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Polaris Ranger 500 2x4 2007 Service Manual

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Summary of Contents for Polaris Ranger 500 2x4 2007

  • Page 2 GENERAL INFORMATION MAINTENANCE ENGINE CARBURETION / EFI BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...

  • Page 3: Table Of Contents

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

  • Page 4: Vehicle Identification

    GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification R 0 7 R B 5 0 A A Emissions & Model Year Model Option Designation Basic Chassis Engine Designation Designation...

  • Page 5: 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 6: Vehicle Dimensions

    GENERAL INFORMATION VEHICLE DIMENSIONS RANGER 2X4, 4X4 75 in. 190.50 cm RANGER 2X4, 4X4 10 in. 25.4 cm 58 in. 147 cm...
  • Page 7 GENERAL INFORMATION VEHICLE DIMENSIONS RANGER 2X4, 4X4 113 in. 287 cm 58 in. 147 cm 76 in. 193 cm...

  • Page 8: General Specifications

    GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: RANGER 2X4 MODEL NUMBER: R07RB50AA ENGINE MODEL: EH50PLE 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 9: Model: Ranger 4X4 Efi

    GENERAL INFORMATION MODEL: RANGER 4X4 EFI MODEL NUMBER: R07RH50AF,AR,AT ENGINE MODEL: EH50PLE 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 2X4

    EH500PLE168 Shift Type In Line Shift - H / L / N / R Engine Displacement 499 cc Trans. Oil Requirements Polaris AGL Gearcase Lube Number of Cylinders Belt 3211077 Bore & Stroke 92 x 75 mm Drive Belt Deflection 1.125”...

  • Page 11: Model: Ranger 4X4 Carb

    Engine Displacement 499 cc Shift Type In Line Shift - H / L / N / R Number of Cylinders Trans. Oil Requirements Polaris AGL Gearcase Lube Bore & Stroke (mm) 92 x 75 mm Belt 3211077 Compression Ratio 10.2:1 Drive Belt Deflection 1.125”...

  • Page 12: Model: Ranger 4X4 Efi

    3.818:1 Engine Displacement 499 cc Shift Type In Line Shift - H / L / N / R Trans. Oil Requirements Polaris AGL Gearcase Lube Number of Cylinders Belt 3211077 Bore & Stroke (mm) 92 x 75 mm Drive Belt Deflection 1.125”...

  • Page 13: Vehicle Information

    2007 RANGER 4X4 EFI R07RH50AF,AR,AT 9920635 9920905 NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. Paint Codes Painted Part Color Description Polaris Number...

  • Page 14: Special Tools

    Special Tools may be required while servicing your machine. Some of the tools listed are mandatory and other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris special tools when servicing any Polaris product. STANDARD TOOLS AND ENGINE TOOLS...
  • Page 15 GENERAL INFORMATION STANDARD TOOLS AND ENGINE TOOLS 2871283 - Crank/Water Pump Seal Install Kit 2870303 - Hone Kit Clutch (PVT) Tools 2870506 - Drive Clutch Puller 2870305 - Stone Replacement Kit 2870913 - Driven Clutch Puller 2870588 - Hone Oil (12 oz.) 2870654 - Clutch Align Tool 2870459 - Dial Indicator 9914177 - A - Drive Clutch Holding Tool...
  • Page 16 GENERAL INFORMATION CLUTCH (PVT) TOOLS SUSPENSION TOOLS 2870871 - Ball Joint Tool Kit 2870341 - Drive Clutch Spider Removal Tool 2870910 - Roll Pin Tool 2871071 - Shock Body Holding Tool 2871226 - Clutch Bushing Replacement Kit 2870623 - Shock Spring Compressor 8700220 - Clutch Compression Tool 2871573 &...
  • Page 17 GENERAL INFORMATION SUSPENSION AND TRANSMISSION TOOLS ELECTRICAL TOOLS 2870872 - Shock Spanner wrench 2870630 - Timing Light 2872608 - Roll Pin Removal Tool Electrical Tools 2871745 - Static Timing Light Harness PV - 43568 - Fluke 77 Multimeter PV - 39991 - Peak Reading Adapter 2460761 - Hall Sensor probe Harness PV - 37453 - Christie Se- Sulfating Multi-Battery Charger...

  • Page 18: 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 1.16...

  • Page 19: 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. 1.17...

  • Page 20: Sae Tap / Drill Sizes

    GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes 1.18...

  • Page 21: 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 22 MAINTENANCE REFERENCES ......... . . 2.10 POLARIS LUBRICANT SYMBOL IDENTIFICATION ......2.10 ENGINE LUBRICATION .
  • Page 23 MAINTENANCE COOLING SYSTEM ........... . 2.28 LIQUID COOLING SYSTEM OVERVIEW .

  • Page 24: 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 25: 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 26: 50 - 100 Hour Maintenance Interval

    12 M Inspect routing, condition (if applicable) Valve Clearance 100 H 12 M Inspect; adjust 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 27 300 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 28: General Component Location

    MAINTENANCE GENERAL COMPONENT LOCATION RH Side and Dash View Power Distribution Module (PDM) Front Gearcase (Behind Radiator) Rear Gearcase Gas Tank (4X4) Engine (under seat) Dash Components 1. Indicator Lights 2. Gear Shifter 3. Ignition Key 4. Choke 5. 12V accessory 6.

  • Page 29: Lh Side And Rear View

    MAINTENANCE LH Side and Rear View Battery Rear Prop Shaft PVT Cover Front Prop Shaft (4x4) Transmission Tail Gate Latch Air Cleaner Muffler 2" Hitch Drive Shafts (2x4, 4x4)

  • Page 30: Service Products And Lubes

    MAINTENANCE 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 31: Maintenance References

    MAINTENANCE MAINTENANCE REFERENCES Polaris Lubricant Symbol Identification Polaris Polaris Synthetic Polaris Synthetic Polaris Demand Polaris ATV Brake Fluid Gearcase Lube OW-40 Oil Drive Hub Fluid Angle drive Fluid Polaris U-Joint Lube Polaris All Season Grease Engine Lubrication Item Lube Rec.

  • Page 32: Component Fluid Type And Use

    * More often under severe use, such as operated in water or under severe loads. **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 Transmission Fill Plug Brake Master Cylinder 3.

  • Page 33: Component Lubrication Points

    * More often under severe use, such as operated in water or under severe loads. ***Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special Yoke 7.

  • Page 34: General Vehicle Inspection And Maintenance

    MAINTENANCE 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 35: Fuel System And Air Intake

    MAINTENANCE Fuel Filter (Carb Models) Use this procedure to loosen or tighten the shift linkage cable as needed. The fuel filter should be replaced in accordance with the Periodic Maintenance Chart or whenever sediment is visible in Clockwise Inside Jam Nut the filter.

  • Page 36: Throttle Freeplay Adjustment

    MAINTENANCE Check the throttle pedal play periodically in accordance with the Check for proper throttle operation and correct freeplay in Periodic Maintenance Chart and adjust the play if necessary. all handlebar positions. Throttle Freeplay Adjustment Throttle Cable Inspection Adjuster Apply the parking brake. Lock Nut Put the gear shift lever in the N (Neutral) position.

  • Page 37: Pilot Screw (Carb Models)

    MAINTENANCE Push on the choke knob lightly while turning the adjuster the opposite way. Boot Boot Adjuster Sleeve Locknut Pilot Screw Location Turn the adjuster until the knob contacts the boot. Tighten adjuster nut. Slide boots back over cable adjuster sleeve until they touch at the middle point of the adjuster.

  • Page 38: Idle Speed Adjustment (Carb Models)

    MAINTENANCE Turn pilot screw in (clockwise) until lightly seated. Turn NOTE: Adjusting the idle speed affects throttle cable freeplay. Always check throttle cable freeplay screw out the specified number of turns. after adjusting idle speed and adjust if necessary. NOTE: Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be Carburetor Draining (Carb Models) permanently damaged.

  • Page 39: Air Intake Inspection

    MAINTENANCE Air Intake Inspection Air Box Foam Engine Intake Duct Air Baffing Air Filter Service Lift the hood. It is recommended that the air filter be replaced annually. When Inspect the foam inserts in the air baffle boxes. If the foam riding in extremely dusty conditions replacement will be inserts are dirty, clean the foam with a high flash point required more often.

  • Page 40: Fuel System (Efi)

    MAINTENANCE FUEL SYSTEM (EFI) Inspect main element and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced. Fuel Filter Breather Filter The RANGER 4x4 500 EFI Engine uses a non-serviceable, high- Cover Seal volume, high-pressure, 60-micron internal fuel pump filter and an internal 10-micron filter located before the pump regulator.

  • Page 41: Breather Filter Inspection

    MAINTENANCE Breather Filter Inspection • Do not open the crankcase drain unless the engine has ingested water. Some engine oil will be lost if The engines are equipped with a breather filter. The in-line filter crankcase drain is opened. is similar in appearance to a fuel filter, and is visible on the left side (Location A).

  • Page 42: Engine Oil And Filter Change

    (C) clockwise until the nipple of the screen fitting (C) Recommended engine Oil: aligns with the marking on the tank. NOTE: Maximum torque for the screen fitting (C) is Polaris Premium Synthetic OW-40 25 ft.lbs. (34 Nm), do not overtighten. (PN 2871281) (Quart) Ambient Temperature Range -40°...

