Polaris 2008 RZR Service Manual

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MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

MODEL: 2008 RANGER RAZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

GENERAL INFORMATION

CHAPTER 1

1.1

Chapters

Table of Contents

Troubleshooting

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Summary of Contents for Polaris 2008 RZR

Page 1: Table Of Contents
GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION MODEL INFORMATION ..........1.2 MODEL IDENTIFICATION .
Page 2: 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 8 V H 7 6 A D Emissions & Model Year Model Option Designation Basic Chassis Engine Designation Designation...
Page 3: Unit Serial Number (Vin) Location
GENERAL INFORMATION Unit Serial Number (VIN) Location The machine model number and serial number (VIN) are important for vehicle identification. The VIN number (A) is stamped on a portion of the LH frame rail close to the front wheel. The model and VIN numbers are also located on a sticker under the hood (B).
Page 4: General Specifications
GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2008 RANGER RZR MODEL NUMBER: R08VH76AD, AG ENGINE MODEL: EH076OLE021 FRONT Category Dimension / Capacity Length 102 in. / 259 cm Width 50 in. / 127 cm Height 68.5 in. / 174 cm Wheel Base 77 in.
Page 5 MODEL NUMBER: R08VH76AD, AG Transmission Type Polaris Automatic PVT ENGINE MODEL: EH076OLE021 Gear Ratio: Front / Rear Engine High 3.14:1 8.71:1 Polaris Domestic Twin Cylinder, Platform 5.94:1 Liquid Cooled, 4-Stroke Drive Ratio - Front 3.82:1 Engine Model Number EH076OLE021 Drive Ratio - Final 3.70:1...
Page 6: Vehicle Information
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris...
Page 7: Misc. Specifications And Charts
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C...
Page 8: Standard Torque Specifications
GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.
Page 9: Sae Tap / Drill Sizes
GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes...
Page 10: Glossary Of Terms
CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
Page 11 LUBRICANTS / SERVICE PRODUCTS ........2.8 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS ... . 2.8 MAINTENANCE REFERENCES .
Page 12 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM ........2.25 BATTERY MAINTENANCE .
Page 13: Periodic Maintenance Chart
Polaris dealer. = SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked could result in component failure and lead to serious injury or death.
Page 14: Pre-Ride - 25 Hour Maintenance Interval
Engine Oil Change 25 H 250 (400) Perform a break-in oil change at one month (Break-In Period) Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
Page 15: 50 - 300 Hour Maintenance Interval
Clean out Inspect periodically; adjust when parts are Toe Adjustment replaced Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
Page 16: Component Inspection / Service Locations
MAINTENANCE COMPONENT INSPECTION / SERVICE LOCATIONS Front and Rear View...
Page 17: Rh And Lh Side Views
MAINTENANCE RH and LH Side Views...
Page 18: Lubricants / Service Products
MAINTENANCE LUBRICANTS / SERVICE PRODUCTS NOTE: Each item can be purchased separately at your local Polaris dealer. Polaris Lubricants, Maintenance and Service Part No. Description Products Additives / Sealants / Thread Locking Agents / Misc. Part No. Description 2870585 Loctite™ Primer N, Aerosol, 25 g Engine Lubricant Loctite™...
Page 19: Maintenance References
Semi-annually** Lube (PN 2871551) grease gun. Locate grease fittings on the upper and lower A-arms of Control Arm Pivot Polaris Premium All Season the front and rear suspension Page 2.6 Semi-annually** Bushings, FT / RR Grease (PN 2871423) and grease with grease gun.
Page 20: General Vehicle Inspection And Maintenance
MAINTENANCE GENERAL VEHICLE INSPECTION Shift Cable Inspection / Adjustment AND MAINTENANCE Shift cable adjustment may be necessary if symptoms include: • No AWD or gear position display on instrument cluster Pre-Ride / Daily Inspection • Ratcheting noise on deceleration Perform the following pre-ride inspection daily, and when •...
Page 21: Fuel System And Air Intake
MAINTENANCE Once the proper adjustment is obtained, place the shift Be sure fuel line is routed properly. cable and upper jam nut into the mount. Tighten the lower IMPORTANT: Make sure line is not kinked or pinched. jam nut against the mount. Replace fuel line every two years.
Page 22: Throttle Pedal Inspection
MAINTENANCE Throttle Pedal Inspection Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster. If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully.
Page 23 MAINTENANCE Remove air filter assembly and remove the pre-filter sleeve. Installation Inspect the main air filter element and replace if necessary. Clean the air box thoroughly. Do not clean the main filter, the filter should be replaced. Install a new or clean pre-filter over the main air filter NOTE: If the filter has been soaked with fuel or oil it element.
Page 24: Engine
MAINTENANCE ENGINE Lever Lock Engine Oil Level The twin cylinder engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below. Dipstick SAFE ADD 8 OZ Dipstick Reinstall the dipstick completely, but do not lock it.
Page 25: Engine Oil And Filter Service
13. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn. 14. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4-Cycle Synthetic Oil (PN 2871281). Crankcase Drain Plug Torque: 16 ft. lbs. (22 Nm) NOTE: Drain plug is accessed through the skid plate.
