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Polaris RANGER 2x4 Manual

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CHAPTER 1
. . . . . . . . . . . . . . . . . . . . . . .
Models Numbers / Replacement Key
Specifications - RANGER 2X4
Specifications - RANGER 4X4
Specifications - RANGER 6X6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
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1.2
1.2
1.3
1.4-1.5
1.6-1.7
1.8-1.9
1.10-1.11
1.12
1.12
1.12
1.1
1

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Summary of Contents for Polaris RANGER 2x4

  • Page 1: Table Of Contents

    ..... 1.4-1.5 Specifications - RANGER 2X4 ... . . 1.6-1.7 Specifications - RANGER 4X4 .

  • Page 2: General Information

    GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 1 1 R F 5 0 A B Emissions & Model Option Series Designation Basic Chassis Designation Engine Designation Engine Designation Number EH42PLE06 Single, L/C, SOHC 4 Stroke, Electric Start...
  • Page 3 GENERAL INFORMATION MACHINE MODEL NUMBER AND SERIAL NUMBER LOCATION The machine model number and serial number are important for vehicle identification. The machine serial number (A) is stamped on the lower frame rail close to the front drive wheel. The model and serial number (B) are also located on a sticker on the hood liner.

  • Page 4: Machine Dimensions

    GENERAL INFORMATION MACHINE DIMENSIONS 75 in 190.50 cm 13 in (Front of Box) 23 cm 7.2 in 18 cm 58 in 147 cm...
  • Page 5 GENERAL INFORMATION MACHINE DIMENSIONS 120 in 305 cm 48 in 152 cm 90 in 229 cm 113 in 33 cm 42 in 107 cm 7.2 in 18.25 cm 76 in 193 cm...
  • Page 6 ..Dash Receptacle *PPS Polaris Premium Synthetic Gear Case Oil Battery ... 30 Amp (12 Volt) *PP4 Polaris 0W--40 Synthetic Engine Lubricant...
  • Page 7 GENERAL INFORMATION MODEL SPECIFICATIONS RANGER 2X4 MODEL: ..MODEL NUMBER: A11RB42AA ENGINE MODEL: EH42PLE06 CARBURETION Type ....
  • Page 8 ..Dash Receptacle *PPS Polaris Premium Synthetic Gear Case Oil Battery ... 30 Amp (12 Volt) *PP4 Polaris 0W--40 Synthetic Engine Lubricant...
  • Page 9 GENERAL INFORMATION MODEL SPECIFICATIONS RANGER MODEL: ..MODEL NUMBER: A11RD50AB ENGINE MODEL: EH50PLE16 CARBURETION Type ....BST 34 Mikuni CV JETTING CHART Main Jet...
  • Page 10 ..Dash Receptacle *PPS Polaris Premium Synthetic Gear Case Oil Battery ... 30 Amp (12 Volt) *PP4 Polaris 0W--40 Synthetic Engine Lubricant...
  • Page 11 GENERAL INFORMATION MODEL SPECIFICATIONS RANGER 6x6 MODEL: ..MODEL NUMBER: A11RF50AA ENGINE MODEL: EH50PLE16 CARBURETION Type ....BST 34 Mikuni CV JETTING CHART Main Jet...

  • Page 12: Publication Numbers

    Model Model No. Owner’s Parts Service Parts Manual PN Manual PN Manual PN Micro Fiche RANGER 2x4 A11RB42AA 9918176 99118179 9918071 9918180 RANGER 4x4 A11RD50AA RANGER 6x6 A11RF50AA When ordering service parts be sure to use the correct parts manual.
  • Page 13 ....2.2--2.3 Polaris Lubricant and Service Part Numbers Special Tools ......

  • Page 14: Periodic Maintenance Chart

    Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 mph. Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer.
  • Page 15 Pre-Ride Inspection Item CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an authorized Polaris dealer. " Vehicles subjected to severe use (operation in wet or dusty areas, low speed heavy load operation, prolonged idle) should be inspected and serviced more frequently.
  • Page 16 GENERAL INFORMATION POLARIS LUBRICANTS,MAINTENANCE AND SERVICE PRODUCTS Part No. Description Part No. Description Engine Lubricant 2871954 Loctitet Threadlock 271 (36 ml.) (6 Count) 2870791 Fogging Oil (12 oz. Aerosol) 2870584 Loctitet 680-Retaining Compound (10 2871098 Premium 2 Cycle Engine Oil (Quart) (12 ml.)

  • Page 17: Special Tools

    GENERAL INFORMATION SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN PA- -44689 Valve Clutch Adjuster 2872105 Water Pump Mechanical Seal Puller 8712100 or 8712500 Tachometer 2,10 2200634 Valve Seat Reconditioning Kit 2870390 Piston Support Block 2871043 Flywheel Puller 2871283 Crankshaft/Water Pump Seal Install Kit 5131135...
  • Page 18 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) © Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) ¢ Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special...
  • Page 19 © 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 4. Fill Plug 5. Fill Plug...
  • Page 20 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) © Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) ¢ Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special...

  • Page 21: Front Gearcase Lubrication

    6. Fill with the recommended fluid amount or fill to proceeding. 0.75 in. (19 mm) below the threads of the fill plug. Check vent hose to be sure it is routed properly and unobstructed. correct middle gearcase lubricant to use is Polaris Gear Drive Fluid...

  • Page 22: Rear Gearcase Lubrication

    1. With the RANGER on a level surface, remove the Specified Lubricant: fill plug and check the lubricant level. Lubricant Polaris Gear Drive Fluid (PN 2871653) should be kept at the specified level, according to the proper gearcase specifications listed.

  • Page 23: Transmission Lubrication

    4. Clean and reinstall drain plug using a new sealing TRANSMISSION SPECIFICATIONS washer. Specified Lubricant: Polaris Premium Synthetic Gearcase Lubricant REAR GEARCASE (All Models) (PN 2871477) (Gallon) (PN 2871478) (12 oz.) Make sure vent is unobstructed Approximate Capacity at Change: 4x4 &...
  • Page 24 GENERAL INFORMATION Examples of Measuring Instruments 4x4 & 6x6 Transmission 4x4 & 6x6 Models 2x4 Model Measuring Instrument Top Fill Plug Thread 3/4” (19 mm) 1 1/2” (38 mm) Below top thread Below top thread of fill plug. of fill plug. 1 1/2”...

  • Page 25: Shift Linkage Adjustment

    GENERAL INFORMATION SHIFT LINKAGE end, also. Inside Jam Nut INSPECTION/ADJUSTMENT Outside Jam Nut Linkage rod adjustment is necessary when symptoms include: No All Wheel Drive light Noise on deceleration Inability to engage a gear Excessive gear clash (noise) Shift selectors moving out of desired range NOTE: Remove necessary components to gain...

  • Page 26: Throttle Pedal Inspection

    GENERAL INFORMATION THROTTLE PEDAL Adjuster Lock- INSPECTION Sleeve Boot Boot Throttle Freeplay THROTTLE CABLE ADJUSTMENT Parking Brake NOTE: If the proper freeplay cannot be obtained with Throttle Pedal the throttle block adjuster, adjust the cable at the carburetor using the following procedure. 1.
  • Page 27 GENERAL INFORMATION If cable slack is excessive, the choke fuel passage will not open far enough, which may cause cold starting difficulty. Also, the half-choke position used for intermittent applications will not function properly. FRONT (Engine) Pilot Screw Pilot Screw Adjustment Refer to Specifications 2.

  • Page 28: Fuel System

    GENERAL INFORMATION IDLE SPEED ADJUSTMENT Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and 1. Start engine and warm it up thoroughly. can result loss of consciousness or death in a short time. CV Carburetor Never drain the float bowl when the engine is hot.

  • Page 29: Battery Maintenance

    GENERAL INFORMATION 5. Start engine and inspect for leaks. BATTERY MAINTENANCE CARBURETOR DRAINING WARNING The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before extended periods of storage. Battery electrolyte is poisonous. It contains NOTE: The bowl drain screw is located on the bottom sulfuric acid.

  • Page 30: Spark Plug / Electrical

    GENERAL INFORMATION To remove the battery: SPARK PLUG 1. Disconnect holder strap and remove cover. 1. Remove spark plug high tension lead. Clean plug 2. Disconnect battery negative (-) (black) cable first, area so no dirt and debris can fall into engine followed by the positive (+) (red) cable.
  • Page 31 Straight water or antifreeze may cause the system to freeze, corrode, or overheat. LIQUID COOLING SYSTEM Polaris 60/40 Anti-Freeze / Coolant OVERVIEW (PN 2871323) The engine coolant level is controlled or maintained by the recovery system.
  • Page 32 GENERAL INFORMATION 1. Remove reservoir cap. Inner splash cap vent hole must be clear and open. 2. Fill reservoir to upper mark with Polaris Premium Radiator Cap 60/40 Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.
  • Page 33 GENERAL INFORMATION the frame. CAUTION: Do not over-tighten hose clamps at radiator, or radiator fitting may distort, causing a restriction to coolant flow. Radiator hose clamp torque is 36 in. lbs. Bolts (4 Nm). COOLING SYSTEM PRESSURE TEST Wheel Well Refer to Page 3.5 for pressure test procedure.

  • Page 34: Air Filter / Breather Filter

    GENERAL INFORMATION 6. Remove the radiator. Breather Filter Inlet Radiator Hose Cover Seal Mounting Screws Surge Tank Hose Filter Cover Installation Outlet Radiator 1. Reinstall the filter into the air box container. Be Hose Temp. Sensor Plug sure the filter fits tightly in the air box. NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before AIR FILTER/ BREATHER...
  • Page 35 GENERAL INFORMATION BREATHER FILTER INSPECTION The engines are equipped with a breather filter. The in-line filter is similar in appearance to a fuel filter, and is visible on the left side (Location A). Follow right hand breather line out of the side of the airbox and locate filter.

  • Page 36: Flywheel Housing

    GENERAL INFORMATION AIR INTAKE INSPECTION Air Box Foam Engine Intake Duct Air Baffling 1. Lift the hood. 2. Inspect the foam inserts in the air baffle boxes. If the foam inserts are dirty, clean the foam with a high flash point solvent, followed by hot soapy water.

  • Page 37: Oil Level And Filter Change

    GENERAL INFORMATION ENGINE OIL LEVEL OIL AND FILTER CHANGE The oil tank is located on the left side of the vehicle. WARNING To check the oil level: Personal injury can occur when 1. Set machine on a level surface. handling used oil. Hot oil can cause 2.

  • Page 38: 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. 23. Prime oil pump using procedure below. Stop...

  • Page 39: Valve Adjustment

    GENERAL INFORMATION VALVE CLEARANCE Inspect and adjust valve clearance while the engine is cold and the piston positioned at Top Dead Center (TDC) on compression stroke. 1. Remove the seat. 2. Remove body panels and fuel tank as necessary to gain access to valve cover. 3.
  • Page 40 Due to the critical nature of the procedures out- lined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD- -certi- fied technician when replacing worn or dam- aged steering parts. Use only genuine Polaris replacement parts.
  • Page 41 GENERAL INFORMATION Hold Rod End Incorrectly Correctly Tightened Tightened Jam Nut Jam Nut Ill.2 Ill.2 To adjust toe alignment: Check for Loose Wheel or Hub Hold tie rod end to keep it from rotating. If abnormal movement is detected, Loosen jam nuts at both end of the tie rod. inspect the hub and wheel assembly Shorten or lengthen the tie rod until to determine the cause (loose wheel...

