Table of Contents
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ASAP Service and Maintenance Manual
ASAP Installed Systems
Maintenance: 3-47
Component Manuals: 48
Charging Air Force: 3-6
Charging System with Battery Brain and No Generator:7-10
Charging System with Battery Brain and Generator without Push Button: 11-15
Charging System with Battery Brain and Generator: 16-20
Charging System without Load Manager: 21-24
Dropping the Generator: 25-26
Getting to the Drive Belt: 27-28
Getting to the Drive Belt New Style: 29-31
Removing Blue Power Steering Wire: 32-33
Removing Load Manager (Wiring Schematic): 34
Rewinding the Roll-Up Door: 35-36
Wiring Diagrams: 37-47
Battery Brain: 48-55
Blizzard Wizard: 56-59
Curtis Cab: 60-69
Darley Davey Pump: 70-89
Dual Pro Charger: 90-96
Dometic Climate Control: 97-105
Federal Signal: 106-128
Electra Steer: 129-140
Hannay Hose Reel: 141-147
Honda Pump Engine: 148-167
Pro Tournament Battery Charger: 168-176
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Troubleshooting
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Summary of Contents for Polaris MS4000
- Page 1 ASAP Service and Maintenance Manual ASAP Installed Systems Maintenance: 3-47 Charging Air Force: 3-6 Charging System with Battery Brain and No Generator:7-10 Charging System with Battery Brain and Generator without Push Button: 11-15 Charging System with Battery Brain and Generator: 16-20 Charging System without Load Manager: 21-24 Dropping the Generator: 25-26 Getting to the Drive Belt: 27-28...
- Page 2 Warn Winch: 177-208 Whelen Lightbar: 209-211 Polaris Chassis: 174-672 Polaris Owner’s Manual: 212-348 Polaris Service Manual: 349-708...
- Page 3 Charging Air Force Introduction The ASAP has two batteries, one battery is located under the hood. This battery is for the Polaris Ranger functions. This battery starts the engine, runs the ignition system, headlights, turn signals, power steering system and Aux. cooling fan. This battery is for all Polaris chassis related items. The other battery is located under the driver’s seat (this can be accessed by pulling up on the front edge of the seat, lifting in the areas of between the driver’s legs and the passenger legs).
- Page 4 The Polaris battery is located under the hood and the steel solenoid is located near this battery. This battery size is considered a CB30L-B. Always replace it with one that is equivalent. Deep Cycle Battery: The deep cycle battery is charged only one way: 1.
- Page 5 The deep cycle battery is located under the driver. Its size is considered a group 27. When replacing this battery always replace it with a Group 27 Deep Cycle battery. This battery needs to be charged daily to prevent discharge. If the deep cycle battery gets discharged completely (less than 2 volts), the onboard battery charger will not start charging the battery.
- Page 6 The following picture shows the charging status. Notice that even with three red lights on, the battery has 14.0 volts in it. That’s still a pretty good battery. If the battery was completely dead, it will take at least 8 hours to recharge the deep cycle battery up to a full charge status.
- Page 7 Charging System with Battery Brain and No Generator Introduction The ASAP has two batteries, one battery is located under the hood. This battery is for the Polaris Ranger functions. This battery starts the engine, run’s the ignition system, headlights, turn signals, power steering system and (optional) aux.
- Page 8 Deep Cycle Battery: The deep cycle battery is charged only one way: 1. Onboard battery charger If the shoreline is plugged in, the onboard battery charger charges the battery. The deep cycle battery is located under the driver. Its size is considered a group 27. When replacing this battery always replace it with a Group 27 Deep Cycle battery.
- Page 9 If you find yourself in an emergency situation and your deep cycle battery drops below the 10.5 volts which will cut or turn off all auxiliary power you can push the push button on the dash near the windshield to regain 12 volt battery power. At that point you are running on only the remaining battery voltage and you will run the battery dead.
- Page 11 Charging System with Battery Brain and Generator without Push Button Introduction The ASAP has two batteries, one battery is located under the hood. This battery is for the Polaris Ranger functions. This battery starts the engine, runs the ignition system, headlights, turn signals, power steering system and the optional auxiliary cooling fan.
- Page 12 The Polaris battery is located under the hood and the steel solenoid is located near this battery. This battery size is considered a CB30L-B. Always replace it with one that is equivalent. Deep Cycle Battery: The deep cycle battery is charged only one way: 1.
- Page 13 A quick way to determine what is connected to the deep cycle battery is to turn off the master switch that is located between the driver’s legs. This switch runs everything that is connected to the deep cycle battery. So if you’re not sure, turn that item in question “on” and then turn the master switch off.
- Page 14 The deep cycle battery has a load manager device that monitors the battery voltage at all times. As long as the battery voltage is above 10.5 volts the green light is illuminated on the dash indicating the battery voltage is in an okay status. If the voltage drops below 10.5 volts the green light will go out indicating the battery needs charging.
- Page 16 Charging System with Battery Brain and Generator Introduction The ASAP has two batteries, one battery is located under the hood. This battery is for the Polaris Ranger functions. This battery starts the engine, runs the ignition system, headlights, turn signals, power steering system and (optional) aux.
- Page 17 The Polaris battery is located under the hood and the steel solenoid is located near this battery. This battery size is considered a CB30L-B. Always replace it with one that is equivalent. Deep Cycle Battery: The deep cycle battery is charged only one way: 1.
- Page 18 The deep cycle battery is located under the driver. Its size is considered a group 27. When replacing this battery always replace it with a Group 27 Deep Cycle battery. This battery needs to be charged daily to prevent discharge. The deep cycle battery has a load manager device that monitors the battery voltage at all times.
- Page 19 necessary. It would be better to start the generator which would turn on the on board battery charger. NOTE: You might find yourself in a situation where you have the master switch in the on position, the ignition key in the on position and the green light is not on but you know that the deep cycle battery is up in charge.
- Page 20 Shoreline Location: The shoreline is located near the driver’s door.
- Page 21 Charging System without Load Manager Introduction The ASAP has two batteries, one battery is located under the hood. This battery is for the Polaris Ranger functions. This battery starts the engine, runs the ignition system, headlights, turn signals, power steering system and Aux. cooling fan. This battery is for all Polaris chassis related items. The other battery is located under the driver’s seat (this can be accessed by pulling up on the front edge of the seat, lifting in the areas of between the driver’s legs and the passenger legs).
- Page 22 The Polaris battery is located under the hood and the steel solenoid is located near this battery. This battery size is considered a CB30L-B. Always replace it with one that is equivalent. Deep Cycle Battery: The deep cycle battery is charged only one way: 1.
- Page 23 The deep cycle battery is located under the driver. Its size is considered a group 27. When replacing this battery always replace it with a Group 27 Deep Cycle battery. This battery needs to be charged daily to prevent discharge. If the deep cycle battery gets discharged completely (less than 2 volts), the onboard battery charger will not start charging the battery.
- Page 24 The following picture shows the charging status. Notice that even with three red lights on, the battery has 14.0 volts in it. That’s still a pretty good battery. If the battery was completely dead, it will take at least 8 hours to recharge the deep cycle battery up to a full charge status.
- Page 25 Dropping the generator 1. Place jack under generator 2. Remove the four bolts holding the generator to the frame. 3. There are a bundle of cables located in the top of the frame. They are looped so that the generator can be lowered down some what in order for the connections to the generator to be unhooked.
- Page 26 4. There will be three plugs that will need to be unplugged (see above) along with the fuel line. The fuel line will need to have the hose clamp removed at the generator.
- Page 27 Step 1: Open the driver’s side lower storage compartment and loosen the six bolts that are in the top of the box. Then pull the compartment towards you. It will slide out and come completely off the unit. (Some of the earlier units may require you to remove the six bolts completely in order to remove the storage box) Step 2: Now remove the black plastic panel that is beside the deep cycle battery.
- Page 28 Step 3: The drive belt is located behind the cover shown here in this photo. There are a row of bolts holding the cover on. See photo below Remove all of the bolts and pull the cover off the reveal the drive belt.
- Page 29 Step 1: Open the driver’s side lower storage compartment and remove the six bolts that are in the top of the box. Then pull the compartment out and completely off the unit. Step 2: Now remove the black plastic panel that is beside the deep cycle battery. It takes a 7mm socket to remove the four screws...
- Page 30 Step 3: The drive belt is located behind the cover shown here in this photo. There are a row of bolts holding the cover on. See photo below Remove all of the bolts and pull the cover off the reveal the drive belt. Your unit has a high performance drive belt and clutch installed in it.
- Page 32 You will need to switch out the power steering module. After you switch them out, there is a blue wire coming out of the module. If the blue wire is only 4-5 inches long like in the photo below that is good. If the blue wire continues on you will need to proceed with this procedure.
- Page 33 Coil Pack The other end of the blue wire is tapped into the green\white wire coming out of the coil pack. I would like for you to cut the wire here also and retape the green\white wire. By doing this, it will eliminate any corruption that the coil may be seeing in that line that was running up to the power steering unit.
- Page 35 Rewinding the rear roll up door barrel Find the decal on the barrel that indicates the number of factory preset turns of the barrel. Then find the box that indicates the number that the barrel can be turned additionally. (This one in the photo can be turned a total of 16 times.) Find your numbers and add them up.
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Page 49: Installation Instructions
Installation Instructions Battery Brain is an innovative accessory that easily installs to any battery. Using unique micro-electronic technology it continually monitors the battery power. When Battery Brain detects power falling below the level required to start your engine, it automatically isolates the battery from the electrical system. - Page 50 Technical Specifi cations Battery Brain Battery Brain Kit includes DIMENSIONS GENERAL BATTERY BRAIN UNIT: Type IV Only-This unit has the same remote capacities as the type III, but uses a push button (5) instead of a remote Base 1 5/8” (4cm) x 2 1/4” (5.5cm), Height (including The Battery Brain is installed on the positive (+) battery post 1.
- Page 51 Aluminum Positive Post with Butterfl y L-Bracket & Straight Mounting Brackets Optional: Connector with Bolt and Lock Washer Vibration Sensor - Available separately, can be used in place of the Engine On Wire *(See your retailer for details) Remote Control (Type II & III Models Only) Remote Control Frequency: TX433.92 Mhz Aluminum Positive Post with Bolt and Lock Washer Battery Type: 12 V 27 A (The batteries are already installed)
- Page 52 Installation Instructions NOTE: Battery location and position differ in vehicles. With the supplied accessories you can mount the Battery Brain on the D) Side mount only: Connect the positive side of the STEP 1: Disconnecting Battery Cables: vehicle using the Top Mount, Side Mount or Chassis Mount positions. Battery Brain (with the sign 12V +) to the positive post on A) Disconnect the black/negative (–) cable from the the battery using the provided side mount screw.
- Page 53 STEP 4: Install Black Engine On Wire. STEP 5: Red Accessory Bypass Wire Installation [Optional] MULTI BATTERY INSTALLATION Installation of the Engine On wire will prevent the Battery Installation of the red accessory bypass wire will provide If your vehicle has a multi-battery confi guration, Battery Brain can be mounted to any battery confi guration. However, any Brain from disconnecting the battery while the engine you with continuous 12V power to an accessory or primary live positive battery post must have its own Battery Brain.
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Page 54: Limited Warranty
Testing the Installation Trouble Shooting Limited Warranty A) TO TEST FOR SUCCESSFUL INSTALLATION: AFTER INSTALLATION, THE BATTERY BRAIN DOESN’T Your Battery Brain™ is covered by a conditional, limited YOU CANNOT DETERMINE A BATTERY BRAIN SEEM TO BE WORKING. INSTALLATION CONFIGURATION FOR YOUR VEHICLE warranty to the original purchaser. - Page 55 Battery Brain is an innovative accessory that easily installs to any battery. Using unique micro-electronic technology it continually monitors the battery power. When Battery Brain detects power falling below the level required to start your engine, it automatically isolates the battery from the electrical system.
- Page 60 CAB INSTALLATION INSTRUCTIONS POLARIS RANGER/UTV CAB KIT (p/n 2874660) To install this cab kit (p/n 2874660), you will need mount kit p/n 2874689. Available optional kits: Vinyl Doors (p/n 2874693); Hard Rear Panel (p/n 2859091). The contents of this envelope are the property of the owner. Be sure to leave with the owner when installation is complete.
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Page 61: Before You Start
CAB INSTALLATION BEFORE YOU START HELPFUL REMINDERS: A. Leave all bolts loose for later adjustment unless otherwise specified. B. Read and understand all instructions before beginning. C. Plastic washers have been supplied to provide a weather seal around all exterior fasteners. The plastic washer should be installed under each bolt head directly against the outside cab surface. -
Page 62: Rear Panel
MODEL: POLARIS RANGER CAB KIT INSTALLATION INSTRUCTIONS 1. VEHICLE PREP. 1.1 Remove the roll bar from the vehicle so the vehicle appears as shown in fig- ure 1.1. 1.2 Remove the seat back (the actual back portion of the seat) from the roll bar tubing as shown in fig. - Page 63 MODEL: POLARIS RANGER CAB KIT INSTALLATION INSTRUCTIONS 3. REAR PANEL (cont’d.) 3.3 Place the rear panel assembly on the vehicle as shown in fig. 3.3. (NOTE: the bottom of the rear panel is to remain in front of the four (4) welded tubes as shown in fig.
- Page 64 MODEL: POLARIS RANGER CAB KIT INSTALLATION INSTRUCTIONS 8. WINDSHIELD With assistance, install the windshield to the windshield support (see fig- ure 8.1). Use six (6) 5/16 x 1 3/4” long flat head screws and 3/4” thick plas- tic spacer blocks (placed between the plastic hinge and the windshield sup- port as shown in fig.
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Page 65: Care And Maintenance
MODEL: POLARIS RANGER CAB KIT INSTALLATION INSTRUCTIONS 11. MOUNTING BRACKET 11.1 Lift the dump bed. 11.2 Using a 13/32” drill bit, and using the approximate center of the mounting bracket slots as a guide, drill four (4) holes through the sheet metal on the ve- hicle as shown in the enlarged view below (fig. - Page 66 POLARIS MAIN CAB BODY - RANGER / UTV (p/n 2874660) REAR CURTAIN ROOF WINDSHIELD QTY. QTY. QTY. UTV-06 UTV-02 UTV-01 HEYCO PLUGS SNAPS (PASSENGER'S SIDE ONLY) REFLECTORS SEAM BULB SNAPS HEADLINER HINGES WINDSHIELD COLOR TO BE: 5/8" TRIM-LOK CLUB CAR WHITE SIDE SUPPORT QTY.
- Page 67 DOOR INSTALLATION INSTRUCTIONS POLARIS RANGER/UTV STEEL DOORS (p/n 2875941-067) The contents of this envelope are the property of the owner. Be sure to leave with the owner when installation is complete. Exposure to Carbon Monoxide can ADDED Cause illness, serious injury or death. WEIGHT Never operate vehicle if suspicious of Curtis Cabs, blades and general accessories...
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Page 68: Tools Required
POLARIS RANGER/UTV DOOR KIT (STEEL DOORS) INSTALLATION INSTRUCTIONS TOOLS REQUIRED: 7/16 IN. 3/8 DRIVE SOCKET 1/2 IN. 7/16 IN. 3/4 IN. 3/16 INCH OPEN OPEN OPEN ALLEN DRIVE WRENCH WRENCH WRENCH 3/8 DRIVE 3/8 DRIVE RATCHET 1. REAR MOUNTS Remove existing rear mounts (part number 2874689) from the cab rear panel and install left and right mounts from this kit in their place as shown in figure 1.1. - Page 70 7AK306/5213HE/NPT 2 Stage 13 HP Honda...
- Page 71 7AK306/5213HE/NPT 2 Stage 13 HP Honda...
- Page 72 7AK306/5213HE/NPT 2 Stage 13 HP Honda...
- Page 73 7AK306/5213HE/NPT 2 Stage 13 HP Honda...
- Page 74 7AK306/5213HE/NPT 2 Stage 13 HP Honda...
- Page 75 7AK306/5213HE/NPT 2 Stage 13 HP Honda...
- Page 76 7AK306/5213HE/NPT 2 Stage 13 HP Honda Part # Description/Price Davey Prod. Notes Code 3822201 Discharge Gasket/$13.64 5320902 Valve Flap Assembly/$41.37 KE00509 Spark Arrestor Kit/$62.24 2904820 Impeller 1 Stage/$89.81 Sold as set – Top Part #2904801 Davey Part #13381 & Bottom Part #2904821 Davey Part #13380 2904825...
- Page 77 Two Stage 5 Series Work Instructions...
- Page 78 Two Stage 5 Series Work Instructions...
- Page 79 Two Stage 5 Series Work Instructions...
- Page 80 Two Stage 5 Series Work Instructions...
- Page 81 Two Stage 5 Series Work Instructions...
- Page 82 Two Stage 5 Series Work Instructions...
- Page 83 Two Stage 5 Series Work Instructions...
- Page 84 Two Stage 5 Series Work Instructions...
- Page 85 Two Stage 5 Series Work Instructions...
- Page 86 Two Stage 5 Series Work Instructions...
- Page 87 Two Stage 5 Series Work Instructions...
- Page 89 LIMITED THREE-YEAR WARRANTY AIR CONDITIONERS & HEAT PUMPS THE SELLER NAMED BELOW MAKES THE FOLLOWING WARRANTY WITH RESPECT TO THE DOMETIC PRODUCT: This warranty is made only to the first purchaser (herein after referred to as the “Original Purchaser”) who acquires the product for his own use and is installed and operated within the continental United States and Canada.
- Page 105 LIMITED THREE-YEAR WARRANTY AIR CONDITIONERS & HEAT PUMPS THE SELLER NAMED BELOW MAKES THE FOLLOWING WARRANTY WITH RESPECT TO THE DOMETIC PRODUCT: This warranty is made only to the first purchaser (herein after referred to as the “Original Purchaser”) who acquires the product for his own use and is installed and operated within the continental United States and Canada.
- Page 106 Installing 100 Watt Speaker Models ES100, ES100-DEU, and ES100-UNI 2562433A Rev. A 409 Safety Message to Installers of Siren Speakers People’s lives depend on your proper installation and servicing of Federal Signal products. It is important to read and follow all instructions shipped with this product and the original product.
- Page 107 2 ES100, ES100-DEU, and ES100-UNI 100 Watt Speakers • Be sure the siren amplifier and speaker(s) in your installation have compatible wattage ratings. • In order for the electronic siren to function properly, the ground connection must be made to the NEGATIVE battery terminal. • Sound output will be severely reduced if any objects are in front of the speaker. If maximum sound output is required for your application, you should ensure that the front of the speaker is clear of any obstructions. • Install the speaker(s) as far forward on the vehicle as possible, in a location that provides maximum signaling effectiveness while minimizing the sound reaching the vehicle’s occupants. Refer to the National Institute of Justice Guide 500-00 for further information. • Mounting the speakers behind the grille will reduce the sound output and warning effectiveness of the siren system. Before mounting speakers behind the grille, make sure the vehicle operators are trained and understand that this type of installation is less effective for warning others. • Sound propagation and warning effectiveness will be severely reduced if the speaker is not facing forward. Carefully follow the installation instructions and always install the speaker with the projector facing forward. • DO NOT install the speaker(s) or route the speaker wires where they may interfere with the operation of airbag sensors. • Installation of two speakers requires that you wire the speakers in phase. • Never attempt to install aftermarket equipment, which connects to the vehicle wiring, without reviewing a vehicle wiring diagram, which is available from the vehicle manufacturer. Insure that your installation will not affect vehicle operation and safety functions or circuits. Always check vehicle for proper operation after installation.
- Page 108 ES100, ES100-DEU, and ES100-UNI 100 Watt Speakers Unpacking the Kit After unpacking the kit, inspect it for damage that may have occurred in transit. If it has been damaged, do not install it. File a claim immediately with the carrier, stating the extent of damage. Carefully check all envelopes, shipping labels, and tags before removing or destroying them. Ensure that the parts listed in Table 1 are included in the package. Table 1: Kit contents ES100, ES100-DEU, ES100-UNI (Kit Number 8567207) Qty. Description Part Number Side Mounting Bolt, 5/16-18, 5/8" Long 7007010-10 Mounting the Speaker MOUNTING PRECAUTIONS: ES100 SERIES SPEAKER WIRES To avoid reducing the sound output and damaging the speaker, ensure that the speaker is mounted with the wires protruding from the bottom of the speaker.
- Page 109 4 ES100, ES100-DEU, and ES100-UNI 100 Watt Speakers Wiring the Speaker IMPORTANT: The ES100 series speakers comply with the requirements of SAE J1849 EVS3 and CCR Title 13 Class A when they are used with Federal Signal Corporation electronic sirens. The ES100 Series speaker includes the three models shown in Figure 1. ES100 ES100-DEU ES100-UNI 290A6257 HOLE FOR WIRE LEADS MOUNTING BOLT (2) DEUTSCH DELPHI CONNECTOR CONNECTOR Figure 1: ES100 speaker models ES100 (18 AWG tinned wire leads) Connect the black ground lead (#1) and white power lead (#2) from the speaker to the speaker cable from the electronic siren (Figure 1, ES100). Refer to the instructions included with the electronic siren for details.