Page 26: Engine Breather Hose Inspection
MAINTENANCE Engine Breather Hose Inspection A smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition The engine is equipped with a breather hose. Inspect the problems above idle speed. breather hose for possible kinks or wear. The hose is form fit- A cylinder leakdown test is the best indication of engine ted for a proper fit.
Page 27: Transmission And Gearcases
MAINTENANCE TRANSMISSION AND GEARCASES Transmission / Gearcase Specification Chart RAIN EVEL HECK EARCASE UBRICANT APACITY ORQUE ORQUE Transmission AGL - Synthetic ATV 24 oz. (710 ml) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm) (Main Gearcase) Gearcase Lubricant Transmission AGL - Synthetic ATV 14 oz.
Page 28 MAINTENANCE Main Gearcase - Lubricant Level Check: The fill plug is located on the side of the gearcase just below the shift lever bell crank. Maintain the fluid level even with the bottom of the fill plug hole. Position vehicle on a level surface. Remove the fill plug.
Page 29: Front Gearcase Lubrication
MAINTENANCE Front Gearcase Lubrication Position vehicle on a level surface. The front gearcase lubricant level should be checked and Remove the fill plug and check the fluid level. changed in accordance with the maintenance schedule. Add the recommended fluid as needed. •...
Page 30: Rear Gearcase Lubrication
MAINTENANCE Rear Gearcase Lubrication Lubricant Change: The drain plug is located on the bottom right side of the rear Rear Gearcase Specifications gearcase. Specified Lubricant: ATV Angle Drive Fluid (PN 2871653) Capacity: 18 oz. (532 ml) Fill Plug Fill Plug Torque: 40-50 ft. lbs. (54-68 Nm) Drain Plug Torque: 30-45 in.
Page 31: Cooling System
Remove recovery bottle cap and add coolant using a funnel. Polaris Premium 60/40 is already premixed and ready to use. Do Fill recovery bottle to MAX level with Polaris 60/40 not dilute with water.
Page 32: Cooling System Pressure Test
MAINTENANCE Cooling System Pressure Test Carefully straighten any bent radiator fins. Refer to Chapter 3 for cooling system pressure test procedure. Remove any obstructions with compressed air or low pressure water. Cooling System Hoses Inspect all hoses for cracks, deterioration, abrasion or CAUTION leaks.
Page 33: Final Drive / Wheel And Tire
MAINTENANCE FINAL DRIVE / WHEEL AND TIRE Radiator Removal Remove the front bumper (see Chapter 5). Wheel, Hub, and Spindle Torque Table Remove the upper engine outlet hose and recovery hose from the top of the radiator. Item Nut Type Specification Remove the (2) upper radiator retaining bolts and the (4) Aluminum Wheels...
Page 34: Tire Inspection
MAINTENANCE Carefully lower the vehicle to the ground. WARNING Torque the wheel nuts and/or hub nut to the proper torque specification listed in the torque table at the beginning of this section. Operating a RANGER with worn tires will increase the possibility of the vehicle skidding If hub nut was removed, install a new cotter pin after the easily with possible loss of control.
Page 35: Electrical And Ignition System
MAINTENANCE ELECTRICAL AND IGNITION SYSTEM Battery Removal Remove the driver’s seat to access the battery. Battery Maintenance Keep battery terminals and connections free of corrosion. If Battery cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water.
Page 36: Battery Off Season Storage
NOTE: Battery charge can be maintained by using a A hot exhaust system and engine can cause serious Polaris battery tender charger or by charging about burns. Allow engine to cool or wear protective once a month to make up for normal self-discharge.
Page 37: Engine To Frame Ground
12. Install spark plug and torque to specification. Due to the critical nature of the procedures outlined in Recommended Spark Plug: this chapter, Polaris recommends steering component Champion RC7YC3 repair and adjustment be performed by an authorized Polaris MSD certified technician when replacing Spark Plug Torque: worn or damaged steering parts.
Page 38: Steering Inspection / Tie Rod Ends And Hubs
MAINTENANCE Steering Inspection / Tie Rod Ends and Hubs Toe Alignment Inspection • To check for play in the tie rod end, grasp the steering Place machine on a smooth level surface. tie rod and pull in all directions feeling for movement. Set steering wheel in a straight ahead position and secure the steering wheel in this position.
Page 39: Toe Adjustment
MAINTENANCE Toe Adjustment Suspension Spring Adjustment Position the vehicle on a level surface. If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod Stop the engine. needs adjusting. Raise and safely support the front or rear of the vehicle off NOTE: Be sure steering wheel is straight ahead the ground to allow the suspension to fully extend.
Page 40: 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 41 ENGINE CHAPTER 3 ENGINE ENGINE SPECIFICATIONS ..........3.2 CRANKCASE EXPLODED VIEWS .
Page 42: Engine Specifications
ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views...
Page 43 ENGINE Oil Pump / Water Pump / Engine Cover Exploded View...
Page 44 ENGINE Stator Cover / Starter / Water Pump Oil Filter / Pressure Relief / Exploded View...
Page 45 ENGINE Cylinder / Cylinder Head / Piston Exploded View...
Page 46 ENGINE Engine EFI Sensors / Valve Cover General Component Exploded View NOTE: See Chapter 4 for more information on the EFI System...