  • Page 42: Exhaust Pipe

    1. Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir. Use Polaris DOT 3 Brake Fluid (PN 2870990) or DOT 4 Brake Fluid. Ill.1 Clean Out Plug Check brake system for fluid leaks.
  • Page 43 GENERAL INFORMATION BRAKE PAD INSPECTION 1. Stop the engine, place the transmission in gear and lock the parking brake. Pads should be changed when the friction material is 2. Loosen the wheel nuts slightly. worn to 3/64² (.1 cm), or about the thickness of a dime. 3.

  • Page 44: Suspension

    GENERAL INFORMATION TIRE PRESSURE that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. Check all rear suspension components CAUTION: for wear or damage. Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle. FRONT SUSPENSION Tire Pressure Inspection (PSI - Cold) Front...
  • Page 45 GENERAL INFORMATION REAR SUSPENSION Rear Suspension Swing Arm U--Bolt Coil Over Bushings Washer & Bolt Shock Pivot Bolt Pivot Bolt Lock Frame Rear Axle Compress and release rear suspension. Damping should be smooth throughout the range of travel. Check all rear suspension components for wear or damage.
  • Page 46 GENERAL INFORMATION NOTES 2.34...
  • Page 47 ENGINE CHAPTER 3 ENGINE Torque Specifications ......Special Tools ....... Service Data .

  • Page 48: Torque Specifications

    ENGINE TORQUE SPECIFICATIONS Water Pump 5-6.5 (7-9 Nm) Housing Cover Stator Plate 5-6.5 (7-9 Nm) TORQUE SPECIFICATIONS Starter Motor 5-6.5 (7-9 Nm) Fastener Size EH42PLE/ EH50PLE Spark Plug 14mm 9-11 (12-15 Nm) Ft. Lbs. (Nm) Blind Plug (Oil 1/8 PT 6.5-11 (9-15 Nm) Pressure) (28tpi)

  • Page 49: Service Data

    ENGINE ENGINE SERVICE DATA Cylinder Head / Valve EH42PLE EH50PLE Rocker Arm Rocker arm ID .8669-.8678² (22.020-22.041 mm) .8669-.8678² (22.020-22.041 mm) Rocker shaft OD .8656-.8661² (21.987-22.0 mm) .8656-.8661² (21.987-22.0 mm) Rocker shaft Oil Clearance .0008-.0021² (.020-.054 mm) .0008-.0021² (.020-.054 mm) Limit .0039²...
  • Page 50 ENGINE ENGINE SERVICE DATA Cylinder / Piston / Connecting Rod EH42PLE EH50PLE Cylinder Surface warpage limit (mating with cylinder head) .0020² (.05 mm) .0020² (.05 mm) Cylinder bore 3.4606-3.614² (87.900-87.920 mm) 3.6221-3.6228² (92.00-92.02 mm) Taper limit .0020² (.050 mm) .0020² (.050 mm) Out of round limit .0020²...

  • Page 51: Torque Patterns

    ENGINE ENGINE FASTENER TORQUE Engine Oversize Piston Standard Model Length Piston Iden- Available* PATTERNS tification (mm) Tighten cylinder head, cylinder base, and crankcase EH50PLE 72 mm fasteners in 3 steps following the sequence outlined below. EH42PLE 66 mm *Pistons and rings marked 25 equal .25mm (.010I) oversized Pistons and rings marked 50 equal .50mm (.020I) oversized...
  • Page 52 ENGINE COOLING SYSTEM and serious burns may result. Allow the engine and cooling system to cool before servicing. WARNING: Never remove radiator cap when engine System Pressure Test is warm or hot. The cooling system is under pressure 1. Remove front cover. 2.

  • Page 53: Cooling System Specifications

    Polaris Premium 60/40 ENGINE REMOVAL (TYPICAL) Antifreeze/Coolant is recommended for use in all cooling systems, and comes pre-mixed and ready to 1.

  • Page 54: 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. 1. Use only Polaris Premium 4 All Season synthetic oil. Never substitute or mix oil brands. Serious engine damage can result.
  • Page 55 Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 2 Cycle Lubricant. CRANKSHAFT STRAIGHTENING Lubricate the bearings and clamp the crankshaft securely in the Crankshaft Truing Stand (PN 2870569).

  • Page 56: Engine Lubrication

    3. Start engine and allow it to reach operating temperature, monitoring gauge indicator. NOTE: Use Polaris Premium 4 Synthetic Engine Lubricant (PN 2871281). 2. To correct a situation like the one shown in the...
  • Page 57 ENGINE OIL FLOW - - EH42PL/EH50PL The chart on Page 3.12 describes the flow of oil through the EH42PL/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. The feed side of the oil pump draws oil through the hose and into the crankcase oil gallery, and then pumps the oil through another passage to the one way valve.
  • Page 58 ENGINE EH42PL/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 feed or intake exhaust or return from bottom of Oil Tank to tank...

  • Page 59: Engine Exploded View

    ENGINE EH42PL/EH50PL ENGINE EXPLODED VIEW Crankcase Cylinder/ Cylinder Head Crankshaft Valve Train and Piston 3.13...
  • Page 60 ENGINE ENGINE REMOVAL should have clearance at this point. REFER TO PAGE 3.7- - 3.8 FOR ENGINE REMOVAL / INSTALLATION NOTES. CAM CHAIN TENSIONER/ROCKER ARM/CAMSHAFT REMOVAL 1. Remove ignition timing inspection plug from recoil housing. 5. Remove cam chain tensioner plug, sealing TDC “T”...
  • Page 61 ENGINE CAM CHAIN TENSIONER ROCKER ARM/SHAFT INSPECTION INSPECTION 1. Pull cam chain tensioner plunger outward to the 1. Mark or tag rocker arms to keep them in order for end of its travel. Inspect teeth on ratchet pawl (A) assembly. and plunger teeth (B) for wear or damage.
  • Page 62 ENGINE ROCKER ARM/SHAFT INSPECTION, CONT. Rocker Shaft Oil Clearance: Std: .0008-.0021I (.020-.054 mm) Limit: .0039I (.10 mm) 5. Measure I.D. of both rocker arm shaft supports and visually inspect surface. Compare to specifications. 6. Subtract rocker shaft O.D. from rocker arm & shaft support I.D.
  • Page 63 ENGINE 3. Loosen three camshaft sprocket bolts. 7. Slide camshaft inward to allow removal of cam sprocket and remove sprocket from camshaft and chain. 8. Secure cam chain with a wire to prevent it from falling into the crankcase. Sprocket Teeth 4.
  • Page 64 ENGINE Stop pin Spring in relaxed position 1. Check release lever shaft (A) for smooth operation throughout the entire range of rotation. The spring (B) should hold the shaft weight against the stop pin. In this position, the actuator ball (C) will be held outward in the compression release mode.
  • Page 65 ENGINE Camshaft Oil Clearance: Std: .0022-.0035I (.055-.090 mm) Limit: .0039I (.10 mm) Lubrication holes NOTE: Replace camshaft if damaged or if any part is worn past the service limit. Lobe height NOTE: Replace cylinder head if camshaft journal bore is damaged or worn excessively. CYLINDER HEAD EXPLODED Cam Lobe Height (Intake &...
  • Page 66 ENGINE CYLINDER HEAD EXPLODED VIEW, EH42PL/EH50PL EH42PL/EH50PL 3.20...
  • Page 67 ENGINE CYLINDER HEAD CYLINDER HEAD INSPECTION DISASSEMBLY WARNING: Wear eye protection or a face shield during cylinder head disassembly and reassembly. NOTE: Keep all parts in order with respect to their location in the cylinder head. 1. Thoroughly clean cylinder head (A) surface to remove all traces of gasket material and carbon.
  • Page 68 ENGINE 4. Measure free length of spring with a Vernier indicator. caliper. Check spring for squareness. Compare to specifications. Replace spring if either measurement is out of specification 3. Check end of valve stem for flaring, pitting, wear or damage (A). 4.

  • Page 69: Valve Seat Service

    ENGINE Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush. VALVE SEAT RECONDITIONING Valve Seat Inspection Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned.
  • Page 70 ENGINE Reaming The Valve Guide Good Uneven Wide Narrow NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around.
  • Page 71 ENGINE If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation and must be Valve Seat Width: replaced. Be sure the cylinder head is at the proper temperature and replace the Intake Std: .028I (.7 mm) guide.

  • Page 72: Cylinder Head Assembly

    ENGINE 1. Install new valve seals on valve guides. 2. Apply engine oil to valve guides and seats. 3. Coat valve stem with molybdenum disulfide grease. 4. Install valve carefully with a rotating motion to avoid damaging valve seal. 5. Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head.
  • Page 73 ENGINE EXHAUST VALVE CLEARANCE ADJUSTMENT 425/500 Engine Feeler Gauge for Both Valves 1. Remove cam chain guide at front of cylinder. NOTE:The exhaust valves share a common rocker arm, and must be adjusted using two feeler gauges. 1. Insert .006 feeler gauge(s) between end of exhaust valve stem and adjuster screw(s).
  • Page 74 ENGINE 6. Tap cylinder lightly with a plastic hammer in the reinforced areas only until loose. 7. Rock cylinder forward and backward and lift it from the crankcase, supporting piston and connecting rod. Support piston with Piston Support Block (PN 2870390). 8.
  • Page 75 ENGINE scratch the ring lands. 2. Inspect the top of the cylinder for warpage using a straight edge and feeler gauge. Cylinder Warpage: .002² (.05 mm) 3. Inspect cylinder for wear, scratches, or damage. 1/2² Down From Top of Cylinder 4.
  • Page 76 ENGINE PISTON-TO-CYLINDER CLEARANCE Piston 40 mm Piston Pin Measurement Locations Piston Pin Piston Pin O.D. .9053-.9055I (22.994-23.0 mm) 1. Measure piston outside diameter at a point 40 mm down from the top of the piston at a right angle to the direction of the piston pin.
  • Page 77 ENGINE below specified limit, file ring ends until gap is within specified range. Piston Ring-to-Groove Clearance NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. A Top Ring Std: .0016-.0031I (.040-.080 mm) re-bored cylinder should always be scrubbed Limit: .0059I (15 mm) thoroughly with hot soapy water, rinsed, and dried Second Ring Std: .0012-.0028I (.030-.070 mm)
  • Page 78 ENGINE 5. Replace crankshaft seal (A). Std. Bushing ID: .4735²-.4740² (11.11-12.04 mm) Std. Shaft OD: .470²-.472² (11.93-11.99 mm) Starter Drive Bushing Clearance: Std: .0015²-.004² (.038-.102 mm) Service Limit: .008² (.203 mm) 4. Measure the OD of the starter drive shaft on both ends and record.
  • Page 79 ENGINE 2. Remove blade and inspect for cracks, wear, or damage. 1. Remove cap bolt (A), sealing washer (B), spring (C), and one way valve (D) from PTO side 3. Remove cam chain (B). Inspect chain for worn or crankcase. missing rollers or damage.
  • Page 80 ENGINE 2. Separate crankcase by tapping with a soft faced hammer in reinforced areas. 3. Tap lightly on balancer gear with a brass drift through the hole in the crankcase if necessary, to ensure the balancer shaft stays in the PTO side crankcase.
  • Page 81 ENGINE 8. Remove pump body screw and feed chamber 11. Measure rotor tip clearance with a feeler gauge. cover. 12. Remove inner and outer feed rotor and pump chamber body. 13. Repeat measurements for scavenge rotor. 14. Remove inner and outer scavenge rotor and inspect pump shaft for wear.
  • Page 82 ENGINE 1. Remove the shim washer (A) from the counter CRANKSHAFT balancer shaft. REMOVAL/INSPECTION 1. Remove the shim washer (A) from the crankshaft. 2. Note the alignment dots on the balancer and crankshaft gears, the marks must be aligned 2. Support the PTO side crankcase and crankshaft; during reassembly.
  • Page 83 ENGINE 5. Measure the connecting rod big end radial PUMP SHAFT OIL SEAL/ clearance. WATER PUMP MECHANICAL SEAL REMOVAL (ENGINE Big End Radial Clearance: DISASSEMBLED) Std: .0004-.0015I (.011-.038 mm) Limit: .0020I (.05 mm) NOTE: The water pump mechanical seal can be removed without removing the engine.