  • Page 43: Oil Pump Priming Procedure

    20. Reinstall drain plug. 21. Remove dipstick and fill tank with 2 quarts (1.9 l) of Polaris Premium 4 Synthetic Oil (PN 2871281). 22. Place gear selector in neutral and set parking brake.

  • Page 44: Valve Clearance

    MAINTENANCE Remove the clamp from the vent hose. The oil pump will Remove the flywheel cover (D) and rotate flywheel so the now be properly primed and ready for field operation. piston is at TDC. NOTE: If the system is primed properly you should hear some air release.

  • Page 45: Intake Valve Clearance Adjustment

    MAINTENANCE NOTE: At this point watch the camshaft sprocket NOTE: Both feeler gauges should remain inserted locating pin and slowly rotate engine until locating during adjustment of each valve. pin is facing upward, directly in line with the Loosen locknut(s) and turn adjuster screw(s) until there is crankshaft to camshaft center line as shown.

  • Page 46: Transmission And Gearcases

    MAINTENANCE TRANSMISSION AND GEARCASES Place the transmission in Park and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times. Transmission Lubrication If some carbon is expelled, cover the exhaust outlet and NOTE: It is very important to follow a regular lightly tap on the pipe around the clean out plugs with a transmission fluid check/change schedule.

  • Page 47: Front Gearcase Lubrication (4X4)

    • Be sure vehicle is level with parking brake on before proceeding. • Check vent hose to be sure it is routed properly and unobstructed. Fill Plug Threads • The correct front gearcase lubricant to use is Polaris Proper Premium Demand Hub Fluid. Fluid Level...

  • Page 48: Rear Gearcase Lubrication

    MAINTENANCE 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 49: Cooling System

    Clean and reinstall the drain plug with a new sealing washer system. and tighten to 30-45 in. lbs. (3-5 Nm). Polaris Premium 60/40 is already premixed and ready to use. Do Remove fill plug. not dilute with water. Fill Plug 40 ft.

  • Page 50: Coolant Level Inspection

    NOTE: Use of a non-standard pressure cap will not Fill reservoir to upper mark with Polaris Premium 60/40 allow the recovery system to function properly. Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze To access the radiator pressure cap raise the front hood.

  • Page 51: Cooling System Pressure Test

    MAINTENANCE Cooling System Pressure Test Coolant Drain / Radiator Removal Refer to Chapter 3 for cooling system pressure test procedure. Remove the front bumper. Remove three bolts that secure the bumper to the bottom of the frame. Remove six screws Cooling System Hoses (both sides) that secure the wheel well panel to the frame.

  • Page 52: Final Drive / Wheel And Tire

    If the rubber boot Remove the radiator. exhibits any of these symptoms, replace the boot. Refer to Inlet Radiator Hose Chapter 7 for CV boot replacement, or have you Polaris dealer replace the boot. Mounting Screws Surge Tank Hose...

  • Page 53: Tire Inspection

    MAINTENANCE Tire Pressure Securely tighten the wheel nuts to the proper torque listed in the torque table at the beginning of this section. CAUTION CAUTION Maintain proper tire pressure. If wheels are improperly installed it could affect Refer to the warning tire pressure decal vehicle handling and tire wear.

  • Page 54: Battery Fluid Level (Conventional Battery)

    NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging about once a month to make up for normal self-discharge. Battery tenders can be left connected during the...

  • Page 55: Spark Plug Service

    RANGER 2X4, 4X4 - .036" (0.914 mm) replaced, check front end alignment. Use only genuine Polaris parts. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used. Apply a small amount of anti-seize compound to the spark plug threads.

  • Page 56: Tie Rod End / Steering Inspection

    Set steering wheel in a straight ahead position and secure Due to the critical nature of the procedures the steering wheel in this position. outlined in this chapter, Polaris recommends Place a chalk mark on the center line of the front tires steering component repair and adjustment be approximately 10”...

  • Page 57: Front Suspension

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

  • Page 58: Rear Suspension

    MAINTENANCE Rear Suspension Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjustment cam either clockwise or counterclockwise to increase or decrease spring tension. To adjust the suspension, use the adjustment cam located near the bottom of the rear shock. This will allow you to increase or decrease the amount of spring preload.

  • Page 59: Brake System

    • Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir. New Rotor Disc Thickness • Use Polaris DOT 3 or DOT 4 Brake Fluid. 0.150” - 0.164” (3.81 - 4.16 mm) • Check brake system for fluid leaks.
  • Page 60 ENGINE CHAPTER 3 ENGINE SPECIAL TOOLS ............3.3 SPECIFICATIONS .
  • Page 61 ENGINE CAM CHAIN / TENSIONER BLADE........3.34 ONE WAY VALVE .

  • Page 62: Special Tools

    ENGINE SPECIAL TOOLS Oil Drain Bolt 14mm 14-17 (19-23 Nm) (Crankcase) PART NUMBER TOOL DESCRIPTION Oil Filter Pipe Fitting 20mm 36-43 (49-59 Nm) Valve Seat Reconditioning 2200634 Hard Metal Oil Line 11-16 (15-21 Nm) 2870390 Piston Support Block Banjo Fitting 1/8 Pipe 2871043 Flywheel Puller...

  • Page 63: Engine Service Data

    ENGINE Engine Service Data Cylinder Head / Valve EH50PLE Rocker arm ID .8669-.8678”(22.020-22.041 mm) Rocker shaft OD .8656-.8661 (21.987-22.0 mm) Rocker Arm .0008-.0021” (.020-.054 mm) Rocker shaft Oil Clearance Limit .0039” (.10 mm) 1.2884-1.2924" (32.726-32.826 mm) Limit 1.2766" (32.426 mm) Cam lobe height 1.2884-1.2924"...
  • Page 64 ENGINE Engine Service Data Cylinder / Piston / Connecting Rod EH50PLE Surface warpage limit (mating with cylinder head) .0020” (0.05 mm) Cylinder bore 3.6221-3.6228" (92.00-92.02 mm) Taper limit .0020” (0.050 mm) Cylinder Out of round limit .0020” (0.050 mm) .0006-.0018" (0.015-0.045 mm) Piston clearance Limit .0024"...

  • Page 65: Engine Fastener Torque Patterns

    ENGINE GENERAL ENGINE SERVICE Engine Fastener Torque Patterns Tighten cylinder head, cylinder base, and crankcase fasteners in Piston Identification 3 steps following the sequence outlined below. The piston may have an identification mark or the piston may not have an identification mark for piston placement. Cylinder Head If the piston has an identification mark, follow the directions Cylinder Base...

  • Page 66: Accessible Components

    ENGINE Accessible Components Engine Removal 1. Clean work area The following components can be serviced or removed with the engine installed in the frame: Thoroughly clean the engine and chassis • Flywheel Disconnect negative (-) battery cable Remove the seat •...
  • Page 67 ENGINE • Drain the carburetor bowl Remove top motor mount bracket and dampener bracket. Remove any heat shields. NOTE: Drain and properly dispose of the fuel. • Disconnect fuel line • Remove bolts securing carburetor to the dampener bracket • Remove carburetor Vent Line Carb Model Shown Remove air box hose, rear clutch hose and the starter...
  • Page 68 ENGINE Disconnect exhaust from the engine. 13. Carefully remove engine through top of seat frame. Lift the engine from bottom mounts and then lift the engine from rear mounts. 10. Remove airbox. 11. Remove oil and coolant lines. NOTE: Use caution when lifting the engine out of frame.

  • Page 69: Engine Installation Notes

    4 Cycle Engine Break-In Period is defined as the first 10 hours of engine operation or 2 full tanks of fuel. Use only Polaris Premium 4 All Season synthetic oil. Never substitute or mix oil brands. Serious engine damage can result.

  • Page 70: Cleaning The Cylinder After Honing

    Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 2 Cycle Lubricant. 3.11...

  • Page 71: Engine Lubrication - Eh50Pl

    NOTE: Maximum allowable runout is .0024” Engine Lubrication - EH50PL Oil Type: ..Polaris Premium 4 Synthetic (2871281) Capacity: ..Approximately 2 U.S. Quarts (1.9 l) Oil Filter: .

  • Page 72: Oil Flow - Eh50Pl

    ENGINE Oil Flow - EH50PL The chart on Page 3.14 describes the flow of oil through the EH50PL engine. Beginning at the oil tank, the oil flows through a screen fitting in the bottom of the tank and into the oil supply hose.

  • Page 73: Eh50Pl Oil Flow Diagram

    ENGINE EH50PL Oil Flow Diagram Internal passage to camshaft (front left head bolt) Oil filter Oil feed to filter From filter to crankshaft One way valve Top fitting is oil Bottom fitting is oil exhaust feed or intake Oil Tank from bottom of tank or return to tank Oil Flow Chart...

  • Page 74: Eh50Pl Engine Exploded View

    ENGINE EH50PL Engine Exploded View Crankcase Cylinder / Cylinder Head (EFI Shown) Valve Train Crankshaft and Piston 3.15...