Page 47: 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 48: 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 49: 800 Efi Engine Service Specifications
ENGINE 800 EFI Engine Service Specifications Cylinder Head - Engine Specifications Main Component: Cylinder Head EH076OLE021 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 50 ENGINE Cylinder / Piston - Engine Specifications Main Components: Cylinder / Piston / Connecting Rod EH076OLE021 Cylinder - Surface warp limit 0.004" (0.10 mm) (mating with cylinder head) Cylinder Bore - Standard 3.1495" (80 mm) Cylinder Cylinder Taper Limit 0.00031" (0.008 mm) Cylinder Out of Round Limit 0.00030"...
Page 51: 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 52: Engine Cooling System
CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.
Page 53: Cooling System Exploded View
ENGINE Cooling System Exploded View Engine Outlet Hose (Thermostat Housing) Radiator Inlet Hose Engine Inlet Hose (Water Pump Cover) Fan Motor Pressure Cap Shroud Filler Neck To Bottle Recovery Bottle Radiator Outlet Hose If Built After 4/16/2007 Radiator To Filler Neck Coolant Flow Diagram Filler Neck Engine...
Page 54: Cooling System Bleeding Procedure
Park machine on a level surface. Place the vehicle in of air. neutral and set the parking brake. Add Polaris Premium Antifreeze to the radiator if the level CAUTION goes down. Tighten the bleed screw to 70 ± 10 in.lbs. (8 ± 1.13 Nm) on...
Page 55: General Engine Service
Place the vehicle in neutral and set the parking brake. Block the rear wheels. Capacity - Approximately 2 U.S. Quarts (1.9 L) Pressure Cap Oil Type - Polaris Premium 0W-40 Synthetic Filter Wrench - PV-43527 or equivalent - Oil Pressure Specification - 27-35 psi @ 6000 RPM, Polaris 0W-40 Synthetic, Engine at operating temperature.
Page 56: Oil Flow Chart
ENGINE Oil Flow Chart This chart describes the flow of oil through the 800 EFI engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.
Page 57: Engine Removal
Engine Removal Remove the (2) push rivets from the rear of the center console. Because of its design configuration, Polaris recommends removing the engine, transmission, and rear gearcase as one assembly. Use the following procedure when engine removal is required.
Page 58 ENGINE 12. Elevate the rear of the vehicle off the ground using a 18. Remove the (6) fasteners retaining the upper bolt-in frame suitable ATV lift and remove both rear wheels. brace and remove it from the vehicle with the ignition coil and PVT duct attached.
Page 59 ENGINE 22. Loosen the hose clamp between the throttle body and intake 25. Remove the airbox and throttle body from the vehicle as an adaptor. assembly. Take care in not allowing the throttle cable to bend excessively or kink. Carefully place the assembly on the floor next to the vehicle.
Page 60 ENGINE 29. Mark the upper jam nut and loosen the lower jam nut. Pull 32. Disconnect the stator / alternator harness. the shift cable out of the mount. Stator Mark Upper Connector Jam Nut Lower Jam Nut 33. Disconnect the transmission speed sensor harness. NOTE: If the upper jam nut is moved, shift cable adjustment will...
Page 61 ENGINE 35. Remove the through-bolt that attaches the upper A-arm to 38. Disconnect the engine coolant temperature (ECT) sensor the rear hub on both sides of the vehicle. harness. Connector 36. Pivot the A-arms upward and rear hub carriers downward 39.
Page 62 ENGINE 44. Remove RH engine mount fastener. 47. Using an engine hoist, hook a chain between the engine / transmission mounting plate and the transmission / rear gearcase mounting plate. 45. Remove LH transmission mount fastener. Engine/Transmission Mount Plate Transmission/Gearcase Mount Plate 46.
Page 63: Engine / Transmission Separation
ENGINE 49. Remove propshaft from the transmission output shaft. Remove only the (4) outer fasteners retaining the engine to the transmission bracket. 50. Then move assembly towards the front of the vehicle while lifting it out to allow the rear gearcase to clear the rear portion of the frame.
Page 64: 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 3.24...
Page 65: Rocker Arms / Push Rods
ENGINE Rocker Arms If the push rod (A) is visibly bent, it should be replaced. Remove the valve cover. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. Cylinder Head Removal NOTE: The cargo box assembly and the upper frame bolt-in brace must be removed to allow enough clearance to remove all the cylinder head bolts.
Page 66: 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 67: 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 68: 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 69: Combustion Chamber
Combustion Area Install pilot into valve guide. Valve Seat Reconditioning Apply cutting oil to valve seat and cutter. NOTE: Polaris recommends that the work be done ° by a local machine shop that specializes in this area. Place 46 cutter on the pilot and make a light cut.
Page 70 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.
Page 71: 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 72: 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 73: 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 74: 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 75: Cylinder Hone Selection And Honing Procedure
IMPORTANT: Clean the cylinder after honing for honing is not advised for nicasil cylinders. Polaris recommends using a rigid hone or arbor If cylinder wear or damage is excessive, it will be necessary to honing machine. Cylinders may be wet or dry replace the cylinder.