  • Page 84: Crankshaft End Play Inspection

    ENGINE BEARING INSTALLATION NOTE: To ease bearing installation, warm the crankcase until hot to the touch. Place the bearings in a freezer. 1. Install the bearings so the numbers are visible. 2. Drive or press new bearings into the crankcases, using the proper driver.
  • Page 85 ENGINE 4. Measure the distance from the Magneto 7. Measure the width of the crankshaft at the crankcase mating surface to the main bearing bearing seats with a micrometer or dial caliper using the same method and record. and record. Crankshaft Width 8.

  • Page 86: Oil Pump Shaft End Play Inspection

    ENGINE COUNTER BALANCER SHAFT END PLAY ADJUST. Counter Balancer Shaft End Play: .008²-.016² (.02-.04 cm) Step 2 OIL PUMP SHAFT END PLAY ADJUSTMENT 1. Make sure the pump shaft bearing is firmly seated in the Magneto side crankcase. 1. Make sure all bearings are firmly seated in the crankcase.
  • Page 87 ENGINE difficult, install two nuts on the end of the threaded rod and tighten against each other. Pump Shaft End Play: 3. Install the proper shim on the magneto end of the crankshaft. .008²-.016² (.02-.04 cm) 4. Place the balancer shaft in the PTO crankcase aligning the timing marks on the crankshaft and balancer gears.
  • Page 88 ENGINE Sealing Washer Crankcase Sealant: Sealing Washer (Copper or Aluminum) (PN 2871557) Coolant Drain Bolt WATER PUMP MECHANICAL Seal SEAL INSTALLATION Impeller 1. Clean the seal cavity to remove all traces of old sealer. Mechanical Seal Ill. 1 2. Place a new mechanical seal in the seal drive collar, and install on the pump shaft.
  • Page 89 ENGINE 7. The Water Pump Install Kit (PN 5131135) is required to install the new mechanical seal. This tool is available separately and it is also included Main puller in the Crankshaft/Water Pump Seal Installation body Kit (PN 2871283). ONE WAY VALVE INSTALLATION Install the one way valve plunger, spring, and plug Position the split...
  • Page 90 ENGINE TENSIONER BLADE 5. Install the top ring (chrome faced) with the “R” mark facing up and the end gap facing forward INSTALLATION (toward the exhaust). (See ILL. 1). 6. Check to make sure the rings rotate freely in the 1.
  • Page 91 ENGINE compress the new clip more than necessary upon 3. Apply clean engine oil to the ring compressor installation to prevent loss of radial tension. Severe (Snap Ont PN RCL30) and install the engine damage may result if circlips are re-used or compressor following manufacturers...
  • Page 92 ENGINE 9. Tighten the cylinder bolts in three steps in a criss cross pattern and torque to specifications. 10. Install the two 6 mm bolts. Cylinder Bolt Torque: 10mm - 46 ft. lbs. (62 Nm) Guide in 6mm - 6 ft. lbs. (8 Nm) recess CYLINDER HEAD INSTALLATION...
  • Page 93 ENGINE 1. 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). 2. Install the camshaft with the lobes facing downward and the sprocket alignment pin facing upward.
  • Page 94 ENGINE CAMSHAFT TIMING Crankshaft to Camshaft Centerline Dots Sprocket Alignment Pin Single TDC Mark Aligned TDC Mark Rotation Do Not Use Advance Marks 3.48...
  • Page 95 ENGINE CAM CHAIN TENSIONER 1. Apply a light film of grease to the crankshaft seal. Apply molybdenum disulfide grease or assembly INSTALLATION lubricant to the crankshaft bushing. 2. Install a new O-Ring in the oil passage recess in the crankcase. 3.
  • Page 96 ENGINE Starter Drive 5. Be sure the dowel pins are in place and install the rocker shaft assembly. 6. Apply a light film of engine oil to the threads of the bolts and tighten evenly. Rocker Shaft Support Tower Bolt Torque: 9 ft.
  • Page 97 ENGINE OIL PIPES 11. Remove center bolt from recoil friction plate (A). Install the oil pipes with new sealing washers. Tighten all bolts evenly to specified torque. Oil Pipe Bolt Torque: 20 ft. lbs. (27 Nm) RECOIL DISASSEMBLY/INSPECTION CAUTION: The recoil is under spring tension. A face shield and eye protection is required during this 12.
  • Page 98 ENGINE 1. Hook outer tab in place in recoil housing and wind spring in a counterclockwise direction one coil at a time while holding the installed coils in place. 2. Lubricate the spring with light lubricant such as Premium All Season Grease (PN 2871423). To complete recoil assembly: 1.

  • Page 99: Spark Plug Fouling Checklist

    ENGINE SPARK PLUG FOULING Dead battery Starter motor does not turn Spark plug cap loose or faulty Engine seized, rusted, Choke cable adjustment mechanical failure plunger/cable sticking Engine Runs But Will Not Idle Foreign material on choke plunger Restricted carburetor pilot system seat or plunger Carburetor misadjusted Incorrect spark plug heat range or...
  • Page 100 ENGINE Cylinder head gasket leak Ignition timing misadjusted valve clearance incorrectly Low oil level adjusted Spark plug incorrect heat range Cylinder or piston worn Faulty hot light circuit Piston rings worn, leaking, broken, or Thermostat stuck closed or not opening sticking completely Bent valve or stuck valve...
  • Page 101 FUEL SYSTEM/CARBURETION CHAPTER 4 FUEL SYSTEM/CARBURETION Exploded View, Mikuni BST 34 Carburetor . . . Fuel Tank Asm. Exploded View ... . Fuel Flow Diagram ..... . . Special Tool &...
  • Page 102 FUEL SYSTEM/CARBURETION 1. Carburetor Assembly BST 34 CARBURETOR 2. Screw 3. Throttle Valve EXPLODED VIEW 4. Cover, Diaphragm 5. Jet Block Assembly 6. Spring 7. Diaphragm Assembly 8. Ring 9. “E” Ring 10. Ring 11. Needle Jet 12. Cover 13. O-Ring 14.

  • Page 103: Fuel Flow Diagram

    FUEL SYSTEM/CARBURETION FUEL TANK ASSEMBLY A. Fuel Line Components B. Fuel Cap/Gauge C. Fuel Tank D. Tank Support E. Fuel Pump F. Fuel Filter & Line G. Tank Secure Strap H. Tank Venting I. Tank Foil FUEL FLOW DIAGRAM Fuel Tank Fuel Tank Vent Fitting Screens Fuel Pump...

  • Page 104: Carburetor Jetting

    3130571 dense with reduced oxygen. 157.5 3130572 3131141 Polaris ATV Carburetors are calibrated for an altitude 162.5 3131142 0-6000 ft. (0-1800 meters) and ambient 3131143 temperatures between +40 and +80° F (+5° to +26°...

  • Page 105: Cv Carburetor System Function (4 Cycle)

    FUEL SYSTEM/CARBURETION CV CARBURETOR SYSTEM VENT SYSTEMS - CV FUNCTION CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl. The lines Carburetor Component Function must be free of kinks, restrictions and be properly System Main Main Main routed.
  • Page 106 FUEL SYSTEM/CARBURETION CARBURETOR OPERATION CONT’D When the throttle plate is opened and engine speed begins to increase, the pressure in the venturi (and therefore in the chamber above the diaphragm) becomes significantly lower than atmospheric. Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward, raising the slide against spring pressure.
  • Page 107 FUEL SYSTEM/CARBURETION FLOAT SYSTEM MAIN SYSTEM Fuel enters the float chamber (3) by means of the inlet As throttle valve (1) is opened, engine speed rises, pipe and passage, through a screen on the back of the and this increases negative pressure in the venturi. inlet needle seat (4), and around the inlet needle (2).
  • Page 108 G Drain line DISASSEMBLY - MIKUNI CV G Fuel line G Throttle cable NOTE: Series 11 RANGER 2x4, 4x4 ,and 6x6 will have tamper resistant screws on Diaphragm Cover G Choke cable per 2003 CARB standards for LSI (large spark ignition) engines.
  • Page 109 FUEL SYSTEM/CARBURETION 2. Remove inlet needle seat retaining screw along NOTE: The starter jet is not removeable. Upon with plate, and carefully remove needle seat. disassembly, place the parts in a container for safe NOTE: Do not use a pliers to remove the seat or keeping.
  • Page 110 FUEL SYSTEM/CARBURETION CARBURETOR INSPECTION Pilot Mixture Screw Base Setting 1. Inspect the inlet needle tapered surface for any (Set at Factory) sign of wear or damage. Be sure the spring loaded pin is free moving and returns freely when Refer to Specifications in Chapter 1 pushed.

  • Page 111: Needle & Seat Leakage Test

    FUEL SYSTEM/CARBURETION 3. If adjustment is necessary, bend the tongue slightly. Be sure float measurement is even on left and right side. Float arms even Bend to adjust float NEEDLE AND SEAT LEAKAGE TEST 1. Install the float bowl. Invert the carburetor and install a Mity-Vact (PN 2870975) to the fuel inlet fitting.

  • Page 112: Fuel Level

    FUEL SYSTEM/CARBURETION FUEL LEVEL Be careful not to damage fuel pump. A fuel level test can be performed on some models if Passenger Side the drain hose fitting is accessible. Be sure to re-attach the bowl drain hose after performing the test.

