counterclockwise). Pad Adjuster Screw Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. Be sure fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap.
Page 272: Front Caliper
BRAKES FRONT CALIPER Front Caliper Exploded View DURING ASSEMBLY FRONT CALIPER EXPLODED VIEW Square O-rings Bleeder Screw 30-60 in. lbs. Dust Boots (3.4-6.8 Nm) Pads Adjuster Screw (Finger Tight) Caliper Body Piston Caliper Mount Caliper Removal Caliper Disassembly Elevate and support front of machine. Remove brake pad adjuster screw (A).
Page 273: Caliper Inspection
Front Caliper Piston Bore I.D. Std. 1.5050-1.5040” (32.27-30.202 mm) Service Limit 1.5060” (38.252 mm) Coat the piston with clean Polaris DOT 4 Brake Fluid (P/N 2872189). Install piston (B) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
Page 274: Caliper Installation
BRAKES Lubricate the mounting bracket pins with Polaris Premium Install the adjuster screw and turn until stationary pad All Season Grease (PN 2871423), and install the rubber contacts disc, then back off 1/2 turn. dust seal boots. Pad Adjuster Screw...
Page 275: Front Brake Disc
BRAKES FRONT BRAKE DISC Disc Removal / Replacement Remove bolts and disc. Disc Inspection Bolts 18 ft. lbs. Visually inspect the brake disc for nicks, scratches, or (24 Nm) damage. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1"micrometer.
Page 276 BRAKES Pad Inspection Clean caliper area before removal. Clean the caliper with brake cleaner or alcohol. Remove caliper mounting bolts and lift caliper off of disc. Measure the thickness of the pad material. Replace pads if NOTE: When removing caliper, be careful not to worn beyond the service limit.
Page 277: Rear Brake Pad (6X6)
BRAKES Clean caliper area before removal. Rear Brake Caliper Mounting Bolt: Remove caliper mounting bolts and lift caliper off of disc. Torque 18 ft. lbs. (24 Nm) NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line.
Page 278 BRAKES Pad Inspection Pad Installation Clean the caliper with brake cleaner or alcohol. Install new pads in caliper body. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Measure Install caliper and torque mounting bolts. Thickness Rear Brake Pad Thickness 18ft.
Page 279: Rear Caliper
BRAKES REAR CALIPER Rear Caliper Exploded View DURING ASSEMBLY Piston Bleeder Screw 30-60 IN. LBS. Caliper Body (4-6.5 NM) Square Pads O-rings Caliper Mount Dust Boots Adjuster Screw (Finger Tight) Caliper Removal (4x4) After the fluid has drained into the container, remove the two caliper mounting bolts and remove caliper.
Page 280: Caliper Removal (6X6)
BRAKES Caliper Removal (6x6) Caliper Disassembly Safely support the rear of the machine. Remove brake pad adjuster screw (A). Push upper pad retainer pin inward and slip brake pads past CAUTION edge, if pads are still installed. Remove mounting bracket (B) and dust boot (C) Use care when supporting vehicle so that it does not tip or fall.
Page 281 Coat the piston with clean Polaris DOT 4 Brake Fluid (P/N 2872189). Install piston (B) with a twisting motion Rear Caliper Piston Bore I.D.
Page 282: Caliper Installation (4X4, 6X6)
BRAKES Caliper Installation (4x4, 6x6) REAR BRAKE DISC Install the rear caliper with the mounting bolts. Torque Disc Inspection mounting bolts to 18 ft.lbs. (24 Nm). Visually inspect disc for scoring, scratches, or gouges. Install brake line banjo bolt. Torque banjo bolt to 15 ft. lbs. Replace the disc if any deep scratches are evident.
Page 283: Troubleshooting
BRAKES TROUBLESHOOTING Brakes Squeal / Poor Brake Performance • Air in system • Water in system (brake fluid contaminated) • Caliper/disc misaligned • Caliper dirty or damaged • Brake line damaged or lining ruptured • Worn disc and/or friction pads •...
Page 284 ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION ..........10.3 SPECIAL TOOLS .
Page 285 ELECTRICAL CHARGING SYSTEM ..........10.22 CURRENT DRAW - KEY OFF .