Page 76: 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 77: 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 78: 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 79 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 80 ENGINE Use a white pen to accent the timing marks on the following gears: camshaft gear (K), crankshaft gear (M), or CAUTION counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears. Wear safety glasses at all times. Use caution when working with the top gear.
Page 81 ENGINE 14. Inspect the gear teeth and the three tabs on the gears for To Assemble: wear. • Hold the spring with one finger. • Start the pointed end of the tapered pin into the cam Inspect Teeth & Tabs gear hole.
Page 82 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 83 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 84 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 85 ENGINE 34. Press shaft into the new bearing.. 37. Remove thrust plate (U). Press On Bearing 35. Press the bearing/shaft assembly using the bearing's outer race. Do not use the shaft to press the assembly into the 38. Remove PTO end engine mount. Remove crankcase bolts. housing, as bearing damage may result.
Page 86: Camshaft Inspection
ENGINE Camshaft Inspection 39. Remove and clean oil pick up (V) and oil baffle weldment (W). Thoroughly clean the cam shaft. Visually inspect each cam lobe for wear, chafing or damage. Measure height of each cam lobe using a micrometer. Compare to specification.
Page 87: 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 88 ENGINE NOTE: Always install new balance shaft bearings. Assemble the crankcase halves. Apply LocTite™ 242 (PN 2871949) to the threads and pipe sealant to the bolt flanges. Apply assembly lube to cam journals and balance shaft Torque bolts to specification following torque pattern at bearing surfaces of the MAG case halve.
Page 89 ENGINE 10. Lubricate connecting rods with 0W-40 engine oil. 13. Install piston assemblies into cylinder aligning the piston pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons. 11.
Page 90 ENGINE NOTE: While installing in piston circlips, cover all 17. Assemble rotors as marked when disassembled. Use a engine passages. The clip could fall into the engine cleaner to remove the marks previously made on the rotors. during installation. Line Up Marks 18.
Page 91 ENGINE 20. Install oil pump housing bolts (H). The new bolts contain 22. Before installing the crankshaft gear (I), heat the crankshaft ° ° ™ patch lock, so Loctite is not needed on the new bolts. gear to 250 F (121 C) on a hot plate (J).
Page 92 ENGINE NOTE: Cam Spanner Wrench (PU-45498) is only 25. Install counter balance shaft gear (J) with new key, aligning needed to rotate the camshaft when the entire valve timing marks with crankshaft gear (I). Install washer and bolt. Use the Gear Holder (PU-45838). Torque to train is assembled.
Page 93 ENGINE 28. Before installing the gear / stator housing, replace the seals NOTE: Install the crankshaft seal (P) with the seal lip facing out (towards the crankcase). in the cover. Install a new water pump seal (N) into the gear / stator housing.
Page 94 ENGINE 32. Before installing the gear/stator housing cover, install the Water Pump Seal Saver (PA-45401) onto the water pump shaft. PA-45401 35. Install the gear/stator housing gasket onto he crankcase. Gear / Stator Housing Gasket 33. Install a NEW gasket to the gear/stator housing cover and crankcase.
Page 95 ENGINE NOTE: Before assembly, clean the bolts and bolt 39. Install water pump cover (R) with new O-ring seal. Torque holes with Primer N (PN 2870585) to remove any bolts to specification in proper sequence (see Page 3.4). debris. This will ensure proper sealing when installing bolts.
Page 96: Flywheel / Stator Installation
ENGINE Flywheel / Stator Installation NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when Flywheel Nut Torque installing bolts. 65 ± 7 ft.lbs. (88 ± 9.50 Nm) Install stator assembly (S) and bolts.
Page 97 ENGINE Lubricate threads and top of washers underside of bolt head Lubricate rockers (E) with engine oil. with engine oil. Install head bolts (C) and torque to specification. Verify pushrods are engaged in lifters. Install rockers. Be sure that tab of fulcrum (F) is seated in head stand-off.
Page 98: Oil Pump Priming
ENGINE Install breather reed (G) into rocker cover (H). Lightly 11. Install thermostat (J), new O-ring, and thermostat housing. apply black RTV sealant to the outer edges of the breather Torque to specification. reed. The reed has a tab and will assemble one-way only. Torque the breather bolts to specification.
Page 99: Engine Installation
Remove primer plug from the engine. Install Oil System Priming Adapter (PU-45778) into the oil plug hole. Push 3-5 oz. (approx.) of Polaris 0W-40 into the adapter or until resistance is felt. Remove the adapter. Apply sealant to the plug threads. Install the plug and torque to specification.
Page 100 ENGINE Lightly tighten all fasteners evenly to eliminate any gaps • Install engine / transmission / rear gearcase mounting that may be present in the mounting areas. hardware and torque to specification. Torque fasteners to specification using a 2 part sequence. •...
Page 101: Engine Break-In Period
ENGINE Engine Break-In Period The break-in period for a Polaris 4-Cycle engine is defined as the first ten hours of operation, or the time it takes to use two full tanks of gasoline. No single action on your part is as important as a proper break-in period.
Page 102: 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 103: 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 104 ENGINE NOTES 3.64...
Page 105 ELECTRONIC FUEL INJECTION CHAPTER 4 ELECTRONIC FUEL INJECTION GENERAL INFORMATION ..........4.2 SPECIAL TOOLS .