  • Page 113: Troubleshooting

    FUEL SYSTEM/CARBURETION GJet needle position incorrect 5. Remove the two nuts that secure the tank straps. GIncorrect pilot screw adjustment 6. Pull the straps over the tank. Slide the gas tank out of the tank support. NOTE: The side panel on the right side of the fuel tank RICH MIXTURE may have to be loosened to ease the removal of the Symptoms: Fouls spark plugs, black, sooty exhaust...
  • Page 114 FUEL SYSTEM/CARBURETION GWorn jet needle/needle jet NOTES GPlugged or restricted idle jet Erratic Idle GChoke cable bending or incorrectly adjusted GThrottle cable incorrectly adjusted GAir leaks, dirty carburetor passages (pilot circuit) GPilot mixture screw damaged or adjusted incorrectly GTight valves GIgnition timing incorrect GBelt dragging GDirty air cleaner...
  • Page 115 BODY/STEERING/SUSPENSION CHAPTER 5 BODY AND STEERING Torque Specifications and Special Tools ..Body / Panel Removal ..... . . Cab Frame &...
  • Page 116 BODY/STEERING/SUSPENSION TORQUE SPECIFICATIONS Strut Casting Pinch 15 ft. lbs. (21 Nm) Bolt ITEM TORQUE VALUE Tie Rod End Jam Nut 12-14 ft. lbs. (17-19 Front A-Arm Attaching 30 ft. lbs. (41 Nm) Bolt Tie Rod End Castle 40-45 ft. lbs. (54-61 Front A-Arm Ball Joint 25 ft.

  • Page 117: Body/Panel Removal

    BODY/STEERING/SUSPENSION BODY/PANEL REMOVAL To Remove: Perform These Steps: Seat ..... . . Remove: Pull up on front of seat and then pull forward Console .

  • Page 118: Cab Frame & Seat Exploded View

    BODY/STEERING/SUSPENSION CAB FRAME & SEAT EXPLODED VIEW Cab Frame and Seat Assembly Cab Frame Seat Assembly Seat Belts...

  • Page 119: Frame/Body Assembly Exploded View

    BODY/STEERING/SUSPENSION FRAME/BODY ASSEMBLY EXPLODED VIEW Chassis/Body Assembly Seat Frame Panel RH Floor Support Frame Extension (6x6) Front Cab Support Seat Base Main Frame Oil Tank Bracket Bumper LH Floor Support Grills...

  • Page 120: Body Molding Exploded View

    BODY/STEERING/SUSPENSION BODY MOLDING EXPLODED VIEW Body Molding Dog House Cover Drive Shaft Foil Cover Floor Cover Floor Foil RH Rear Fender Main Floor Main Frame RH Front Fender LH Rear Fender Wheel Well Panel Skid Plate LH Front Fender...

  • Page 121: Hood Exploded View

    BODY/STEERING/SUSPENSION HOOD EXPLODED VIEW Glove Box Assembly Cup Holder Hinge Dash Headlight Hood Hood Latch Strap Hood Liner...

  • Page 122: Cargo Box Exploded View

    BODY/STEERING/SUSPENSION CARGO BOX EXPLODED VIEW Cargo Box Latches & Shafts Tailgate Cover Paddle Latch Tailgate Latch Rod Hinge Cable Bracket Tail/Brake Light Exhaust Shield Reflector Dump Box Shock Bushings Hinge Pin Screw Screws Box Base Spring Box Latch...

  • Page 123: Dash Instruments & Controls

    BODY/STEERING/SUSPENSION DASH INSTRUMENTS AND CONTROLS 1. Storage Box 2. Cup Holder 3. Indicator Lights 4. Light Switch 5. AWD Switch (4x4 & 6x6) 6. Hour Meter 7. Glove Box 8. 12V Acc. Plug 9. Storage Tray 10. Choke Knob 11. Ignition Switch 12.

  • Page 124: Steering Assembly Exploded View

    BODY/STEERING/SUSPENSION STEERING ASSEMBLY EXPLODED VIEW Rod End & Jam Nut Steering Wheel Bushing Wave Washers Screw & Lock Washer Screw & Nut Upper Steering Shaft Tie Rod Bolt Lower Steering Shaft Boots Tie Rod Steering Box End Bolt Apply Loctitet 242 5.10...
  • Page 125 BODY/STEERING/SUSPENSION A- -ARM/STRUT ASSEMBLY EXPLODED VIEW (All MODELS) NOTE: To avoid damage to the tie rod ends and other steering components, be sure to install tie rod Always use new Always use new bolts end bolts in the proper direction. The steering post cotter pins upon upon reassembly arm bolt (B) points up;...

  • Page 126: A-Arm Replacement

    BODY/STEERING/SUSPENSION A-ARM REPLACEMENT (ALL MODELS) 1. Elevate and safely support vehicle with weight removed from front wheel(s). 2. Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud. 3.
  • Page 127 BODY/STEERING/SUSPENSION MID AXLE A-ARM REPLACEMENT (6X6) 1. Elevate and safely support the center of the vehicle with weight removed from center wheel(s). 2. Remove the bolts that secure the shock to the upper and lower mid A--arms. 3. Loosen two bolts on A-arm bushing by alternating each about 1/3 of the way until A-arm can be removed. Perform this procedure on the upper and lower mid A--arms.
  • Page 128 BODY/STEERING/SUSPENSION REAR DRIVE AXLE AND SWINGARM (ALL MODELS) Retaining Wheel 60 ft. lbs. Axle Tube Screw & Washer Ring Bearing (81 Nm) Vehicle Frame 60 ft. lbs. Screw & Washer (81 Nm) Swing Arm Axle Wheel Bearing 150 ft. lbs. (203 Nm) Axle Tube U--Bolt Nut &...

  • Page 129: Rear Axle & Swingarm

    BODY/STEERING/SUSPENSION SWING ARM REMOVAL AND INSTALLATION Swing Arm Removal 1. Support machine on a level surface. 2. Remove rear wheels. NOTE: The rear axle may be removed to ease the removal of the swing arm. Refer to Chapter 7, REAR AXLE HOUSING REMOVAL/INSPECTION.
  • Page 130 BODY/STEERING/SUSPENSION STRUT ASSEMBLY 15 ft. lbs. Strut Bumper (21 Nm) Washer Spacer Rubber Front Strut Top Pivot Ball Spacer Washer Clamp Bottom Pivot Ball 18 ft. lbs. (25 Nm) Spring Retainer Bolt Spring Washer Retaining Ring Bearing NOTE: Grease fitting (2) location. Check lubrication guide for recommended service intervals. 5.16...

  • Page 131: Front Strut Cartridge Replacement

    BODY/STEERING/SUSPENSION FRONT STRUT CARTIDGE REPLACEMENT Refer to Illustration on Page 5.16. 1. Hold strut rod and remove top nut. 2. Compress spring using strut spring compressor tools. Strut Spring Compressor Tools (PN 2871573) and (PN 2871574) 7. Using ball joint removal / installation tool kit (PN 2870871), remove ball joint (F) from strut 3.
  • Page 132 BODY/STEERING/SUSPENSION 9. Apply Loctitet 242 (PN 2871949) to threads of retaining plate screws or install new screws with pre-applied locking agent. Torque screws to 8 ft. lbs. (11 Nm). 10. Install A-arm on ball joint and torque castle nut to 25 ft.

  • Page 133: Box Removal / Installation

    BODY/STEERING/SUSPENSION BOX REMOVAL / INSTALLATION Hinge PIn Box Removal 1. Lift the box into the dump position. 2. Remove the box shock pin from the frame (both sides). 3. Remove the shocks from the shock brackets. Let the shocks fully extend. CAUTION: Safely support the box during the rest of the removal process.

  • Page 134: Decal Replacement

    BODY/STEERING/SUSPENSION DECAL REPLACEMENT area, away from gasoline or other flammable materials. Be sure the area to be flame treated is clean and free Plastic polyethylene material must be “flame treated” of gasoline or flammable residue. prior to installing a decal to ensure good adhesion. To flame treat the decal area: The flame treating procedure can often be used to reduce or eliminate the whitish stress marks that are...
  • Page 135 CLUTCH CHAPTER 6 PVT SYSTEM Service Tools and Supplies ....PVT System Torques ..... PVT System Operation Overview .

  • Page 136: Service Tools And Supplies

    2871226 control engagement (initial vehicle movement), clutch Replacement Tool upshift and backshift. During the development of a Polaris ATV, the PVT system is matched first to the Piston Pin Puller 2870386 engine power curve; then to average riding conditions Clutch 8700220 and the vehicle’s intended usage.

  • Page 137: Pvt Maintenance/Inspection

    CLUTCH DRIVEN CLUTCH OPERATION CONT’D cover. All connecting air ducts (as well as the inner and outer covers) must be properly sealed As engine RPM and horsepower increase, the load to ensure clean air is being used for cooling the from the drive belt increases, resulting in the belt PVT system and also to prevent water and other rotating up toward the outer diameter of the drive...
  • Page 138 CLUTCH PVT OVERHEATING/DIANOSIS During routine maintenance or whenever PVT temperatures. The RANGER should be operated system overheating is evident, it’s important to in D--1 when pulling or plowing heavy loads, or if check the inlet and outlet ducting for obstructions. extended low speed operation is anticipated.

  • Page 139: Pvt Disassembly

    CLUTCH PVT DISASSEMBLY 8. Remove driven clutch retaining bolt and driven clutch. Use the Driven Clutch Puller (PN 2870913) if necessary. NOTE: Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. (See Page 6.7). Driven Clutch Puller (PN 2870913) 1.

  • Page 140: Pvt Assembly

    CLUTCH PVT ASSEMBLY Inner Cover Bolt Torque (Rear): 12 ft. lbs. (16.6 Nm) Outer Cover Bolt Torque: Seal this edge to cover on engine side 45- -50 in.lbs. (5- -5.6 Nm) Driven Clutch Retaining Bolt Torque: 17 ft. lbs. (23.5 Nm) Drive Clutch Retaining Bolt Torque: 40 ft.

  • Page 141: Pvt Sealing And Ducting Components

    CLUTCH PVT SEALING AND DUCTING COMPONENTS Clutch Outlet Duct Inner Cover Clamps Inner Cover Seal Retainer Outer Cover Seal Cover Bolts PVT Outer Cover DRIVE CLUTCH EXPLODED VIEW Drive Clutch Teflont coated brass bushing Teflont coated brass bushing Mark with permanent marker before disassembly...

  • Page 142: Drive Clutch Spring Specifications

    CLUTCH DRIVE CLUTCH SPRING SPECIFICATIONS FULL UPSHIFT NEUTRAL The drive clutch spring has two primary functions: ATV TRAVEL 1. To control clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM.

  • Page 143: Shift Weights

    CLUTCH SHIFT WEIGHTS and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they Shown below are the shift weights which have been may have on belt to sheave clearance, clutch balance designed for, or which may be used in the PVT and shifting pattern.

  • Page 144: Drive Clutch Inspection

    REMOVAL” Page 6.11. clutch assembly! All PVT system maintenance repairs must be performed only by 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...
  • Page 145 CLUTCH 2. Remove cover bolts evenly in a cross pattern, and SPIDER REMOVAL remove cover plate. Cover Bushing Inspection: Replace the cover bushing if more Clutch Holding Fixture: brass than Teflont is visible on the (PN 2871358) bushing. Refer to bushing replacement in this chapter.

  • Page 146: Drive Clutch Assembly

    CLUTCH ROLLER, PIN AND THRUST DRIVE CLUTCH ASSEMBLY WASHER INSPECTION NOTE: It is important that the same number and 1. Inspect all rollers, bushings and roller pins by thickness of washers are reinstalled beneath the pulling a flat metal rod across the roller. Turn roller spider during assembly.