- Page 110 ES100, ES100-DEU, and ES100-UNI 100 Watt Speakers After the installation, test the siren system to ensure that it is operating properly. Also test all vehicle functions, including horn operation, vehicle safety functions, and vehicle lighting systems to insure proper operation. Ensure that the installation has not affected the vehicle operation or changed any vehicle safety functions or circuits. Do not test the sound and light system of the vehicle while driving. Operating the vehicle warning systems may pose a hazard to the operator and other drivers if the systems do not function as expected. Test the vehicle only in a controlled environment. Safety Message To Personnel Operating Federal Signal Siren Speakers People’s lives depend on your safe operation of Federal products. It is important to read and follow all instructions shipped with the products. In addition, listed below are some other important safety instructions and precautions you should follow: Qualifications •...
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Page 111: Ordering Replacement Parts
6 ES100, ES100-DEU, and ES100-UNI 100 Watt Speakers • Although your warning system is operating properly, it may not alert everyone. People may not hear, see, or heed your warning signal. You must recognize this fact and continue driving cautiously. • Situations may occur which obstruct your warning signal when natural or man-made objects are between your vehicle and others. This can also occur when you raise your hood or trunk lid. If these situations occur, be especially careful. Driving Limitations • At the start of your shift, you should ensure that the light/sound system is securely attached to the vehicle and operating properly. • If the unique combination of emergency vehicle equipment installed in your vehicle has resulted in the siren controls being installed in a position that does not allow you to operate them by touch only, OPERATE CONTROLS ONLY WHILE YOUR VEHICLE IS STOPPED. • If driving conditions require your full attention, you should avoid operating the siren controls while the vehicle is in motion. Continuing Education • File these instructions in a safe place and refer to them periodically. Give a copy of these instructions to new recruits and trainees. Failure to follow these safety precautions may result in property damage, serious injury, or death to you, to passengers, or to others. - Page 112 ES100, ES100-DEU, and ES100-UNI 100 Watt Speakers • Your Federal Signal customer or account number. • The purchase order number under which the items were purchased. • The shipping method. • The model or part number of the product being returned. • The quantity of products being returned. • Drop ship information as needed. • Any estimate required. When you receive your RMA Number: • Write the RMA number on the outside of the box of returned items. • Reference the RMA number on your paperwork inside of the box. • Write the RMA number down so that you can easily check on status of the returned equipment. Send all material with the issued RMA Number to: Federal Signal Corporation 2645 Federal Signal Drive University Park, IL 60466 Attn: Service Department RMA: #__________...
- Page 113 2645 Federal Signal Drive, University Park, IL 60466-3195 Tel.: (800) 264-3578 • Fax: (800) 682-8022 www.fedsig.com © 2009 Federal Signal Corporation...
- Page 114 MAN – MS4000 INSTALL REV: 1/26/01 255331B INSTALLATION AND OPERATING INSTRUCTIONS MS4000/MS4000U Mini-Siren...
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Page 116: Table Of Contents
Section Title Page General Description ....…..… Specifications ........… Safety Message To Installers....Installation……………………....Safety Message To Operators....Operation……………………….……….. Safety Message For Service....VIII Service....…………….…………. Priority Sound Elimination………………. -
Page 117: General Description
SECTION I GENERAL DESCRIPTION MS4000 MS4000U Features: The Federal Signal MS4000 siren series is an advanced, efficient, and economical Mini-Siren. It offers • Economical small and compact - mounts value packed performance for those who do not require virtually anywhere. -
Page 118: Specifications
SECTION II SPECIFICATIONS Input voltage 9 Vdc to 15 Vdc Input current, operating 10 amps max Polarity Negative grounded systems only Standby current 60mA nominal Operating temperature range -30°C to +65°C Frequency ranges 725 to 1575 Hz Cycle range WAIL 12 cycles/min YELP 240 cycles/min MANUAL 1425 Hz peak Output voltage... -
Page 119: Safety Message To Installers
SECTION III SAFETY MESSAGE TO INSTALLERS OF FEDERAL SIGNAL LIGHT AND SOUND SYSTEMS WARNING The lives of people depend on your safe instal- • Install the speaker in a location which provides lation and servicing of Federal products. It is maximum signaling effectiveness and minimizes important to read and follow all instructions the sound reaching the vehicle’s occupants. -
Page 120: Installation
SECTION IV INSTALLATION 4-1 INSPECTION OF UNIT WARNING After unpacking the MS4000 series siren, examine When installing equipment inside air bag equipped it for damage that may have occurred in transit. If the vehicles, the installer MUST ensure that the... - Page 121 Positive (+) battery terminal. The power and speaker cables are included on the siren (see figures 4-3 and 4-4). The various wires must be connected as indicated below. Figure 4-3. MS4000 Wire location Figure 4-4. MS4000U wire location Page 5...
- Page 122 A. Speaker. a. BLACK wire to the CENTER pole of the momentary switch. The unit is designed to operate with one 11- ohm impedance speaker. b. BLUE wire to the AIR HORN pole of the momentary switch. A speaker is not included as part of the electronic siren.
- Page 123 (-) terminal. CAUTION 3. Connect the red in-line fuse holder lead to The MS4000 Series Sirens do not have an on- the selected 12-volt source. off switch. If power is obtained directly from the vehicle battery, it will continuously draw 4-4 TESTING AFTER INSTALLATION approximately 0.060A.
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Page 124: Safety Message To Operators
SECTION V SAFETY MESSAGE TO OPERATORS OF FEDERAL SIGNAL LIGHT/SOUND SYSTEMS WARNING Signaling Limitations The lives of people depend on your safe operation • Be aware that the use of your visual and audible of Federal products. It is important to read and signaling devices do not give you the right to follow all instructions shipped with the products. -
Page 125: Operation
All controls utilized during normal operation of the is depressed, a 5-second YELP tone is generated. The MS4000 are located on the front panel (see figure 6-1) unit then returns to the WAIL mode (see chart in or on the remote switch panel for the MS4000U. - Page 126 SECTION VII SAFETY MESSAGE TO PERSONNEL SERVICING FEDERAL SIGNAL ELECTRONIC SIRENS WARNING The lives of people depend on your safe servicing of • All effective sirens and horns produce loud products. It is important to read and follow all sounds, which may cause, in certain situations, instructions shipped with the products.
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Page 127: Service
SECTION VIII SERVICE The factory can and will service your equipment or Service Department: assist you with technical problems that cannot be FS/Unitrol handled satisfactorily and promptly locally. 1108 Raymond Way Anaheim, CA 92801 Servicing, other than cosmetic features, should be performed by a qualified Federal Signal service center. -
Page 128: Priority Sound Elimination
SECTION IX Priority Sound Elimination MS4000/MS4000U SHUNT TO BE INSTALLED For agencies that operate in areas where the PRIORITY sounds are not authorized we are providing a shunt to be placed on the circuit board at location JMP1. If the end user installs this shunt, the unit will not produce the PRIORITY sounds. - Page 129 ELECTRA STEER™ ELECTRA STEER™ KIT NUMBER 8051440 Polaris Electric Steering Installation Manual Thank you for purchasing our ELECTRA-STEER™ 12v electric assist power steering system. Please carefully read this instruction sheet entirely before you begin to install the system. Remember, before beginning installation, insure that you are in a level well lit, organized, work area.
- Page 130 Full refund will NOT be granted to any kits that are damaged, scratched, or altered in any fashion. INSTALLATION TIPS: Due to minor variations in vehicle frames, we recommend that you leave all the U-Joint pinch bolts loose until the motor is mounted. Then rock the steering wheel back and forth to allow the U-Joints to align themselves.
- Page 131 NOTE: PINK COLOR BANDS FACE VEHICLE SPLINES AND WHITE FACE MOTOR SPLINES: REMOVAL OF EXISTING SHAFT ASSEMBLY: 1. Remove center cap from steering wheel & remove the 15/16” nut from steering wheel. Have a second person carefully tap on the upper shaft while you pull up on the wheel to remove it from the taper on the shaft.
- Page 132 2. Put the bracket on the underside of the frame and install a 3/8 bolt from the bottom side of the bracket and install the lock washer and nut on the topside and snug but leave loose. 3. The bracket must be flush on the bottom and side. When the bracket is secure on the frame, using the hole in the mounting bracket as a pilot, you may drill the front side hole and install a 3/8”...
- Page 133 4. When you have your motor hanging in place, you can install the lower shaft assy. 5. When installing the lower shaft it is necessary to put the pinion side (rack side) of the shaft on first. Once you have the pinion side on and in place you will have to wiggle the motor &...
- Page 134 6. You may now torque the bracket bolts to 30 ft lbs. 7. To install the upper shaft, you have to fish the shaft through the column frame and slide the shaft onto the spline of the motor. The steering wheel shaft can then get dropped down through the column and splined onto the u-joint at the top.
- Page 135 10. The module wiring is described in the schematic supplied. The white wire gets a single spade terminal. The purple or brown wire also gets a spade terminal. Note: these two wires are used for trouble code reading and clearing. They need to be located in an accessible place.
- Page 136 11. The LED needs to be mounted in the dash where it is visible. To install the light it’s a simple matter of drilling a ½ inch hole and snapping the light into place from the front side. NOTE: Pay special attention to what is behind your dash before drilling a hole. 12.
- Page 137 2. To locate where your pilot hole should be, you need to stand outside the vehicle with the hood open, facing the firewall. 3. With a tape measure, measure from the left side of the brake pedal mounting bracket over 2-7/8” mark the center of the frame channel. This is where you drill a 3/8”...
- Page 138 In some cases the purple above wire may be substituted for a brown wire!! The Electra-Steer™Power Steering Assist Unit is intended to be used in accordance with all safety recommendations of the original manufacturer of the vehicle as specified in the Owners Manual. This product is intended for normal operation of the vehicle as specified by the original manufacturer.
- Page 139 Electra Steer Diagnosis Trouble Code Reading and Code Clearing 1. Verify that your trouble code light is on steady. 2. Peel back a small portion of the orange trouble code light wire to expose the copper portion of it. 3. Next use a jumper wire and go from the purple wire with the single spade connector on it and touch or spike it to the exposed part of the orange wire.
- Page 140 (12/18/07)
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Page 141: Parts List
ISO 84 PARTS LIST 1˝ HOSE REEL Hannay Reels, Inc., 553 State Route 143 Westerlo, NY 12193 Telephone 518-797-3791 FAX 1-800-REELING (733-5464) INT’L FAX (518) 797-3259 Website: www.hannay.com E-mail: reels@hannay.com Hannay ISO Parts Lists are available 5M HP 5-08 Form H-8400-1˝-P at www.hannay.com Rev. - Page 142 PARTS LIST ISO 84 1˝ Hose Reels When ordering parts BE SURE TO SPECIFY COMPLETE MODEL NUMBER and SERIAL NUMBER OF REEL. USE PART NUMBER! PART NUMBER Item No. Description Quantity Drum, 10-1/2˝ Diameter ............(Specify Model) 9905.3131 Front Disc, 19-20 Series ............(Specify Model) 9903.0821 Front Disc, 21-22 Series ............(Specify Model) 9903.0921...
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Page 143: Safety Guidelines
WARNING: PINCH POINT AREAS POWER REWIND REELS SAFETY USE CAUTION WHEN OPERATING NEAR CHAIN AND USE CIRCUIT BREAKERS FOR ELECTRIC REWIND SPROCKETS. MOTORS. GUIDELINES Make sure that the circuit breaker is properly sized for the motor. Also, check all electrical Where chain guards are furnished, the reels should not be operated with them removed. - Page 144 A VERTISSEMENT : POINTS DE PINCEMENT ENROULEURS À REMBOBINAGE MOTORISÉ CONSIGNES ÊTRE TRÈS PRUDENT LORS DU FONCTIONNEMENT UTILISER DES DISJONCTEURS POUR LES MOTEURS PRÈS DE CHAÎNES ET DE PIGNONS. ÉLECTRIQUES DE REMBOBINAGE. DE SÉCURITÉ Si les enrouleurs sont fournies avec des protections de chaîne, il ne faut pas les utiliser avec les S’assurer que le disjoncteur soit correctement dimensionné...
- Page 145 WAARSCHUWING: KNELPUNTEN MOTORISCH BEDIENDE HASPELS WEES VOORZICHTIG ALS U NABIJ DE KETTING GEBRUIK EEN THERMISCHE BEVEILIGING BIJ EN TANDWIELEN WERKT. TOEPASSING VAN EEN ELEKTRISCHE MOTOR. VEILIGHEIDSVOORSCHRIFTEN De haspels niet gebruiken als de kettingbeschermers verwijderd zijn. Verzeker u ervan dat de thermische beveiliging afgestemd is op de motor. Kijk ook alle elek- trische verbindingen nat t.a.v.
- Page 146 ADVERTENCIA: PUNTOS DE APRIETE CARRETES DE ENROLLAMIENTO DIRECTRICES DE TENER CUIDADO CUANDO SE TRABAJE CERCA DE LA CADE- MOTORIZADO NA Y RUEDAS DENT ADAS. En los casos en que se suministran protectores de cadenas, no se debe usar los carretes si se USAR LOS DISYUNTORES DE CIRCUITO PARA LOS han sacado los protectores.
- Page 147 ACHTUNG: VERLETZUNGSGEFAHR TROMMELN MIT MOTORRÜCKSPULUNG RICHTLINIEN VORSICHT BEI ARBEITEN IM BEREICH VON KETTE UND BEI TROMMELN MIT ELEKTROMOTORISCHER ZAHNRÄDERN. RÜCKSPULUNG SIND SICHERUNGEN EINZUSETZEN. Ist ein Kettenschutz Bestandteil der Lieferung, sind die T rommeln nicht ohne diesen in ZUR SICHERHEIT Es ist sicherzustellen, daß die Sicherung für den Motor ausreichend bemessen ist. Darüber Betrieb zu nehmen.
- Page 148 S p e c i f i c a t i o n s & A c c e s s o r i e s S a f e t y I n s t r u c t i o n s Personal Safety Precautions Continued Specifications Never smoke or allow a spark or a flame in the vicinity of a battery or engine.
- Page 149 P r o To u r n a m e n t O v e r v i e w Tr o u b l e s h o o t i n g Trouble Shooting Guide General Overview The ProTournament is an Professional Grade 3 Step Marine Battery Charger that is pre-wired for easy installation and is 100% waterproof for all fresh and salt No Red or Green LED Indicator water applications.
- Page 150 P r o To u r n a m e n t O v e r v i e w M a i n t e n a n c e Owner's Periodic Maintenance Guide ProTournament Charger vs. Leading Traditional Linear Charger ProTournament's "Distributed On-Demand ™...
- Page 151 P r o To u r n a m e n t O v e r v i e w C h a r g i n g Yo u r B a t t e r i e s General Operation Note: When only using one battery connect output 1, output 2, and output 3 red wires Install your ProTournament Professional Grade 3 Step Marine Battery Charger...
- Page 152 P r o To u r n a m e n t O v e r v i e w I n s t a l l a t i o n G u i d e l i n e s Charge Mode Indicator and Operation ProTournament Series Wiring Diagrams When the ProTournament Marine Battery Charger is activated the on-board...
- Page 153 I n s t a l l a t i o n G u i d e l i n e s I n s t a l l a t i o n G u i d e l i n e s Installation Installation Continued All ProTournament Battery Chargers are designed to be permanently mounted...
- Page 154 ® TREUIL POUR ATV WARN ® WARN ATV WINCH GARANTIE À VIE LIMITÉE POUR LES COMPOSANTS MÉCANIQUES LIMITED LIFETIME WARRANTY FOR MECHANICAL COMPONENTS GARANTIE LIMITÉE D’UN (1) AN POUR LES COMPOSANTS LIMITED ONE (1) YEAR WARRANTY FOR ELECTRICAL COMPONENTS ÉLECTRIQUES Warn Industries, Inc.
- Page 155 CABRESTANTE WARN ® PARA VEHÍCULOS TODOTERRENO GARANTÍA LIMITADA DE POR VIDA PARA LOS COMPONENTES MECÁNICOS GARANTÍA LIMITADA DE UN (1) AÑO PARA LOS COMPONENTES ELÉCTRICOS Warn Industries, Inc. (WARN) garantiza al comprador original, por el periodo de un (1) año a partir de la fecha original de compra, que los componentes mecánicos y eléctricos de los Productos “WARN”...
- Page 156 The Basic Guide to Winching Techniques Every winching situation has the potential for personal injury. In order to minimize that risk, it is important that you read this Basic Guide carefully, familiarize yourself with the operation of your winch before having to use it, and be constantly safety oriented. In this Guide, we will set forth many of the basic rules of safe winch operation.
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Page 157: General Safety Precautions
GENERAL SAFETY PRECAUTIONS WA R N I N G As you read these instructions, you will see WARNINGS, CAUTIONS, NOTICES and NOTES. Each message has a specific purpose. WARNINGS are safety messages that indicate a potentially hazardous situation, which, if not avoided could result in serious injury or death. - Page 158 C AU T I O N C AU T I O N C AU T I O N C AU T I O N MOVING PARTS ENTANGLEMENT MOVING PARTS ENTANGLEMENT MOVING PARTS ENTANGLEMENT HAZARD HAZARD HAZARD Failure to observe these instructions Failure to observe these instructions Failure to observe these instructions could lead to minor or moderate...
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Page 159: Winch Basics
ELECTRIC WINCH BASICS So, you have your Warn winch and emphasize that the information in this you’re ready to get out on the trails: climb guide is general in nature. Because no a few boulders, splash a little mud, two situations are alike, it would be WARNING traverse the occasional stream. -
Page 160: How The Winch Works
HOW THE WINCH WORKS WINCH ACCESSORIES YOU’LL WANT TO HAVE WITH YOU Alone, the winch is not much more Winch Mechanics than a simple tool. But when used with Now that you’ve familiarized yourself certain accessories and enhancements, with your Warn winch and its your Warn winch can become a components, we can begin reviewing versatile and productive tool. -
Page 161: Stretching Wire Rope
STRETCHING WIRE ROPE The life of a wire rope is directly rope. Never exit the vehicle with a load related to the use and care it receives. on the winch wire rope. Tensioning the wire rope is critical to 6) Use care to evenly wrap each layer ensure a long product life. -
Page 162: Before You Pull
BEFORE YOU PULL WARNING Single line pull Practice using your winch before you Never use the get stuck. A real situation is no time to be WARNING winch as a learning how to use your winch. Never operate hoist. Whether you’re recovering another winch with less vehicle or pulling a stump from the than 5 wraps of... -
Page 163: Pulling
PULLING As you probably have already noticed, there are many things to do and consider before you actually begin pulling. Think through what you’re doing and you can keep yourself and those around you out of harm’s way. Operating your winch properly is so Step 6: ATTACH THE CLEVIS/D- important, in fact, you should practice SHACKLE AND HOOK STRAP. - Page 164 How to spool under no load What to look for under load Establish “no people” zones: Arrange the rope so it will not kink or tangle The rope must always spool when spooled. Be sure any rope already on the onto the drum on the side nearest spooling drum is wound tightly and evenly the mounting plate as indicated by...
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Page 165: Rigging Techniques
SUB-ZERO OPERATION RIGGING TECHNIQUES MAINTENANCE • Inspect the rope before and after each Freespooling of rope from the winch Various winching situations will require winching operation. If the rope has drum may be more difficult at sub- application of other winching techniques. become kinked or frayed, the rope freezing temperatures. - Page 166 Le manuel de base des techniques de treuillage Chaque situation de treuillage peut potentiellement occasionner des blessures. Pour minimiser ce risque, il est important que vous lisiez ce guide de base avec attention, que vous vous familiarisiez avec le maniement du treuil avant de l'utiliser, et que vous vous préoccupiez avant tout de la sécurité.
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Page 167: Mesures Générales De Sécurité
MESURES GÉNÉRALES DE SÉCURITÉ AVERTISSEMENT Les directives suivantes comprennent des indications intitulées AVERTISSEMENT, ATTENTION, AVIS et REMARQUE. Chacune a un objectif bien précis : AVERTISSEMENT présente des consignes de sécurité soulignant un danger potentiel qui, s'il n'est pas évité, RISQUES ASSOCIÉS AUX PRODUITS peut entraîner des blessures graves ou la mort. - Page 168 AT T E N T I O N AT T E N T I O N AT T E N T I O N AT T E N T I O N DANGER DE HAPPEMENT PAR DES DANGER DE HAPPEMENT PAR DES PIÈCES DANGER DE HAPPEMENT PAR DES PIÈCES MOBILES MOBILES...