Page 106: General Information
NOTE: Voltage Regulator 4010264 is required if using TPS harness PU-47082. If your dealership sells Polaris snowmobiles, you may already have this regulator from TPS tool PN 2201519. If you do not have this regulator, you must order one from...
Page 107 The pressure adapter has an integrated relief valve. Connect to the test valve and release the pressure. NOTE: If your dealership sells Polaris snowmobiles, Fuel Pressure Gauge Kit PU-43506-A you may already have this regulator from TPS tool PN 2201519.
Page 108 PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. This module kit is used on all 8 pin connector-based Polaris EFI systems. This kit is available to Polaris dealers through our tool supplier SPX at (1-800-328- 6657) or http://polaris.spx.com...
Page 109: Service Notes
• 80% of all EFI problems are caused by wiring harness connections. • For the purpose of troubleshooting difficult running issues, a known-good ECU from another Polaris RANGER RZR EFI of the same model may be used without damaging system or engine components.
Page 110: Efi System Exploded View
ELECTRONIC FUEL INJECTION EFI System Exploded View 1. Electronic Control Unit (ECU) 2. Intake Air Temperature / Manifold 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 111: 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 behind the driver’s seat next to the seat belt assembly and just above the voltage regulator.
Page 112 ELECTRONIC FUEL INJECTION Throttle Body Ignition Coil - Located between the rubber air box boot and the rubber - Located behind the driver’s seat and rear service panel just cylinder head adaptor. above the PVT cover. Ignition Coil Throttle Body Throttle Position Sensor (TPS) - Located on the right-hand side of the throttle body.
Page 113: Fuel Tank
ELECTRONIC FUEL INJECTION FUEL TANK Exploded View Screw Screw Rear Front Tank Bracket Tank Bracket Hi-Temp Flex Conduit Quick Connect Fuel Line Fuel Pump Asm Gasket Fuel Tank Fuel Flow Fuel Injectors Fuel Rail Fuel Tank Pressure Regulator Fuel Pump Assembly Fuel Filters Quick Connect Fuel Line...
Page 114: Fuel Lines - Quick Connect
ELECTRONIC FUEL INJECTION Fuel Lines - Quick Connect ELECTRONIC FUEL INJECTION RANGER EFI models use quick connect fuel lines. Refer to the Principal Components steps below for fuel line removal. The Electronic Fuel Injection (EFI) system is a complete engine Place a shop towel around the fuel line to catch any fuel and ignition management design.
Page 115: Initial Priming / Starting Procedure
ELECTRONIC FUEL INJECTION ELECTRONIC CONTROL UNIT (ECU) The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for air temperature, barometric air pressure, engine temperature, speed Operation Overview (RPM), and throttle position (load). These primary signals are The ECU is the brain or central processing computer of the compared to the programming in the ECU computer chip, and entire EFI fuel/ignition management system.
Page 116: Temperature And Barometric Air Pressure Sensor (T-Bap)
Software (dealer only). Refer to the EFI Diagnostic For the purpose of troubleshooting, a known-good ECU from Software Manual for more information. another Polaris RANGER RZR EFI of the same model may be T-BAP Replacement used without system or engine component damage.
Page 117: Crankshaft Position Sensor (Cps)
ELECTRONIC FUEL INJECTION Install new sensor using a light coating of oil on the o-ring The two-tooth gap creates an “interrupt” input signal, to aid installation. corresponding to specific crankshaft position for PTO cylinder. This signal serves as a reference for the control of ignition Bolt timing by the ECU.
Page 118: Cps Replacement
ELECTRONIC FUEL INJECTION If the resistance is correct. Remove the (3) bolts retaining the front portion of the - Test the main harness circuit between the sensor mounting bracket to the transmission. Retain the bolts, connector terminals and the corresponding pin terminals at washers, and spacers for installation.
Page 119 ELECTRONIC FUEL INJECTION Lift the mounting bracket straight up and out from the Installation vehicle. IMPORTANT: When reinstalling the transmission to rear gearcase mount bracket, it is extremely important Remove to torque all (7) fasteners to specification. Refer to the Bracket following procedure.
Page 120 ELECTRONIC FUEL INJECTION Using special tool (PA-48873), torque the (3) bolts that Remove the special tool and attach an extension to the retain the front portion of the mounting bracket to the torque wrench. Torque the bottom bolt that attaches the transmission.
Page 121 ELECTRONIC FUEL INJECTION Upper Rear Gearcase Bolt Torque the remaining bolt that attaches the bracket to the front side of the rear gearcase. Front Rear Gearcase Bolt NOTE: A multi-directional torque wrench is required in this application because of the limited access to this bolt.
Page 122: Fuel Injectors
ELECTRONIC FUEL INJECTION FUEL INJECTORS • When temperatures prohibit touching, listen for a buzzing or clicking sound with a screwdriver or mechanic's stethoscope. Operation Overview • Disconnect the electrical connector from an injector and NOTE: All EFI units utilize quick connect fuel lines. listen for a change in idle performance (only running on The fuel injectors mount into the cylinder head, and the fuel rail one cylinder) or a change in injector noise or vibration.
Page 123 ELECTRONIC FUEL INJECTION Fuel Injector Test Fuel Injector Replacement NOTE: The Bosch harness connector and locking Be sure the engine has cooled enough to work on. spring is bonded to the fuel injectors with an epoxy Depressurize the fuel system by connecting the Fuel mix.