  • Page 75: Cooling System

    ENGINE COOLING SYSTEM Cooling System Layout and Testing Cooling System Specifications (Non-EFI) WARNING Thermistor Never remove radiator cap when engine is 26 + 2.1 ft. lbs. warm or hot. The cooling system is under (35 + 3 Nm) pressure and serious burns may result. Allow the engine and cooling system to cool before servicing.
  • Page 76 IMPORTANT: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/ Coolant is recommended for use in all cooling systems, and comes pre-mixed and ready to use.

  • Page 77: Engine Disassembly

    ENGINE ENGINE DISASSEMBLY Align single (TDC) mark on flywheel with projection in inspection hole, and the cam sprocket pin (facing upward) Engine Removal aligned with the camshaft to crankshaft center line. NOTE: The cam lobe should be pointing down and Refer to page 3.7 - 3.10 for Engine Removal / Installation valves should have clearance at this point.

  • Page 78: Rocker Arm / Shaft Inspection

    ENGINE Measure O.D. of rocker shaft. Inspect it for wear or damage. Compare to specifications. Tensioner Spring Free Length: 2.02” (5.13 cm) Measure free length of tensioner spring. Replace spring if excessively worn. Compare to specifications. Rocker Shaft O.D.: .8656-.8661” (21.987-22.0 mm) Measure I.D.

  • Page 79: Camshaft Removal

    ENGINE Subtract rocker shaft O.D. from rocker arm & shaft support Inspect camshaft end cap (thrust face) for wear. Replace if I.D. This is the oil clearance. Compare to specifications. worn or damaged. Rocker Shaft Oil Clearance: Std: .0008 - .0021” (.020 - .054 mm) Limit: .0039”...

  • Page 80: Automatic Compression Release Removal / Inspection

    ENGINE Automatic Compression Release Removal / Automatic Compression Release Installation Inspection Slide spring onto shaft. Apply engine oil to release lever shaft. Decompressor Shaft The actuator ball must be held outward to allow installation of the release lever shaft. Stop Pin Decompressor Ball Spring in relaxed position Retainer Sleeve...

  • Page 81: Camshaft Inspection

    ENGINE Camshaft Inspection Calculate oil clearance by subtracting journal OD from journal bore ID. Compare to specifications. Visually inspect each cam lobe for wear, chafing or damage. Camshaft Oil Clearance: Thoroughly clean the cam shaft, making sure the oil feed Std: .0022-.0035”...

  • Page 82: Cylinder Head Exploded View, Eh50Pl (Efi Shown)

    ENGINE Cylinder Head Exploded View, EH50PL (EFI Shown) 3.23...

  • Page 83: Cylinder Head Inspection

    ENGINE Cylinder Head Inspection Using a valve spring compressor (C), compress the valve spring and remove the split keeper. NOTE: To prevent loss of tension, do not compress 1. Thoroughly clean cylinder head (B) surface to remove all the valve spring more than necessary. traces of gasket material and carbon.

  • Page 84: Valve Inspection

    ENGINE Remove valve seals. CAUTION: Replace seals whenever the cylinder head is Valve Stem Diameter: disassembled. Hardened, cracked or worn valve seals will Intake: .2343-.2348” (5.950-5.965 mm) cause excessive oil consumption and carbon buildup. Exhaust: .2341-.2346” (5.945-5.960 mm) Measure valve guide inside diameter at the top middle and Valve Inspection end of the guide using a small hole gauge and a micrometer.

  • Page 85: Valve Seat Reconditioning

    ENGINE Valve Seat Reconditioning NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The Valve Seat Inspection valve must contact the valve seat over the entire circumference of the seat, and the seat must be the Inspect valve seat in cylinder head for pitting, burnt spots, proper width all the way around.
  • Page 86 ENGINE Reaming The Valve Guide • If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a Allow cylinder head to cool to room temperature. Apply new seat surface is evident. cutting oil to the reamer.

  • Page 87: Cylinder Head Assembly

    ENGINE 19. If oil passage blind plug was removed, apply Crankcase Sealant (PN 2871557) or equivalent sealer to the threads and install, torquing to 8 ft. lbs. (11 Nm). CAUTION: Do not allow sealant to enter oil passage. Seat 20. Spray electrical contact cleaner into oil passage and dry Width using compressed air.

  • Page 88: Valve Sealing Test

    ENGINE Place retainer on spring and install valve spring Repeat adjustment procedure if necessary until clearance is compressor. Compress spring only enough to allow split correct with locknut secured. keeper installation to prevent loss of spring tension. Install Cylinder / Piston Removal and Inspection split keepers with the gap even on both sides.

  • Page 89: Piston Removal

    ENGINE Loosen each of the four large cylinder base bolts 1/4 turn Remove piston circlip and push piston pin out of piston. If at a time in a criss-cross pattern until loose and remove necessary, heat the crown of the piston slightly with a bolts.

  • Page 90: Cylinder Inspection

    ENGINE Cylinder Inspection Record measurements. If cylinder is tapered, or out of round beyond .002, the cylinder must be re-bored oversize, Remove all gasket material from the cylinder sealing or replaced. surfaces. Cylinder Taper Limit: .002 Max. Cylinder Out of Round Limit: .002 Max.

  • Page 91: Piston / Rod Inspection

    ENGINE Piston / Rod Inspection Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Measure piston pin bore. Replace piston and rings if ring-to-groove clearance exceeds service limits. Piston Ring Feeler Gauge Piston Pin Bore...

  • Page 92: Crankcase Disassembly

    ENGINE NOTE: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round. If the bottom installed gap measurement exceeds the service limit, replace the rings. If ring gap is below specified limit, file ring ends until gap is within specified range.

  • Page 93: Cam Chain / Tensioner Blade

    ENGINE Remove oil passage O-Ring (C). Remove cam chain (E). Inspect chain for worn or missing rollers or damage. Stretch chain tight on a flat surface and apply a 10 lb. (4.53 kg) load. Measure length of a 20 pitch section of chain.

  • Page 94: Crankcase Separation

    ENGINE Inspect valve for wear. Inspect drive gear teeth for cracks, damage or excessive wear. 4. Check seat area for nicks or foreign material that may prevent proper sealing of valve. Remove three oil pump retaining bolts and pump. Crankcase Separation Remove flange bolts (10) from magneto side crankcase evenly in a criss-cross pattern.

  • Page 95: Oil Pump Assembly

    ENGINE Oil Pump Assembly Measure pump end clearance using a feeler gauge and straight edge. 1. Clean and dry all parts thoroughly. Apply clean engine oil to all parts. Do not use gasket sealer on the pump body mating surfaces or oil passages will become plugged. Install pump shaft and scavenge rotor drive pin.

  • Page 96: Crankshaft Removal / Inspection

    ENGINE 11. Turn the shaft until balancer counter weights clear the Use a feeler gauge to measure the connecting rod big end crankshaft and remove the balancer shaft from the side clearance. crankcase. 12. Inspect the balancer drive gear and pump shaft drive gear. Connecting Rod Big End Side Clearance: 13.

  • Page 97: Oil Seal / Mechanical Seal Removal (Engine Disassembled)

    ENGINE Crankcase Inspection NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected Remove all traces of gasket sealer from the crankcase visually, and by feel. Look for signs of discoloration, mating surfaces. Inspect the surfaces closely for nicks, scoring or galling.
  • Page 98 ENGINE Measure the distance from the PTO crankcase mating Subtract the thickness of the straightedge from the surface to the main bearing using a dial caliper and a measurement obtained in Step 4 and record. straight edge. Mag Case Depth______________________ Subtract the thickness of the straightedge from the measurement obtained in Step 2 and record.

  • Page 99: Counter Balancer Shaft End Play Adjustment

    ENGINE Counter Balancer Shaft End Play Adjustment Oil Pump Shaft End Play Adjustment Make sure all bearings are firmly seated in the crankcase. Make sure the pump shaft bearing is firmly seated in the Measure the width of the counter balancer shaft at the Magneto side crankcase.

  • Page 100: Engine Reassembly

    ENGINE ENGINE REASSEMBLY NOTE: After engine is assembled and the vehicle is prepared for field operation, oil pump MUST be primed. Follow oil pump priming procedure on Page Pump Shaft Oil Seal Installation 3.12. Oil Pump Bolt Torque: 6. ft. lbs. (8 Nm) Align the drive gear with the drive pin on the pump shaft and install the gear.

  • Page 101: Water Pump Mechanical Seal Removal (Engine Installed)

    ENGINE Water Pump Mechanical Seal Removal Insert the puller legs between the water pump drive shaft and the remaining portion of the mechanical seal. Attach (Engine Installed) the puller legs to the main puller body. Water Pump Mechanical Seal Puller: Main puller (PN 2872105) body...

  • Page 102: One Way Valve Installation

    ENGINE One Way Valve Installation NOTE: The top rail has a locating tab to prevent rotation. The tab must be positioned in the notch on Install the one way valve plunger, spring, and plug using a new the side of the piston as shown (C). sealing washer.

  • Page 103: Piston Installation

    ENGINE Piston Installation Cylinder Installation 1. Clean the gasket surfaces on the cylinder and crankcase. 1. Place the dowel pins in the crankcase and install a new Remove all traces of old gasket material. cylinder base gasket. Make sure the cylinder mounting bolt holes are clean and Position the Piston Support Block (PN 2870390) (A) free of debris.