- Page 169 DONNÉES ESSENTIELLES SUR LE TREUIL ÉLECTRIQUE Vous voilà propriétaire d’un treuil Warn globale du treuil et vous enseigner les et vous êtes prêt à partir sur les pistes : techniques de treuillage. Mais avant de escalader quelques éboulis, faire gicler commencer, nous devons souligner que AVERTISSEMENT un peu de boue, traverser un cours d'eau...
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Page 170: Comment Fonctionne Le Treuil
COMMENT FONCTIONNE LE TREUIL ACCESSOIRES DE TREUILLAGE UTILES Le treuil d'un point de vue Seul, le treuil n'est guère plus qu'un mécanique simple outil. Mais utilisé conjointement avec Maintenant que vous vous êtes un certain nombre d'accessoires, votre familiarisé avec le treuil Warn et ses treuil Warn devient un outil polyvalent composants, vous pouvez commencer à... -
Page 171: Étirement Initial Du Cable
ÉTIREMENT INITIAL DU CABLE La durée de vie du câble est prise et couper le contact chaque fois que directement liée à son utilisation et à l'on quitte le véhicule pour inspecter le l’entretien qu’il reçoit. Le tensionnement du câble du treuil. Ne jamais quitter le câble est essentiel si l'on veut assurer une véhicule lorsque le câble est sous charge. -
Page 172: Avant De Treuiller
AVANT DE TREUILLER AVERTISSEMENT Traction avec Ne jamais utiliser AVERTISSEMENT Entraînez-vous à utiliser le treuil avant un câble le treuil avec d'être coincé quelque part. Une situation N'utilisez jamais réelle n'est pas le moment approprié moins de 5 spires le treuil comme pour apprendre à... -
Page 173: Treuillage
TREUILLAGE Comme vous l'avez certainement déjà remarqué, il y a de nombreuses choses à faire et à prendre en compte avant de commencer le treuillage. Soyez attentif à ce que vous faites afin d'éviter tout accident. L'utilisation correcte du treuil est si Étape 6 : ATTACHEZ LA MANILLE importante que vous devriez vous D'ANCRAGE ET LE CORDON DU... - Page 174 Comment rembobiner à vide Arrangez le câble à enrouler de manière à ce Établissez des « zones interdites » : Ce qu’il faut surveiller sous qu’il ne s’entortille ni ne s’emmêle pendant le charge rembobinage. Assurez-vous que le câble qui est Le câble doit toujours être enroulé...
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Page 175: Techniques De Câblage
TECHNIQUES DE CÂBLAGE MAINTENANCE • Inspectez le câble avant et après • Inspectez, le cas échéant, la Différentes situations de treuillage chaque utilisation du treuil. S’il y a un télécommande au cas où elle serait nécessitent d'autres techniques de vrillage dans le câble ou que celui-ci ATTENTION endommagée. - Page 176 Guía básica de técnicas para el uso del cabrestante En cada situación donde se utiliza un cabrestante existe el potencial de ocasionar daños personales. Para reducir al mínimo este peligro es importante leer esta guía atentamente y familiarizarse con el funcionamiento del cabrestante antes de tener que usarlo; también debe poner atención continuamente en su protección.
- Page 177 PRECAUCIONES GENERALES DE SEGURIDAD ADVERTENCIA Al leer estas instrucciones, verá ADVERTENCIAS, PRECAUCIONES, AVISOS y NOTAS. Cada mensaje tiene un propósito específico. Las ADVERTENCIAS son mensajes de seguridad que indican que está ante una situación potencialmente peligrosa que, si no se evita, PELIGRO DE INCENDIO Y DE puede acarrear lesiones graves o la muerte.
- Page 178 PRECAUCIÓN PRECAUCIÓN PRECAUCIÓN PRECAUCIÓN PELIGRO DE ENREDARSE EN LAS PIEZAS PELIGRO DE ENREDARSE EN LAS PIEZAS PELIGRO DE ENREDARSE EN LAS MÓVILES MÓVILES PIEZAS MÓVILES De no seguirse estas instrucciones, podrían De no seguirse estas instrucciones, podrían De no seguirse estas instrucciones, podrían producirse lesiones menores o de moderada producirse lesiones menores o de moderada producirse lesiones menores o de moderada...
- Page 179 LO FUNDAMENTAL DEL CABRESTANTE ELÉCTRICO De modo que ya tiene el cabrestante apropiadas de uso. Pero antes de Warn y está preparado para probarlo: comenzar debemos poner énfasis en que subir a unas cuantas rocas, salpicar un la información en esta guía es solamente ADVERTENCIA poco de barro y atravesar algún que otro de carácter general.
- Page 180 CÓMO FUNCIONA EL CABRESTANTE LOS ACCESORIOS DEL CABRESTANTE QUE NECESITARÁ El cabrestante no es mucho más que Mecánica del cabrestante una simple herramienta. Pero cuando se Ahora que ya se ha familiarizado con utiliza con ciertos accesorios y mejoras, el el cabrestante Warn y sus componentes, cabrestante Warn puede convertirse en podemos empezar a ver cómo funciona.
- Page 181 TENSIÓN DEL CABLE La vida útil del cable está directamente inspeccionar el cable. No salga nunca del relacionada con la forma en que se utiliza y se vehículo con una carga aplicada al cable. cuida el mismo. Tensar el cable es 6) Procure enrollar cada vuelta parejamente fundamental para garantizar una larga vida útil para evitar daños al cable.
- Page 182 ANTES DE USAR EL CABRESTANTE Tracción con cable Practique el uso del cabrestante antes ADVERTENCIA ADVERTENCIA sencillo de quedarse estancado. Una situación No accione nunca Nunca utilice el real no es el momento para aprender a el cabrestante si cabrestante como utilizarlo.
- Page 183 TRACCIÓN Como ya habrá notado, hay mucho que hacer y que tener en cuenta antes de empezar la tracción. Piense en lo que está haciendo para poder protegerse así mismo y a los demás. Es muy importante accionar correctamente el cabrestante; de hecho, Fase 6: ACOPLE EL ENGANCHE EN debería practicar estas técnicas antes de FORMA DE D Y LA CORREA DEL...
- Page 184 Cómo enrollar el cable cuando no Establezca las zonas “prohibidas para Qué hay que considerar hay carga. las personas”: cuando haya carga Disponga el cable de forma que no se doble El cable debe enrollarse siempre ni se trabe al enrollarlo. Asegúrese de que el en el tambor empezando por el lado cable ya enrollado en el tambor esté...
- Page 185 TÉCNICAS DE MANIOBRADO MANTENIMIENTO • Inspeccione el cable de tiro antes y • Inspeccione el control remoto, si lo En varias situaciones donde se utiliza después de cada operación efectuada tuviera, para cerciorarse de que no el cabrestante se requieren aplicaciones con el cabrestante.
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Page 186: Safety First
® ENGINEERING COMPANY INC. Installation Guide: 51 Winthrop Road Chester, Connecticut 06412-0684 Dominator™ Lightbar Phone: (860) 526-9504 (with End Flashers) Fax: (860) 526-4078 Model(s): D2**, D4****, D6******, D8***** Internet: www.whelen.com Sales e-mail: autosale@whelen.com Canadian Sales e-mail: autocan@whelen.com Customer Service e-mail: custserv@whelen.com Safety First This document provides all the necessary information to allow your Whelen product to be properly and safely installed. - Page 187 Specifications: SET A PATTERN AS DEFAULT: When the desired pattern is displayed, allow it to run for more than 5 seconds. The lighthead will now display this Input Voltage: 12.8 VDC +/- 20% pattern when active. Input Current - Sim: Peak - 3.2 Amps (Avg.: 1.28 Amps) RESET TO THE FACTORY DEFAULT PATTERN: Turn off power and apply Input Current - Alt:...
- Page 188 QTY QTY QTY QTY ITEM PART NUMBER DESCRIPTION "A" 0 1 - 0 6 8 4 6 0 7 - ( ) DOMINATOR ™ / FLASHER - 2 LT 7.11 0 1 - 0 6 8 4 6 0 7 - ( ) DOMINATOR ™...
- Page 191 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
- Page 192 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today.
- Page 193 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result between the actual vehicle and the information presented in this publi- cation.
- Page 194 TABLE OF CONTENTS Vehicle Identification Numbers... . . 4 Safety ....... . . 5 Features and Controls .
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Page 195: Vehicle Identification Numbers
VEHICLE IDENTIFICATION NUMBERS Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost. -
Page 196: Safety
SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection. Read and follow the instructions of the decals on the vehicle carefully. If any of the decals depicted in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle. - Page 197 SAFETY Safety Decals and Locations Cab Frame/Seat Belt Warning Clutch Cover Warning Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.
- Page 198 SAFETY Safety Decals and Locations Shift Caution CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle. Discretionary Warning Shift Caution WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER: • Operate on public roads. A collision can occur with a another vehicle.
- Page 199 SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
- Page 200 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.
- Page 201 SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this manual and all labels carefully. Follow the operating proce- dures described.
- Page 202 SAFETY Operator Safety • Always follow proper procedures for turning as described in this manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident.
- Page 203 SAFETY Operator Safety • Never modify this vehicle through improper installation or use of accessories. • Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and fol- low the instructions in this manual for hauling cargo or pulling a trailer.
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Page 204: Equipment Modifications
SAFETY Operator Safety WARNING Make sure your RANGER is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride. Polaris RANGERs are designed to provide safe operation when used as directed. - Page 205 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes. Engage the park brake after fully stopped.
- Page 206 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain.
- Page 207 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Driving a RANGER requires your full attention.
- Page 208 SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving. WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the vehicle and/or the operator fall through the ice.
- Page 209 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it's in safe operating condition.
- Page 210 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver's license should operate a Polaris RANGER. Even though a child may be within the age group for which some vehicles are recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious...
- Page 211 SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.
- Page 212 SAFETY Fuel Safety WARNING Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always stop the engine when refueling. Always refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored.
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Page 213: Features And Controls
FEATURES AND CONTROLS Component Locations Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 110. Cab Frame (if Equipped) Steering Wheel Hip Bar Console Storage Box... - Page 214 FEATURES AND CONTROLS Component Locations Headlights Radiator (if equipped) Hood Hold-Down Strap Front Bumper/Brush Guard...
- Page 215 FEATURES AND CONTROLS Component Locations Tailgate Latch Release Taillights Taillights Tailgate Air Box CV Boot/Rear Caliper Receiver Hitch Muffler (Spark Arrestor) Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 52-55.
- Page 216 FEATURES AND CONTROLS Component Locations Instrument Cluster Your RANGER is equipped with an instrument cluster that senses vehi- cle speed from the right front wheel. The instrument cluster measures distance in miles as well as time, hours of operation and engine RPM. Refer to page 34 for the location of the instrument cluster.
- Page 217 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All seg- ments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer.
- Page 218 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the yellow mode button located under the speedometer to toggle through the mode options. See page 34. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip.
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Page 219: Diagnostic Mode
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1. - Page 220 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD).
- Page 221 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about seven (7) seconds, until either ON or OFF appears in the Rider Information Center, depend- ing on your preference.
- Page 222 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 32 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download blink codes (failure codes) from the EFI module.
- Page 223 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code No RPM Signal Loss of Synchronization Barometric Pressure Sensor: Circuit Low Input Barometric Pressure Sensor: Circuit High Input TPS: Open or Short Circuit to Ground TPS: Short Circuit to Battery RAM Error: Defective ECU Engine Temp Sensor Circuit: Short to Ground Engine Temp Sensor Circuit: Open or Short to Battery...
- Page 224 FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.
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Page 225: Mode Button
FEATURES AND CONTROLS Console Instrument Park Brake Gauge Lever Gear Selector (Shifter) Holder Holder Accessory Storage Storage Outlet Compartment Storage (with lid) Mode Tray Button Auxiliary Outlet The 12-volt accessory plug receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. -
Page 226: Gear Selector
FEATURES AND CONTROLS Gear Selector H: High Gear L: Low Gear N: Neutral Gear R: Reverse Selector NOTE: Low gear is the primary driving range for the RANGER. High gear is intended for use on hard- packed surfaces with light loads. - Page 227 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal Throttle Brake Pedal Push the pedal down to Pedal increase engine speed. Spring pressure returns the pedal to the rest position when released.
- Page 228 FEATURES AND CONTROLS Park Brake Lever To help prevent the vehicle from rolling, engage the park brake when parking the vehicle. When the park brake is fully engaged and the park brake indicator is illuminated, engine speed is limited to 1300 RPM in all gears, including neutral.
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Page 229: Ignition Switch
FEATURES AND CONTROLS Switches AWD/Differential Switch (if equipped) Light Switch Ignition Switch Ignition Switch The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. The engine is off. Electrical circuits are off, except Acc, 12V. Electrical circuits are on. - Page 230 FEATURES AND CONTROLS Switches Light Switch The ignition switch key must be in the ON/ RUN position to operate the headlights. Use the light switch to turn the headlights on or off. AWD/Differential Lock Switch The AWD/Differential Switch has three posi- tions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/ turf mode).
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Page 231: Operation
OPERATION Break-In Period The break-in period for your new Polaris RANGER is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break- in period. - Page 232 OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Item Remarks Page Brake system/pedal travel Ensure proper operation Brake fluid Ensure proper level...
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Page 233: Starting The Engine
OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Sit in the driver's seat and fasten the seat belt. 2. -
Page 234: Stopping The Engine
OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Turn the engine off. 3. Engage the park brake. WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine. Braking 1. - Page 235 OPERATION Driving Safely Driving Procedure 1. Sit in the driver's seat and fasten the seat belt. 2. After starting the engine and allowing it to warm up, apply the ser- vice brakes, and shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.
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Page 236: Driving On Slippery Surfaces
OPERATION Driving Safely Driving on Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these con- ditions, follow these precautions: 1. Slow down when entering slippery areas. 2. -
Page 237: Driving Uphill
OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the floor. 4. Proceed at a 15° maximum steady rate of speed and throttle opening. -
Page 238: Driving Downhill
OPERATION Driving Safely Driving on a Sidehill (Sidehilling) WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid operating on steep hills (15°... -
Page 239: Driving Through Water
OPERATION Driving Safely Driving Through Water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast-flowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fast-flowing water with your RANGER. Your Polaris RANGER can operate through water up to a maximum... -
Page 240: Driving Over Obstacles
OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Watch for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle. -
Page 241: Driving In Reverse
OPERATION Driving Safely Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6. - Page 242 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Place the transmission in gear. 2. Engage the park brake. 3. Turn the engine off. 4. Block the rear wheels on the downhill side. WARNING A rolling vehicle can cause property damage and serious injury.
- Page 243 OPERATION Driving Safely Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
- Page 244 OPERATION Driving Safely Hauling Cargo The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Model Maximum Capacities Cargo Box (Level Ground) RANGER 4X4 EFI 1500 lbs.
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Page 245: Dumping The Cargo Box
OPERATION Driving Safely Dumping the Cargo Box WARNING Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions. - Page 246 OPERATION Driving Safely Towing Loads WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when towing: Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. Do not operate the vehicle faster than 10 mph (16 km/h) when towing.
- Page 247 OPERATION Driving Safely Parking the Vehicle WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine. 1. Stop the vehicle on a level surface. 2. Turn the engine off. 3. Engage the park brake. 4.
- Page 248 OPERATION Differential Lock (4X4 Models) Locking the Differential The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. Locking the differential in slippery or low traction conditions helps improve traction.
- Page 249 OPERATION All Wheel Drive (AWD) The illuminated amber AWD switch indicates that the vehicle is AWD Switch in AWD. When the AWD switch is on, the front wheels will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage.
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Page 250: Emission Control Systems
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. - Page 251 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.
- Page 252 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California) Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death.
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Page 253: Maintenance
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Steering Pre-Ride Make adjustments as need ed. See Pre-Ride Checklist Front suspension Pre-Ride on page 41. Rear suspension Pre-Ride Tires... - Page 254 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Engine breather 25 H Monthly Inspect; replace if necessary filter (if equipped) Engine oil change 25 H Perform a break-in oil change (break-in) at one month Park brake cable 25 H Check tension, adjust...
- Page 255 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Fuel system 100 H 12 M Check for leaks at tank cap, lines, fuel valve, filter, pump, throttle body; replace lines every two years Fuel filter 100 H 12 M Replace yearly...
- Page 256 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 60, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.
- Page 257 MAINTENANCE Lubrication Recommendations Prop Shaft U-Joints Ball Joint Swing Arm Bushings...
- Page 258 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Always change the oil filter whenever changing oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W-50 4-cycle oil or a similar oil.
- Page 259 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Always use the recommended engine oil. Oil Check The oil dipstick and fill tube is located on the engine. 1.
- Page 260 MAINTENANCE Engine Oil Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 60.
- Page 261 MAINTENANCE Engine Oil Oil and Filter Change 12. Remove the dipstick and fill the sump with two quarts (1.9 l) of rec- ommended oil. 13. Shift the transmission to neutral. 14. Engage the park brake. 15. Apply the brakes. Start the engine. Allow it to idle for one to two minutes.
- Page 262 MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Maintain the oil level even with the bottom of the fill plug hole. Refer to the Gearcase Specifications Chart on page 70 for recommended lubricants, capacities and torque specifications.
- Page 263 MAINTENANCE Gearcases Transmission (Main Gearcase) Oil Change The drain plug is located on the bottom of the transmission. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug. 2. Place a drain pan under the drain plug.
- Page 264 MAINTENANCE Gearcases Front Gearcases Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 70 for recommended lubricants, capacities and torque specifications.
- Page 265 MAINTENANCE Gearcases Middle Gearcase (6X6) Always check and change the middle gearcase oil at the intervals out- lined in the Periodic Maintenance Chart beginning on page 60. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 70 for recommended lubricants, capacities and torque specifications.
- Page 266 MAINTENANCE Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Refer to the Gearcase Specifications Chart on page 70 for recommended lubricants, capacities and torque specifications. See page 114 for the part numbers of Polaris products.
- Page 267 MAINTENANCE Gearcases Rear Gearcase Oil Change 1. Remove the fill plug. 2. Place a drain pan under the drain plug. Remove the drain plug. 3. Drain the oil. Dispose of used oil properly. 4. Clean the drain plug. Reinstall the drain plug. Torque to specifica- tion.
- Page 268 MAINTENANCE Spark Plugs CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 110. Spark Plug Gap/Torque Model Electrode Gap New Plug Torque Used Plug Torque RANGER .035"...
- Page 269 MAINTENANCE Spark Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not be white.
- Page 270 MAINTENANCE Cooling System Operation The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radia- tor filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle.
- Page 271 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 60. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiator or behind the cooling fan.
- Page 272 MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 60. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiator or behind the cooling fan.
- Page 273 MAINTENANCE Polaris Variable Transmission (PVT) System Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT components (belt, cover, etc.).
- Page 274 MAINTENANCE PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced.
- Page 275 MAINTENANCE PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Loosen the bottom screws that secure the clutch cover. 2.
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Page 276: Air Filter
MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. 1. Lift the cargo box to access the air box. 2. Remove the air box Air Filter cover and inspect the gasket. - Page 277 MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.
- Page 278 MAINTENANCE Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal.
- Page 279 MAINTENANCE Throttle System Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Freeplay Adjustment 1. Remove the seat. 2. Locate the throttle cable adjuster.
- Page 280 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 36. Brake Fluid Inspect the brake system rou- Brake Fluid tinely. Inspect the level of the Reservoir brake fluid before each opera- tion.
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Page 281: Brake Inspection
MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Inspect the brake disc spline and pad wear surface for excessive wear. - Page 282 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3.
- Page 283 MAINTENANCE Seat Belts Inspect all three seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched.
- Page 284 MAINTENANCE Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8" (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury.
- Page 285 MAINTENANCE Tires WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed.
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Page 286: Headlight Lamp Replacement
MAINTENANCE Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. -
Page 287: Headlight Beam Adjustment
MAINTENANCE Lights Headlight Beam Adjustment 25 ft. (7.6 m) 8" (20 cm) 1. Place the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. - Page 288 MAINTENANCE Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your RANGER to a dealer before starting it, fol- low the steps outlined below.
- Page 289 MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identi- fied by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Battery Always keep battery terminals and connections free of corrosion.
- Page 290 MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1.
- Page 291 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 102 before installing the battery.
- Page 292 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.
- Page 293 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 99. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.
- Page 294 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Voltage Action (Using constant current Charge charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 None required...
- Page 295 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces.
- Page 296 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the follow- ing items: •...
- Page 297 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.
- Page 298 MAINTENANCE Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 104.
- Page 299 MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. Follow the instruc- tions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2.
- Page 300 MAINTENANCE Removal from Storage 1. Check the battery electrolyte level and charge the battery if neces- sary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2.
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Page 301: Specifications
SPECIFICATIONS RANGER 4X4 700 EFI Maximum Weight Capacity 1500 lbs. (682 kg) (includes weight of operator, passenger, cargo, accessories) Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (2.1 l) Coolant Capacity 3.25 qts. (3 l) Towing Capacity 2000 lbs. - Page 302 SPECIFICATIONS RANGER 4X4 700 EFI Lubrication System Pressurized Wet Sump Engine Oil 2W-50 Driving System Type PVT, 4-wheel independent shaft, lockable differ- ential Shift Type Single Lever (H/L/N/R) Gear Reduction - Low 8.71:1 Gear Reduction - Reverse 5.94:1 Gear Reduction - High 3.14:1 Drive Ratio - Front: 3.83:1...