Page 286: General Information
ELECTRICAL GENERAL INFORMATION • When measuring resistance of a component that has a resistance value under 10 Ohms, remember to subtract Special Tools meter lead resistance from the reading. Connect the leads together and record the resistance. The resistance of the component is equal to tested value minus the lead Part Number Tool Description resistance.
Page 287: Switches / Controls
ELECTRICAL SWITCHES / CONTROLS Test the switch connections and check for continuity at the following pins shown in the illustration. Headlamp Switch AWD / REAR DIFFERENTIAL SWITCH Lift the front hood. The wires are located on the back side of the instrument panel.
Page 288: Brake Light Switch
ELECTRICAL Differential Solenoid Circuit Operation If the rear carrier fails to switch from operational modes: When the switch is pushed to activate “Turf” mode, the White/ • Check the connector located under the left rear fender. Green wire is connected to ground via the Brown wire at the Look for loose wires or bad connections.
Page 289: Parking Brake Switch
ELECTRICAL Parking Brake Switch TESTING PARK BRAKE SWITCH Disconnect the Orange/Red wire and Red/White wire from The parking brake switch is located under the dash or under the the switch. hood. Follow the parking brake lever under the dash to locate the switch.
Page 290: Instrument Cluster
ELECTRICAL INSTRUMENT CLUSTER Rider Information Display The rider information display is located in the instrument Overview cluster. All segments will light up for 2.5 seconds at start-up. The RANGER instrument cluster senses vehicle speed from the NOTE: If the instrument cluster fails to illuminate, a right front wheel.
Page 291: Standard Display Modes
ELECTRICAL Standard Display Modes Clock Screen Use the yellow mode button located under the speedometer to toggle through the mode options. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip.
Page 292 ELECTRICAL AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil. NOTE: A 10 - 20% variance from these readings is within normal parameters. Programmable Service Interval Gear Circuit Diagnostic Screen When the hours of engine operation equal the programmed This screen displays the resistance value (in ohms) being read at service interval setting, the wrench icon will flash for 5 seconds the gear switch input of the gauge.
Page 293: Viewing Diagnostic Codes
ELECTRICAL To enable or disable the service interval: Enter the diagnostic mode. Toggle to the service interval screen. Press and hold the mode button for about seven (7) seconds, until either ON or OFF appears in the Rider Information Display, depending on your preference. To reset the service interval: Enter the diagnostic mode.
Page 294: Instrument Cluster Removal
ELECTRICAL Any blink code numbers stored in the EFI module will Push the instrument cluster out from the back side of the display, one at a time, on the screen. dash panel, while securely holding the panel and rubber Example below shows a Blink Code of “42”. mount.
Page 295: Instrument Cluster Troubleshooting Tests
ELECTRICAL INSTRUMENT CLUSTER TROUBLESHOOTING TESTS Test 1 - No All Wheel Drive 10.12...
Page 296: Test 2 - No Display
ELECTRICAL TEST 2 - No Display TEST 3 - Wheel Speed Sensor 10.13...
Page 297: Test 4 - No Awd Hub Safety Limiter
ELECTRICAL TEST 4 - No AWD Hub Safety Limiter 10.14...
Page 298: Test 5 - Fuel Gauge Display Not Working
ELECTRICAL TEST 5 - Fuel Gauge Display Not Working TEST 6 - Shift Indicator Not Working (Transmission Switch) 10.15...
Page 299: All Wheel Drive (Awd) Coil
ELECTRICAL ALL WHEEL DRIVE (AWD) COIL GEAR POSITION INDICATOR SWITCH Operation Overview Test Diagram • When the AWD switch is “ON”, 12 VDC power is NOTE: Also see “INSTRUMENT CLUSTER present at the hub coil. TROUBLESHOOTING” for switch circuit. TRANSMISSION SWITCH •...
Page 300: Head Lights