  • Page 147: Drive Belt Tension

    CLUTCH 5. Torque spider to specification using the holding DRIVE BELT TENSION fixture and spider tool. Torque with smooth motion to avoid damage to the stationary sheave. Straight Edge Refer to Page 6.2 for torque specification. 1 1/8² (28.5 mm) CAUTION: Be sure the spider spacer washers are fully seated in the recessed area in the spider.

  • Page 148: Drive Belt Removal/Inspection

    CLUTCH DRIVE BELT REMOVAL/INSPECTION Belt Width: New 1.174 - 1.188² 1. Remove outer PVT cover as described in PVT (2.98-3.02 cm) Disassembly. 2. Mark drive belt direction of rotation so that it can Wear Limit 1.125² (2.86 cm) be installed in the same direction. NOTE: Normally positioned so part numbers are easily 4.

  • Page 149: Drive Belt Installation

    CLUTCH 8. Replace belt if worn past the service limit. Belts 1. Remove belt and install the Clutch Offset with thin spots, burn marks, etc., should be Alignment Tool (PN 2870654) as shown. replaced to eliminate noise, vibration, or erratic 2.

  • Page 150: Drive Clutch Bushing Service

    CLUTCH CLUTCH OFFSET P--90 Driven Clutch 5020631 Cover Bushing Re- moval Tool Offset Alignment Tool Main Puller Adapter 5020632 (PN 2870654) Adapter Reducer 5010279 Number Two Puller 5020633 Adapter DRIVE CLUTCH MOVEABLE SHEAVE - BUSHING 1/8I +0 / -- 1/16 REMOVAL 3.2mm +0 / -- 1.6 mm) Important:...
  • Page 151 CLUTCH 3. Install the Main Puller Adapter (#8) (PN 5020632) onto the Piston Pin Puller (PN 2870386). Bushing (PN 3576504) Loctitet 680 (PN 2870584) 3. Insert the Clutch Bushing Installation Tool (#2) (PN 5020628) into center of sheave and with towers pointing away from vise, slide sheave onto puller rod.

  • Page 152: Driven Clutch Disassembly/Inspection

    CLUTCH 2. From outside of clutch cover, insert the Drive 1. Apply Loctitet 680 (PN 2870584) to the back Cover Bushing Remover (#3) (PN 5020629) into side of new bushing. Working from inside of cover bushing. cover, insert bushing and bushing installation tool into center of clutch cover.
  • Page 153 CLUTCH 6. Inspect ramp buttons in the moveable sheave and replace if worn. NOTE: The ramp buttons are secured by Torxt screws (T20). Belt deflection adjustment washers 1. Apply and hold downward pressure on the helix, or place driven clutch in the Clutch Compression Tool (PN 8700220).

  • Page 154: Driven Clutch Assembly

    CLUTCH DRIVEN CLUTCH ASSEMBLY 4. Line up boss spline and push helix down until it engages the splines 1/2² to 3/4². turn Moveable Spring Example: Helix Sheave Tension - - 1 Heavy Spring/ - - 2 5. While holding downward pressure on helix, wind Position - - 1 moveable...
  • Page 155 CLUTCH 3. Remove ramp buttons from moveable sheave. 6. Install sheave onto puller. 7. Install nut onto puller rod and tighten by hand. Turn puller barrel for further tension if needed. 4. Using a hand held propane torch, apply heat directly on bushing until tiny smoke tailings appear.
  • Page 156 CLUTCH 2. Start new bushing evenly in moveable sheave. Apply Loctitet 680 (PN 2870584) to the back side of new bushing. 8. Repeat installation procedure for other moveable bushing. 3. Install sheave onto puller with new bushing upward as shown. Install the Number Two Puller Adapter (#10) (PN 5020633).