- Page 303 SPECIFICATIONS RANGER 6X6 700 EFI Maximum Weight Capacity 1750 lbs. (795 kg) (includes weight of operator, passenger, cargo, accessories) Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (2.1 l) Coolant Capacity 3.25 qts. (3 l) Towing Capacity 2000 lbs.
- Page 304 SPECIFICATIONS RANGER 6X6 700 EFI Lubrication System Pressurized Wet Sump Engine Oil 2W-50 Driving System Type Shift Type Single Lever, Console (H/L/N/R) Gear Reduction - Low 8.71:1 Gear Reduction - Reverse 5.9:1 Gear Reduction - High 3.14:1 Drive Ratio - Front: 3.83:1 Drive Ratio - Final 3.70:1...
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Page 305: Polaris Products
POLARIS PRODUCTS Part Description Number Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Premium AGL Synthetic Gearcase Lube (gal.) 2871653... -
Page 306: Troubleshooting
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or Use low range during loading. tall trailer in high range Starting out going up a Use low range. See warnings on page 46. steep incline Driving at low RPM or Drive at a higher speed or use low range more frequently. - Page 307 TROUBLESHOOTING Park Brake Engine Limiting Feature Fails to Disengage Possible Cause Solution Park brake is not completely disengaged Ensure lever is in forward-most position Park brake connector malfunction or Disconnect the connector if temporary switch movement or failure continued operation is necessary, see your dealer promptly for service Engine Doesn't Turn Over Possible Cause...
- Page 308 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs...
- Page 309 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range...
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Page 310: Warranty
WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris RANGER against defects in mate- rial or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. - Page 311 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR- TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.
- Page 312 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries.
- Page 313 WARRANTY U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
- Page 314 WARRANTY California Emission Control Warranty Statement The Air Index of this Engine is 3 Most Clean Least Clean Note: The lower the Air Index, the less pollution. This engine is certified to be emission compliant for 1000 hours of use. Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein "POLARIS") are pleased to explain the emission con-...
- Page 315 WARRANTY California Emission Control Warranty Statement Owner's Warranty Responsibilities: • As the LSI engine owner, you are responsible for the performance of the required maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's Manual"). POLARIS recommends that you retain all receipts covering maintenance on your LSI engine, but POLARIS cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
- Page 316 WARRANTY California Emission Control Warranty Statement Emission-Related Parts Covered Under This Warranty (1) Fuel Metering System (i) Carburetor and internal parts (and/or pressure regulator or fuel injection system) (ii) Air/fuel ratio feedback and control system, if applicable (iii) Cold start enrichment system, if applicable (iv) Regulator assy (gaseous fuel, if applicable) (2) Air Induction System (i) Intake manifold, if applicable...
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Page 317: Maintenance Schedule
WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission-related part which malfunctions, fails or is damaged due to alterations and/or modifications such as changing, adding or removing parts. When the LSI engine is being serviced under warranty, POLARIS and any of its autho- rized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience. - Page 318 WARRANTY Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Have an authorized Polaris dealer perform these services Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Air filter, pre-filter Daily Inspect; clean often Air box sediment Daily Drain deposits when visible...
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Page 319: Maintenance Log
MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS... - Page 320 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
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Page 321: Index
INDEX Accessory Outlet ....34 Cap, Fuel ..... . 33 Adding Coolant . - Page 322 INDEX Drivetrain Break-In....40 Freeplay Adjustment, Throttle ..88 Driving Downhill ....47 Freeplay, Steering Wheel .
- Page 323 INDEX Key, Periodic Maintenance Chart . . 61 Oil Change, Transmission ..72 Kilometers to Miles Toggle ..30 Oil Check, Front Gearcase..73 Oil Check, Main Gearcase.
- Page 324 INDEX Removal, Battery ....99 Switches ....38-39 Removal, Seat .
- Page 325 Owner’s Manual Supplement Owner’s Manual Supplement 2008 RANGER 2008 RANGER P/N 9921696 P/N 9921696 Please keep this supplement with your owner’s manual at all times. Please keep this supplement with your owner’s manual at all times. Park Brake Cable Tension Park Brake Cable Tension When the park brake is fully engaged and the park brake indicator When the park brake is fully engaged and the park brake indicator...
- Page 326 2009 RANGER 700 4X4 CREW / 6X6 SERVICE MANUAL PN 9921885...
- Page 327 2009 RANGER 700 4X4 CREW / 6X6 SERVICE MANUAL FOREWORD The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com. This Service Manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference.
- Page 328 UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.
- Page 329 GENERAL INFORMATION MAINTENANCE ENGINE ELECTRONIC FUEL INJECTION BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...
- Page 331 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION MODEL INFORMATION ..........1.2 MODEL IDENTIFICATION .
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Page 332: General Information
GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification R 0 9 W H 6 8 A G Emissions & Model Year Model Option Designation Basic Chassis Engine Designation Designation... -
Page 333: Vehicle Identification Number (Vin) Location
GENERAL INFORMATION Vehicle Identification Number (VIN) Location Transmission I.D. Number Location The machine model number and serial number are important for The transmission I.D. number is located on the vehicle identification. The vehicle identification number (A) is right side when installed in the vehicle. stamped on the lower LH frame rail close to the front drive wheel. -
Page 334: Vehicle Dimensions
GENERAL INFORMATION VEHICLE DIMENSIONS RANGER 4x4 CREW / 6X6 (Height and Width) 75 in. 190.5 cm 11.5 in. 29.2 cm 60 in. 152.4 cm... -
Page 335: Ranger 6X6 (Length And Wheel Base)
GENERAL INFORMATION RANGER 6X6 (Length and Wheel Base) 120 in. 305 cm 42.5 in. 108 cm 27 in. 69 cm 90 in. 229 cm RANGER 4x4 CREW (Length and Wheel Base) 145 in. 386 cm 36.5 in. 92.7 cm 108 in. 274 cm... -
Page 336: General Specifications
GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2009 RANGER 4X4 CREW MODEL NUMBER: R09WH68AC, AG, AH, AR ENGINE MODEL: EH68OLE Category Dimension / Capacity Length 145 in. / 386 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 108 in. - Page 337 GENERAL INFORMATION MODEL: 2009 RANGER 4X4 CREW Drivetrain MODEL NUMBER: R09WH68AC, AG, AH, AR Transmission Type Polaris Automatic PVT ENGINE MODEL: EH68OLE Transmission Gear Ratio: Engine Front / Rear High 4.43:1 / 3.83:1 Polaris Domestic Twin Cylinder, Platform 10.08:1 / 8.71:1 Liquid Cooled, 4-Stroke Reverse 6.87:1 / 5.94:1...
- Page 338 GENERAL INFORMATION MODEL: 2009 RANGER 6X6 MODEL NUMBER: R09RF68AF, AR ENGINE MODEL: EH068OLE Category Dimension / Capacity Length 120 in. / 305 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 90 in. / 229 cm Ground Clearance 7.2 in.
- Page 339 GENERAL INFORMATION MODEL: 2009 RANGER 6X6 Drivetrain MODEL NUMBER: R09RF68AF, AR Transmission Type Polaris Automatic PVT ENGINE MODEL: EH68OLE Transmission Gear Ratio: Engine Front / Rear High 4.43:1 / 3.83:1 Polaris Domestic Twin Cylinder, Platform 10.08:1 / 8.71:1 Liquid Cooled, 4-Stroke Reverse 6.87:1 / 5.94:1 Engine Model Number...
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Page 340: Vehicle Information
GENERAL INFORMATION VEHICLE INFORMATION Publication Numbers Model Model No. Owner’s Manual PN Parts Manual PN 2009 RANGER 4x4 CREW R09WH68AC, AG, AH, AR 9921882 9921884 2009 RANGER 6x6 R09RF68AF, AR 9921871 9921874 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. -
Page 341: Misc. Specifications And Charts
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C 1.11... -
Page 342: Standard Torque Specifications
GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque. 1.12... -
Page 343: Sae Tap / Drill Sizes
GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes 1.13... -
Page 344: Glossary Of Terms
GENERAL INFORMATION Glossary of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. - Page 345 MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART ......... 2.3 PERIODIC MAINTENANCE OVERVIEW .
- Page 346 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM ........2.26 BATTERY MAINTENANCE .
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Page 347: Periodic Maintenance Chart
MAINTENANCE PERIODIC MAINTENANCE CHART Periodic Maintenance Overview Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. -
Page 348: Pre-Ride - 25 Hour Maintenance Interval
MAINTENANCE Pre-Ride - 25 Hour Maintenance Interval Maintenance Interval (whichever comes first) Item Remarks Miles Hours Calendar (KM) Steering Pre-Ride Front Suspension Pre-Ride Rear Suspension Pre-Ride Tires Pre-Ride Brake Fluid Level Pre-Ride Make adjustments as needed. Brake Pedal Travel Pre-Ride See Pre-Ride Checklist on Page 2.13. -
Page 349: 50 - 100 Hour Maintenance Interval
MAINTENANCE 50 - 100 Hour Maintenance Interval Maintenance Interval (whichever comes first) Item Remarks Miles Hours Calendar (KM) Lubricate all grease fittings, pivots, cables, General Lubrication 50 H etc. Shift Linkage 50 H Inspect, lubricate, adjust Steering 50 H Lubricate Front Suspension 50 H Lubricate... - Page 350 MAINTENANCE 100 - 300 Hour Maintenance Interval Maintenance Interval (whichever comes first) Item Remarks Miles Hours Calendar (Km) Check for leaks at tank cap, fuel lines, fuel Fuel System 100 H pump, and fuel rail. Replace lines every two years. Radiator 100 H Inspect;...
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Page 351: Service Products And Lubes
MAINTENANCE SERVICE PRODUCTS AND LUBES Polaris Lubricants, Maintenance and Service NOTE: Each item can be purchased separately at your local Polaris dealer. Products Part No. Description Part No. Description Additives / Sealants / Thread Locking Agents / Misc. Engine Lubricant 2870585 Loctite™... -
Page 352: Maintenance References
MAINTENANCE MAINTENANCE REFERENCES Item Lube Rec. Method Frequency* Change after 1st month (25 hrs), 6 Polaris PS-4 PLUS Add oil to proper level months or 100 hours thereafter; Change 1. Engine Oil Performance Synthetic 2W-50 indicated on dipstick. more often in extremely dirty conditions, 4-Cycle Engine Oil (2876244) or short trip cold weather operation. -
Page 353: Maintenance References, Continued
MAINTENANCE Maintenance References, Continued..Item Lube Rec. Method Frequency* Polaris All Season Grease (PN Locate grease fitting on 6. Swing Arm Pivot Semi-annually** 2871423) inside of the swing arm pivot. Polaris Premium U-Joint Lube Locate fittings and grease 7. Rear Prop Shaft Yoke Semi-annually** (PN 2871551) with grease gun. -
Page 354: General Vehicle Inspection And Maintenance
MAINTENANCE GENERAL VEHICLE INSPECTION Shift Linkage Inspection / Adjustment AND MAINTENANCE Linkage rod adjustment is necessary when symptoms include: • No All Wheel Drive light Pre-Ride / Daily Inspection • Noise on deceleration Perform the following pre-ride inspection daily, and when •... -
Page 355: Fuel System And Air Intake
MAINTENANCE Fuel Filter Use this procedure to loosen or tighten the shift linkage cable as needed. The fuel pump on the RANGER 700 EFI is non-serviceable. If Clockwise Inside Jam Nut the internal fuel pump filters require service, the fuel tank and fuel pump must be replaced as an assembly. -
Page 356: Throttle Freeplay Adjustment
MAINTENANCE Throttle Freeplay Adjustment Air Filter Service Inspection It is recommended that the air filter be replaced annually. When riding in extremely dusty conditions replacement will be Apply the parking brake. required more often. Put the gear shift lever in the N (Neutral) position. The filter should be inspected periodically before each ride, using the following procedure. -
Page 357: Air Intake Inspection
MAINTENANCE Air Intake Inspection NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before Lift the hood. installing. Inspect the foam insert in the engine intake air baffle box. Check air box. If oil or water deposits are found, drain them If the foam insert is dirty, clean the foam with a high flash into a suitable container. -
Page 358: Engine
MAINTENANCE ENGINE Engine Oil Level The twin cylinder engine is a wet-sump engine, meaning the oil Compression and Leakdown Test is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below. NOTE: This engine does NOT have decompression components. -
Page 359: Engine Oil And Filter Change
MAINTENANCE Engine Oil and Filter Change Reinstall dipstick and push it into place. Do not lock the dipstick. WARNING NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of dipstick consistent. -
Page 360: Exhaust Pipe
MAINTENANCE NOTE: The sealing surface on the drain plug should Exhaust Pipe be clean and free of burrs, nicks or scratches. WARNING Reinstall drain plug and torque to 16 ± 2 ft. lbs. (21.7 ± 2.7 Nm). Do not perform clean out immediately after the engine Place shop towels beneath oil filter. -
Page 361: Transmission And Gearcases
MAINTENANCE TRANSMISSION AND GEARCASES If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the hand brake and block the Transmission Lubrication wheels. -
Page 362: Front Gearcase Lubrication
MAINTENANCE Transmission Lubricant Change Front Gearcase Lubrication Access the drain plug on the right-hand side of the vehicle The gearcase lubricant level should be checked and changed in through the skid plate. accordance with the maintenance schedule. Remove the fill plug (refer to “Transmission Lubricant •... -
Page 363: Middle Gearcase Lubrication (6X6)
MAINTENANCE To change gearcase lubricant: Remove fill plug (8 mm hex) and check the O-ring. Remove gearcase drain plug (B) (11 mm) located on the bottom of the gearcase and drain oil. (The drain plug is Fill Plug accessible through the skid plate.) Catch and discard used oil properly. -
Page 364: Rear Gearcase Lubrication (4X4 Crew)
MAINTENANCE Rear Gearcase Lubrication (4x4 CREW) • The correct middle gearcase lubricant to use is ATV Angle Drive Fluid To check the lubricant level: The gearcase must be drained and re-filled with the proper amount of lubricant. Refer to the procedure below. Rear Gearcase Specifications (4x4 CREW) To change middle gearcase lubricant: Specified Lubricant:... -
Page 365: Rear Gearcase Lubrication (6X6)
MAINTENANCE Rear Gearcase Lubrication (6x6) Lubricant Change: The drain plug is located on the bottom right side of the rear gearcase. Fill Plug Rear Gearcase Specifications (6x6) Specified Lubricant: ATV Angle Drive Fluid (PN 2871653) Capacity: 10 oz. (300 ml) The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. -
Page 366: Cooling System
MAINTENANCE Coolant Level Inspection Remove fill plug (A). The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle. Surge Tank Cap Fill with 10 oz. (300 ml.) or fill to the bottom of the threads of the fill plug hole. -
Page 367: Radiator Coolant Level Inspection
MAINTENANCE Radiator Coolant Level Inspection • Straight water or antifreeze may cause the system to freeze, corrode, or overheat. NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or Polaris 60/40 Anti-Freeze / Coolant repair. -
Page 368: Radiator
MAINTENANCE Radiator Remove the drain plug and drain the coolant from the radiator. Drain the coolant into a suitable container and Check radiator (A) air passages for restrictions or damage. properly dispose of the coolant. Remove the outlet radiator hose, inlet radiator hose, surge tank hose, and overflow hose from the radiator. -
Page 369: Final Drive / Wheel And Tire
MAINTENANCE FINAL DRIVE / WHEEL AND TIRE Wheel Removal Wheel and Hub Torque Table Front & Rear Wheel Nuts (4) Item Nut Type Specification Aluminum Wheels Lug Nut (1) 90 ft. lbs. (122 Nm) (Cast) Front Hub Nut 60 ft. lbs. (81 Nm) Steel Wheels Flange Nut (2) 35 ft. -
Page 370: Tire Inspection
MAINTENANCE Tire Inspection ELECTRICAL AND IGNITION SYSTEM • Improper tire inflation may affect vehicle Battery Maintenance maneuverability. Keep battery terminals and connections free of corrosion. If • When replacing a tire always use original equipment cleaning is necessary, remove the corrosion with a stiff wire size and type. -
Page 371: Battery Fluid Level (Conventional Battery)
MAINTENANCE Battery Fluid Level (Conventional Battery) Battery Installation A poorly maintained battery will deteriorate rapidly. Check the Using a new battery that has not been fully charged can damage battery fluid level often. Maintain the fluid level between the the battery and result in a shorter life. It can also hinder vehicle upper and lower level marks. -
Page 372: Spark Plug Service
MAINTENANCE Spark Plug Service Install spark plug and torque to specification. Remove both spark plug high tension leads (A). Clean Recommended Spark Plug: plug area so no dirt and debris can fall into engine when Champion RC7YC3 plug is removed. Spark Plug Torque: 18 ft. -
Page 373: Steering And Suspension
MAINTENANCE STEERING AND SUSPENSION • If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut). Steering • Refer to the Final Drive chapter for more information. The steering components should be checked periodically for loose fasteners, worn tie rod ends, and damage. -
Page 374: Toe Adjustment
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 375: Rear Suspension
MAINTENANCE Rear Suspension Rear Suspension Adjustment (4x4 CREW) The rear suspension may be adjusted to provide a stiffer suspension if necessary. Remove the top shock mounting bolts from the inside mounting holes. Reposition the shocks to the outside mounting holes. Reinstall the shock mounting bolts. -
Page 376: Brake System
MAINTENANCE BRAKE SYSTEM Brake Pad / Disc Inspection Check the brake pads for wear, damage, or looseness. Brake Fluid Inspection Inspect the brake pad wear surface for excessive wear. Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. -
Page 377: Parking Brake Pad Inspection
MAINTENANCE Loss of tension in the parking brake cable will cause illumination of the parking brake light and activation of the limiting feature. If this occurs, inspect and adjust parking brake cable tension. If performing this service is difficult due to conditions or location, open the hood and temporarily disconnect the parking brake connector. - Page 378 MAINTENANCE NOTES 2.34...
- Page 379 ENGINE CHAPTER 3 ENGINE ENGINE SPECIFICATIONS ..........3.2 CRANKCASE EXPLODED VIEWS .
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Page 380: Engine Specifications
ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views A. Journal Bearings B. Camshaft C. Thrust Plate D. Balance Shaft E. Woodruff Key F. Flange Seal G. Crankshaft H. Oil Pickup I. Journal Bearings J. Baffle K. Oil Plug L. Washer M. O-ring N. - Page 381 ENGINE Oil Pump / Water Pump / Engine Cover Exploded View A. Split Gear B. Washer C. Bolt D. Oil Rotor E. Oil Pump F. Mag Gasket Cover G. Impeller H. Washer I. Nut J. Counterbalance Gear K. Washer L. Bolt M.
- Page 382 ENGINE Stator Cover / Starter / Water Pump Exploded View Apply Polaris Water Pump Cover Starter Grease Bolt Tighten Sequence Apply Polaris 2W-50 oil to seal Loctite™ Pipe Sealant (PN 2871956) No Grease or Oil 84 ± 8 ft.lbs. (9.5 ± 0.9 Nm) 96 ±...
- Page 383 ENGINE Oil Filter / Pressure Relief / Dipstick Assembly Exploded View A. Clamp B. Oil Fill Tube C. Dipstick D. O-ring E. Hex Plug F. Oil Filter Nipple G. Oil Filter H. Dowel I. Galley Plug Asm. J. Screw K. Relief Spring 50 ±...
- Page 384 ENGINE Cylinder / Cylinder Head / Piston Exploded View Initial: ± ± Lubricate threads & between 4 ft. lbs (47.5 5.5 Nm) washers and underside of bolt heads in sequence. Finalize sequence with engine oil. by tightening an additional 90° Torque in sequence provided.
- Page 385 ENGINE Engine Sensors / Valve Cover / General Component Exploded View 84 ± 8 in. lbs. (9.5 ± 0.9 Nm) A. Screws 20 ± 5 in. lbs. B. Rocker Cover (2.5 ± 0.55 Nm) C. Breather D. O-ring Seal 18 ± 2 ft. lbs. E.
- Page 386 ENGINE EFI Harness / Fuel Injection Exploded View A. Fuel Injector B. Fuel Rail C. EFI Harness 18 ± 2 ft. lbs. (24.5 ± 2.7 Nm) NOTE: See Chapter 4 for more information on the EFI system.