  • Page 104: Cylinder Head Installation

    ENGINE Remove the ring compressor and support block. The following procedure must be used to torque the cylinder head properly: Torque all bolts evenly in a criss cross pattern *Torque bolts to 22 ft. lbs. (30 Nm) *Torque bolts to 51 ft. lbs. (70 Nm) *Loosen bolts evenly 180 (1/2 turn) *Loosen bolts again another 180...

  • Page 105: Camshaft Timing

    Top Dead Center (TDC). facing directly upward. Camshaft Timing Pin Notch Apply Polaris Premium Starter Drive Grease (PN 2871460) to the camshaft main journals and cam lobes. Lubricate automatic compression release mechanism with clean engine oil. (To install the compression release mechanism, refer to Page 3.21).

  • Page 106: Camshaft Timing Illustration

    ENGINE Camshaft Timing Illustration Crankshaft to Camshaft Centerline Dots Sprocket Alignment Pin Single TDC Mark Aligned TDC mark Rotation Do Not Use Advance Marks 3.47...

  • Page 107: Cam Chain Tensioner Installation

    ENGINE Cam Chain Tensioner Installation Install the stator plate being careful not to damage the seal. Align timing reference marks on the plate and crankcase. Release the ratchet pawl (A) and push the tensioner Be sure the plate is fully seated. plunger (B) all the way into the tensioner body.

  • Page 108: Rocker Shaft / Rocker Arm Assembly Installation

    ENGINE Apply starter drive grease to the drive bushing in the Place a new rocker cover gasket on the cylinder head and crankcase and all moving surfaces of the starter drive install the cover and bolts. mechanism. Install the starter drive. Rocker Cover Bolt Torque: 6 ft.

  • Page 109: Troubleshooting

    ENGINE TROUBLESHOOTING • Restricted exhaust system Engine Has Low Power Engine • Spark plug fouled Engine Turns Over But Fails to Start • Cylinder, piston, ring, or valve wear or damage (check • No fuel compression) • Dirt in fuel line or filter •...

  • Page 110: Spark Plug Fouling

    ENGINE Backfiring • ETC switch mis-adjusted • ETC or speed limiter system malfunction • Restricted air filter (main or pre-cleaner) or breather system • Fouled spark plug or incorrect plug or plug gap • Improperly assembled air intake system • Carburetion faulty - lean condition •...
  • Page 111 CARBURETION SYSTEM CHAPTER 4 CARBURETION SYSTEM SPECIAL TOOLS ............4.4 CARBURETOR JETTING .
  • Page 112 Leave room for expansion of fuel. Polaris Carburetors are calibrated for an altitude of 0-6000 ft. (0- 1800 meters) and ambient temperatures between +40 and +80° Never start the engine or let it run in an F (+5°...

  • Page 113: Mikuni Cv Carburetor

    CARBURETION SYSTEM MIKUNI CV CARBURETOR Exploded View ESCRIPTION ESCRIPTION Washer (10) Float Asm. Main Jet, #135 Adjust Screw Spring E-Ring Throttle Valve, 100 Packing Spring Seal Ring Float Pin Screw Pilot Jet, #42.5 Throttle Shaft Asm O-Ring Cable Guide Needle Valve Screw Plate Cover...

  • Page 114: System Function - Mikuni Cv Carb

    CARBURETION SYSTEM System Function - Mikuni CV Carb Operation - Mikuni CV Carb The constant velocity carburetor incorporates a mechanically Carburetor Component Function operated throttle plate and a vacuum controlled slide valve Main Main Main (vacuum slide). The venturi cross-sectional area in the System Components Function...

  • Page 115: Pilot System (Idle And Slow Speed)

    CARBURETION SYSTEM Pilot System (Idle and Slow Speed) Carburetor Operation Cont’d When the throttle plate is opened and engine speed begins to This system supplies fuel during engine operation with throttle increase, the pressure in the venturi (and therefore in the valve closed (1) or slightly opened.

  • Page 116: Starter System (Choke Or Enrichment)

    CARBURETION SYSTEM Starter System (Choke or Enrichment) Float System When the choke cable (1) is activated, the starter plunger (5) is Fuel enters the float chamber (3) by means of the inlet pipe and lifted off the seat. passage, through a screen on the back of the inlet needle seat (4), and around the inlet needle (2).

  • Page 117: Main System

    CARBURETION SYSTEM Main System Pilot Screw As throttle valve (1) is opened, engine speed rises, and this The pilot system supplies fuel during engine operation with the increases negative pressure in the venturi. Consequently the throttle valve closed or slightly opened. The fuel/air mixture is vacuum slide (2) moves upward.

  • Page 118: Carburetor Service

    CARBURETION SYSTEM CARBURETOR SERVICE Remove carburetor. Place a shop towel in carb flange to prevent dirt from entering. Carburetor Removal Clamp Remove the seat. 2 Screws Carburetor Disassembly NOTE: RANGER 2x4 and 4x4 models will have Disconnect: tamper resistant screws on Diaphragm Cover per •...

  • Page 119: Carburetor Cleaning

    CARBURETION SYSTEM Remove float bowl and carefully remove the pressed float NOTE: The starter jet is not removable. Upon disassembly, place the parts in a container for safe pin. keeping. Support Here Pilot Screw Starter Jet NOTE: Be careful not to damage the float pin tower during the float pin removal.

  • Page 120: Carburetor Inspection

    CARBURETION SYSTEM Carburetor Inspection Measure the height from the float bowl mating surface to the top of step in float as shown. Both sides of float should Inspect the inlet needle tapered surface for any sign of be parallel to each other. The measurement should be made wear or damage.

  • Page 121: Fuel Level

    CARBURETION SYSTEM Fuel Level Carburetor Assembly NOTE: Refer to the exploded view of the BST 34 A fuel level test can be performed on some models if the drain hose fitting is accessible. Be sure to re-attach the bowl drain carburetor at the beginning of this chapter for hose after performing the test.

  • Page 122: Air Box Assembly

    CARBURETION SYSTEM AIR BOX ASSEMBLY Exploded View A. Cover Seal B. Air Filter C. Air Box Assembly D. Narrow Band Clamp E. Carb Boot F. Breather Hose G. Hose Clamp H. Breather Filter J. P-Clamp K. Breather Line L. O-Ring M.

  • Page 123: Fuel Tank Assembly

    CARBURETION SYSTEM FUEL TANK ASSEMBLY Fuel Tank / Fuel Pump Exploded View A. Fuel Inlet Components B. Tank Vent C. In-Line Fuel Filter D. Hose Clamp E. Fuel Pump F. Fuel Line with Conduit G. Heat Shield Foil H. Fuel Tank J.

  • Page 124: Fuel Tank Removal

    CARBURETION SYSTEM Fuel Tank Removal Remove the two outer lower bolts that hold the fuel tank to the frame. Remove the seat. Disconnect the negative battery cable. Disconnect the fuel pump wiring harness (A). Remove the fuel lines (B) and remove the tank vent line (C). NOTE: Mark or tag the hoses for correct installation of the hoses.

  • Page 125: Fuel Pump

    CARBURETION SYSTEM FUEL PUMP Replacement Remove the seat. Disconnect the fuel pump wiring harness (A). Remove the fuel line clamps and remove the fuel lines from each side of the fuel pump (B). Remove two screws that secure the fuel pump (B) to the main floor.

  • Page 126: Troubleshooting

    CARBURETION SYSTEM TROUBLESHOOTING • Poor fuel quality (old fuel) • Loose jets Fuel Starvation / Lean Mixture • Worn jet needle/needle jet or other carburetor parts Symptoms: Hard start or no start, bog, backfire, popping • Dirty carburetor (air bleed passages or jets) through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle •...
  • Page 127 ELECTRONIC FUEL INJECTION CHAPTER 4 ELECTRONIC FUEL INJECTION SPECIAL TOOLS ............4.21 PART NUMBERS / DESCRIPTIONS .
  • Page 128 ELECTRONIC FUEL INJECTION FUEL SYSTEM TROUBLESHOOTING........4.43 FUEL STARVATION / LEAN MIXTURE .

  • Page 129: Special Tools

    ELECTRONIC FUEL INJECTION SPECIAL TOOLS Fuel Pressure Tester - PU-43506-A IMPORTANT: The EFI fuel system remains under high Part Numbers / Descriptions pressure, even when the engine is not running. Before attempting to service any part of the fuel PART NUMBER TOOL DESCRIPTION system, the pressure must be relieved.
  • Page 130 Digital Wrench™ Diagnostic Connector (Located Under the Hood) Throttle Position Sensor Tester - 2201519 This tester allows the use of a digital multi-meter to test TPS function as well perform initialization procedures. Polaris Dealers can order special tools from SPX.

  • Page 131: Efi Service Notes

    ECM (from another 500 EFI) could be connected and tested for problem resolution. • For the purpose of troubleshooting difficult running issues, a known-good ECM from another Polaris 500 EFI system may be used without damaging system or engine components.

  • Page 132: Efi System

    ELECTRONIC FUEL INJECTION EFI SYSTEM Exploded View 1. Electronic Control Module (ECM) 2. Manifold Absolute Pressure Sensor (MAP) 3. Intake Air Temperature Sensor (IAT) 4. Idle Air Control (IAC) 5. Crankshaft Position Sensor (CPS - inside cover) 6. Fuel Injector 7.