  • Page 157: Troubleshooting

    CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Engine RPM -Wrong or broken drive clutch spring. -Replace with recommended spring. below specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application. range, although engine is prop- -Driven clutch spring broken or installed in -Replace spring;...
  • Page 158 CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Belt slippage -Belt worn out -Replace belt. -Water ingestion -Inspect and seal PVT system. -Belt contaminated with oil or grease -Inspect and clean. Belt burnt, thin -Abuse (continued throttle application when -Caution operator to operate machine within guidelines. spots vehicle is stationary, excess load) -Dragging brake...
  • Page 159 FINAL DRIVE CHAPTER 7 FINAL DRIVE Special Tools and Final Drive Torque Specs ..2x4 Front Hub Removal/Inspection ... . . 7.2--7.3 2x4 Front Hub Installation .
  • Page 160 WHEEL, HUB, AND SPINDLE TORQUE TABLE Model Item Specifica- tion Front Wheel 35 Ft. Lbs. RANGER 2x4 & 4x4 Nuts (47 Nm) Rear Wheel 35 Ft. Lbs. Nuts (47 Nm) Front Spindle 40 Ft. Lbs.
  • Page 161 FINAL DRIVE Inspect the spindle splines for wear. Inspect Spindle Inspect Bearing 4. Apply grease to washer and install with domed side out. 2X4 FRONT HUB INSTALLATION 1. Inspect the hubstrut bearing surface for wear or Cone damage. Washer 2. Apply grease to spindle. 5.
  • Page 162 FINAL DRIVE 10. IInstall brake caliper using new bolts. Tighten bolts to specified torque. Flange Nuts: Flat side against wheel Brake Caliper Bolt Torque 35 ft.lbs. 18 ft. lbs. (24 Nm) (47 Nm) CAUTION: New bolts have a pre-applied locking agent which is destroyed upon removal.
  • Page 163 FINAL DRIVE FRONT HUB REMOVAL/INSPECTION (4X4 & 6X6) 1. 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. Wear eye protection when removing bearings and seals.
  • Page 164 FINAL DRIVE Flange Nuts: Flat side against wheel Cone Washer 5. Install spindle nut and tighten to specification. Front Wheel Nut Torque 35 ft. lbs. (47 Nm) FRONT HUB BEARING REPLACEMENT (4X4 & 6X6) 6. Install a new cotter pin. Tighten nut slightly if 1.
  • Page 165 FINAL DRIVE support casting on outer edges so bearing can be 4. Inspect bearing. removed. 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 166 FINAL DRIVE FRONT DRIVE AXLE 5. Remove wheel. 6. Remove hub. REMOVAL (4X4 & 6X6) 1. 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 167 FINAL DRIVE 4. Install hub and tighten spindle nut to 40 ft. lbs. (55 Nm). Front Spindle Nut Torque 40 ft. lbs. (55 Nm) DRIVESHAFT AND CV JOINT HANDLING TIPS Care should be exercised during driveshaft removal or when servicing CV joints. Driveshaft components are precision parts.
  • Page 168 FINAL DRIVE FRONT DRIVE SHAFT CV JOINT BOOT REPLACEMENT Retaining ring 1. Remove wheel, brake caliper and wheel hub. Refer to front hub disassembly Page 7.5 for procedure. 2. Remove cotter pin and castle nut from A-arm ball joint. Pull shaft to remove from CV joint 6.
  • Page 169 FINAL DRIVE clamp. FRONT PROP SHAFT REMOVAL (4X4 & 6X6) CV Joint Grease - 30g PN 1350046 CV Joint Grease - 30g PN 1350046 1. Elevate front end and safely support machine under footrest / frame area. CV Boot Clamp Pliers: CV Boot Clamp Pliers: Earless Type 8700226...
  • Page 170 FINAL DRIVE Roll Pin Removal Tool (PN 2872608) NOTE: Remove the drive shaft floor cover to help align the roll pin removal tool to the roll pin for removal. The drive shaft can be removed through the floor covering. 2. Support inner yoke as shown and drive outer yoke down (bearing cap out) with a soft face hammer.
  • Page 171 FINAL DRIVE 4. Force U-joint cross to one side and lift out of inner yoke. U-JOINT ASSEMBLY 4. Install outer yoke, aligning marks made before disassembly. 5. Repeat Steps 1-3 to install bearing caps on outer yoke. 1. Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft.
  • Page 172 FINAL DRIVE FRONT GEARCASE the same speed the front wheels will overdrive the output hubs and the rollers are forced outward, OPERATION FOR (4X4 & 6X6 disengaging AWD. The vehicle is now back to rear wheel drive. - - CENTRALIZED HILLIARD) Roller Cage and Bearing’s Rotate Inward and Grip the Output Hub for AWD Engagement Normal Operation: With the AWD switch off the...
  • Page 173 FINAL DRIVE Gearcase Coil Resistance NOTE: To test the gearcase coils resistance, use the coil harness. The gearcase coils should measure between 22.8 ohms and 25.2 ohms. 6. Repeat Step 1 through Step 5 on the opposite side. 7. Pull each axle out from the front gearcase. 8.
  • Page 174 FINAL DRIVE 5. Remove the roll cage assembly, rollers, and H--springs. H--spring 9. Remove the ring gear (C), the output hub (D), the 6. Thoroughly clean all parts. Inspect the rollers (A) shim (E), and the armature plate (F) from the for nics and scratches.
  • Page 175 FINAL DRIVE 12. Remove the other output hub from the main gearcase. FRONT GEARCASE ASSEMBLY/INSPECTION (4X4 & 6X6) 1. Replace all O--rings, seals, and worn components. 2. Press the pinion shaft seal into the pinion cover, until the seal is flush with the sealing surface. 3.
  • Page 176 FINAL DRIVE 8. Install the shim onto the ring gear. Cover Bolts Torque 14 ft. lbs. (19 Nm) 5. Install the output hub into the gearcase housing. The output hub should spin freely. 9. Install the armature plate onto the ring gear. NOTE: Be sure armature plate tabs are placed into the slots on roll cage.
  • Page 177 FINAL DRIVE 13. Install the drain plug and torque the drain plug to 11. Install output cover with new o-ring and torque 14 ft.lbs. (19 Nm). bolts to 14 ft. lbs. (19 Nm). 14. Set the gearcase on a level surface. Remove the fill plug and fill the gearcase with 5 oz.
  • Page 178 FINAL DRIVE FRONT GEARCASE bands (one band inside the other). If only one band of wear is present (or if there is wear INSTALLATION (4X4 & 6X6) between the two bands, inspect the coil area as indicated in Step 4. A band with an interrupted 1.
  • Page 179 FINAL DRIVE 5. Inspect the rollers for nics and scratches. The rollers must slide up and down and in and out freely within the roll cage sliding surfaces. Gearcase Cover Coil U--shaped insert Side Cutaway View of Centralized Hilliard Cover Rollers 7.21...
  • Page 180 FINAL DRIVE FRONT GEARCASE EXPLODED VIEW Ref. Qty. Description Ref. Qty. Description 1 Asm., Mid Gearcase 1 O--Ring 1 Cover, Output 1 Seal 1 O--Ring 11 Kit, Bolt 1 Insert 1 Cover, Input 1 Coil 1 Bearing, Roller Ball 1 Kit, Shim Set (Incl. Shims) 1 Shaft, Pinion, 11T 2 Bearing, Roller Ball 1 Bushing...
  • Page 181 FINAL DRIVE MID DRIVE BEARING CARRIER/HUB REMOVAL 4. Remove the hub nut, domed washer, and flat washer. (6X6) 1. Lock the emergency parking brake. Safely raise the center of the machine with a floor jack. Raise the machine just enough to remove the middle wheel.
  • Page 182 FINAL DRIVE 6. Remove the upper control arm bolt. 3. Install and torque both lower control arm bolts. 7. Remove the both lower A--arm bolts. Lower Control Arm Bolt Torque: 8. Remove the bearing carrier from the A--arm 40 ft. lbs. (54 Nm) assembly.
  • Page 183 FINAL DRIVE 5. Pull drive shaft outward and install hub onto driveshaft splines. Rear Hub Nut Torque: 110 ft. lbs. (149 Nm) Rear Wheel Nut Torque 35 ft. lbs. (47 Nm) 9. Install a new cotter pin. Tighten nut slightly to align holes if required.
  • Page 184 FINAL DRIVE 2. Start bearing (B) in housing (A). 3. Inspect bearing. 3. Press bearing into place until outer race bottoms on NOTE: Due to extremely close tolerances and housing. minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, CAUTION: inspect for rough spots, discoloration, or corrosion.
  • Page 185 FINAL DRIVE MID DRIVE HUB EXPLODED VIEW (6X6) BUSHING MID UPPER A--ARM BEARING CARRIER MID DRIVE AXLE BEARING SHAFT BUSHING BUSHING SNAP RING MID LOWER A--ARM MID DRIVE SHAFT REMOVAL (6X6) 1. Repeat Steps 1--6 in the “MID DRIVE BEARING spring pin secures the yolk of the middle axle to CARRIER/HUB REMOVAL”...
  • Page 186 FINAL DRIVE 4. Pull the middle axle (C) straight out of the frame. middle driveshaft (A) onto the middle gearcase output shaft. Be sure to align the roll pin holes of the middle driveshaft (A) and middle gearcase. 3. Install a new roll pin to secure the middle driveshaft (A) to the middle gearcase.
  • Page 187 FINAL DRIVE 5. Install hub, flat washer, domed washer (domed side 6. Install rear wheel and torque wheel nuts to out) and nut. Torque center nut to 110 ft. lbs. (149 specification. Nm). Install new cotter pin and hub cap. 110 ft.
  • Page 188 2. Install the drive shaft boot on one of the drive shaft halves. 3. Grease the splines of the shaft with Polaris Premium U--Joint Grease (PN 2871551). 4. To prevent driveline vibration, the inner and outer yokes must be aligned properly. Assemble the rear drive shaft , aligning the inner and outer yokes and grease fittings.
  • Page 189 FINAL DRIVE MID DRIVE GEARCASE REMOVAL CLAMPS T--FITTING VENT LINES MID DRIVE GEARCASE COUPLER MID DRIVESHAFT MOUNTING BOLTS & WASHERS (4) Vent Tube NOTE: To ease the removal of the middle axle gearcase, remove the box from the frame. Refer to the Box Removal Procedure in Chapter 5.
  • Page 190 FINAL DRIVE MID DRIVE GEARCASE DISASSEMBLY 1. Drain the oil from the mid drive gearcase. Properly dispose of the oil. 2. Remove the output cover bolts (A) and the output cover (B). 5. Remove the wave spring (G) from the gearcase assembly.
  • Page 191 FINAL DRIVE 6. Remove the bolts from the input cover (H). 9. Inspect the pinion gear (K) and 26T output gear (L) 7. Remove the input cover bolts (I). Remove the input for nics or uneven wear. Inspect the bearing (M), cover (H) and pinion gear assembly from the the bearing should spin smoothly.
  • Page 192 FINAL DRIVE chipped teeth. 11. Remove the retaining ring (O) and shim (P) from 14. Inspect the two flange bearings (S) inside the the rear output thru shaft. gearcase. Inspect the pinion shaft bushing (T) for wear that is inside the gearcase. 12.
  • Page 193 FINAL DRIVE 3. Assemble the pinion shaft assembly (if previously disassembled). Install the 26T gear (G) and bearing (H) onto the pinion shaft (I). NOTE: When replacing the 26T output, be sure the step of the gear is facing towards the bearing (See Below and next page).
  • Page 194 FINAL DRIVE 5. Apply Polaris Crankcase Sealant (PN 2871557) to Pinion Shaft Assembly Assembled the inside surface of the input cover (J). Sealant 4. Install the pinion shaft assembly into the input 6. Install the pinion shaft assembly and input cover cover.
  • Page 195 FINAL DRIVE 7. Install the wave spring (L) into the gearcase assembly. Be sure the wave spring is fully seated into the bearing cup of the gearcase. 10. Install a new O--ring (O) onto the output cover. 8. Install the output shaft and ring gear into the gearcase.
  • Page 196 12. Remove the fill plug (P) and fill the mid gearcase Fill Plug Torque: 14 ft. lbs. (19 Nm) with 6.75 oz. (200 ml) of Polaris Gearcase Lube (PN 2871653). Torque the fill plug to 14 ft. lbs. (19 Nm).
  • Page 197 FINAL DRIVE MID DRIVE GEARCASE INSTALLATION VENT TUBE MIDDLE GEARCASE ROLL PIN COUPLER MOUNTING BOLTS FRAME ROLL PIN (2) MIDDLE DRIVESHAFT (2) 1. Place the middle gearcase in the frame assembly. 2. Install the coupler to the middle gearcase, but do not install the new roll pin yet.
  • Page 198 FINAL DRIVE MID DRIVE GEARCASE EXPLODED VIEW (6X6) 12. 13. 10. 11. Ref. Qty. Description Ref. Qty. Description 1 Asm., Mid Gearcase 1 Seal, Triple Lip 15 Screw 2 Ring, Retaining 3 Plug 2 Washer, Thrust 2 Seal 2 Bushing 1 Tube, Vent 1 Gearcase, R11 1 Cover, Output...
  • Page 199 FINAL DRIVE REAR HUB INSPECTION 5. Pull the hub off of the axle. 1. Support machine securely with rear wheels elevated. 2. Grasp wheel/hub and check for movement. 3. If movement is detected, inspect hub, hub nut torque and bearing condition and correct as necessary.
  • Page 200 FINAL DRIVE reassembly. Mark U--bolt Positions 10. Remove the two bolts that secure the rear axle housing to the frame. 12. Loosen the four U--bolts. Loosen each U--bolt nut a few turns at a time, this will reduce stress on all of the U--bolts during U--bolt removal.
  • Page 201 FINAL DRIVE 13. With the U--bolts removed, carefully lower the rear 17. Remove the axle and axle tube’s from the rear axle assembly from the frame. Pull the axle gearcase. Note the placement of the axle spacer assembly out from the frame. seals for placement during reassembly.
  • Page 202 FINAL DRIVE Bearing Removal/Installation NOTE: The bearing should be properly lubricated before installation. 20. Remove the retaining ring from the axle tube. 23. Reinstall the retaining ring. REAR AXLE HOUSING INSTALLATION 1. Lube the splines of the rear gearcase with anti--seize.
  • Page 203 FINAL DRIVE 4. Fit the rear axle assembly up to the frame. Slide the NOTE: Use a floor jack to help align the rear axle rear driveshaft yoke onto the rear gearcase input assembly for the U--bolt installation. shaft. Driveshaft Yoke U--bolt Alignment Marks 7.
  • Page 204 FINAL DRIVE 9. Torque the U--bolts nuts to 40 ft.lbs. (54 Nm). 11. Reinstall the vent hose and clamp to the rear gearcase housing. 12. Apply anti--seize to the splines of the axle. 40 ft.lbs. (54 Nm) Reinstall the hub onto the axle. Reinstall the domed washer, and spindle nut onto the axle.
  • Page 205 FINAL DRIVE 15. Install the tire and four wheel nuts. Torque the REAR DIFFERENTIAL castle nut and the wheel nuts to specifications. REMOVAL 1. Refer to Steps 1--17 in the REAR DIFFERENTIAL REMOVAL/INSPECTION section Page 7.41--7.43 for the removal of the rear gearcase. REAR DIFFERENTIAL DISASSEMBLY (2X4 &...
  • Page 206 FINAL DRIVE 4. Remove the shift dog from the output shaft. 6. Remove retaining ring and the shim from the ring gear. 7. Remove the pinion gear cover and the pinion shaft 5. Remove the ring gear from the differential housing from the differential housing.
  • Page 207 FINAL DRIVE Rear Differential Actuator Removal REAR DIFFERENTIAL 8. With two small prybars or suitable tools, pry up and ASSEMBLY (2X4 & 4X4) outward on the actuator arm. Lift the actuator arm 1. Inspect the pinion shaft bushing for wear. out of the differential cover.
  • Page 208 FINAL DRIVE 3. Install the pinion shaft into the differential housing. Retaining Ring Groove Install a new O--ring onto the pinion shaft cover. Install the cover and torque the cover bolts to 20 ft. lbs. (27 Nm). Install Actuator Pinion Gear Cover New O--ring 4 Bolts 5.
  • Page 209 FINAL DRIVE 6. Install the ring gear into the differential housing. 9. Lubricate the shim with grease and place the shim 7. Install a new O--ring onto the lip of the gearcase in the differential housing cover. housing. NOTE: The O--ring is a smaller diameter than the gearcase.
  • Page 210 20 ft. lbs. (27 Nm) REAR DIFFERENTIAL INSTALLATION 1. Refer REAR AXLE HOUSING INSTALLATION section on Pages 7.44--7.45 for the installation of the rear gearcase and axle. 2. Add Polaris Premium Gearcase Lubricant (PN 2871477) to rear gearcase. Refer to Chapter 2 for 7.52...
  • Page 211 FINAL DRIVE REAR DIFFERENTIAL EXPLODED VIEW (2X4 & 4X4) Ref. Qty. Description Ref. Qty. Description 1 Asm., Rear Gearcase 1 Spring, Torsion 1 Seal 1 Washer 1 Cover, Input 1 Pin, Clip 1 O-Ring 1 Seal 1 Bearing, Ball 1 Actuator 1 Pinion, 10T 1 O-Ring 1 Bushing...
  • Page 212 FINAL DRIVE REAR DIFFERENTIAL OPERATION (2x4 & 4x4) NOTE: The pictures below show a cutaway view of Differential in Locked Position the rear differential for display purposes only. 1. The rear differential on the can be in a locked When the rear differential is in the locked position the position or an unlocked position.
  • Page 213 FINAL DRIVE Differential in Unlocked Position Engagement Dog in Un- 4. Illustration 4 shows the lever down. The rear differential is now in the unlocked position. Locked Position Lever in Unlocked Position Ill. 6 Ill. 4 5. Illustration 5 shows the actuator on the rear differential in the unlocked position.
  • Page 214 FINAL DRIVE REAR DIFFERENTIAL LINKAGE INSPECTION/ADJUSTMENT Rear Differential Linkage rod adjustment is necessary when symptoms include: The rear differential does not go into the “Locked Position” The rear differential does not go into Back Off Both Jam Nuts the “Unlocked Position” Excessive gear clash (Continuous clicking noise...
  • Page 215 FINAL DRIVE DIFFERENTIAL LOCK LEVER Tighten Jam Nuts REMOVAL/INSTALLATION (2X4 & 4X4) 1. Disconnect linkage cable from lock differential. Bracket 2. Remove the cotter key, washers and bushings that attach lock differential to the cable and frame. 3. Pull off the shifter knob. 4.
  • Page 216 FINAL DRIVE REAR DIFFERENTIAL 4. Remove the output shaft and ring gear from the differential. Inspect the ring gear for abnormal DISASSEMBLY (6X6) wear, broken, or chipped teeth. Inspect the bearings for wear. Spin the bearings by hand, the 1. Drain and properly dispose of used oil. bearings should roll smoothly.
  • Page 217 FINAL DRIVE 6. Remove the four bolts that secure the pinion gear 8. Inspect the pinion shaft bushing for wear. cover to the differential. Remove the pinion gear cover and O--ring. Pinion Gear Cover O--ring 4 Bolts REAR DIFFERENTIAL 7. Remove the pinion shaft from the differential. ASSEMBLY (6X6) Inspect for abnormal wear, broken, or chipped teeth.
  • Page 218 FINAL DRIVE 2. Install the pinion shaft into the differential housing. 4. Install the wave spring into the differential assembly. Be sure to properly seat the wave spring into the differential. 3. Replace the pinion shaft cover O--ring and install the cover.
  • Page 219 REAR AXLE HOUSING INSTALLATION section on Pages 7.44--7.45 for the installation of the rear gearcase and axle. 2. Add Polaris Premium Synthetic Gearcase Lubricant (PN 2871447) to rear gearcase. Torque the drain plug to 14 ft. lbs. (19 Nm). Fill Plug 7.
  • Page 220 FINAL DRIVE REAR DIFFERENTIAL EXPLODED VIEW (6X6) Ref. Qty. Description Ref. Qty. Description 1 Asm., Rear Gearcase 1 Bearing, Ball 1 Seal 1 Shaft, Output 1 Cover, Input 1 Gear, Ring 37T 1 O-Ring 1 Bearing, Ball 1 Bearing, Ball 1 Plug, Expansion 1 Pinion, 10T 3 Clip...
  • Page 221 TRANSMISSION CHAPTER 8 TRANSMISSION SERVICE Torque Specifications/Lubrication ... Gear Shift Selector Removal/Installation ..Shift Linkage Adjustment ....8.2--8.3 Transmission Removal .
  • Page 222 TRANSMISSION Shift Lever TORQUE SPECIFICATIONS Transmission Case Bolts ..20 ft. lbs. (27 Nm) Bell Crank Nut ....15 ft. lbs. (20 Nm) Transmission Drain Plug .