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Page 387: Engine Fastener Torque Patterns
ENGINE Engine Fastener Torque Patterns Crankcase Bolt Tighten Sequence 22 ± 2 ft. lbs. (30 ± 3 Nm) Cylinder Head Bolt Tighten Sequence Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, then °... -
Page 388: Torque Specifications
ENGINE Torque Specifications Engine Torque Specifications Fastener Size in. lbs. (Nm) ft. lbs. (Nm) Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 115 ± 12 (13 ± 1.35) 9.5 ± 1 (13 ± 1.35) Throttle Body Adaptor Bolts 8 mm 216 ±... -
Page 389: 700 Efi Engine Service Specifications
ENGINE 700 EFI Engine Service Specifications Cylinder Head - Engine Specifications Main Component: Cylinder Head EH068OLE Cam Lobe Height - Intake / Exhaust 1.3334" (33.8674 mm) 1.654" ± 0.00039" (42 ± 0.010 mm) Camshaft Journal Outer Diameter - Mag 1.634"± 0.00039" (41.50 ± 0.010 mm) Camshaft Journal Outer Diameter - Center 1.614"... - Page 390 ENGINE Cylinder / Piston - Engine Specifications Main Components: Cylinder / Piston / Connecting Rod EH068OLE Cylinder - Surface warp limit 0.004" (0.10 mm) (mating with cylinder head) Cylinder Bore - Standard 3.1495" (80 mm) Cylinder Cylinder Taper Limit 0.00031" (0.008 mm) Cylinder Out of Round Limit 0.00030"...
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Page 391: Special Tools
ENGINE Special Tools Part Number Tool Description PV-43527 OIL FILTER WRENCH 2200634 VALVE SEAT RECONDITIONING KIT PU-45257 VALVE SPRING COMPRESSOR PU-45652 VALVE PRESSURE HOSE 2871043 FLYWHEEL PULLER 2870390 PISTON SUPPORT BLOCK PU-45497-1 CAM GEAR SPRING INSTALLATION KIT PU-45497-2 CAM GEAR TOOTH ALIGNMENT TOOL PU-45498 CAM SPANNER WRENCH PU-45838... -
Page 392: Cooling System Pressure Test
ENGINE Recommended Coolant Radiator Cap Pressure Test Use only high quality antifreeze/coolant mixed with distilled WARNING water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area. CAUTION: Using tap water in the cooling system will lead to Never remove radiator cap when engine is a buildup of deposits which may restrict coolant flow and reduce warm or hot. -
Page 393: Cooling System Exploded View
ENGINE Cooling System Exploded View Radiator Inlet Hose Engine Outlet Hose Engine Inlet Hose Radiator Outlet Hose Radiator Cap Surge Tank Radiator Shroud Drain Plug Cooling System Bleeding Procedure Place the vehicle in Neutral and set the parking brake. CAUTION WARNING Be sure the engine has cooled and there is no Always wear safety glasses and proper shop... - Page 394 ENGINE Elevate the driver’s side of the vehicle 20” (50.8 cm) off Add Polaris Premium Antifreeze to the radiator if the level the ground so the thermostat housing is at the highest point goes down. on the cylinder head. This will allow any trapped air to Tighten the bleed screw to 70 ±...
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Page 395: Valve Cover Removal - 6X6 Models (Engine Installed)
ENGINE Valve Cover Removal - 6x6 Models Remove the heat shield shown below and loosen the exhaust mounts. (Engine Installed) The RANGER 6x6 models have a different engine mounting system that makes it more difficult to access and remove the Loosen Remove engine valve cover. -
Page 396: Engine Removal
ENGINE Engine Removal 12. Disconnect the air intake hose (D) from the air box and remove the air intake hose. WARNING Always wear safety glasses and proper shop clothing when performing the procedures in this manual. Failing to do so may lead to possible injury or death. -
Page 397: Engine Installation Notes
ENGINE 16. Remove the crank position sensor (I) located on the mag NOTE: Use caution when lifting the engine out of frame. Use an engine lift or other means if the engine cover. is too heavy to be lifted manually. 17. -
Page 398: Engine Lubrication Specifications
ENGINE Engine Lubrication Specifications Exhaust Replace exhaust gaskets. Seal connections with high temp silicone sealant. Check to be sure all springs are in good condition. Capacity - Approximately 2 U.S. Quarts (1.9 l) Bleed Cooling System Oil Type - Polaris PS-4 PLUS 2W-50 Synthetic NOTE: Follow coolant bleeding procedure outlined earlier in this chapter Filter Wrench - PV-43527 or equivalent... -
Page 399: Oil Flow Chart
ENGINE Oil Flow Chart This chart describes the flow of oil through the 700 engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. -
Page 400: Engine Disassembly And Inspection
ENGINE ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Rocker Arms Retainer Locks (keepers) Push Rods Spring Retainers Springs Valve Seals Valve Spring Seats Cylinder Head Hydraulic Lifters Valves 3.22... -
Page 401: Rocker Arms / Push Rods
ENGINE Rocker Arms If the push rod (A) is visibly bent, it should be replaced. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. Cylinder Head Removal Inspect the wear pad at the valve end of the rocker arm for Loosen the six cylinder head bolts evenly 1/8 turn each in indications of scuffing or abnormal wear. -
Page 402: Cylinder Head Inspection / Warp
ENGINE Cylinder Head Inspection Valve Seal / Spring Service (On Engine) NOTE: The following procedure is only for servicing Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon. the top end of the valve train when replacing valve springs or replacing valve seals. -
Page 403: Cylinder Head Disassembly
ENGINE Cylinder Head Disassembly Remove valve guide seals. Carefully remove the cylinder components. IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. Mark the valves with a white pen. -
Page 404: Valve Inspection
ENGINE Valve Inspection Remove all carbon from valves with a soft wire wheel or = In. / mm. brush. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” Valve Stem Diameter: blocks and a dial indicator. -
Page 405: Combustion Chamber
ENGINE Combustion Chamber NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The Clean all accumulated carbon deposits from combustion valve must contact the valve seat over the entire chamber and valve seat area with carbon cleaner and a soft circumference of the seat, and the seat must be the plastic scraper. - Page 406 ENGINE NOTE: When using an interference angle, the seat Inspect the cut area of the seat: contact point on the valve will be very narrow, and is * If the contact area is less than 75% of the circumference of the a normal condition.
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Page 407: Cylinder Head Reassembly
ENGINE Cylinder Head Reassembly Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. NOTE: Assemble the valves one at a time to maintain proper order. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the Apply engine oil to valve guides and seats. -
Page 408: Valve Sealing Test
ENGINE Valve Sealing Test Valve Lifter Removal / Inspection Clean and dry the combustion chamber area (A). Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand. Thoroughly clean the lifters in cleaning solvent and wipe them with a clean, lint-free cloth. -
Page 409: Piston Removal
ENGINE Piston Removal The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. The top rail has Remove circlip (A). Mark the piston with a white pen to a locating tab on the end which fits into a notch (B) in the upper ensure proper orientation (if reused) during assembly. -
Page 410: Cylinder Inspection
ENGINE Cylinder Inspection Inspect cylinder for wear, scratches, or damage. Remove all gasket material from the cylinder sealing surfaces. Inspect the top of the cylinder (B) for warp using a straight edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. -
Page 411: Cylinder Hone Selection And Honing Procedure
ENGINE Cylinder Hone Selection And Honing If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. The cylinders are lined with a nicasil Procedure coating and are not repairable. Hone only enough to de-glaze the outer layer of the cylinder bore. Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. -
Page 412: Piston-To-Cylinder Clearance
ENGINE Piston-to-Cylinder Clearance Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin. -
Page 413: Piston Ring Installed Gap
ENGINE Measure piston ring to groove clearance by placing the ring If the bottom installed gap measurement exceeds the in the ring land and measuring with a thickness gauge. service limit, replace the rings. If ring gap is smaller than Replace piston and rings if ring-to-groove clearance the specified limit, file ring ends until gap is within exceeds service limits. -
Page 414: Flywheel / Stator Removal / Inspection
ENGINE Inspect gear teeth on starter drive (A). Replace starter drive if gear teeth are cracked, worn, or broken. Inspect the bendix bushing (C) in the mag cover for wear. Replace as needed. 2871043 Use caution when removing the wire holddown (B) and the stator assembly (D). - Page 415 ENGINE Remove the nylok nut (C), washer (D), and water pump Remove the starter bendix (G), wire holddown plate (H), impeller (E). Remove part of the water pump seal behind and the woodruff key (I) from the crankshaft. The stator the impeller.
- Page 416 ENGINE Use a white pen to accent the timing marks on the following CAUTION gears: camshaft gear (K), crankshaft gear (M), or counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears. Wear safety glasses at all times. Use caution when working with the top gear.
- Page 417 ENGINE 14. Inspect the gear teeth and the three tabs on the gears for To Assemble: wear. * Hold the spring with one finger. * Start the pointed end of the tapered pin into the cam gear hole Inspect Teeth & Tabs and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring.
- Page 418 ENGINE 19. Once the gears are pressed together, firmly hold the gears 21. To remove the balance shaft gear, the flat side of the together with one hand. Carefully remove the Tapered Pins camshaft (P) must face the balance shaft gear. To rotate the (PU-45497-1) by pulling them out one at a time with the camshaft, use the Cam Spanner Wrench (PU-45498) to other hand.
- Page 419 ENGINE 23. Inspect the crankshaft gear (Q) for broken or worn teeth. If 26. Rotate the water/oil pump gear (S), so that all four bolts are the crankshaft gear does not need to be replaced, it does not visible though the gear. Remove the four bolts with a hex need to be removed.
- Page 420 ENGINE 29. Remove the oil pressure relief. The oil pressure relief 31. Carefully press the gear off the assembly while supporting consists of a bolt, washer, spring, and valve (dowel). the housing assembly. Inspect the valve (dowel) for signs of possible obstructions. Use compressed air to blow out any debris.
- Page 421 ENGINE 34. Press shaft into the new bearing.. 37. Remove thrust plate (U). Press On Bearing 35. Press the bearing/shaft assembly using the bearing's outer race. Do not use the shaft to press the assembly into the 38. Remove PTO end engine mount. Remove crankcase bolts. housing, as bearing damage may result.
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Page 422: Camshaft Inspection
ENGINE Camshaft Inspection 40. Remove balance shaft and crankshaft. Thoroughly clean the cam shaft. Visually inspect each cam lobe for wear or damage. Measure height of each cam lobe using a micrometer. Compare to specification. 41. Remove and inspect crankshaft main journal bearings for abnormal wear. -
Page 423: Engine Reassembly
ENGINE ENGINE REASSEMBLY Measure ID of camshaft journal bores. Crankcase Reassembly = In. / mm. CAUTION Camshaft Journal Bore I.D.: (Mag): 1.656" ± 0.00039" (42.07± 0.010 mm) After any reassembly or rebuild, the engine (Ctr.) 1.637" ± 0.00039" (41.58 ± 0.010 mm) must be primed using the Oil Priming Adapter (PTO) 1.617"... - Page 424 ENGINE Install the balance shaft. Inspect balance shaft clearance Apply Crankcase Sealant (PN 2871557) to the top gearcase (C) in both gearcase halves. Rotate balance shaft to ensure halve. there is clearance between it and the oil baffle weldment. NOTE: Do not apply sealant to cam relief hole (E). Assemble the crankcase halves.
- Page 425 ENGINE NOTE: Always replace the camshaft and lifters as a 12. Orientate the piston rings on the piston before installation set. into the cylinders. Set the gaps of the rings every 120° (See Illustration Below). Piston Ring Orientation 1. Top Ring 2.
- Page 426 ENGINE NOTE: New bolts have patch lock on the threads 14. Position cylinder and piston assemblies onto the connecting and do not require Loctite™. rods and push the piston pins through the piston and connecting rods. Push in Piston Pins 15.
- Page 427 ENGINE 19. Align the bolt holes and install oil pump assembly into 21. Apply Loctite™ 242 (PN 2871949) to the crankshaft. crankcase. Rotate the rotors in the housing during installation, as this checks for binding if new rotors are used. NOTE: For assembly of the gears, the cam gear and the crankshaft gear are stamped with “This Side Out."...
- Page 428 ENGINE 24. Install the crankshaft gear (I) onto the crankshaft. 26. Use the Cam Gear Alignment Tool (PU-45497-2) to align the teeth of the cam gear (M). Install the cam gear (M) (with NOTE: For assembly of the gears, the cam gear and the Cam Gear Alignment Tool still in place) onto the the crankshaft gear are stamped with This Side Out."...
- Page 429 ENGINE NOTE: Be sure all of the timing marks are properly IMPORTANT: Due to seal design and construction, aligned. seals MUST be installed DRY (no lubricant) during assembly. Use of lubricants (oil, soapy water, etc.) Water Pump Gear will not allow the seal to wear-in and seal properly. Do not touch seal surface or allow seal surface to come Timing Marks in contact with contaminates during installation.
- Page 430 ENGINE 30. Once the crankshaft seal is installed into the gear / stator 32. Before installing the gear/stator housing cover, install the housing cover, set the direction of the paper lip by sliding Water Pump Seal Saver (PA-45401) onto the water pump the Main Crankshaft Seal Saver (PA-45658) into the shaft.
- Page 431 ENGINE NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris. This will ensure proper sealing when installing bolts. 37. Install shaft seal with ceramic surface facing inward. 35. Install the gear/stator housing gasket onto he crankcase. Gear / Stator Housing Gasket 38.
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Page 432: Flywheel / Stator Installation
ENGINE Flywheel / Stator Installation 39. Install water pump cover (R) with new O-ring seal. Torque bolts to specification in proper sequence (See front of this NOTE: Before assembly, clean the bolts and bolt chapter). holes with Primer N (PN 2874275) to remove any debris. -
Page 433: Cylinder Head Reassembly
ENGINE Lubricate threads and top of washers underside of bolt head with engine oil. Install head bolts (C) and torque to specification. Flywheel Nut Torque 65 ± 7 ft.lbs. (88 ± 9.50 Nm) Install stator housing with new o-rings. Torque the bolts to specification and follow proper bolt torque sequence at the beginning of this chapter. - Page 434 ENGINE Lubricate rockers (E) with engine oil. Breather Bolt Toque: ± ± 5 in. lbs. (2.5 0.55 Nm) NOTE: When applying RTV, do not get any RTV inside the reed assembly. Place a new seal (I) into the bottom of the cover. Be sure the seal is seated into the cover properly.
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Page 435: Oil Pump Priming
ENGINE Remove primer plug from the engine. Install Oil System Priming Adapter (PU-45778) into the oil plug hole. Push 3-5 oz. (approx.) of Polaris PS-4 PLUS 2W-50 Synthetic into the adapter or until resistance is felt. Remove the Thermostat Housing Bolt Torque: adapter. -
Page 436: Troubleshooting
ENGINE TROUBLESHOOTING Engine Idles But Will Not Accelerate • Spark plug fouled/weak spark Engine • Broken throttle cable Spark Plug Fouling • Obstruction in air intake • Spark plug cap loose or faulty • Air box removed (reinstall all intake components) •... -
Page 437: Cooling System
ENGINE Cooling System Excessive Smoke and Carbon Buildup • Excessive piston-to-cylinder clearance Overheating • Wet sumping due to over-full crankcase • Low coolant level • Worn rings, piston, or cylinder • Air in cooling system • Worn valve guides or seals •... - Page 438 ENGINE NOTES 3.60...
- Page 439 ELECTRONIC FUEL INJECTION CHAPTER 4 ELECTRONIC FUEL INJECTION GENERAL INFORMATION ..........4.2 SPECIAL TOOLS .
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Page 440: General Information
ELECTRONIC FUEL INJECTION GENERAL INFORMATION Special Tools PART WARNING TOOL DESCRIPTION NUMBER PU-43506-A Fuel Pressure Gauge Kit Gasoline is extremely flammable and explosive under certain conditions. PV-48656 Fuel Pressure Gauge Adaptor * EFI components are under high pressure. Verify PU-47082 Throttle Position Sensor Tester system pressure has been relieved before disassembly. - Page 441 ELECTRONIC FUEL INJECTION Fuel Pressure Gauge Kit - PU-43506-A Throttle Position Sensor Tester - PU-47082 IMPORTANT: The EFI fuel system remains under high This tester allows the use of a digital multi-meter to test TPS pressure, even when the engine is not running. function and perform the TPS Adjustment procedure.
- Page 442 ELECTRONIC FUEL INJECTION ™ ™ Digital Wrench Diagnostic Software Digital Wrench - Download Website PU-47063 Located at: www.polaris.diagsys.com This dealer-only software installs on laptop computers equipped with a CD drive and serial port connection, and is designed to replace multiple shop tools often used to test EFI components. It also includes step-by-step diagnostic procedures to aid technician repair and troubleshooting.
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Page 443: Efi Service Notes
ELECTRONIC FUEL INJECTION EFI Service Notes • For more convenient and accurate testing of EFI components, it is recommended dealers utilize the Digital Wrench Diagnostic Software (dealer only), or testing may be done manually using the ™ procedures provided. • 80% of all EFI problems are caused by wiring harness connections. •... -
Page 444: Fuel Tank Exploded View
ELECTRONIC FUEL INJECTION Fuel Tank Exploded View PFA Nut Fuel Sender Float Arm Fuel Pump / Regulator PFA Gasket Preliminary Filter Fuel Tank Assembly NOTE: Fuel Pump is NOT Serviceable Fuel Flow Fuel Injectors Fuel Rail Fuel Tank Pressure Regulator Fuel Pump Assembly Fuel Filters Quick Connect Fuel Line... -
Page 445: Efi System Exploded View
ELECTRONIC FUEL INJECTION EFI System Exploded View 1. Electronic Control Unit (ECU) 2. Intake Air Temperature / Barometric Air Pressure Sensor (T-BAP) 3. Crankshaft Position Sensor (CPS) 4. Fuel Injectors 5. Fuel Filter 6. Fuel Pump / Regulator / Gauge Sender Asm. (Located in tank as an assembly) 7. -
Page 446: Efi System Component Locations
ELECTRONIC FUEL INJECTION EFI System Component Locations Fuel Injectors / Fuel Rail Attached to the fuel rail located in the intake track of the Electronic Control Unit (ECU) cylinder head. Located under the seat on the driver’s side. Fuel Pump / Regulator / Fuel Gauge Sender Assembly Intake Air Temperature and Barometric Air Pressure Located in fuel tank as an assembly. -
Page 447: Fuel Lines - Quick Connect Removal / Installation
ELECTRONIC FUEL INJECTION Fuel Lines - Quick Connect Throttle Position Sensor (TPS) Located on the right-hand side of the throttle body. Removal / Installation CAUTION Verify fuel system has been depressurized before performing this procedure. RANGER 700 EFI models use quick connect fuel lines. Refer to the steps for fuel line removal / installation: Thoroughly clean the connector and place a shop towel around the fuel line to catch any dripping fuel. -
Page 448: Principal Components / Efi Operation Overview
ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for air temperature, barometric air pressure, engine temperature, speed Principal Components (RPM), and throttle position (load). These primary signals are The Electronic Fuel Injection (EFI) system is a complete engine compared to the programming in the ECU computer chip, and fuel and ignition management design. -
Page 449: Electronic Control Unit (Ecu)
ELECTRONIC FUEL INJECTION ELECTRONIC CONTROL UNIT (ECU) RANGER 700 EFI RPM Limit: Hard Limit - Injector suppression occurs Operation Overview • High: 6200 The ECU is the brain or central processing computer of the • Low: 6200 entire EFI fuel/ignition management system. During operation, sensors continuously gather data which is relayed through the •... -
Page 450: Fuel Pump
ELECTRONIC FUEL INJECTION FUEL PUMP Fuel Sender Test If the fuel gauge reading on the instrument cluster is not Operation Overview working, or if the display reading differs in large comparison to the fuel in the tank, perform a resistance test on the fuel sender. NOTE: All EFI units utilize quick connect lines. -
Page 451: Fuel Pump / Tank Assembly Replacement
ELECTRONIC FUEL INJECTION Fuel Pump / Tank Assembly Replacement Connect the hose from the Fuel Pressure Gauge Kit (PU- 43506-A) to the test valve on the Fuel Pressure Gauge NOTE: All EFI units utilize quick connect fuel lines. Adaptor. Route the clear hose into a portable gasoline container or the vehicle’s fuel tank. -
Page 452: Fuel Pressure Regulator
ELECTRONIC FUEL INJECTION Fuel Tank Installation Remove the two inner bolts that hold the fuel tank to the frame. Reinstall the fuel pump / tank assembly. Reinstall the four fuel tank mounting bolts that were removed. Reconnect the electrical harness. Install the fuel line and vent line and verify they are secure. -
Page 453: Fuel Injectors
ELECTRONIC FUEL INJECTION FUEL INJECTORS NOTE: Do not apply voltage directly to the fuel injector(s). Excessive voltage will burn them out. Do not ground the injector(s) with the ignition on. Operation Overview lnjector(s) will open/turn on if relay is energized. The fuel injectors mount into the intake manifold, and the fuel If an injector is not operating, it can indicate either a bad injector, rail attaches to them at the top end. -
Page 454: Crankshaft Position Sensor (Cps)
ELECTRONIC FUEL INJECTION CRANKSHAFT POSITION SENSOR CPS Test (CPS) The crankshaft position sensor is a sealed, non-serviceable assembly. If fault code diagnosis indicates a problem within this Operation Overview area, test and correct as follows: The engine speed sensor is essential to engine operation, Disconnect main harness connector from ECU. -
Page 455: Temperature / Barometric Air Pressure Sensor (T-Bap)
ELECTRONIC FUEL INJECTION TEMPERATURE / BAROMETRIC AIR THROTTLE POSITION SENSOR (TPS) PRESSURE SENSOR (T-BAP) Operation Overview Operation Overview The throttle position sensor (TPS) is used to indicate throttle plate angle to the ECU. Mounted on the throttle body intake, the temperature and barometric air pressure sensor (T-BAP) performs two functions Mounted on the throttle body and operated directly off the end in one unit. - Page 456 ELECTRONIC FUEL INJECTION Verify TPS Tester Reference Voltage Set-up the TPS Tester Adapter Harness (PU-47082), according to the instructions that accompanied the tester. Make sure the 9 A 5 volt reference voltage from the TPS Tester harness is Volt battery is new. required for the TPS test to be accurate.