Page 124 ELECTRONIC FUEL INJECTION Disconnect the harness for the fuel injector(s) located next Using a 6mm hex wrench, loosen the fuel rail mounting to the ignition coil. Cut the plastic tie strap and push the screw from the cylinder head. Carefully pull the rail away harness for the fuel injector(s) up over the air box to allow from the injectors and remove the injector(s) from the fuel injector removal.
Page 125: Fuel Pump
ELECTRONIC FUEL INJECTION FUEL PUMP • If the engine is stopped with the key switch "on" (as in the case of an accident). Operation Overview In these situations, the “check engine” light will go on, but will turn off after 4 cranking revolutions if system function is OK. NOTE: All EFI units utilize quick connect lines.
Page 126 Disconnect and Test Here Test Valve Pin “C” Brown Connect the pressure hose of the Polaris pressure tester (PU-43506-A) to the test valve on the fuel rail. Route the Pin “A” clear hose into a portable gasoline container or the equipment fuel tank.
Page 127: Fuel Tank / Fuel Pump Replacement
ELECTRONIC FUEL INJECTION Fuel Tank / Fuel Pump Replacement Disconnect the fuel pump electrical harness. IMPORTANT: Syphon as much fuel from the tank as Disconnect Here possible before attempting to remove it from the vehicle. WARNING Always wear safety goggles when working with high pressure or flammable fluids.
Page 128 ELECTRONIC FUEL INJECTION Remove the (2) fasteners from the rear seat base and 11. Remove the (3) Torx fasteners from the rear RH fender well remove the assembly from the vehicle. and remove the fender well from the vehicle. NOTE: Lift fender well up over the fuel tank filler Remove the (11) push rivets and (4) Torx screws retaining neck and out from the vehicle.
Page 129: Fuel Pressure Regulator
ELECTRONIC FUEL INJECTION Fuel Pump Removal / Installation Fuel Tank Installation Remove the (6) mounting screws and carefully remove the Carefully reinstall the fuel tank assembly. fuel pump from the tank. Take care not to damage the fuel Reinstall the (2) tank brackets and fasteners. sender float or fuel pick-up screen.
Page 130: Throttle Position Sensor (Tps)
Throttle Body (4010264). 4010264 TPS Tester Regulator Yellow (Output) TPS Connector NOTE: If your dealership sells Polaris snowmobiles, Black Blue you may already have this regulator from TPS tool (Ground) (Input) PN 2201519. If you do not have this regulator, you must order one from SPX at 1-800-328-6657.
Page 131 ELECTRONIC FUEL INJECTION Verify TPS Tester Reference Voltage Move the throttle open and closed slowly while reading the display. The voltage should increase and decrease A 5 volt reference voltage from the harness is required for the smoothly with no “jumps” when the throttle is applied. TPS test to be accurate.
Page 132: Tps Initialization
ELECTRONIC FUEL INJECTION TPS Initialization Back out air flow screw until it no longer is in contact with throttle plate cam. The throttle plate should seal off throttle NOTE: The correct TPS position is established and bore completely. set at the factory. Use this procedure only if the TPS Back Air Flow Screw Out was repositioned, replaced or loosened.
Page 133: Tps Replacement
ELECTRONIC FUEL INJECTION TPS Replacement 12. If it does not read .528 ± .01 volts, loosen the screw holding the TPS to the throttle body. Rotate TPS until voltmeter NOTE: The correct position reads .528 ± .01 volts. established and set at the factory. Do not loosen the 13.
Page 134: Engine Coolant Temperature Sensor (Ect)
‘HOT’ should indicate on the instrument cluster. This indicates all other components are working properly. Refer to Chapter 10 for ECT testing. Polaris dealers can also test the sensor by using the Digital Wrench™ Diagnostic Software (dealer only). Refer to the Digital Wrench™ User Guide for more information.
Page 135: Ignition Coil
ELECTRONIC FUEL INJECTION IGNITION COIL Primary Test Operation Overview Measure Between The ignition coil is used to provide high voltage to fire the spark Connector Pins plugs. When the ignition key is on, DC voltage is present in 0.4 Ω primary side of the ignition coil windings.
Page 136: 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” NOTE: The EFI diagnostic mode is intended to The word “End”...
Page 137: Efi Troubleshooting
ELECTRONIC FUEL INJECTION EFI Troubleshooting Poor Idle Symptom: Idle Too High (If greater than 1300 RPM when Fuel Starvation / Lean Mixture engine is warm) Symptoms: Hard start or no start, bog, backfire, popping • Throttle stop screw set incorrect through intake / exhaust, hesitation, detonation, low power, •...
Page 138: Efi System Breakout Diagrams
ELECTRONIC FUEL INJECTION EFI SYSTEM BREAKOUT DIAGRAMS Diagnostic Connector Circuit Malfunction Indicator Lamp (MIL) Circuit 4.34...
Page 139: Fuel Injector (Pto) Circuit
ELECTRONIC FUEL INJECTION Fuel Injector (PTO) Circuit Fuel Injector (MAG) Circuit 4.35...