  • Page 133: Efi Component Locations

    ELECTRONIC FUEL INJECTION EFI COMPONENT LOCATIONS Idle Air Control (IAC) Located on top of the Throttle body Identification / Location Electronic Control Module (ECM) Located under the seat on the driver’s side. Crankshaft Position Sensor (CPS) Located inside the magneto cover on the right-hand side of the engine.
  • Page 134 ELECTRONIC FUEL INJECTION Fuel Injector 10. Engine Coolant Temperature Sensor (ECT) Located in the intake manifold. Located in the cylinder head. 4 & 7 9 & 10 Fuel Pump / Regulator / Gauge Sender Assembly Located in the fuel tank as an assembly. 4 &...

  • Page 135: Fuel Tank

    ELECTRONIC FUEL INJECTION FUEL TANK Exploded View 1. Gas Cap w/ Gauge 2. Fuel Tank w/ Pump 3. Vent Line 4. Tank Foil 5. Fuel Line 6. Fuel Tank Brackets Fuel Flow Fuel Tank * Fuel Filter * Fuel Pump / (30 micron) Pressure Regulator Fuel Supply Rail...

  • Page 136: General Information

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

  • Page 137: Fuel Lines

    ELECTRONIC FUEL INJECTION FUEL LINES ELECTRONIC CONTROL MODULE (ECM) Quick Connect Removal / Installation Operation Overview CAUTION The ECM is the brain or central processing computer of the entire EFI fuel / ignition management system. During operation, sensors continuously gather data which is relayed through the Verify fuel system has been depressurized wiring harness to input circuits within the ECM.

  • Page 138: Ecm Service

    TPS is faulty, or the mounting position of the TPS is altered, the TPS must be re-initialized. For the purpose of troubleshooting, a known-good ECM from another Polaris 500 EFI may be used without system or engine component damage. Remove the 4 screws and nuts holding the ECM.

  • Page 139: Fuel Pump Assembly

    Insert the fuel test valve adapter PU-47476. Connect the pressure hose of the Polaris pressure tester (PN PU-43506- When the key switch is turned to "ON", the ECM activates the A) to the test valve. Route the clear hose into a portable fuel pump, which pressurizes the system for start-up.

  • Page 140: Fuel Pump / Tank Assembly Replacement

    ELECTRONIC FUEL INJECTION Fuel Pump / Tank Assembly Replacement Turn on the key switch to activate the pump and check the system pressure on the gauge. If system pressure of 39 psi NOTE: All EFI units utilize quick connect fuel lines. ±...
  • Page 141 ELECTRONIC FUEL INJECTION Remove the fuel tank vent hose Remove the two outer lower bolts that hold the fuel tank to the frame. NOTE: A small amount of fuel may come out of the fuel line or tank. Plug the fuel line and tank inlet or use a shop towel during removal.

  • Page 142: Fuel Pressure Regulator

    ELECTRONIC FUEL INJECTION FUEL PRESSURE REGULATOR The “director plate” at the tip of the injector contains a series of calibrated openings which directs the fuel into the intake port in General Information a cone-shaped spray pattern. The fuel pressure regulator maintains the required operating The injector is opened and closed once every other crankshaft system pressure of 39 psi + 3psi.

  • Page 143: Crankshaft Position Sensor (Cps)

    ELECTRONIC FUEL INJECTION CRANKSHAFT POSITION SENSOR Fuel Injector Resistance Test (CPS) If an injector is not operating, it can indicate either a bad injector, or a wiring/electrical connection problem. Check as follows: General Information • Using an ohmmeter, test for continuity by placing the The engine speed sensor is essential to engine operation, test leads on each pin of the injector.

  • Page 144: Manifold Air Pressure Sensor (Map)

    ELECTRONIC FUEL INJECTION MANIFOLD AIR PRESSURE SENSOR NOTE: If the resistance reading is incorrect, remove the screws securing the sensor to the mounting (MAP) bracket and replace the sensor. If the resistance in step 2 was incorrect, but the resistance of the General Information sensor alone was correct, test the main harness Mounted on the throttle body intake, the manifold air pressure...

  • Page 145: Intake Air Temperature Sensor (Iat)

    ELECTRONIC FUEL INJECTION IDLE AIR CONTROL (IAC) Install the retaining bracket. NOTE: Do not allow the retaining bracket to contact the MAP body. Torque the retaining screw to 29 in. lbs. (3.3 Nm). General Information The Idle Air Control (IAC) is used to stabilize the idle quality of the engine at cold start-up and after warm-up operations.

  • Page 146: Throttle Position Sensor (Tps)

    ELECTRONIC FUEL INJECTION Idle Air Control Replacement Using an ohmmeter- With the test leads connected and the meter set to the ohms scale, Disconnect the IAC from the engine harness. observe the reading at the following pin locations of the TPS: Using a suitable tool, remove the retaining screws and replace the sensor.

  • Page 147: Throttle Position Sensor Replacement

    ELECTRONIC FUEL INJECTION Throttle Position Sensor Replacement • Connect the test leads connected as shown in Figure 2 and the meter set to the “vdc” scale, move the throttle NOTE: The correct position open and closed slowly while reading the display. The established and set at the factory.

  • Page 148: Engine Temperature Sensor

    “R” port and BLACK meter lead to ™ Polaris dealers can test the sensor by using the Digital Wrench the “Y” port of the TPS Tester Harness 2201519, verify Diagnostic Software (dealer only). Refer to the Digital the voltage output of the TPS reads 1.10 - 1.14 vdc.

  • Page 149: Diagnostics Using 'Blink Codes

    ELECTRONIC FUEL INJECTION DIAGNOSTICS USING ‘BLINK CODES’ • The Orange MIL light will then remain lit when finished. 3. When the diagnostic mode is complete, the Orange MIL light Blink Codes - Operation will remain illuminated until the key is switched off. To enable the blink codes: NOTE: To clear codes manually, disconnect the positive battery lead for 20 seconds.
  • Page 150 ELECTRONIC FUEL INJECTION DIAGNOSTIC “BLINK CODES” CHART Blink MIL Light Name Code BEGIN SEQUENCE Loss of Synchronization TPS Circuit: Sensor Low TPS Circuit: Sensor High System Voltage Low System Voltage High Air Temp Sensor (IAT): Low Voltage Air Temp Sensor (IAT): High Voltage Engine Temperature Sensor Circuit (ECT): Low Voltage Engine Temperature Sensor Circuit (ECT): High Voltage CPS Circuit Fault...

  • Page 151: Fuel System Troubleshooting

    ELECTRONIC FUEL INJECTION FUEL SYSTEM TROUBLESHOOTING Poor Idle Symptom: Idle Too High (If greater than 1300 RPM when The correct position of the throttle body engine is warm) idle stop is established and set at the • Throttle stop screw tampering - replace throttle body factory.

  • Page 152: Efi System Break-Out Diagrams

    ELECTRONIC FUEL INJECTION EFI SYSTEM BREAK-OUT DIAGRAMS Fuel Injector Circuit Crankshaft Position Sensor (CPS) Circuit 4.44...

  • Page 153: Fuel Pump Circuit

    ELECTRONIC FUEL INJECTION Fuel Pump Circuit Ignition Coil Circuit 4.45...

  • Page 154: Idle Air Control (Iac) Circuit

    ELECTRONIC FUEL INJECTION Idle Air Control (IAC) Circuit Throttle Position Sensor (TPS) Circuit 4.46...

  • Page 155: Manifold Air Pressure Sensor (Map) Circuit

    ELECTRONIC FUEL INJECTION Manifold Air Pressure Sensor (MAP) Circuit Engine Coolant Temperature Sensor Circuit 4.47...

  • Page 156: Intake Air Temperature Sensor (Iat) Circuit

    ELECTRONIC FUEL INJECTION Intake Air Temperature Sensor (IAT) Circuit Malfunction Indicator Light (MIL) Circuit 4.48...

  • Page 157: Diagnostic Connector Circuit

    ELECTRONIC FUEL INJECTION Diagnostic Connector Circuit 4.49...
  • Page 158 BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS..........5.2 SPECIAL TOOLS .

  • Page 159: 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 160: 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 161: Lower Body Components

    BODY / STEERING / SUSPENSION Lower Body Components Engine Access 4-5 ft. lbs. Cover (5-6 Nm) Foil Cover T-27 4-5 ft. lbs. Drive Shaft (5-6 Nm) Main Floor Floor Cover Foil T-27 Rear Fender Main Frame 4-5 ft. lbs. (5-6 Nm) T-27 Front Fender 20-30 in.

  • Page 162: 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 163: Dash Instruments And Controls

    BODY / STEERING / SUSPENSION Dash Instruments and Controls A. Indicator Panel B. Hour Meter C. Headlight Switch D. 2WD/AWD Switch E. 12 Volt Accessory Receptacle F. Malfunction Indicator Lamp (MIL) G. Key Switch...

  • Page 164: 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 165: Chassis / Main Frame

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

  • Page 166: 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 167: 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 168: 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 169: 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 170: Front Strut

    BODY / STEERING / SUSPENSION FRONT STRUT Exploded View 15 ft. lbs. Strut Bumper (21 Nm) Washer Front Strut Spacer Rubber Top Pivot Ball Washer Spacer Clamp Bottom Pivot Ball 18 ft. lbs. (25 Nm) Bolt Spring Retainer Spring Washer Bearing Retaining Ring 5.13...