- Page 457 ELECTRONIC FUEL INJECTION Checking TPS Reading Allow the throttle foot pedal to rest in the idle position. The voltmeter should read .660 ± .010 volts. Remove the lower seat base to access the sensor connector. PU-47082 Tester Assemble the TPS Tester according to the instructions. Refer to “TPS Tester / Regulator”...
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Page 458: Tps Replacement
ELECTRONIC FUEL INJECTION TPS Replacement Coolant passes through the cylinder and by the sensor probe, varying a resistance reading which is relayed to the ECU. This NOTE: The correct position of the TPS angle on the signal is processed by the ECU and compared to its throttle body is established and set at the factory. -
Page 459: Ignition Coil
ELECTRONIC FUEL INJECTION IGNITION COIL Primary Test Operation Overview The ignition coil is used to provide high voltage to fire the spark plugs. When the ignition key is on, DC voltage is present in primary side of the ignition coil windings. During engine rotation, an AC pulse is created within the crankshaft position sensor for each passing tooth on the flywheel. -
Page 460: General Troubleshooting
ELECTRONIC FUEL INJECTION GENERAL TROUBLESHOOTING Any “blink codes” stored in the ECU will display a numerical “blink code”, one at a time, in numerical order, on the instrument cluster display. Diagnostic “Blink Codes” The word “End” will display after all of the codes have been NOTE: The EFI diagnostic mode is intended to displayed or if no codes are present. -
Page 461: Efi Troubleshooting
ELECTRONIC FUEL INJECTION EFI Troubleshooting Poor Idle Symptom: Idle Too High (If greater than 1300 RPM when Fuel Starvation / Lean Mixture engine is warm) Symptoms: Hard start or no start, bog, backfire, popping • Throttle stop screw set incorrect through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle •... -
Page 462: Efi System Break-Out Diagrams
ELECTRONIC FUEL INJECTION EFI SYSTEM BREAK-OUT DIAGRAMS Fuel Injector Circuit (PTO) Fuel Injector Circuit (MAG) 4.24... -
Page 463: Crankshaft Position Sensor (Cps) Circuit
ELECTRONIC FUEL INJECTION Crankshaft Position Sensor (CPS) Circuit Fuel Pump Circuit 4.25... -
Page 464: Engine Coolant Temperature Sensor (Ect)
ELECTRONIC FUEL INJECTION Engine Coolant Temperature Sensor (ECT) Temperature Overheat Indicator Lamp Circuit 4.26... -
Page 465: Throttle Position Sensor (Tps) Circuit
ELECTRONIC FUEL INJECTION Throttle Position Sensor (TPS) Circuit Air Temperature / Barometric Air Pressure Sensor (T-BAP) Circuit 4.27... -
Page 466: Diagnostic Connector Circuit
ELECTRONIC FUEL INJECTION Diagnostic Connector Circuit Diagnostic Indicator Lamp Circuit 4.28... - Page 467 BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS..........5.2 SPECIAL TOOLS .
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Page 468: 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 469: 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 470: Lower Body, Floor And Fenders (4X4 Crew)
BODY / STEERING / SUSPENSION Lower Body, Floor and Fenders (4x4 CREW) Speed Foam Rear Floor Foil T-27 Foil Foil Rear Fender Foam T-27 Foam T-27 Floor T-27 Cover Mid Fender Foil Dog House T-27 Cover Main Floor Floor Receptacle Bracket Rear Floor Ext. -
Page 471: Lower Body, Floor And Fenders (6X6)
BODY / STEERING / SUSPENSION Lower Body, Floor and Fenders (6x6) Foam Foil Foil Main Floor Foil Foam Floor T-27 Cover T-27 Foam Speed T-27 Foil U-Type Rear Dog House Fender Cover Front Fender T-27 T-27 Speed T-27 Rear Fender T-25 T-27 Front... -
Page 472: Hood / Dash Components
BODY / STEERING / SUSPENSION Hood / Dash Components T-27 Glove Box Assembly T-30 Hinges Cup Holder T-27 Hood T-27 Grille Headlights Hood Liner Hood Latch Strap TORQUE SPECIFICATIONS T-30 Screws: 8-10 in. lbs. (0.9-1 Nm) T-27 Screws: 4-5 ft. lbs. (5-6 Nm) -
Page 473: Dash Instruments And Controls
BODY / STEERING / SUSPENSION Dash Instruments and Controls A. Speedometer B. Headlight Switch C. 2WD/AWD Switch D. 12 Volt Accessory Receptacle E. Speedometer “Mode” Button F. Key Switch G. Speedometer Mount Plate... -
Page 474: Cab Frame
BODY / STEERING / SUSPENSION CAB FRAME Assembly / Removal (6x6) Assemble the two rear cab frames at the coupler joint and secure with two 3/8" screws and nuts. Assemble the front frame in same manner. Leave all fasteners finger tight. Assemble the center cross bracket to the rear cab frame and secure with two 5/16”-18 x .75”... -
Page 475: Assembly / Removal (4X4 Crew)
BODY / STEERING / SUSPENSION Assembly / Removal (4x4 CREW) Assemble the two rear cab frames at the coupler joint and secure with two 3/8" screws and nuts. Assemble the center frame and the front frame in same manner. Tighten all 3/8" screws to 25-28 ft. lbs. (34-38 Nm). Assemble the center cross bracket to the rear cab frame and secure with two 5/16”-18 x .75”... -
Page 476: Seat / Head Rest
BODY / STEERING / SUSPENSION SEAT / HEAD REST Seat Back / Head Rests Fasten the seat back to the rear cab frame(s) using the Torx-head screws. NOTE: For seats that have staples visible from the rear, the seat back cover will need to be placed between the rear cab frame and seat back assembly. Tighten all Torx- head fasteners to 18-20 in. -
Page 477: Chassis / Main Frame (4X4 Crew)
BODY / STEERING / SUSPENSION CHASSIS / MAIN FRAME (4X4 CREW) Exploded View (2) Seat Base Main Frame (2) RH Floor Support Front Cab Support 28-32 ft. lbs. (38-43 Nm) 35 ft. lbs. (47 Nm) Bumper Grills T-27 13-15 ft. lbs. 28-32 ft. -
Page 478: Chassis / Main Frame (6X6)
BODY / STEERING / SUSPENSION CHASSIS / MAIN FRAME (6X6) Exploded View Seat Base Frame Extension Front Cab Support RH Floor Support 45 ft. lbs. (61 Nm) Main Frame 28-32 ft. lbs. (38-43 Nm) Bumper Grills 13-15 ft. lbs. (17-20 Nm) LH Floor Support T-27 28-32 ft. -
Page 479: Steering Assembly
BODY / STEERING / SUSPENSION STEERING ASSEMBLY Exploded View 28 ft. lbs. (38 Nm) Rod End & Jam Nut Steering Wheel Bushing Wave Washers 17 ft. lbs. (23 Nm) 30 ft. lbs. 16 ft. lbs. (41 Nm) (22 Nm) Upper Steering Shaft Tie Rod Lower Steering Shaft 16 ft. -
Page 480: Steering And Suspension
BODY / STEERING / SUSPENSION STEERING AND SUSPENSION Exploded View NOTE: To avoid damage to the tie rod ends and Always use new other steering components, be sure to install tie Always use new bolts cotter pins upon rod end bolts in the proper direction. upon reassembly reassembly. -
Page 481: Front A-Arm
BODY / STEERING / SUSPENSION FRONT A-ARM Attach A-arm to hub strut assembly. Tighten ball joint nut to 30 ft. lbs. (41 Nm). If cotter pin holes are not aligned, tighten nut slightly to align. Install a new cotter pin with Replacement open ends toward rear of machine. -
Page 482: Front Strut
BODY / STEERING / SUSPENSION FRONT STRUT Exploded View Pivot Ball Spring 15 ft. lbs. Retainer (21 Nm) Spacer Rubber Bottom Pivot Ball Washer Spacer Front Strut Clamp Washer 18 ft. lbs. (24 Nm) Spring Bolt 17 ft. lbs. Strut Bumper (23 Nm) Wheel Speed Sensor (Hall Effect Sensor) -
Page 483: Front Strut Cartridge Replacement
BODY / STEERING / SUSPENSION Front Strut Cartridge Replacement Remove cotter pin (A) from ball joint castlenut. Remove castle nut (B) and separate A-arm (C) from ball Refer to Front Strut Exploded View. joint stud. Hold strut rod and remove top nut. Remove screws (D) and ball joint retaining plate (E). -
Page 484: Mid Axle A-Arm (6X6)
BODY / STEERING / SUSPENSION Apply Loctite™ 242 (PN 2871949) to threads of retaining WARNING plate screws or install new screws with pre-applied locking agent. Torque screws to 8 ft. lbs. (11 Nm). The locking features on the existing bolts were 10. -
Page 485: Rear A-Arm (4X4 Crew)
BODY / STEERING / SUSPENSION REAR A-ARM (4X4 CREW) Remove the hub and brake disc assembly by sliding it off of the axle. Replacement NOTE: Use the exploded view on the next page as reference during the procedure. Elevate and safely support vehicle with weight removed from the rear wheel(s). - Page 486 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.
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Page 487: Rear Stabilizer Bar (4X4 Crew)
BODY / STEERING / SUSPENSION REAR STABILIZER BAR (4X4 CREW) Remove the two bolts that secure the stabilizer bar to the main frame, each side. Removal / Installation Elevate and safely support vehicle with weight removed from the rear wheel(s). Remove the rear wheel to gain access to the stabilizer bar, each side. -
Page 488: Swing Arm (6X6)
BODY / STEERING / SUSPENSION SWING ARM (6X6) Removal Support machine on a level surface. Remove rear wheels. NOTE: The rear axle may be removed to ease the removal of the swing arm. Refer to Chapter 7, “REAR AXLE HOUSING REMOVAL/INSPECTION”. Support swing arm, remove rear axle shocks. -
Page 489: Rear Drive Axle And Swing Arm Exploded View (6X6)
BODY / STEERING / SUSPENSION REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6X6) Retaining Ring Axle Tube Wheel Screw & Washer Bearing 60 ft. lbs. (81 Nm) Vehicle Frame Screw & Washer 60 ft. lbs. (81 Nm) Swing Arm Axle Wheel Bearing... -
Page 490: 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 491: 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 492 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.
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Page 493: Storage Box (4X4 Crew)
BODY / STEERING / SUSPENSION STORAGE BOX (4X4 CREW) DECAL REPLACEMENT Plastic polyethylene material must be “flame treated” prior to Removal installing a decal to ensure good adhesion. The flame treating procedure can often be used to reduce or eliminate the whitish Remove the two bottom T-27 torx screws. - Page 494 BODY / STEERING / SUSPENSION NOTES 5.28...
- Page 495 CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES ......... . 6.2 TORQUE SPECIFICATIONS.
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Page 496: Special Tools And Supplies
CLUTCHING SPECIAL TOOLS AND SUPPLIES PVT SYSTEM OVERVIEW General Operation TOOL DESCRIPTION PART NUMBER Drive Clutch Puller 2870506 WARNING Clutch Holding Wrench 9314177 Clutch Holding Fixture 2871358 All PVT maintenance or repairs should be Drive Clutch Spider Removal and 2870341 performed only by a certified Polaris Master Install Tool Service Dealer (MSD) technician who has... -
Page 497: Driven Clutch Operation
CLUTCHING Driven Clutch Operation Maintenance / Inspection Under normal use the PVT system will provide years of trouble Driven clutches primarily sense torque, opening and closing free operation. Periodic inspection and maintenance is required according to the forces applied to it from the drive belt and the to keep the system operating at peak performance. -
Page 498: Overheating / Diagnosis
CLUTCHING Overheating / Diagnosis During routine maintenance, or whenever PVT system overheating is evident, it’s important to check the inlet and outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures. The vehicle should be operated in Low when plowing or pulling heavy loads, or if extended low speed operation is anticipated. -
Page 499: Pvt System Service
CLUTCHING PVT SYSTEM SERVICE PVT Sealing, Guard, and Ducting Components SEALING AND DUCTING COMPONENTS Clutch Outlet Duct Inner Cover Clamps Inner Cover Seal Retainer Outer Cover Seal Cover Bolts PVT Outer Cover Disassembly Some fasteners and procedures will vary. Refer to the Install the Drive Clutch Holder (PN 9314177) (A). -
Page 500: Assembly
CLUTCHING Remove driven clutch alignment washer(s) from the Apply RTV silicone sealant to outside edge of inner cover- transmission input shaft. to-engine seal, to ensure a water tight fit between the seal and the cover. Surfaces must be clean to ensure adhesion Note Number of Washers of silicone sealant. -
Page 501: Drive Belt
CLUTCHING DRIVE BELT 13. Reinstall drive belt noting direction of rotation. If a new belt is installed, install so numbers can be easily read. Belt Removal 14. Replace PVT outer clutch cover rubber gasket. Remove outer PVT cover as described in PVT 15. -
Page 502: Pvt Break-In (Drive Belt / Clutches)
CLUTCHING Belt Inspection PVT Break-In (Drive Belt / Clutches) Inspect belt for hour glassing (extreme circular wear in at A proper break-in of the clutches and drive belt will ensure a least one spot and on both sides of the belt). Hour glassing longer life and better performance. -
Page 503: Clutch Center Distance
CLUTCHING Place the alignment tool in the sheaves of the driven clutch 10. If the alignment tool touches the shaft bearing but has an and hold firmly as you rotate it down between the sheaves excessive amount of clearance between the tool and of the drive clutch. -
Page 504: Drive Clutch Service
CLUTCHING DRIVE CLUTCH SERVICE Spring Specifications The drive clutch spring has two primary functions: To control clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM. Red/White To control the rate at which the drive belt moves 7043349 upward in the drive clutch sheaves. -
Page 505: Shift Weights
CLUTCHING Shift Weights Shown below are the shift weights which have been designed for the PVT system. These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern. -
Page 506: Exploded View
CLUTCHING Exploded View Bushing Lock Washer Spring Cover Bearing Spider Bolt Bearing Flat Non-Braking Washer Spacer Bearing Cover Button Screws Roller Washers Button Bolt Shift Washers Weight Clutch Disassembly Using a permanent marker, mark the cover, spider, and Inspect cover bushing (A). The outer cover bushing is ™... -
Page 507: Spider Removal
CLUTCHING Inspect area on shaft where bushing rides for wear, galling, NOTE: It is important that the same number and thickness of washers are reinstalled beneath the nicks, or scratches. Replace clutch assembly if worn or damaged. spider during assembly. Be sure to note the number and thickness of these washers. -
Page 508: Roller, Pin, And Thrust Washer Inspection
CLUTCHING Roller, Pin, and Thrust Washer Inspection Button To Tower Clearance Inspection Inspect all rollers, bushings and roller pins by pulling a flat Inspect for any clearance between spider button to tower. metal rod across the roller. Turn roller with your finger. If If clearance exists, replace all buttons and inspect surface you notice resistance, galling, or flat spots, replace rollers, of towers. -
Page 509: Bearing Inspection
CLUTCHING Clutch Inspection Remove shift weight bolts and weights. Inspect as shown. The contact surface of the weight should be smooth and free NOTE: Remove cover, spring, and spider following of dents or gall marks. Inspect the weight pivot bore and instructions for drive clutch removal, then proceed pivot bolts for wear or galling. -
Page 510: Moveable Sheave Bushing Inspection
CLUTCHING Moveable Sheave Bushing Inspection Inspect surface of shaft for pitting, grooves, or damage. Measure outside diameter compare Inspect the Teflon™ coating (arrow) on the moveable sheave specifications. Replace the drive clutch assembly if shaft bushing. Inspect both sheaves for signs of wear, grooving or is worn or damaged. -
Page 511: Bushing Service
CLUTCHING Bushing Service CAUTION IMPORTANT: Special Tools Required EBS Clutch Bushing Tool Kit - 2201379 Clutch components will be hot! In order to avoid serious burns, wear insulated gloves during the Item Qty. Part Description Part # removal process. A, B EBS Puller Tool 5132027 Moveable Sheave - Bushing Removal... - Page 512 CLUTCHING NOTE: Use Bushing Tool PA-47336. Cover Bushing Removal Install main adapter (Item 8) on puller. Install nut (C) onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Using Removal Tool Nut (C) a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear.
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Page 513: Clutch Assembly
CLUTCHING Clutch Assembly Torque spider to specification using the holding fixture and spider tool. Torque with smooth motion to avoid damage NOTE: It is important that the same number and to the stationary sheave. thickness of washers are reinstalled beneath the spider during assembly. -
Page 514: Driven Clutch Service
CLUTCHING DRIVEN CLUTCH SERVICE Exploded View DRIVEN CLUTCH Compression Spring Outer Spring Retainer Secondary Stationary Sheave Retaining Ring Inner Spring Retainer Moveable Inner Sheave Clutch Disassembly / Inspection Place the clutch into the Clutch Compression Tool PN 8700220. Using Compression Extensions PN PS-45909, apply and hold downward pressure on the outer spring CAUTION retainer. - Page 515 CLUTCHING With the snap ring (A) removed and spring pressure Remove the inner spring retainer from the inner sheave. relieved, remove the outer spring retainer (B), compression Inspect for wear and replace as needed. spring (C), and inner spring retainer (D). Inspect for Abnormal Wear Check the rollers in the stationary sheave for wear.
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Page 516: Clutch Assembly
CLUTCHING 10. Inspect the Teflon™ coating on the moveable sheave bearings. 11. Inspect driven clutch sheave faces for wear or damage. 12. Clean and inspect splines on helix and transmission input shaft. 13. Lube splines with a light film of grease. Do not lubricate the bearings! Clutch Assembly Assemble Sheaves... -
Page 517: 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 518 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 519 FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIAL TOOLS ............7.3 TORQUE SPECIFICATIONS.
- Page 520 FINAL DRIVE REAR DRIVE SHAFT (4X4 CREW) ........7.41 REMOVAL .
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Page 521: Special Tools
FINAL DRIVE SPECIAL TOOLS FRONT HUB Hub Removal / Inspection PART NUMBER TOOL DESCRIPTION Elevate front end and safely support machine under Roller Pin Removal Tool 2872608 footrest / frame area. CV Boot Clamp Pliers 8700226 Axle Boot Clamp Tool CAUTION PU-48951 Serious injury may result if machine tips or falls. -
Page 522: Hubstrut Bearing Replacement
FINAL DRIVE Remove hub cap, cotter pin, front spindle nut, and washer. Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. Rotate each bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. -
Page 523: Hub Installation
FINAL DRIVE Hub Installation 10. Install brake caliper using new bolts. Tighten bolts to specified torque. Inspect the hubstrut bearing surface for wear or damage. Apply grease to drive axle spindle. Install spindle through the backside of the hubstrut. Install the hub onto the spindle. -
Page 524: Front Hub Exploded View
FINAL DRIVE Front Hub Exploded View Disc Brake Stud Front Hub Tire 18 ft. lbs. (24 Nm) Use new bolts with pre-applied locking agent. Wheel Nut (Spec on page 7.3) Dust Cover Washer Slotted Nut Cotter Pin 70 ft. lbs. (95 Nm) -
Page 525: Front Drive Shaft
FINAL DRIVE FRONT DRIVE SHAFT Remove the front wheel hub. Removal Elevate front of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. -
Page 526: Drive Shaft / Cv Joint Handling Tips
FINAL DRIVE Pull strut assembly out while pivoting front drive shaft • Never use a hammer or sharp tools to remove or to downward until it clears strut assembly. install boot clamps. • Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned. - Page 527 FINAL DRIVE IMPORTANT: If the grease in the joint is obviously 13. Slide the joint onto the drive shaft splines and align the contaminated with water and/or dirt, the joint should circlip with the lead-in chamfer on the inner race of the be replaced.