Page 140: Engine Coolant Temperature Sensor (Ect) Circuit
ELECTRONIC FUEL INJECTION Engine Coolant Temperature Sensor (ECT) Circuit Engine Overheat Lamp Driver Circuit 4.36...
Page 141: Crankshaft Position Sensor (Cps) Circuit
ELECTRONIC FUEL INJECTION Crankshaft Position Sensor (CPS) Circuit Air Temperature / Manifold Air Pressure Sensor (T-BAP) Circuit 4.37...
Page 142: Throttle Position Sensor (Tps) Circuit
ELECTRONIC FUEL INJECTION Throttle Position Sensor (TPS) Circuit Fuel Pump Circuit 4.38...
Page 143 BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS..........5.2 SPECIAL TOOLS .
Page 144: Torque Specifications
BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS SPECIAL TOOLS ITEM TORQUE VALUE TOOL DESCRIPTION PART NUMBER ft.lbs. (Nm) Shock Spanner Wrench 2870872 Front LH / RH Upper 37 ft. lbs. (50 Nm) Shock Spring Compressor Tool 2870623 A-Arm Bolt Multi-Function Pliers 2876389 Front LH / RH Lower 37 ft.
Page 145: Cab Frame
BODY / STEERING / SUSPENSION CAB FRAME Assembly / Removal NOTE: Finger tighten all components until cab frame is completely assembled on vehicle, then tighten to specifications listed. Assemble the rear cab frame and the front cab frame at the coupler joints and secure with four (3/8-16 x 1 1/4) screws and (3/8-16 Nyloc) nuts.
Page 146: Body Exploded Views
BODY / STEERING / SUSPENSION BODY EXPLODED VIEWS Dash Instruments / Controls A. Instrument Cluster (Speedo) B. Headlight Switch C. 2WD/AWD Switch D. 12 Volt Accessory Receptacle E. Speedometer “Mode” Button F. Key Switch G. Work Light Switch...
Page 147: Front Bumper
BODY / STEERING / SUSPENSION Front Bumper Front Bumper Support Screws Front Bumper Torx Radiator Screen Screw Washer O-Ring Screw Screw Screw Headlight Winch Pocket Cover Screws Rear Bumper LH Tail/Work Light RH Tail/Work Light Screw Speed Screws Nuts Rear Bumper Screws...
Page 148: Hood / Front Body Work
BODY / STEERING / SUSPENSION Hood / Front Body Work Center Hood Panel Push Rivets Front LH Fender Flair Grommet Grommet Push Rivets Hood / Dash Screws Push Rivets Push Rivets Front RH Fender Flair Reflector Front Bumper Winch Pocket Cover...
Page 149: Seat Assembly
BODY / STEERING / SUSPENSION Seat Assembly Seat Back Seat Hoop Tube 48 in. lbs. (5.4 Nm) Seat Bottom Latch Body Nuts Lever Seat Base Asm. Spring Plate 41-57 in. lbs. 41-57 in. lbs. Grommets (4.6-6.4 Nm) (4.6-6.4 Nm) Seat Belts / Mounting Driver 3 Point Seat...
Page 150: Floor / Rocker Panels
BODY / STEERING / SUSPENSION Floor / Rocker Panels Self-Tapping Plastic Dart Screw LH Rocker Rear Support Bracket Push Rivets Console Cover Self-Tapping Screws Rear Support Bracket Cup Holder Front Self-Tapping Support Bracket Screw Plastic Dart Screw Self-Tapping U-Type Screw Nuts Push Rivets Torx...
Page 151: Rear Cargo Box / Fenders
BODY / STEERING / SUSPENSION Rear Cargo Box / Fenders Tie Down Bracket Rear LH Fender Flair Push Rivets Tie Down Rear LH Fender Bracket Torx Screw & Nut Rear Cargo Box Torx Screw & Nut Screws Torx Screws Screws Rear LH Rear RH Panel Divider...
Page 152: Chassis / Main Frame
BODY / STEERING / SUSPENSION Chassis / Main Frame 15 ft. lbs. Bolt-In Brace (20 Nm) Rear Bumper Support Main Frame 15 ft. lbs. 17 ft. lbs. (20 Nm) (23 Nm) Hitch 30 ft. lbs. (41 Nm) Skid Plate 6-8 ft. lbs. (8-11 Nm) 5.10...
Page 153: Body Component Removal
BODY / STEERING / SUSPENSION BODY COMPONENT REMOVAL Front Bumper Remove the (4) push rivets from the sides of the front Seats bumper. To remove the driver or passenger seat, lift upward on the latch lever located behind the seat bottom. Latch Lever Push...
Page 154: Hood And Front Body Work
BODY / STEERING / SUSPENSION Hood and Front Body Work Remove the (8) push rivets that attach the dash assembly to the rocker panels on each side. Hood Removal To remove the hood, lift up on the rear portion of the hood to disengage the pins from the grommets.
Page 155: Rocker Panels, Console And Floor
BODY / STEERING / SUSPENSION Rocker Panels, Console and Floor Rear Fender, Flair and Tie Down Removal Rocker Panel Removal Remove the rear bumper (see “BODY COMPONENT REMOVAL - Rear Bumper”). Remove the (11) push rivets and (4) Torx screws from the Remove the (8) push rivets that retain the rear portion of RH rocker panel and remove panel from the vehicle.