  • Page 171: 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 5.13. joint stud. Hold strut rod and remove top nut. Remove screws (D) and ball joint retaining plate (E).

  • Page 172: Rear A-Arm

    BODY / STEERING / SUSPENSION Apply Loctite™ 242 (PN 2871949) to threads of retaining Remove the hub and brake disc assembly by sliding it off plate screws or install new screws with pre-applied locking of the axle. agent. Torque screws to 8 ft. lbs. (11 Nm). 10.
  • Page 173 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 174: Rear Stabilizer Bar

    BODY / STEERING / SUSPENSION REAR STABILIZER BAR 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 175: 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 176: 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 177: 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 178: Decal Replacement

    BODY / STEERING / SUSPENSION DECAL REPLACEMENT To flame treat the decal area: Pass the flame of a propane torch back and forth quickly Plastic polyethylene material must be “flame treated” prior to over the area where the decal is to be applied until the installing a decal to ensure good adhesion.
  • Page 179 CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES ......... . 6.2 TORQUE SPECIFICATIONS.

  • Page 180: Special Tools And Supplies

    2870386 factory authorized special tools and service procedures. Clutch Compression Tool 8700220 Clutch Bushing Replacement Tool The Polaris Variable Transmission (PVT) consists of three 2871025 major assemblies: Standard Clutch Alignment Tool 2870654 1) The Drive Clutch 2) The Driven Clutch...

  • Page 181: 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 182: 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. Clutch malfunction. Shift transmission to Low during loading of the vehicle to prevent belt burning.

  • Page 183: 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 184: 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 185: 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 186: Belt Inspection

    CLUTCHING NOTE: Belt is normally positioned so that part • The top edges have been trimmed on some drive belts. numbers are easily read. It will be necessary to project the side profiles and measure from corner to corner. • Place a straight edge on each side of the drive belt. •...

  • Page 187: Belt Installation

    CLUTCHING Belt Installation With tool touching rear of driven clutch inner sheave, the distance at point “A” should be 1/8". Loop belt over the drive clutch and over top of the driven sheave. If the distance is greater than 1/8" or less than 1/16", clutch While pushing down on top of belt, turn the back or alignment must be adjusted as follows: moveable driven sheave clockwise.

  • Page 188: Clutch Offset

    CLUTCHING Clutch Offset IMPORTANT: Inspect clutch alignment and center distance before adjusting offset. Install clutch alignment tool as shown. Offset is correct when rear of tool contacts rear of inner sheave with driven clutch pushed completely inward on shaft and bolt torqued.

  • Page 189: 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 190: 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 191: 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 192: 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 193: 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 194: 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 195: Clutch Cover - Bushing Removal

    CLUTCHING Install nut on puller rod and hand tighten. Turn barrel to With inside of cover toward vise, slide cover onto puller. apply additional tension if needed. Install nut onto puller rod and hand tighten. Turn puller Turn sheave and barrel together counterclockwise until barrel to increase tension as needed.

  • Page 196: 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 197: Driven Clutch Service

    CLUTCHING DRIVEN CLUTCH SERVICE Exploded View DRIVEN CLUTCH Button Ramp Inner Sheave Stationary Ramp Clutch Spring Outer Sheave Spacer Shims Moveable Bearing Driven Clutch Bolt Clutch Disassembly / Inspection Note the location of the spring and remove helix. Note the location of the spring in the moveable sheave, and Apply and hold downward pressure on the helix, or place remove the spring.

  • Page 198: Bushing Service

    CLUTCHING Inspect ramp buttons in the moveable sheave and replace Inspect the Teflon™ coating on the moveable sheave if worn. bushing. Inspect bushing for wear NOTE: The ramp buttons are secured by Torx™ screws (T20). Moveable Sheave Bushing Inspection: Remove moveable sheave and note the number of spacer Replace the bushing if more brass than washers.

  • Page 199: Moveable Sheave - Bushing Installation

    CLUTCHING Remove ramp buttons from moveable sheave. Install sheave onto puller. Install nut onto puller rod and tighten by hand. Turn puller barrel for further tension if needed. Turn clutch sheave counterclockwise until bushing is removed. Repeat Steps 5 - 8 for other bushing. Using an appropriate heat gun, apply heat directly on bushing until tiny smoke tailings appear.

  • Page 200: Clutch Assembly

    CLUTCHING Clutch Assembly Install sheave onto puller with new bushing upward as shown. Install Puller Adapter (#10) (PN 5020633). Install nut onto puller rod and hand tighten against installation tool. Turn clutch sheave counterclockwise until bushing is seated. Moveable Spring Example: Helix Sheave...
  • Page 201 CLUTCHING Line up boss spline and push helix down until it engages the splines 1/2" to 3/4". While holding downward pressure on helix, wind moveable sheave counterclockwise approximately 1/3 turn (120°). Push helix into place and install snap ring. 6.23...

  • Page 202: 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 203 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 204 FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIAL TOOLS ............7.2 TORQUE SPECIFICATIONS.

  • Page 205: Special Tools

    FINAL DRIVE SPECIAL TOOLS Check bearings for side play by grasping the tire / wheel firmly and checking for movement. Grasp the top and bottom of the tire. The tire should rotate smoothly without PART NUMBER TOOL DESCRIPTION binding or rough spots. 2872608 Roller Pin Removal Tool 8700226...

  • Page 206: Hub Installation

    FINAL DRIVE Hub Installation Torque the spindle nut to 70 ft. lbs. (95 Nm). Inspect the hubstrut bearing surface for wear or damage. Apply grease to spindle. Grease Spindle 2X4 Spindle Nut Torque: Install spindle through the backside of the hubstrut. Install 70 ft.

  • Page 207: Exploded View (2X4)

    FINAL DRIVE Exploded View (2X4) Disc Brake Stud Front Hub Tire 18 ft. lbs. (24.9 Nm) Use new bolts with pre-applied locking agent. Wheel Nut (Spec on page 7.2) Washer Spindle Shaft Dust Cover Slotted Nut 70 ft. lbs. (95 Nm) Cotter Pin...

  • Page 208: Front Hub (4X4)

    FINAL DRIVE FRONT HUB (4X4) Remove hub cap, cotter pin, front spindle nut, and washer. Hub Removal / Inspection Elevate front end and safely support machine under footrest / frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.

  • Page 209: Hub Installation

    FINAL DRIVE Hub Installation Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on Inspect the hubstrut bearing surface for wear or damage. outer edges so bearing can be removed. Apply grease to drive axle spindle.

  • Page 210: Exploded View (4X4)

    FINAL DRIVE 10. Install brake caliper using new bolts. Tighten bolts to CAUTION specified torque. New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 11. Install wheel, washers, wheel nuts, and tighten evenly in a 18 ft.

  • Page 211: Drive Shaft / Propshaft

    FINAL DRIVE DRIVE SHAFT / PROPSHAFT Exploded View RANGER 4X4 Front Driveshaft 30g Grease Packet CV Joint 30g Grease Packet Plunging Joint Inner Clamps Circlip Clamp Boots Clamp RANGER 4X4 Front Propshaft Joint Kit Grease Zerk O-ring Shaft Yoke Front Yoke RANGER 2X4 &...

  • Page 212: 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 213: 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 214 FINAL DRIVE Remove the large end of the boot from the CV joint, slide FRONT SHAFT (4X4) 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 215: Installation

    FINAL DRIVE FRONT PROPSHAFT REMOVAL Installation 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 216: 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 217: 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 218: Front Gearcase Centralized Hilliard

    FINAL DRIVE FRONT GEARCASE CENTRALIZED HILLIARD CAUTION AWD Operation If the rear wheels are spinning, release the throttle before turning the AWD switch on. Engaging Front Gearcase: The AWD switch may be turned on If AWD is engaged while the wheels are or off while the vehicle is moving.

  • Page 219: 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 220: 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 221: 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 222: 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 223 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 224: 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 225 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 226: 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 227: Gearcase Installation

    FINAL DRIVE If a tight spot is felt during rotation, loosen the backlash screw another 1/8 turn. Perform the previous step again. Repeat this procedure until the pinion shaft rotates smoothly 4 times (1 revolution of ring gear). Gearcase Installation To install gearcase, reverse removal procedure.Use new spring pin in front prop shaft.

  • Page 228: Rear Drive

    FINAL DRIVE REAR DRIVE 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 Carrier Bolt...

  • Page 229: 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 230: Hub Assembly / Installation

    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 231: Rear Drive Shaft

    FINAL DRIVE REAR DRIVE SHAFT 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 232: 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 233 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 234: 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 235: Rear Propshaft

    FINAL DRIVE REAR PROPSHAFT 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 236: Rear Gearcase (Differential)

    FINAL DRIVE REAR GEARCASE (DIFFERENTIAL) 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 The RANGER rear gearcase has three traction operational Shift Yoke modes: AWD, Differential Lock, and Differential Unlock.

  • Page 237: 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. 7.34...

  • Page 238: Differential Removal / Disassembly

    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 Disconnect the differential solenoid 2 wire harness.
  • Page 239 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 240 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 241: 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 242 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 243: 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 244: Differential Exploded View

    FINAL DRIVE Differential Exploded View 30-45 in. lbs. (3-5 Nm) 40 ft. lbs. (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 245 TRANSMISSION CHAPTER 8 TRANSMISSION TORQUE SPECIFICATIONS..........8.2 SHIFT LEVER .