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Page 528: Inner Plunging Joint / Boot Replacement
FINAL DRIVE Inner Plunging Joint / Boot Replacement 12. Grease the joint with the special CV joint grease provided in the boot replacement kit. Fill the cavity behind the balls Remove the front drive shaft from the vehicle (see and the splined hole in the joint’s inner race. Pack the ball “FRONT DRIVE SHAFT - Removal”). -
Page 529: Exploded View
FINAL DRIVE Installation 20. Pull out on the drive shaft to center the joint in the housing. Slide a straight O-ring pick or a small slotted screw driver Install new spring ring on drive shaft. Apply an anti-seize between the large end of the boot and the joint housing and compound to splines. -
Page 530: Front Propshaft
FINAL DRIVE FRONT PROPSHAFT NOTE: Remove the drive shaft floor cover to help align the roll pin removal tool. The drive shaft can be removed through the floor covering. 6x6 Removal Elevate and safely support vehicle under the frame. The use of a vehicle hoist is recommended for this procedure. -
Page 531: Propshaft U-Joint Service
FINAL DRIVE PROPSHAFT U-JOINT SERVICE Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps. Disassembly Remove internal or external snap ring from all bearing caps. CAUTION Always wear eye protection. Force U-joint cross to one side and lift out of inner yoke. NOTE: If yoke or bearing is removed, cross bearing must be replaced. - Page 532 FINAL DRIVE Using a suitable arbor, fully seat bearing cap in one side. When installation is complete, yokes must pivot freely in Continually check for free movement of bearing cross as all directions without binding. If the joint is stiff or binding, bearing caps are assembled.
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Page 533: Centralized Hilliard Exploded View
FINAL DRIVE FRONT GEARCASE / CENTRALIZED HILLIARD Centralized Hilliard Exploded View 17 ft. lbs. (23 Nm) 10 ft. lbs. (14 Nm) 8-30 ft. lbs. (11-41 Nm) 17 ft. lbs. (23 Nm) ESCRIPTION ESCRIPTION Thrust Button Asm. w/O-ring Seal Kit (Includes O-rings and Seals) Screw (5/16-18) Roller Ball Bearing Dowel Pin... - Page 534 FINAL DRIVE All Wheel Drive Operation AWD Engagement: When the AWD switch is activated, the AWD coil is powered by a 12 Vdc input which creates a The AWD switch may be turned on or off while the vehicle is magnetic field.
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Page 535: Awd Diagnosis
FINAL DRIVE AWD Diagnosis Possible Symptom: AWD Will Not Engage Wear Ring on Armature Plate Check the gearcase coil resistance. To test the coil resistance, measure between the Grey and Brown/White wires. The measurement should be within specification. OK Condition Bad Condition (Wear from coil on armature plate) -
Page 536: Gearcase Removal
FINAL DRIVE The front gearcase and drive shafts can be accessed from Roll Cage both sides of the vehicle and limited access from the top. Asm. Rollers Top View - From under hood Inspect the roll cage assembly for cracks or excessive wear. If damaged, replace the roll cage assembly. -
Page 537: 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 538 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.
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Page 539: 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 540 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.
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Page 541: Backlash Pad (Thrust Pad) Adjustment
FINAL DRIVE Backlash Pad (Thrust Pad) Adjustment 11. Install the output cover assembly onto the main gearcase. Lay the gearcase on the side with the output cover facing The backlash screw has Loctite applied to it. Use a heat gun to lightly heat up the Loctite on the screw (A). -
Page 542: Gearcase Installation
FINAL DRIVE MID DRIVE HUB / BEARING CARRIER If a tight spot is felt during rotation, loosen the backlash screw another 1/8 turn. Perform the previous step again. (6X6) Repeat this procedure until the pinion shaft rotates smoothly 4 times (1 revolution of ring gear). Removal Lock the emergency parking brake. - Page 543 FINAL DRIVE Remove the upper and lower control arm bolts. NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, Upper Bolt support casting on outer edges so bearing can be removed. Lower Bolt Remove the bearing carrier from the A-arm assembly.
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Page 544: Hub Installation
FINAL DRIVE Start bearing (B) in housing (A). Install upper A-arm bolt and torque both upper and lower bolts. Lower Control Arm Bolt Torque: 35 ft. lbs. (47 Nm) Upper Control Arm Bolt Torque: 35 ft. lbs. (47 Nm) Pull drive shaft outward and install hub onto drive shaft splines. -
Page 545: Mid Drive Exploded View
FINAL DRIVE Mid Drive Exploded View 35 ft. lbs. (47 Nm) BUSHING SHAFT MID UPPER A-ARM 35 ft. lbs. (47 Nm) MID DRIVE AXLE BEARING CARRIER 35 ft. lbs. (47 Nm) BEARING SHAFT BUSHING SNAP RING 35 ft. lbs. MID LOWER A-ARM BUSHING (47 Nm) MID DRIVE SHAFT (6X6) -
Page 546: Installation
FINAL DRIVE Installation Install the flat washer (A) and cone washer (B) with domed side facing outward. (Refer to next photo) Apply Anti-Seize compound onto the mid gearcase output Install the castle nut (C), wheel, and wheel nuts. shaft splines. Slide mid drive shaft (A) onto the mid gearcase output shaft (B). -
Page 547: Mid Drive Gearcase (6X6)
FINAL DRIVE MID DRIVE GEARCASE (6X6) Gearcase Removal Use the Roll Pin Removal Tool (PN 2872608) to remove the roll pins that secure the rear prop shaft and middle prop NOTE: To ease the removal of the middle axle shaft to the mid drive gearcase. gearcase, remove the box from the frame. -
Page 548: Gearcase Disassembly
FINAL DRIVE Gearcase Disassembly Remove the output shaft and ring gear assembly (E) from the gearcase. Inspect the ring gear for abnormal wear, Drain the oil from the mid drive gearcase. Properly dispose broken, or chipped teeth. Inspect and spin the bearings (F), of the oil. - Page 549 FINAL DRIVE Remove the input cover bolts (I). Remove the input cover Inspect the pinion gear (K) and 26T output gear (L) for nics (H) and pinion gear assembly from the gearcase. or uneven wear. Inspect the bearing (M), the bearing should spin smoothly.
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Page 550: Gearcase Assembly
FINAL DRIVE 12. Carefully pull the output thru shaft (Q) through the gearcase. 15. Replace all O-ring, seals, and worn components. Replace 13. Remove the retaining ring (O), shim (P), and input gear (R) the seals as shown in the photo. from the output shaft (Q). - Page 551 FINAL DRIVE Install the 26T input gear (D), shim (E), and a new retaining • Hold the pinion gear assembly ring (F) onto the output shaft. • Use a rubber mallet to lightly tap on the front of the input cover, around the bearing cup •...
- Page 552 FINAL DRIVE Install the wave spring (L) into the gearcase assembly. Be 10. Install a new O-ring (O) onto the output cover. sure the wave spring is fully seated into the bearing cup of the gearcase. 11. Carefully install the output cover onto the gearcase. Install the output cover bolts.
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Page 553: Gearcase Installation
FINAL DRIVE Middle Gearcase Specifications: Capacity: 6.75 oz. (200 ml) Specified Lubricant: ATV Angle Drive Fluid (PN 2871653) Fill Plug Torque: 14 ft. lbs. (19 Nm) Gearcase Installation Place the middle gearcase in the frame assembly. Attach the mid and rear prop shafts to the mid gearcase, but do not install the new roll pins yet. -
Page 554: Mid Gearcase Exploded
FINAL DRIVE Mid Gearcase Exploded 18-23 ft. lbs. (24-31 Nm) 30 ft. lbs. (41 Nm) 18-23 ft. lbs. (24-31 Nm) ESCRIPTION ESCRIPTION Screw (5/16-18 x 1.0) Washer, Thrust Plug, Square Socket Bearing, Plain Flanged Seal, Dual Lip Gearcase Tube, Vent 1/4” Hose Bushing Cover, Output Pinion, 10T... -
Page 555: Rear Hub / Bearing Carrier (4X4)
FINAL DRIVE REAR HUB / BEARING CARRIER (4X4) Remove hub cap, cotter pin, front spindle nut, and washer. Hub Inspection Support machine securely with rear wheels elevated. Grasp wheel / hub and check for movement. If movement is detected, inspect hub, hub nut torque and bearing condition and correct as necessary. -
Page 556: Hub Disassembly
FINAL DRIVE Hub Disassembly Hub Assembly Remove outer snap ring (A). Support bottom of bearing carrier housing. (A) Bearing Carrier Housing; (B) Bearing; (C) Snap Ring From the back side, tap on the outer bearing race with a drift Start bearing (B) in housing (A). punch in the reliefs as shown. -
Page 557: Hub Installation
FINAL DRIVE Hub Installation Install the washer with domed side out. Install the spindle retainer nut. Start the wheel bearing carrier onto the drive shaft. Align the bottom of carrier housing and lower control arm. Slide the lower control arm bushings into place. Secure with the lower control arm bolt. -
Page 558: Exploded View
FINAL DRIVE Exploded View Rear Gearcase 30 ft. lbs. (41 Nm) Coil A-arm bolts Shaft Bushings Shock Upper A-arm Bushings 30 ft. lbs. (41 Nm) Caliper Rear Drive Axle 18 ft. lbs. A-arm bolts (24 Nm) Nuts Bearing Lower A-arm Bushings Carrier Bolt Snap Ring... -
Page 559: Rear Drive Shaft (4X4 Crew)
FINAL DRIVE REAR DRIVE SHAFT (4X4 CREW) Outer CV Joint / Boot Replacement Using a side cutters, cut away and discard the boot clamps. Removal Repeat all steps of the “Rear Hub / Bearing Carrier, Hub Removal” section. Remove upper carrier bolt. Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft. - Page 560 FINAL DRIVE NOTE: Shiny areas in ball tracks and on the cage Make sure the circlip is on the shaft and not left in the joint. spheres are normal. Do not replace CV joints Circlip because parts have polished surfaces. Replace CV joint only if components are cracked, broken, worn or otherwise unserviceable.
- Page 561 FINAL DRIVE 14. Slide the joint onto the drive shaft splines and align the 20. While pulling out on the CV shaft, fully extend the CV joint circlip with the lead-in chamfer on the inner race of the and slide a straight O-ring pick or a small slotted screw joint.
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Page 562: Inner Plunging Joint / Boot Replacement
FINAL DRIVE Inner Plunging Joint / Boot Replacement Make sure the circlip is still on the shaft and not left in the joint. Using a side cutters, cut away and discard the boot clamps. Circlip Remove the boot from the shaft. Remove the large end of the boot from the plunging joint CAUTION and slide the boot down the shaft. - Page 563 FINAL DRIVE 12. Install a NEW circlip on the end of the shaft. 18. Remove excess grease from the plunging joint’s external surfaces and place the excess grease in the boot. 13. Grease the joint with the special CV joint grease provided in the boot replacement kit.
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Page 564: Drive Shaft Exploded View
FINAL DRIVE Drive Shaft Exploded View REAR SHAFT Spring Ring Plunging Joint Gear Side Boot Kit Grease Capacity 100 Grams Grease Capacity 90 Grams Wheel Side Boot Kit CV Joint 7.46... -
Page 565: 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 566: Rear Propshaft (4X4 Crew)
FINAL DRIVE REAR PROPSHAFT (4X4 CREW) Slide the propshaft off the transmission shaft and rear gearcase input shaft. Orientate the shaft so that it’s parallel with the frame supports as shown below. Removal Remove the pin clips from upper and lower cargo box shock pins and remove shock. -
Page 567: Rear Gearcase (4X4 Crew)
FINAL DRIVE REAR GEARCASE (4X4 CREW) Differential - Unlock General Operation Clutch Gear The RANGER rear gearcase has three traction operational Shift Yoke modes: AWD, Differential Lock, and Differential Unlock. Locking the rear differential is beneficial in low traction and rough terrain conditions. -
Page 568: Operation Modes
FINAL DRIVE Operation Modes When the clutch gear is unlocked the rear drive shafts are dependent on the differential allowing tighter turns. When it’s locked it becomes a solid rear axle increasing traction. AWD Mode Differential Clutch Gear Rear Wheels rotate at same speed. Front Wheels rotate at same speed when AWD activated. -
Page 569: Gearcase Removal
FINAL DRIVE Gearcase Removal Gearcase Disassembly IMPORTANT: The pinion gear assembly is NOT Follow “Rear Drive Shaft Removal” procedure to remove the rear drive shafts from each side of the rear differential. intended to be disassembled from the case, as it requires special OEM tooling in order to properly Disconnect the differential solenoid 2-wire harness. - Page 570 FINAL DRIVE Remove the differential assembly from the housing. Remove the shims from the differential assembly. Be sure to keep the shims together for reassembly. Inspect the bevel gear teeth for chipped, worn, or broken teeth. Remove the large bearing from the differential assembly. Inspect the bearing for smoothness and wear.
- Page 571 FINAL DRIVE If the solenoid was removed for servicing, inspect the tip 12. Loosen the lock assembly pin. of the solenoid for wear. If the tip of the solenoid is flattened the solenoid must be replaced. 13. Remove the pin from the gearcase cover. 10.
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Page 572: Rear Gearcase Assembly
FINAL DRIVE 15. Inspect the shift lever (A), shift lever spring (B), shift return springs (C), shift yoke (D), and lock pin bushing (E). Inspect the components for excessive wear or damage and replace as needed. Do Not Disassemble. Replace as an assembly if damaged or worn. - Page 573 FINAL DRIVE Install the original shims (A) onto the differential assembly If previously removed; assembly the shift lever (A), shift (B) on both sides. Install the bearings (C), replace with new lever spring (B), shift return springs (C), shift yoke (D), and bearings if needed.
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Page 574: Rear Gearcase Installation
FINAL DRIVE Rear Gearcase Installation Install the new lightly greased O-ring onto the carrier cover. Place the differential assembly into the frame. Slide the O-Ring rear propshaft onto the rear gearcase input shaft. Install the (4) gearcase mounting fasteners and torque the fasteners to 40 ft. -
Page 575: Rear Gearcase Exploded View (4X4 Crew)
FINAL DRIVE Rear Gearcase Exploded View (4x4 CREW) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm) 25-35 ft. lbs. (34-48 Nm) 30-40 ft. lbs. (41-54 Nm) ESCRIPTION ESCRIPTION ESCRIPTION Hypoid Gear Assembly Bearing Cone - Diff Pinion Nut Carrier Housing Half Bearing Cup - Diff Oil Seal - Pinion... -
Page 576: Rear Axle / Gearcase Service (6X6)
FINAL DRIVE REAR AXLE / GEARCASE SERVICE Remove the bottom shock bolts and shocks (both sides). (6X6) Rear Axle Removal Jack up vehicle and support on frame and swing arm. CAUTION Serious injury could occur if machine tips or falls. Remove rear wheels. -
Page 577: Axle Tube Removal
FINAL DRIVE Axle Tube Removal 10. Loosen the four U-bolts. Loosen each U-bolt nut a few turns at a time, this will reduce stress on all of the U-bolts during Place the rear axle assembly on a clean surface. U-bolt removal. Remove the bolts that secure the rear gearcase to the axle tubes and remove the rear gearcase skid plate Loosen U-bolts... -
Page 578: Axle Tube Bearing Replacement
FINAL DRIVE Axle Tube Bearing Replacement Gearcase Disassembly / Inspection Remove the retaining ring from the axle tube. Drain and properly dispose of used oil. Remove the differential housing cover bolts and the gearcase housing cover. Remove the bearings from the axle tube with a bearing puller. -
Page 579: Gearcase Assembly
FINAL DRIVE Remove the wave spring from the differential assembly. Inspect the pinion shaft bushing for wear. Wave Spring Remove the four bolts that secure the pinion gear cover to the differential. Remove the pinion gear cover and O-ring. Gearcase Assembly Pinion Gear Cover Replace all O-rings, seals, and worn components. -
Page 580: Gearcase / Axle Installation
FINAL DRIVE NOTE: The O-ring is a smaller diameter than the Replace the pinion shaft cover O-ring and install the cover. gearcase. Use two hands to work the O-ring onto the Install the four pinion shaft cover bolts and torque the bolts to 26 ft. - Page 581 FINAL DRIVE NOTE: The two top gearcase / axle tube bolts (B) on Install the four U-bolts. Align the U-bolts with the white the left side are installed into the frame later in this marks previously made on the axle tube for proper rear axle assembly procedure.
- Page 582 FINAL DRIVE Torque the U-bolts nuts to 40 ft. lbs. (54 Nm). 13. Install the brake caliper. Torque the bolts to 18 ft. lbs. (24.8 Nm). U-Bolt Nut Torque: 40 ft. lbs. (54 Nm) Brake Caliper Torque: 18 ft. lbs. (24.8 Nm) 10.
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Page 583: Rear Gearcase Exploded View (6X)
FINAL DRIVE Rear Gearcase Exploded View (6x6) 26 ft. lbs. (35 Nm) 30 ft. lbs. (41 Nm) ESCRIPTION ESCRIPTION Seal, Triple Lip O-Ring Screw (5/16-18 x 1.0) Spring, Wave Cover, Input Bearing, Ball O-Ring Shaft, Output Bearing, Ball Gear, Ring 37T Pinion, 10T Bearing, Ball Bearing, Plain... - Page 584 FINAL DRIVE NOTES 7.66...
- Page 585 TRANSMISSION CHAPTER 8 TRANSMISSION TORQUE SPECIFICATIONS..........8.2 SHIFT LEVER .
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Page 586: Torque Specifications
TRANSMISSION TORQUE SPECIFICATIONS Remove the shift lever cover and then remove the screw. Pull off the shifter knob. Shift Lever ITEM TORQUE VALUE 10-14 ft. lbs. Transmission Fill Plug (14-19 Nm) 10-14 ft. lbs. Transmission Drain Plug (14-19 Nm) 27-34 ft. lbs. Transmission Case Bolts (37-46 Nm) 12-18 ft. -
Page 587: Adjustment
TRANSMISSION Adjustment TRANSMISSION SERVICE Place gear selector in neutral. Make sure the transmission Transmission Removal bell crank is engaged in the neutral position detents. Remove the PVT system from the left side of the transmission. Drive roll pin from rear driveshaft yoke. 4x4 Shown Neutral Position Roll Pin... - Page 588 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.
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Page 589: Transmission Disassembly
TRANSMISSION Transmission Disassembly Mark the detent gear with a white pen. Remove the detent gear from the case. NOTE: Refer to the exploded view at the end of this chapter. NOTE: It may be helpful to place a mark just above the keyed spline. - Page 590 TRANSMISSION Note the transmission gear position and mark the two shift 11. Remove the shift drum. gears before removing them to aid with reassembly. NOTE: You may have to tap the shift drum from the Remove the shift gears from the case. backside of the case to aid in removal.
- Page 591 TRANSMISSION 14. Remove the shift forks from the assembly. Note the correct 17. Remove the bearing from the input shaft with a puller. position of each fork. Shift Fork 18. Remove the snap ring and washer from the reverse shaft. NOTE: The picture above depicts a transmission with a “Park”...
- Page 592 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 593 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.
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Page 594: Transmission Assembly
TRANSMISSION 36. Remove seals from transmission case. 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. - Page 595 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 596 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 597 TRANSMISSION 25. Install drain plug with a new sealing washer. Torque drain 28. Install the lockout disc with the raised edge facing outward. plug to 10-14 ft. lbs. (14-19 Nm). Use the white mars that was previously applied for reference. Lockout Disc 29.
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Page 598: Transmission Installation
TRANSMISSION Transmission Installation 32. Torque the remaining bolts to 7-9 ft.lbs. (10-12 Nm). Install transmission from right side of vehicle. Cover Bolt Torque: Align the front input shaft to the front propshaft yoke on 7-9 ft. lbs. (10-12 Nm) the vehicle and install the propshaft. Align the rear output shaft to the mid or rear propshaft yoke 33. -
Page 599: 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 600: Transmission Exploded Views
TRANSMISSION TRANSMISSION EXPLODED VIEW Exploded View 27-34 ft. lbs. (37-46 Nm) 6-12 ft. lbs. (8-16 Nm) 10-14 ft. lbs. (14-19 Nm) GREASE 7-9 ft. lbs. (10-12 Nm) 15-19 ft. lbs. (20-26 Nm) 10-14 ft. lbs. (14-19 Nm) 27-34 ft. lbs. (37-46 Nm) 12-18 ft. - Page 601 TRANSMISSION Exploded View, Continued Ref. Qty. Description Ref. Qty. Description Plug, Fill Sprocket, 22T Plug, Drain, Magnetic Lockout Disc Screw, Self-Tapping 1/4-20 Detent Pawl Screw, 5/16-18 Detent Star Screw, 1/4-20 Bellcrank, Shift Drum Screws, Self-Tapping 5/16-18 Output Shaft, Front Main Nut, Nylon Lock Thrust Button Nut, Nylon Lock...
- Page 602 TRANSMISSION NOTES 8.18...
- Page 603 BRAKES CHAPTER 9 BRAKES GENERAL SPECIFICATIONS..........9.2 TORQUE SPECIFICATIONS.