ELECTRICAL HEAD LIGHTS Adjust the beam to desired position. Repeat the procedure to adjust the other headlight. High Beam Headlight Adjustment WARNING The headlight beam is adjustable. Due to the nature of light utility vehicles and Place the vehicle on a level surface with the headlight where they are operated, headlight lenses approximately 25 ft.
Page 301: Headlamp Housing Installation
ELECTRICAL TAIL LIGHT / BRAKE LIGHT Remove the O-ring (A) from the headlamp brackets (both sides) Lamp Replacement Before replacing the tail light, use a digital multi-meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present.
Page 302: Cooling System
ELECTRICAL COOLING SYSTEM Cooling System Break-Out Diagram 10.19...
Page 303: 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 304: Relays
ELECTRICAL RELAYS REAR DIFF SOLENOID RELAY Operation OLOR UNCTION Key-On battery power supply, switched on The relays, located under the hood, assist with component Red / White by key switch, enables power to relay. operation like the fan, fuel pump, and rear differential. Brown Ground path for relay.
Page 305: Fuses / Circuit Breaker
ELECTRICAL FUSES / CIRCUIT BREAKER Operation The fuse panel, located under the hood, provides component protection for components such as the Instrument Cluster, ECU, EFI system, Chassis Power and Accessories. A 20-amp circuit breaker protects the fan motor circuit. CHARGING SYSTEM Current Draw - Key Off Current Draw Inspection Key Off...
Page 306: Charging System "Break Even" Test
ELECTRICAL Charging System “Break Even” Test Charging System Alternator Tests Three tests can be performed using a multimeter to determine CAUTION the condition of the stator (alternator). Do not allow the battery cables to become disconnected with the engine running. Follow the steps below as outlined to reduce the chance of Y1 Y2 Y3 damage to electrical components.
Page 307 ELECTRICAL TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM Set the selector dial to measure AC Voltage. Start the engine and let it idle. While holding the engine at a specified RPM, separately measure the voltage across each ’leg’ of the stator by connecting the meter leads to the wires leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to Y3).
Page 308: 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 309: Battery Terminal Block
Indicator Terminal Block Nuts: 20-25 in. lbs. (2.3-2.8 Nm) Side View BATTERY SERVICE Battery Terminals / Bolts Use Polaris corrosion resistant Nyogel™ grease (PN 2871329) SEALED LOW on battery terminal bolts. See “Battery Installation” on Page MAINTENANCE BATTERY 10.28. No Caps...
Page 310: Conventional Battery
ELECTRICAL CONVENTIONAL BATTERY Add electrolyte to bring level back to upper level mark on case. Battery Activation NOTE: This is the last time that electrolyte should be added. If the level becomes low after this point, add only distilled water. WARNING Charge battery at 1/10 of its amp/hour rating.
Page 311: Battery Removal
ELECTRICAL Battery Removal OCV - Open Circuit Voltage Test Disconnect holder strap and remove covers. Battery voltage should be checked with a digital multitester. Disconnect battery negative (-) (black) cable first, followed Readings of 12.6 volts or less require further battery testing and by the positive (+) (red) cable.
Page 312: Charging Procedure
ELECTRICAL • Using a wire brush or knife, remove any corrosion from SPECIFIC GRAVITY the cables and terminals. Conventional State of Charge* YuMicron™ Type • Make sure that the electrolyte is at the proper level. Add Lead-Acid distilled water if necessary. 100% Charged 1.265 1.275...
Page 313: Low Maintenance Battery
ELECTRICAL NOTE: New Batteries: Batteries must be fully After connecting the battery cables, install the cover on the charged before use or battery life will be reduced by battery and attach the hold down strap. 10-30% of full potential. Charge battery for 3-5 hours Install clear battery vent tube from vehicle to battery vent.