  • Page 246: Torque Specifications

    TRANSMISSION TORQUE SPECIFICATIONS Remove the shift lever cover and then remove the screw. Pull off the shifter knob. ITEM TORQUE VALUE Shift Lever 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 247: Adjustment

    TRANSMISSION TRANSMISSION SERVICE Adjustment 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 transmission the front output Neutral Position shaft yolk slides off during the transmission...
  • Page 248 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 249: 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 2x4 transmission disassembly.
  • Page 250 TRANSMISSION Note the transmission gear position and mark the two shift NOTE: You may have to tap the shift drum from the gears before removing them to aid with reassembly. backside of the case to aid in removal. Remove the shift gears from the case. NOTE: Depending on what gear the transmission is 12.
  • Page 251 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 252 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 253 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 254: 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 255 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 256 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 257 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 258: 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 259: 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 260: Transmission Exploded View

    (37-46 Nm) 15-19 ft. lbs. 7-9 ft. lbs. (20-26 Nm) (10-12 Nm) 10-14 ft. lbs. (14-19 Nm) FOR REASSEMBLY 12-18 ft. lbs. Apply White Lithium (16-24 Nm) Based Grease. Apply Polaris Crankcase Sealant. Apply Loctite 262 to the bolt threads. 8.16...
  • Page 261 TRANSMISSION Exploded View (2X4), Cont. Ref. Qty. Description Ref. Qty. Description Asm., 2x4 Transmission Screw Gear Set - 10T / 31T Shift Drum Bellcrank Ball Bearing Cover Screws Spacer Sector Cover Retaining Ring O-ring Bearing Center Drive Cover Detent Pawl Torx Screws Compression Spring 60T Helical Gear...
  • Page 262 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. 8.18...
  • Page 263 TRANSMISSION Exploded View (4X4), 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 264 BRAKES CHAPTER 9 BRAKES GENERAL SPECIFICATIONS..........9.2 TORQUE SPECIFICATIONS.
  • Page 265 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 266 BRAKES BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight, low maintenance, and perform well in the conditions routinely encountered. 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 267 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 268 BRAKES BRAKE SYSTEM EXPLODED VIEW Caliper Banjo Style Fittings: 15 ft. lbs. (21 Nm). All Caliper Bleed Screws: 30-60 in. lbs. (3.4-6.8 Nm) All Flare Style Fittings: 12-15 ft. lbs. (16-21 Nm) LH Front Brake Line LH Rear Line Master Cylinder LH Front Caliper Brake Switch MC Rear...
  • Page 269 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 270 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 271: Exploded View (2X4)

    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 Park Brake Lever Latch Washer Brake Release Park Brake Assembly Bolt Parking Brake Assembly Washer Clip Pin Clip Pin...
  • Page 272 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 273: Exploded View (4X4)

    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 274: Parking Brake

    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 reassembly. Inspect the brake pads linings for excessive wear. Replace as needed. Check the three steel balls for any signs of cracking.

  • Page 275: 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 276: 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 277: Pad Assembly / Installation / Adjustment

    Pad Assembly / Installation 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 278: 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 279: Caliper Inspection / Assembly

    BRAKES Remove piston (D) and square O-rings (E) from the caliper Inspect piston for nicks, scratches, wear or damage. body (F). See Figure 9.15. Measure diameter and replace if damaged or worn beyond service limit. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol.

  • Page 280: 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 281: 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 282: Pad Inspection / Installation

    BRAKES Pad Inspection Clean caliper area before removal. Remove caliper mounting bolts and lift caliper off of disc. Clean the caliper with brake cleaner or alcohol. NOTE: When removing caliper, be careful not to Measure the thickness of the pad material. Replace pads if damage brake line.

  • Page 283: Rear Caliper

    BRAKES Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2"(12.7 mm) of brake fluid in the Rear Brake Caliper Mounting Bolt: reservoir to prevent air from entering the master cylinder. Torque 18 ft. lbs. (24 Nm) Turn adjuster screw back in finger tight using a hex wrench.

  • Page 284: Caliper Removal / Disassembly

    BRAKES Caliper Removal Remove mounting bracket (B) and dust boot (C) Pads Safely support the rear of the machine. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. Use a wrench to remove the brake line.

  • Page 285: Caliper Assembly

    Piston should slide in and out of bore smoothly, with light resistance. Std. 1.2550” (3.227 mm) Lubricate the mounting bracket pins with Polaris Premium Service Limit 1.256” (31.902 mm) All Season Grease, and install the rubber dust seal boots.

  • Page 286: Rear Brake Disc

    BRAKES REAR BRAKE DISC TROUBLESHOOTING Disc Inspection Brakes Squeal / Poor Brake Performance Visually inspect disc for scoring, scratches, or gouges. • Air in system Replace the disc if any deep scratches are evident. • Water in system (brake fluid contaminated) Use a 0-1"micrometer and measure disc thickness at 8 different points around perimeter of disc.
  • Page 287 ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION ..........10.3 SPECIAL TOOLS .
  • Page 288 ELECTRICAL DC / CDI IGNITION SYSTEM (NON-EFI MODELS) ......10.25 DC / CDI IGNITION SYSTEM OVERVIEW ....... . . 10.25 IGNITION SYSTEM TROUBLESHOOTING.

  • Page 289: General Information

    ELECTRICAL GENERAL INFORMATION • When measuring resistance of a component that has a resistance value under 10 Ohms, remember to subtract meter lead resistance from the reading. Connect the Special Tools 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 290: 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 291: Brake Light Switch

    ELECTRICAL Differential Solenoid Circuit Operation CAUTION Power is present at the AWD / Diff-Lock Switch when the ignition key is turned “ON”. Do not power the solenoid with 12 Volts for more When the switch is pushed to activate “Turf” mode, power is than 1 second, or damage may occur sent to the PDM.

  • Page 292: Gear Indicator Light Circuit Operation

    ELECTRICAL The switch remains in the “open” position when the park brake Apply the parking brake. There should be continuity lever is not applied. between the switch terminals. If no continuity exists when the park brake is applied, try to clean the switch terminals and re-test.

  • Page 293: Indicator Lamp Replacement

    ELECTRICAL HEAD LIGHTS Indicator Lamp Replacement Lift the hood. High Beam Headlight Adjustment Reach in behind the console panel and lift on the release to The headlight beam is adjustable. unplug the light from the harness. Place the vehicle on a level surface with the headlight Using a small flathead screwdriver, press on the tab on top approximately 25 ft.

  • Page 294: Headlamp Bulb Replacement

    ELECTRICAL Headlamp Housing Removal Adjust the beam to desired position. Repeat the procedure to adjust the other headlight. Open the hood. WARNING Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring. Due to the nature of light utility vehicles and where they are operated, headlight lenses Remove the O-ring (A) from the headlamp brackets (both...

  • Page 295: Headlamp Housing Installation

    ELECTRICAL TAIL LIGHT / BRAKE LIGHT Headlamp Housing Installation To install the headlamp housing, press the headlamp tabs Lamp Replacement back into the brackets. Before replacing the tail light, use a digital multi-meter to test Secure the headlamp housing with the rubber O-rings on the harness to ensure the lamp is receiving 12 volts and that a each side (A).

  • Page 296: Power Distribution Module (Non-Efi Models)

    ELECTRICAL POWER DISTRIBUTION MODULE (NON-EFI MODELS) PDM Operation 10.10...

  • Page 297: Pdm Block Diagram

    ELECTRICAL PDM Block Diagram PDM ISOLATION TESTS (NON-EFI MODELS) Battery Voltage Test Battery Voltage Test Test Procedure Check DC volts across positive and negative battery terminals. Voltage should be above 12 VDC. What does passing If battery voltage is at or above 12 VDC, the battery and charging system are likely OK. this test indicate? What does failing If battery voltage is below 12 VDC, the battery and charging system may be suspect.

  • Page 298: Ground Test

    ELECTRICAL Ground Test GROUND Test The PDM uses pin N for a ground wire; it connects to the PDM through connector SSCB # 1. Check for Test Procedure continuity between the brown wire at SSCB # 1 and the terminal block ground post. There should be continuity to ground on the wire to pass.

  • Page 299: Battery + Test

    ELECTRICAL Battery + Test BAT + Test 1: Complete the Battery Voltage and GROUND Tests; note your results. Disconnect PDM connector SSCB # 1 and check for DC Volts on the red wire entering pin H at the PDM. The voltage should be at Test Procedure or near Battery Voltage.

  • Page 300: Accessory Power Test

    ELECTRICAL Accessory Power Test ACCESORY POWER Test The ignition switch must be turned to the "ON" position before completing this test. Measure DC volts at the orange/white accessory terminal post leading from pin J on the PDM SSCB #1 connector. Test Procedure Measurement should be at or near Battery voltage when RUN Signal is present at PDM (Ignition Switch in the "ON"...

  • Page 301: Static Thermistor Test

    ELECTRICAL Static Thermistor Test Static Thermistor Test This test should be conducted with the engine near room temperature. Measure the resistance between Test Procedure the two yellow/black wires on Pins E and F of SSCB #1 . The thermistor resistance should be 2200-2700 ohms when the engine is at room temperature.