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Page 604: General Specifications
BRAKES GENERAL SPECIFICATIONS FRONT BRAKE SYSTEM Item Standard Service Limit Front Brake Pad Thickness .298 ± .007" / 7.56 ± .178 mm .180" (4.6 mm) Front Brake Disc Thickness .158" ( 4.01mm) .140" (3.56mm) Front Brake Disc Runout .010" (.254mm) REAR BRAKE SYSTEM Item Standard... -
Page 605: Brake System Service Notes
BRAKES BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life. -
Page 606: Hydraulic Brake System Operation
BRAKES HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure within the brake system. -
Page 607: Brake System Exploded View
BRAKES BRAKE SYSTEM EXPLODED VIEW LH Front Caliper Master Cylinder Top View LH Front Brake Line Master Cylinder 15 ft. lbs. LH Rear Line (20 Nm) RH Front Caliper LH Rear Caliper Cross Fitting Cross Fitting RH Front MC Rear Brake Line Brake Line Brake... -
Page 608: Master Cylinder
BRAKES MASTER CYLINDER FOOT BRAKE PEDAL Removal Pedal Removal Open the hood. Locate the master cylinder. Open the hood. Locate the master cylinder. Remove the retaining clip (A) from the clevis pin (B) that Remove the nut, bushing, tube, and bolt from the brake attaches the master cylinder to the brake pedal lever. -
Page 609: Brake Bleeding / Fluid Change
BRAKES BRAKE BLEEDING / FLUID CHANGE Have an assistant slowly pump foot pedal until pressure builds and holds. Hold brake pedal on to maintain pedal pressure, and open NOTE: When bleeding the brakes or replacing the bleeder screw. Close bleeder screw and release foot pedal. fluid always start with the furthest caliper from the master cylinder. -
Page 610: Parking Brake
BRAKES PARKING BRAKE Exploded View (4x4 CREW) Parking Brake Lever Nuts Clevis Washers Parking Brake Caliper Screw Clevis Clip Clip Washer Bolt Mount Bracket Cable Rear Propshaft Bolts w/Parking Brake Disc Rear Gearcase... -
Page 611: Exploded View (6X6)
BRAKES Exploded View (6x6) Parking Brake Clevis Lever Parking Brake Caliper Nuts Clip Bolt Mount Bracket Washers Clevis Parking Brake Disc Clip Screw Washer Middle Gearcase Cable... - Page 612 BRAKES Inspection Adjustment Procedure Place the vehicle in neutral on a flat level surface. Inspect the parking brake cable and brake pads on the caliper assembly located on the rear propshaft. Carefully lift the rear of the vehicle off the ground and See “Parking Brake Caliper Service”...
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Page 613: Parking Brake Caliper Service
BRAKES PARKING BRAKE CALIPER SERVICE Exploded View Hex Nut Pad & Holder Pad & Holder Plain Washer 18 ft. lbs. (24 Nm) Sleeve Thrust Washer Hex Head Mount Bolt Shim Pack Lever (4 Shims) Asm. Bolt 25 ft. lbs. (34 Nm) Stationary Actuator Spring Pin Compression Spring... -
Page 614: Caliper Disassembly / Inspection
BRAKES Loosen the two brake caliper mounting bolts (B) in equal 10. Measure the thickness of the rear caliper parking brake increments. pads. Replace assembly or pads as needed. See illustration below for proper readings. Inboard pad thickness New .304” (7.72 mm) Limit: 0.24”... -
Page 615: New Brake Pad Installation
BRAKES New Brake Pad Installation Caliper Installation NOTE: Parking Brake Pads can be replaced by Install the parking brake assembly into place. Tighten the ordering one of the following kits: two mounting bolts in increments for proper installation. PN 2203148 - Brake Pad and Shim Kit 18 ft. -
Page 616: Front Brake Pads
BRAKES FRONT BRAKE PADS Push mounting bracket inward and slip outer brake pad past edge. Then remove inner pad. Pad Removal Elevate and support front of vehicle. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. -
Page 617: Pad Assembly / Installation
BRAKES Pad Assembly / Installation Install the pad adjuster set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn Lubricate mounting bracket pins with a light film of (counterclockwise). Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. -
Page 618: Front Caliper Service
BRAKES FRONT CALIPER SERVICE Caliper Exploded View 47 in. lbs. Apply Polaris DOT 4 Brake Fluid (5.3 Nm) to Component Apply Polaris All Purpose Grease A. Socket Set Screw B. Bleeder Screw C. Caliper Assy. D. Boot E. Square O-rings F. -
Page 619: Caliper Disassembly
BRAKES Remove the two caliper mounting bolts and remove the Remove mounting bracket, pin assembly and dust boot. caliper assembly from the front strut. NOTE: Image shown with brake line attached. Be sure to remove prior to this step. Remove Thoroughly clean the brake caliper before disassembly and prepare a clean work area to disassemble the caliper. - Page 620 BRAKES Clean the caliper body, piston, and retaining bracket with Inspect piston for nicks, scratches, pitting or wear. Measure brake cleaner or alcohol. piston diameter and replace if damaged or worn beyond service limit. Clean Components NOTE: Be sure to clean seal grooves in caliper body.
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Page 621: Caliper Installation
BRAKES Lubricate the mounting bracket pins with Polaris Premium Install brake line and torque the banjo bolt to the proper All Season Grease (PN 2871423), and install the rubber torque specification. dust seal boots. 15 ft. lbs. (20 Nm) Install the pad adjustment screw and turn until stationary Compress the mounting bracket and make sure the dust seal pad contacts disc, then back off 1/2 turn. -
Page 622: Front Brake Disc
BRAKES FRONT BRAKE DISC Disc Replacement Remove front brake caliper (see “Front Caliper Service”). Disc Inspection Remove dust cap, cotter pin, castle nut and washers. Visually inspect disc for scoring, scratches, or gouges. Remove the wheel hub assembly from the vehicle and Replace the disc if any deep scratches are evident. -
Page 623: Rear Brake Pads (6X6)
BRAKES REAR BRAKE PADS (6X6) Pad Inspection Push caliper piston into caliper bore slowly with pads Pad Removal installed. Elevate and support rear of machine. NOTE: Brake fluid will forced through compensating port into master cylinder fluid CAUTION reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. -
Page 624: Pad Installation
BRAKES Pad Installation REAR BRAKE PADS (4X4 CREW) Install new pads in caliper body. Pad Removal Elevate and support rear of vehicle. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. Remove the wheel nuts, washers and rear wheel. - Page 625 BRAKES Pad Assembly / Installation Push mounting bracket inward and slip outer brake pad past edge. Then remove inner pad. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Pad Inspection Compress mounting bracket and make sure dust boots are fully seated.
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Page 626: Brake Burnishing Procedure
BRAKES Install the adjustment set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). 1/2 Turn Adjuster Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap. Master Cylinder Fluid Up to MAX line inside reservoir Install wheel and torque wheel nuts to specification (see “Chapter 2 - Maintenance”). -
Page 627: Rear Caliper Service (6X6)
BRAKES REAR CALIPER SERVICE (6X6) Rear Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Component Apply Polaris All Purpose Grease A. Socket Set Screw 47 in. lbs. B. Bleeder Screw (5.3 Nm) C. Caliper Assy. D. Boot E. Square O-rings F. - Page 628 BRAKES Caliper Disassembly Caliper Inspection Remove brake pad adjuster screw (A). Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit. Push upper pad retainer pin inward and slip brake pads past edge, if pads are still installed.
- Page 629 BRAKES Caliper Assembly Caliper Installation Install new square O-rings (A) in caliper body. Be sure the Install the rear caliper with the mounting bolts. Torque grooves are clean and free of residue or brakes may drag. mounting bolts to 18 ft.lbs. (24 Nm). Install brake line banjo bolt.
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Page 630: Rear Caliper Service (4X4 Crew)
BRAKES REAR CALIPER SERVICE (4X4 CREW) Rear Caliper Exploded View 47 in. lbs. Apply Polaris DOT 4 Brake Fluid (5.3 Nm) to Component Apply Polaris All Purpose Grease A. Socket Set Screw B. Bleeder Screw C. Caliper Assy. D. Boot E. -
Page 631: Caliper Disassembly
BRAKES Remove the two caliper mounting bolts and remove the Remove mounting bracket, pin assembly and dust boot. caliper assembly from the rear hub. Remove Thoroughly clean the brake caliper before disassembly and prepare a clean work area to disassemble the caliper. Use low pressure compressed air to remove the pistons Caliper Disassembly from the caliper. - Page 632 BRAKES Clean the caliper body, piston, and retaining bracket with Inspect piston for nicks, scratches, pitting or wear. Measure brake cleaner or alcohol. piston diameter and replace if damaged or worn beyond service limit. Clean Components NOTE: Be sure to clean seal grooves in caliper body.
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Page 633: Caliper Installation
BRAKES Lubricate the mounting bracket pins with Polaris Premium Install brake line and tighten securely with a line wrench. All Season Grease (PN 2871423), and install the rubber Torque the banjo bolt brake line(s) to the proper torque dust seal boots. specification. -
Page 634: Rear Brake Disc
BRAKES REAR BRAKE DISC Remove the wheel hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub. Disc Inspection (4) Bolts Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. Use a 0-1"micrometer and measure disc thickness at 8 Dust different points around perimeter of disc. -
Page 635: Troubleshooting
BRAKES TROUBLESHOOTING Brakes Squeal / Poor Brake Performance • Air in system • Water in system (brake fluid contaminated) • Caliper/disc misaligned • Caliper dirty or damaged • Brake line damaged or lining ruptured • Worn disc and/or friction pads •... - Page 636 BRAKES NOTES 9.34...
- Page 637 ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION ..........10.3 SPECIAL TOOLS .
- Page 638 ELECTRICAL STARTER SYSTEM ........... 10.29 TROUBLESHOOTING .
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Page 639: General Information
ELECTRICAL GENERAL INFORMATION Under-Hood Components The following components can be accessed under the hood. Special Tools • Voltage Regulator Part Number Tool Description • Battery PV-43568 Fluke™ 77 Digital Multimeter • Battery Cables 2870630 Timing Light • Terminal Block 2870836 Battery Hydrometer •... -
Page 640: Switches / Controls
ELECTRICAL SWITCHES / CONTROLS Inspect the switch connections and test the switch for continuity at the appropriate pin terminals as shown in the following illustration. Headlight Switch Lift the front hood. The wires are located on the back side of the instrument panel. -
Page 641: Brake Light Switch
ELECTRICAL Differential Solenoid Circuit Operation If the rear carrier fails to switch from operational modes: The rear differential solenoid relay is located under the hood. • Check the connector located under the left rear fender. Look for loose wires or bad connections. Power is present at the AWD / 2WD / Turf Switch when the •... -
Page 642: Parking Brake Switch
ELECTRICAL Parking Brake Switch Testing The Parking Brake Switch Disconnect the harness connector at the parking brake The parking brake switch is located within the parking brake switch (Orange/Red and Red/White wires). lever. Follow the parking brake lever under the dash to locate the internally mounted switch. -
Page 643: Instrument Cluster
ELECTRICAL INSTRUMENT CLUSTER Rider Information Display The rider information display is located in the instrument Overview cluster. All segments will light up for 2.5 seconds at start-up. The RANGER instrument cluster senses vehicle speed from the NOTE: If the instrument cluster fails to illuminate, a right front wheel. -
Page 644: Standard Display Modes
ELECTRICAL Standard Display Modes Clock Screen Use the yellow mode button located under the speedometer to toggle through the mode options. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records the miles or kilometers traveled by the vehicle on each trip if it's reset before each trip. - Page 645 ELECTRICAL AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil. NOTE: A 10 - 20% variance from these readings is within normal parameters. Programmable Service Interval Gear Circuit Diagnostic Screen When the hours of engine operation equal the programmed This screen displays the resistance value (in ohms) being read at service interval setting, the wrench icon will flash for 5 seconds the gear switch input of the gauge.
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Page 646: Viewing Diagnostic Codes
ELECTRICAL To enable or disable the service interval: Enter the diagnostic mode. Toggle to the service interval screen. Press and hold the mode button for about seven (7) seconds, until either ON or OFF appears in the Rider Information Display, depending on your preference. To reset the service interval: Enter the diagnostic mode. - Page 647 ELECTRICAL Any blink code numbers stored in the EFI module will Push the instrument cluster out from the back side of the display, one at a time, on the screen. dash panel, while securely holding the panel and rubber Example below shows a Blink Code of “42”. mount.
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Page 648: Instrument Cluster Troubleshooting Tests
ELECTRICAL INSTRUMENT CLUSTER TROUBLESHOOTING TESTS Test 1 - No All Wheel Drive 10.12... -
Page 649: Test 2 - No Display
ELECTRICAL TEST 2 - No Display TEST 3 - Wheel Speed Sensor 10.13... -
Page 650: Test 4 - No Awd Hub Safety Limiter
ELECTRICAL TEST 4 - No AWD Hub Safety Limiter 10.14... -
Page 651: Test 5 - Fuel Gauge Display Not Working
ELECTRICAL TEST 5 - Fuel Gauge Display Not Working TEST 6 - Shift Indicator Not Working (Transmission Switch) 10.15... -
Page 652: All Wheel Drive (Awd) Coil
ELECTRICAL ALL WHEEL DRIVE (AWD) COIL GEAR POSITION INDICATOR SWITCH Operation Overview Test Diagram • When the AWD switch is “ON”, 12 VDC power is NOTE: Also see “INSTRUMENT CLUSTER present at the hub coil. TROUBLESHOOTING” for switch circuit. TRANSMISSION SWITCH •... -
Page 653: Headlights
ELECTRICAL HEADLIGHTS Adjust the beam to desired position. Repeat the procedure to adjust the other headlight. Headlight Adjustment WARNING The headlight beam is adjustable. Due to the nature of light utility vehicles and Place the vehicle on a level surface with the headlight where they are operated, headlight lenses approximately 25 ft. -
Page 654: Lamp Replacement
ELECTRICAL TAIL LIGHT / BRAKE LIGHT Remove the O-ring (A) from the headlight brackets (both sides). Lamp Replacement Before replacing the tail light, use a digital multi-meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present. -
Page 655: Cooling System
ELECTRICAL COOLING SYSTEM Cooling System Break-Out Diagram 10.19... -
Page 656: Coolant Temperature Sensor
ELECTRICAL Fan Control Circuit Operation EFI DIAGNOSTICS Power is supplied to the fan via the Orange/Black wire when the EFI Component Testing relay is ON. The ground path for the fan motor is through the Brown harness wire. Refer to “RELAYS” later in this chapter All EFI component information and diagnostic testing for more information on fan functions. -
Page 657: Relays
ELECTRICAL RELAYS REAR DIFF SOLENOID RELAY Operation OLOR UNCTION Key-On battery power supply, switched on The relays, located under the hood, assist with component Red / White by key switch, enables power to relay. operation like the fan, fuel pump, and rear differential. Brown Ground path for relay. -
Page 658: Fuses / Circuit Breaker
ELECTRICAL FUSES / CIRCUIT BREAKER Operation The fuse panel, located under the hood, provides component protection for components such as the Instrument Cluster, ECU, EFI system, Chassis Power and Accessories. A 15-amp circuit breaker protects the fan motor circuit. 10.22... -
Page 659: Charging System
ELECTRICAL CHARGING SYSTEM Charging System “Break Even” Test Current Draw - Key Off CAUTION CAUTION Do not allow the battery cables to become disconnected with the engine running. Follow the steps below as outlined to reduce the chance of Do not connect or disconnect the battery cable damage to electrical components. -
Page 660: Charging System Alternator Tests
ELECTRICAL Charging System Alternator Tests TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM Three tests can be performed using a multi-meter to determine the condition of the stator (alternator). Set the selector dial to measure AC Voltage. Start the engine and let it idle. -
Page 661: 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 662: Battery Service
ELECTRICAL BATTERY SERVICE Battery Activation Battery Terminals / Bolts CONVENTIONAL BATTERY Use Polaris corrosion resistant Nyogel™ grease (PN 2871329) Removable on battery terminal bolts. Caps Top View Electrolyte Level Indicator Apply Side View Nyogel™ WARNING Battery Terminal Block The terminal block is located under the front hood next to the Battery electrolyte is poisonous. -
Page 663: Battery Testing
ELECTRICAL To ensure maximum service life and performance from a new Inspect the battery fluid level. When the battery fluid nears the battery, perform the following steps. NOTE: Do not service the lower level, remove the battery and fill with distilled water only battery unless it will be put into regular service within 30 days. - Page 664 ELECTRICAL Specific Gravity Test A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still may not have the storage A tool such as a Battery Hydrometer (PN 2870836) can be used capacity necessary to properly function in the electrical system.
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Page 665: Starter System
ELECTRICAL STARTER SYSTEM Voltage Drop Test The Voltage Drop Test is used to test for bad connections. When Troubleshooting performing the test, you are testing the amount of voltage drop through the connection. A poor or corroded connection will Starter Motor Does Not Run appear as a high voltage reading. -
Page 666: Brush Inspection / Replacement
ELECTRICAL NOTE: Note the alignment marks on both ends of Measure resistance between insulated brush and starter the starter motor casing. These marks must align housing. Reading should be infinite (OL). Inspect during reassembly. insulation on brush wires for damage and repair or replace as necessary. -
Page 667: Armature Testing
ELECTRICAL Brush Replacement Measure the resistance between each commutator segment and the armature shaft. The reading should be infinite (no Remove terminal nut with lock washer, flat washer, large continuity). phenolic washer, the small phenolic spacers, and sealing O-ring. Inspect O-ring and replace if damaged. Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate. -
Page 668: Starter Drive
ELECTRICAL NOTE: It is important to tighten the bottom starter Install O-ring, two small phenolic spacers, large phenolic bolt first (circle), as the bottom hole acts as a pilot washer, flat washer, lock washer, and terminal nut. hole to properly align the starter drive (bendix) with While holding brush springs away from brushes, push the flywheel. -
Page 669: Starter Solenoid Bench Test
ELECTRICAL Remove the retaining ring, thrust washer, spring retainers and clutch return spring. Screw the overrun clutch off the end of the pinion shaft. Remove the old spring and install a new one. Lightly grease the pinion shaft and reinstall the clutch, spring, retainers, end washer and lock ring in the reverse order. -
Page 670: Starter Exploded View
ELECTRICAL Starter Exploded View 10. Gear Assembly Indicates Do not reuse. 1. Rubber Ring* Replace with new parts. 11. Through Bolt 2. Brush Spring 12. Cover 3. Thrust Washer 13. Stopper 4. Gear Assembly 14. Snap Ring 5. O-Ring* 15. Washer 6. -
Page 671: Starting System Testing Flow Chart
ELECTRICAL STARTING SYSTEM TESTING FLOW CHART Condition: Starter fails to turn over the engine. With the tester on the VDC position, place the tester's black lead on the battery negative and the Remove battery and properly service. Install red lead on the battery positive. Reading should fully charged shop battery to continue test. -
Page 672: 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 673: Electrical Break-Out Diagrams
ELECTRICAL ELECTRICAL BREAK-OUT DIAGRAMS Starting Circuit Key-On Power Circuit 10.37... -
Page 674: Transmission Switch Circuit
ELECTRICAL Transmission Switch Circuit AWD Circuit 10.38... -
Page 675: Speed Sensor Circuit
ELECTRICAL Speed Sensor Circuit Charging System Circuit 10.39... -
Page 676: Cooling Fan Circuit
ELECTRICAL Cooling Fan Circuit Fuel Display / Fuel Pump Circuit 10.40... - Page 677 Air Filter Service ......2.12 Cab Frame, Assembly / Removal (4x4 CREW) ..5.9 Air Intake Inspection .
- Page 678 Engine, Oil Pressure Test ......3.20 Engine, Oil Pump Disassembly ....3.41 EFI Circuit Diagrams .
- Page 679 Fuel Sender Test ......4.12 10.20 Parking Brake Caliper, Removal ....9.11 Fuel System .
- Page 680 Special Tools, Clutching ......6.2 Switch, Headlight ......10.4 Special Tools, EFI .
- Page 681 PN 9921885 Printed in USA...
- Page 682 WIRE DIAGRAM 2009 RANGER 700 4X4 CREW (CHASSIS/BOX) PAGE 1 OF 2 WD-1...
- Page 683 WIRE DIAGRAM 2009 RANGER 700 4X4 CREW (CHASSIS/BOX) PAGE 2 OF 2 WD-2...
- Page 684 WIRE DIAGRAM 2009 RANGER 700 6X6 (CHASSIS) PAGE 1 OF 2 WD-3...
- Page 685 WIRE DIAGRAM 2009 RANGER 700 6X6 (CHASSIS) PAGE 2 OF 2 WD-4...
- Page 686 WIRE DIAGRAM 2009 RANGER 700 4X4 CREW / 6X6 (DASH) WD-5...
- Page 687 WIRE DIAGRAM 2009 RANGER 700 4X4 CREW / 6X6 (BREAKOUTS) WD-6...