Page 314: Battery Installation
ELECTRICAL Battery Installation Load Test Clean battery cables and terminals with a stiff wire brush. CAUTION Corrosion can be removed using a solution of one cup water and one tablespoon baking soda. Rinse well with clean water and dry thoroughly. To prevent shock or component damage, Route the cables correctly.
Page 315: Off-Season Storage
ELECTRICAL Off-Season Storage Battery Charging To prevent battery damage during extended periods of non-use, If battery voltage is 12.8 V or less, the battery may need the following basic battery maintenance items must be recharging. When using an automatic charger, refer to the performed: charger manufacturer’s instructions for recharging.
Page 316: Starter System
ELECTRICAL STARTER SYSTEM To perform the test, place the meter on DC volts and place the meter leads across the connection to be tested. Refer to the Troubleshooting voltage drop tests on the starter system in this chapter. Starter Motor Does Not Run Voltage should not exceed •...
Page 317: Brush Inspection / Replacement
ELECTRICAL Remove the front bracket assembly and the rear bracket Slide positive brush springs to the side, pull brushes out of assembly. Remove the shims from the armature shaft and their guides and remove brush plate. Slide brush end frame inspect the O-rings located on the armature housing.
Page 318: Armature Testing
ELECTRICAL Slide positive brush springs to the side, pull brushes out of Place armature in a growler. Turn growler on and position their guides and remove brush plate. a hacksaw blade or feeler gauge lengthwise 1/8” (.3 cm) ° . If above armature coil laminates.
Page 319: Starter Solenoid Bench Test
ELECTRICAL Starter Drive Using Dielectric Grease (PN 2871329), lubricate brush end bushing and install shims. Pinion Gear - Anti-kick Out Shoe, Garter Align brush plate and install cover and screws. Spring Replacement Lightly grease pinion shaft and install pinion, spring stopper, and snap ring.
Page 320: 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 321: Starter System Testing Flow Chart
ELECTRICAL STARTER SYSTEM TESTING FLOW CHART Condition: Starter fails to turn over the engine. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test With the tester on the VDC position, place the tester's black lead on the battery negative and the Remove battery and properly service.
Page 322: Electric Box Lift Actuator
ELECTRICAL ELECTRIC BOX LIFT ACTUATOR DIAGNOSIS (if equipped) 1. Disconnect the wiring harness to the Disconnect Harness box lift actuator. 2. Connect a multimeter across the box lift actuator harness connection. 3. Actuate the box lift switch in both directions. Verify that there is 12 Volts reaching the box lift actuator.
Page 323 Cooling System Bleeding Procedure ....3.15 Cooling System Hoses ......2.26 Air Filter Service .
Page 324 Engine Crankshaft Installation ....3.46 Exhaust Pipe ........2.19 Engine Cylinder Head Assembly .
Page 325 Rear Driveshaft (4x4), Installation ....7.42 Rear Driveshaft (4x4), Removal ....7.39 Maintenance, Brake System .
Page 326 Speedometer Removal ......10.11 Troubleshooting, Brake System ....9.26 Speedometer Troubleshooting Tests .
Page 327 WIRE DIAGRAM RANGER 700 EFI 4X4 / 6X6 (CHASSIS) PAGE 1 OF 2 11.1...
Page 328 WIRE DIAGRAM RANGER 700 EFI 4X4 / 6X6 (CHASSIS) PAGE 2 OF 2 11.2...
Page 329 WIRE DIAGRAM RANGER 700 EFI 4X4 / 6X6 (DASH) 11.3...
Page 330 WIRE DIAGRAM RANGER 700 EFI 4X4 / 6X6 (BREAKOUTS) 11.4...

This manual is also suitable for:

2008 ranger 700 xp Ranger 700 efi 4x4 2007 Ranger 700 efi 4x6 2007

Polaris RANGER XP 700 4X4 Service Manual

Polaris

General Information Chapter 2 General Information

Chapter 3 Engine

Fuel Injection Chapter 4 Fuel Injection

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

Clutching Chapter 6 Clutching

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