  • Page 302: Differential Solenoid Test

    ELECTRICAL Differential Solenoid Test Differential Solenoid Test Using a known good 12V power source, connect directly to the Differential Solenoid at the harness connection located near the left hand frame rail. Connect battery positive to the solenoid side of the Test Procedure harness on the Orange/Red and Battery negative on the Blue wire.

  • Page 303: Differential Out Test

    ELECTRICAL Differential Out Test Diff OUT Test The following test must be performed with the key switch in the "on" position. Disconnect the solenoid Test Procedure from the harness. Using a Digital Mutimeter check for DC power on the orange/white wire on the harness side of the connector.

  • Page 304: Power Distribution Module (Efi Models)

    ELECTRICAL POWER DISTRIBUTION MODULE (EFI MODELS) PDM Operation Solid State Circuit Breaker (SSCB #1) Pin Signal Name Description Used to carry DC current to and from the battery and PDM. DC output from BAT + the PDM is used to charge the battery. DC input to the PDM is used for power distribution.

  • Page 305: Pdm Function Overview

    The Polaris PDM integrates many electronic features designed activated and disabled when it’s removed. If the maximum for Polaris RANGERs. These features include the rectifier / output current threshold is exceeded, the output current will be regulator, battery protected output, accessory power output, reduced until the devise thermally shuts down.

  • Page 306: Pdm Block Diagram

    ELECTRICAL Hub Coil Drive Differential Solenoid The hub safety interlock control (HSI) prevents the HUB COIL The differential solenoid driver provides a current-regulated - output from activating if the stator coil input frequency is too low-side drive for the solenoid coil. The low side driver sinks high.

  • Page 307: Timing Check Procedure (Non-Efi Models)

    ELECTRICAL TIMING CHECK PROCEDURE Stator Adjustment (NON-EFI MODELS) Remove the magneto housing. Remove the flywheel. Loosen the stator plate screws and adjust the stator plate The ignition timing check hole is in the starter recoil/ position. magneto housing. Remove the check plug. NOTE: Moving the stator plate clockwise retards NOTE: The ignition timing marks are stamped on the (delays) the ignition timing.

  • Page 308: Cooling System

    ELECTRICAL COOLING SYSTEM Non-EFI Cooling System Break-Out Diagram Overheat Indicator Output Thermister Input Fan 12 V Output SSCB#2 SSCB#1 Key-On 12 V Power RD / WH 10.22...

  • Page 309: Efi Cooling System Break-Out Diagram

    ELECTRICAL EFI Cooling System Break-Out Diagram Key-On 12 V Power RD / WH 10.23...

  • Page 310: Coolant Temperature Sensor Test (Non-Efi Models)

    ELECTRICAL Fan Control Circuit Operation / Testing THERMISTOR READING DURING OPERATION The cooling fan is controlled through the Power Distribution Approx. Reading Condition Temperature Module and thermistor. Perform the tests in the next two (Ohms) sections if you are experiencing problems with the cooling fan Hot Light On 185Ω...

  • Page 311: Dc / Cdi Ignition System (Non-Efi Models)

    ELECTRICAL DC / CDI IGNITION SYSTEM (NON-EFI MODELS) DC / CDI Ignition System Overview Operation Overview: The DC / CDI system relies on battery power for ignition. This engine uses a DC / CDI ignition system. Instead of generating DC voltage via magnetic induction, a 12 Some of the advantages of DC ignition are: volt DC current is supplied directly to the CDI unit from the battery.

  • Page 312: Resistance Tests

    ELECTRICAL Cranking Output Tests Using Resistance Tests Peak Reading Adaptor or Volt Ohm Meter Perform these tests using an Ohm meter or multimeter with the The following peak voltage tests will measure the amount of ignition key turned off. All readings are in Ohms. output directly from each component.

  • Page 313: Ignition System Testing Flow Chart

    ELECTRICAL Ignition System Testing Flow Chart Whenever troubleshooting an electrical problem first check all terminal connections to be sure they are clean and tight. Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting. The resistance values are also given on the specification pages.

  • Page 314: Components Of Dc / Cdi Ignition

    ELECTRICAL Components of DC / CDI Ignition NOTE: CDI boxes may look the same but have different internal circuitry. Be sure to always use the correct CDI box part number. Resistor Check coil mount for good Ω) ground to engine (0 - .2 Meter Ω...

  • Page 315: Efi Diagnostics

    ELECTRICAL EFI DIAGNOSTICS Charging System “Break Even” Test EFI Component Testing CAUTION All EFI component information and diagnostic testing procedures are located in Chapter 4. Do not allow the battery cables to become disconnected with the engine running. Follow the Refer to Chapter 4 “Electronic Fuel Injection System (EFI)”...

  • Page 316: Charging System Alternator Tests

    ELECTRICAL Charging System Alternator Tests TEST 2: Resistance Value of Each Stator Leg to Ground Measure the resistance value of each of the stator legs to Three tests can be performed using a multimeter to determine ground: Y1 to Ground, Y2 to Ground, Y3 to Ground. the condition of the stator (alternator).

  • Page 317: 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 318: 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 10.33. No Caps...

  • Page 319: 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 320: Conventional Battery Testing

    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 321: Load Test

    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 322: Low Maintenance Battery

    ELECTRICAL After connecting the battery cables, install the cover on the NOTE: New Batteries: Batteries must be fully battery and attach the hold down strap. charged before use or battery life will be reduced by 10-30% of full potential. Charge battery for 3-5 hours Install clear battery vent tube from vehicle to battery vent.

  • Page 323: 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 324: 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 325: Starter System

    ELECTRICAL STARTER SYSTEM Starter Motor Disassembly NOTE: Use only electrical contact cleaner to clean Troubleshooting starter motor parts. Some solvents may leave a residue or damage internal parts and insulation. Starter Motor Does Not Turn • Battery discharged. Low specific gravity Note the alignment marks on both ends of the starter motor casing.

  • Page 326: Brush Inspection / Replacement

    ELECTRICAL Brush Inspection / Replacement Install the O-Ring over the bolt. Make sure the O-ring is fully seated. Brush Set Using a digital multitester, measure the resistance between Remove the electrical tape and reinstall the two small the cable terminal and the insulated brush. The reading phenolic washers, the large phenolic washer, flat washer, should be .3 ohms or less.

  • Page 327: Starter Reassembly

    Make sure the end washer is positioned properly so Do not drop or strike the housing as magnet that it will hold the lock ring in its groove damage is possible. If magnets are damaged, starter must be replaced. Polaris Premium Starter Drive Grease (PN 2871460) 10.41...

  • Page 328: Starter System Test Flow Chart

    ELECTRICAL Starter System Test Flow Chart Condition: Starter fails to turn motor. 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. NOTE: The footbrake must be compressed to the starter circuit to engage. With the tester on the VDC position, place the tes- Remove battery and properly service.
  • Page 329 ELECTRICAL Starter System Test Flow Chart, cont’d. Test B (from previous page) Continued from previous page Voltage Drop Testing Reconnect the solenoid. Connect the tester black lead to the battery positive and the red lead to the Clean the battery-to-solenoid cable ends solenoid end and actuate the starter.

  • Page 330: 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 331: Electrical Breakout Diagrams (Efi Models)

    ELECTRICAL ELECTRICAL BREAKOUT DIAGRAMS (EFI MODELS) Starting Circuit Key-On Power Circuit 10.45...

  • Page 332: Transmission Switch Circuit

    ELECTRICAL Transmission Switch Circuit Differential Solenoid Circuit 10.46...

  • Page 333: Charging System Circuit

    ELECTRICAL Charging System Circuit Cooling Fan Circuit 10.47...

  • Page 334: Awd Circuit

    ELECTRICAL AWD Circuit 10.48...
  • Page 335 Carburetor, Needle and Seat Test ....4.12 Carburetor, Removal ......4.10 Adjustment, Valve Clearance .
  • Page 336 Driven Clutch, Assembly ......6.22 Fuel Filter ....... .2.14 2.19 Driven Clutch, Bushing Service .
  • Page 337 Oil Pump, Removal ......3.35 Rear Suspension, Maintenance ....2.37 One-Way Valve .
  • Page 338 Torque Specifications, Brakes ..... .9.2 Torque Specifications, Clutching ....6.2 Torque Specifications, Engine .
  • Page 339 WIRE DIAGRAM RANGER 500 2X4 / 4X4 (CHASSIS) WD-1...
  • Page 340 WIRE DIAGRAM RANGER 500 2X4 / 4X4 (DASH) WD-2...
  • Page 341 WIRE DIAGRAM RANGER 500 EFI 4X4 (CHASSIS) PAGE 1 OF 2 WD-3...
  • Page 342 WIRE DIAGRAM RANGER 500 EFI 4X4 (CHASSIS) PAGE 2 OF 2 WD-4...
  • Page 343 WIRE DIAGRAM RANGER 500 EFI 4X4 (DASH) WD-5...
  • Page 344 WIRE DIAGRAM RANGER 500 EFI 4X4 (BREAKOUTS) WD-6...
  • Page 345 WIRE DIAGRAM RANGER 500 2X4 / 4X4 (BREAKOUTS) WD-7...

This manual is also suitable for:

Ranger 500 4x4 2007Ranger 500 4x4 efi 2007

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