  • Page 223: Transmission Removal

    TRANSMISSION 1. Inspect shift linkage cable, clevis pins, and pivot bushings and replace if worn or damaged. Inside Jam Nut Clockwise 2. Be sure idle speed is adjusted properly. 3. Place gear selector in neutral. Make sure the transmission bell crank is engaged in the neutral position detents.
  • Page 224 TRANSMISSION transmission. 6. Loosen the jam nuts for the transmission cable. Remove the cable from the mounting bracket. Vent Tube & Air Intake Hose Jam Nuts 4. Disconnect the transmission switch. 7. Remove mounting bolts from transmission mounting on both sides of the transmission.
  • Page 225 TRANSMISSION 8. Remove the four bottom transmission to frame bolts. 9. Remove the rear transmission to frame bolt. 10. Remove front transmission-to-engine mount bolt. General Transmission Mounting Front 11. Remove transmission from right side of frame.

  • Page 226: Transmission Installation

    TRANSMISSION TRANSMISSION INSTALLATION Transmission Mounting 1. Install transmission from right side of vehicle. Bolts Torque 2. Position transmission in frame. 25 ft. lbs. (34.5 Nm) 3. Loosely install the front transmission to frame bolts. NOTE: Be sure to tighten the lower transmission 4.

  • Page 227: Transmission Disassembly

    TRANSMISSION TRANSMISSION DISASSEMBLY NOTE: The following disassembly procedure shows the 4x4 transmission disassembly. Follow the same procedure for the 2x4 and 6x6 Shift Shaft transmission disassembly. The transmissions are very similar. Refer to the exploded views at Cover the end of this chapter. 1.
  • Page 228 TRANSMISSION Spacer 6. Remove the shift shaft and detent lever. 8. Remove the bolts on the LH transmission case. Tap the cover off with a soft face hammer if necessary. 7. Note the timing marks on the shift gears. Remove the shift gears from the case.
  • Page 229 TRANSMISSION forks’ pins disengage from the drum. 12. Set the upper gear cluster on a flat surface and inspect the components. 10. Remove the shift drum. NOTE: You may have to tap the shift drum from the backside of the case to aid in removal. 13.
  • Page 230 TRANSMISSION have a regular shift dog in the location indicated by the arrow in the photo. Shift Fork 17. Remove the snap ring and washer from the 14. Remove the bearing from the reverse shaft with a reverse shaft. puller. 15.
  • Page 231 TRANSMISSION 20. Remove the rest of the bearings from the shafts. 23. Remove the gear, split bearing, and washer from the reverse shaft. 21. Use a press to remove the gear from the shaft. 24. Slide off the shift dogs and wave springs. 22.
  • Page 232 TRANSMISSION 28. Remove the front housing cover screws. 26. Remove bearing and the helical gear. 29. Remove the front housing cover, shim, thrust button, and thrust button shim. 27. Remove the pinion shaft retainer plate and the pinion shaft. 8.12...

  • Page 233: Transmission Assembly

    Note Location of Hubs 3. Before installing the cover make sure the sealing surfaces are clean and dry, and shafts are fully seated in the transmission case. Apply Polaris Crankcase Sealant to the mating surfaces. 35. Remove seals from transmission case.
  • Page 234 TRANSMISSION 8. Apply Loctitet 262 (Red) (PN 2871951) to screw threads and torque screws to 6--12 ft. lbs. (8--16 Nm). Crankcase Sealant (PN 2871557) 4. Reinstall the thrust button shim, thrust button, and other shims into the cover. Reinstall cover and Pinion Retainer Plate torque bolts in a criss-cross pattern in 3 steps to Bolt Torque:...
  • Page 235 TRANSMISSION 11. Slide the reverse shaft assembly through the silent chain. 16. Carefully install the shaft assembly and gear cluster as a unit into their respective bearing case recesses. Tap with a soft face hammer to seat shaft assemblies. 12. Install a new needle bearing, the low gear, the thrust washer and the snap ring.
  • Page 236 TRANSMISSION 18. Replace and grease the O--ring’s on the shift 21. Install the helical gear and bearing onto the pinion drum before installation. shaft. 22. Clean the mating surfaces of the case and cover. Apply Crankcase Sealant (PN 2871557) to the mating surfaces.
  • Page 237 TRANSMISSION Transmission Detent Star Drain Plug 14--18 ft.lbs. (19--24 Nm) Keyed Spline Drain Plug Torque: 14- - 18 ft. lbs. (19- - 24 Nm) 28. Install the detent pawl and spring. Install a new o--ring onto the shift shaft after the detent pawl is 25.

  • Page 238: Troubleshooting

    If it functions properly, the problem is outside the transmission. If transmission problem remains, disassemble 31. Install transmission and add Polaris Premium transmission and inspect all gear dogs for wear Synthetic Gear Case Lubricant (PN 2871477) in (rounding), damage. Inspect all bearings, circlips, recommended amount.

  • Page 239: 2X4 Transmission, Exploded

    TRANSMISSION 2X4 TRANSMISSION EXPLODED VIEW 17 18 34 35 36 47 48 49 8.19...
  • Page 240 TRANSMISSION 2X4 TRANSMISSION EXPLODED VIEW, CONT. Ref. Qty. Description Ref. Qty. Description 1 Asm., 2x4 Transmission 1 Sprocket, 24T 1 Washer, Flat 1 Washer 5 Screw 1 Washer 1 Cover 1 Gear, 30T 1 Pawl, Detent 1 Gear, 37T 1 O- - Ring 1 Gear, 47T 1 Shaft, Shift 4 Screw...

  • Page 241: 4X4 & 6X6 Transmission, Exploded

    TRANSMISSION 4X4 &6X6 TRANSMISSION EXPLODED VIEW 33 34 29 30 *NOTE: Callout 38B is not included in *NOTE: Callouts 68A and 69A the 4x4 transmission, only the 6x6 trans- are only on the 4x4 transmission. mission. 8.21...
  • Page 242 TRANSMISSION 4X4 & 6X6 TRANSMISSION EXPLODED VIEW, CONT. Ref. Qty. Description Ref. Qty. Description 1 Asm., 4x4 & 6x6 Transmission 1 Gear, 47T 1 Nut 1 Screw 5 Screw 1 Cover, Bearing 1 Cover 38B. 1 Ring, Retaining (6x6 only) 1 Pawl, Detent 1 Spacer 1 O- - Ring...
  • Page 243 BRAKES CHAPTER 9 BRAKES Special Tools/Specifications/Torques ... Brake System Service Notes ....Brake Noise Troubleshooting .
  • Page 244 BRAKES SPECIFICATIONS Front Brake Caliper Item Standard Service Limit .298 ± .0073² / 7.56 ± .185 mm Brake Pad Thickness .165² (4.19 mm) Brake Disc Thickness .150 -.165² ( 3.810 - 4.19mm) .140² (3.556mm) Brake Disc Runout .005² (.127mm) Rear Axle Brake Caliper Item Standard Service Limit...

  • Page 245: Brake System Service Notes

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

  • Page 246: Hydraulic Brake System Operation

    When servicing Polaris brake systems use only Polaris DOT 3 Brake Fluid (PN 2870990) or DOT 4 Brake Fluid. Polaris brake fluid is sold in 5.5 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. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture.

  • Page 247: Brake System Exploded View

    BRAKES BRAKE SYSTEM EXPLODED VIEW Left Front Brake Line Master Cylinder MC Front Brake Line Fitting Tee LH Rear Line Brake Switch Tee Line Screws Banjo Bolt & Seals MC Rear Brake Line Right Front Brake Line RH Rear Line Front Caliper Rear Caliper FRONT BRAKE PEDAL REMOVAL / INSTALL...
  • Page 248 Mity Vac (PN 2870975) 4. Add brake fluid to the indicated MAX level of reservoir. Master Cylinder Fluid Level Polaris DOT 3 Brake Fluid (PN 2870990) Between the MIN line and the MAX line of reservoir. DOT 4 Brake Fluid...

  • Page 249: Parking Brake And Brake Line Inspection

    BRAKES 12. Install master cylinder reservoir cover. 13. Field test machine at low speed before putting into service. Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than 1/2² (1.3 cm). 14.
  • Page 250 BRAKES 2. Carefully lift the rear of the vehicle off the ground 4. Tighten the adjustment bolt (C) until the rear tire and stabilize on jack stands. will not rotate. 3. Loosen the jam nut (B) on the rear caliper 5.

  • Page 251: Parking Brake Lock Exploded View

    BRAKES PARKING BRAKE LOCK EXPLODED VIEW Parking Brake U--bolt Main Parking Handle Brake Cable Washer Catch Spring Clevis Pin Catch Bushing Catch Plate Washer & Cotter Pin Spring Bushing Foot Lever Washer & Cotter Pin Washer Cotter Pin Nylok Nut Brake Lever Nut Equalizer and Pin Assembly...

  • Page 252: Front Pad Removal

    BRAKES FRONT PAD REMOVAL 1. Elevate and support front of machine. CAUTION: Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 5. Push upper pad retainer pin inward and slip outer brake pad past edge.

  • Page 253: Front Pad Assembly

    Service Limit: 150² / 3.81 mm FRONT PAD ASSEMBLY 1. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots. Front Caliper Mounting Bolts Torque 18 ft. lbs. (25 Nm) 4. Slowly pump the brake pedal until pressure has been built up.

  • Page 254: Front Disc Inspection

    BRAKES extend service life and reduce noise. Start machine and slowly increase speed to 30 mph. Master Cylinder Fluid Gradually apply brakes to stop machine. Repeat procedure 10 times. Up to MAX line inside reservoir Front Wheel Nut Torque: 3. Install wheels and torque wheel nuts. 20 ft.

  • Page 255: Front Caliper Removal

    BRAKES Bolts 18 ft. lbs. (25 Nm) Disc FRONT CALIPER 2. Clean mating surface of disc and hub. DISASSEMBLY 3. Install disc on hub. 4. Install new bolts and tighten to specified torque. 1. Remove brake pad adjuster screw. CAUTION: Always use new brake disc mounting 2.

  • Page 256: Front Caliper Inspection

    BRAKES 5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. Front Caliper Piston O.D. NOTE: Be sure to clean seal grooves in caliper body. Std. 1.4985-1.5000² (38.062-38.10 mm) Service Limit 1.4980² (38.049 mm) FRONT CALIPER INSPECTION 3.

  • Page 257: Front Caliper Exploded View

    BRAKES 3. Lubricate the mounting bracket pins with Polaris 4. Compress the mounting bracket and make sure Premium All Season Grease, and install the the dust seals are fully seated. Install the pads as rubber dust seal boots. shown on Page 9.11--9.12. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.

  • Page 258: Front Caliper Installation

    BRAKES FRONT CALIPER INSTALLATION 1. Install caliper on hub strut, and torque mounting bolts. Front Wheel Nut Torque: 35 ft. lbs. (47 Nm). NOTE: If new brake pads are installed, it is recommended that a burnishing procedure be performed to extend pad service life and reduce noise.

  • Page 259: Rear Brake Pad Installation

    BRAKES or bend brake line. Measure Thickness Remove Caliper Bolts Rear Brake Pad Thickness .298 ± .0073² (7.56 ± .185 mm) Service Limit .165² (4.19 mm) 5. Push caliper piston into caliper bore slowly with pads installed. NOTE: Brake fluid will be forced through REAR BRAKE PAD compensating port into master cylinder fluid reservoir when piston is pushed back into caliper.
  • Page 260 BRAKES 2. Install caliper and torque mounting bolts. Rear Brake Caliper: Torque 18 ft. lbs. (24.9 Nm) 3. Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2² (12.7 mm) of brake fluid in the reservoir to prevent air from entering the master cylinder.
  • Page 261 BRAKES Parking Brake Cable Assembly Parking Brake Cable Assembly 5. Remove the two brake caliper assembly attaching bolts. 3. Lift the plunger, washer, and compression spring from the caliper body. Inspect components and 6. Clean disc, caliper body, and pistons with brake replace if needed.
  • Page 262 Be sure grooves are clean and free of residue. Rear Caliper Piston Bore I.D. Std. 1.2550-1.2540² (31.877-31.852 mm) 4. Lubricate the mounting bracket pins with Polaris Service Limit 1.256² (31.902 mm) Premium All Season Grease, and install the rubber dust seal boots.
  • Page 263 BRAKES Gasket 6. Install the spring , washer, and plunger into the caliper assembly. 8. Install the emergency brake actuator onto the caliper body. Be sure the gasket holes line up with the caliper body holes and emergency brake Spring and actuator holes, to ensure no damage is done to Plunger the gasket.
  • Page 264 BRAKES 9. Tighten the screws on the caliper assembly. 12. Install caliper and torque mounting bolts. Install brake lines and tighten with a flare nut wrench. 10. Reinstall the emergency brake cable and assembly onto the brake caliper. Secure the emergency brake cable with the nut and bolt.

  • Page 265: Rear Brake Caliper Exploded View

    BRAKES REAR BRAKE CALIPER EXPLODED VIEW HEX BOLT DURING ASSEMBLY PLUNGER JAM NUT APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT LEVER WASHER APPLY POLARIS ALL PURPOSE GREASE BRACKET BLEED SCREW HOUSING COMPRESSION 35--60 IN. LBS. SPRING (4--6.5 NM) ADJ.

  • Page 266: Troubleshooting

    BRAKES 6. Field test unit for proper braking action before Rear Brake Disc putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. 7.
  • Page 267 ELECTRICAL CHAPTER 10 ELECTRICAL Special Tools/Service Notes ....10.2 Timing Check Procedure ..... 10.3 Coolant Sensor Tests .
  • Page 268 ELECTRICAL SPECIAL TOOLS Ohms, remember to subtract meter lead resistance from the reading. Connect the leads together and record the resistance. PART NUMBER TOOL The resistance of the component is equal DESCRIPTION to tested value minus the lead resistance. PV- -43568 Fluket77 Digital GBecome familiar with the operation of your Multimeter...

  • Page 269: Electrical

    ELECTRICAL TIMING CHECK PROCEDURE Stator Adjustment 1. Remove the magneto housing. 1. The ignition timing check hole is in the starter 2. Remove the flywheel. recoil/magneto housing. Remove the check plug. 3. Loosen the stator plate screws and adjust the NOTE: NOTE: The ignition timing marks are...
  • Page 270 ELECTRICAL COOLANT TEMPERATURE Motor Testing this section). Repair or replace as necessary. SENSOR TEST (HOT LIGHT) FAN MOTOR CURRENT DRAW With the ignition switch (and engine stop switch) “ON”, power is delivered to the hot light via the Red/White A current draw test will provide a good indication of fan wire.

  • Page 271: Flywheel I.d

    ELECTRICAL the chart, and stay conductive until the “OFF” temperature is reached. Flywheel Identification Stamp Location REFER TO PARTS MANUAL FOR FAN SWITCH APPLICATION Fan Switch Continuity No Continuity Part Number (On) (Off) 4010161 180° F (82° C) 149° F (65° C) ±...
  • Page 272 ELECTRICAL COMPONENTS OF 200/250 WATT ALTERNATOR NOTE: CDI boxes may look the same but have different internal circuitry. Be sure to always use the correct CDI box part number. Ignition Coil Primary Winding Resistor Ignition Kill Meter Wire .3 W (Black) 200 W (3 wires)

  • Page 273: 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.

  • Page 274: Ignition System Troubleshooting

    ELECTRICAL IGNITION SYSTEM CDI CRANKING OUTPUT TROUBLESHOOTING TEST WITH PEAK READING VOLTMETER No Spark, Weak or Intermittent Spark GSpark plug gap incorrect The following peak voltage tests will measure the GFouled spark plug amount of output directly from each component. A peak reading voltmeter must be used to perform the GFaulty spark plug cap or poor tests.
  • Page 275 ELECTRICAL 5. Increase engine RPM while observing ammeter and tachometer. Current Draw Inspection 6. Note RPM at which the battery starts to charge Key Off (ammeter indication is positive). 7. With lights and other electrical load off, the “break even” point should occur at approximately 1500 RPM or lower.

  • Page 276: Charging System Testing

    ELECTRICAL CHARGING SYSTEM TESTING FLOW CHART Whenever charging system problems are suspected, proceed with the following system check. Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage (See Remove the battery and properly ser- Page 10.12). It should be 12.4 volts or vice.
  • Page 277 TERMINALS/TERMINAL BOLTS sulfuric acid. Serious burns can result from con- tact with skin, eyes or clothing. Antidote: Use Polaris corrosion resistant Dielectric Grease (PN External: Flush with water. 2871329) on battery bolts. See Battery Installation on Internal: Drink large quantities of water or milk.
  • Page 278 ELECTRICAL OCV - OPEN CIRCUIT CAUTION VOLTAGE TEST Whenever removing or reinstalling the battery, disconnect the negative (black) cable first and Battery voltage should be checked with a digital reinstall the negative cable last! multitester. Readings of 12.6 volts or less require 3.
  • Page 279 ELECTRICAL GCharge at a rate no greater than 1/10 of SPECIFIC GRAVITY the battery’s amp/hr capacity until State of Conventional YuMicront the electrolyte’s specific gravity charge* lead-acid Type reaches 1.270 or greater. GStore the battery either in the machine 100% 1.265 1.275 Charged...
  • Page 280 ELECTRICAL 6. Install clear battery vent tube from vehicle to drop should be 8² (20.3 cm) in 25’ from the center battery vent. WARNING: Vent tube must be free of the low beam lamp. from obstructions and kinks and securely GTurn the right screw clockwise to adjust installed.

  • Page 281: Brake Light Switch

    ELECTRICAL 2. Remove lamp by turning the rubber base 1/4 turn block. The brake pressure switch is installed into and pulling the bulb out. Replace it with this block. recommended lamp. Apply Dielectric Grease (PN 2871329). Brake Switch 3. Reinstall the lens cover removed in step 1. 4.

  • Page 282: Indicator Lamp Replacement

    ELECTRICAL GBattery discharged - low specific INDICATOR LAMP gravity REPLACEMENT GExcessive circuit resistance - poor connections (see Voltage Drop Test 1. Disconnect indicator light harness from the panel below) by lifting the retaining latch. GEngine problem - seized or binding 2.
  • Page 283 ELECTRICAL 4. Remove shims from armature shaft. NOTE: All shims must be replaced during reassembly. BRUSH INSPECTION/REPLACEMENT Brush Set 2. Remove the two bolts, washers, and sealing O-Rings. Inspect O-Rings and replace if damaged. 1. Using digital multitester, measure resistance between the cable terminal and the insulated brush.
  • Page 284 ELECTRICAL housing, and the tab on the brush plate engages the notch in the brush plate housing. 6. Place a wrap of electrical tape on the threads of the terminal bolt to prevent O-Ring damage during reinstallation. 7. Install the O-Ring over the bolt. Make sure the O-ring is fully seated.

  • Page 285: Starter Drive

    ELECTRICAL STARTER ASSEMBLY Starter Motor Exploded View Rear Brkt Assy Carbon Brush Washer Set Armature 1. Place armature in field magnet casing. Rubber Rings Washer 2. Place shims on drive end of armature shaft with O-ring phenolic washer outermost on shaft. Engage tabs of stationary washer in drive end housing, holding it in place with a light film of grease.
  • Page 286 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 for the starter circuit to engage. With the tester on the VDC position, place the tes- ter’s black lead on the battery negative and the red Remove battery and properly service.
  • Page 287 ELECTRICAL STARTER SYSTEM TEST FLOW CHART,CON’T Test B (from previous page) Voltage Drop Testing Continued from previous page See Page 10.16 for instructions. 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 or solenoid end and actuate the starter.
  • Page 288 ELECTRICAL NOTES 10.22...

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