Page 156: Steering Assembly
BODY / STEERING / SUSPENSION STEERING ASSEMBLY Exploded View Steering Wheel 25-31 ft. lbs. 15-19 ft. lbs. (34-42 Nm) (20-26 Nm) Wave Washers Upper Lower Steering Shaft Steering Shaft 23 ft. lbs. (31 Nm) Bushing Pivot Tube 42.5 ft. lbs. (58 Nm) Bushing Bushing...
Page 157: Wheel Hubs
BODY / STEERING / SUSPENSION WHEEL HUBS Front Hub Exploded View Sealed Ball Bearing Bolts Stud Wheel Hub Cone Washers Cotter Pin Bearing Carrier Castle Nut Retaining Ring 80 ft. lbs. (108 Nm) Brake Disc Front Rim Front Tire Flanged Nuts 27 ft.
Page 158: Front A-Arms
BODY / STEERING / SUSPENSION FRONT A-ARMS 15. Using a soft face hammer, tap on bearing carrier to loosen the lower A-arm ball joint end while pushing downward on the lower A-arm. Completely remove the ball joint end Removal / Replacement from the bearing carrier.
Page 159: Exploded View
BODY / STEERING / SUSPENSION Exploded View BALL JOINT SERVICE Removal IMPORTANT: Do not reuse a ball joint if it has been 37 ft. lbs. (50 Nm) removed for any reason. If removed, it must be replaced. Use this removal procedure only when replacing the ball joint.
Page 160: Installation
BODY / STEERING / SUSPENSION Installation Use a press and correct size driver to remove the ball joint from the A-arm. Place the A-arm in the correct position for ball joint Correct installation. Face the A-arm end flat on top of the driver. Driver Placement Carefully drive the ball joint into place until the ball joint is properly seated.
Page 161: Front Stabilizer Bar
BODY / STEERING / SUSPENSION FRONT STABILIZER BAR Remove the (2) upper radiator retaining bolts. Sway Bar Linkage Removal Elevate and safely support the front of the vehicle off the ground. Remove the lower shock mounting fasteners and spacers from both upper A-arms on each side of the vehicle (see “Exploded View”...
Page 162: Exploded View
BODY / STEERING / SUSPENSION Exploded View Remove the (4) bolts retaining the upper radiator mount bracket and remove the bracket from the frame. Main Frame Clamp Screws Stabilizer Grease Zerk Clamp Mount Bushings Bracket Linkage Nuts Linkage Lift up on the stabilizer bar and remove it from the vehicle. 27-33 ft.
Page 163: Rear A-Arms
BODY / STEERING / SUSPENSION REAR A-ARMS WARNING Removal The locking agent on the existing bolts was The following procedure details upper and lower A-arm destroyed during removal. DO NOT reuse old removal and replacement on one side of the vehicle. Repeat the hardware.
Page 164: Installation
BODY / STEERING / SUSPENSION Exploded View 11. Remove the (2) fasteners (E) attaching the lower A-arm to the frame and remove the lower A-arm from the vehicle (see previous illustration). 12. Examine A-arm and bearing carrier bushings and pivot 37 ft.
Page 165: Rear Stabilizer Bar
BODY / STEERING / SUSPENSION REAR STABILIZER BAR Remove the stabilizer bar and bracket from the frame as an assembly. Removal / Installation Remove the exhaust pipe and exhaust silencer from the Bushings vehicle. Remove Fasteners Inspect the stabilizer bar for straightness. Inspect the bushings and replace if needed.
Page 166: Shocks / Springs
BODY / STEERING / SUSPENSION SHOCKS / SPRINGS DECAL REPLACEMENT Exploded View WARNING Spring 27-33 ft. lbs. (37-45 Nm) The following procedure involves the use of an open flame. Perform this procedure in a well ventilated area, away from gasoline or other Spring flammable materials.
Page 167 CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES ......... . 6.2 TORQUE SPECIFICATIONS.
Page 168: Special Tools And Supplies
The internal components of the drive clutch and driven clutch TORQUE SPECIFICATIONS control engagement (initial vehicle movement), clutch upshift and backshift. During the development of the Polaris vehicle, PVT System Fastener Torques the PVT system is matched first to the engine power curve; then to average riding conditions and the vehicle’s intended usage.
Page 169: 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 170: Overheating / Diagnosis
10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD certified Clutch malfunction. technician.
Page 171: Pvt System Service
CLUTCHING PVT SYSTEM SERVICE PVT Sealing and Ducting Components Clutch Clutch Inlet Duct Outlet Duct Push Rivets Inner Clutch Cover Boot Clamps Boot Clamps Bolt/Washer Cover Screws Retainer Screws Outer Outer Cover Seal Clutch Cover Disassembly Mark the drive belt direction of rotation and remove drive belt (see “DRIVE BELT - Belt Removal”).
Page 172: Assembly
CLUTCHING Assembly Remove driven clutch offset spacers from the transmission input shaft. Inspect inner clutch cover-to-engine seal. Replace if cracked or damaged. Keep Spacers In Order (Note Thickness) Place a new foam seal on transmission input shaft. Apply RTV silicone sealant to outside edge of inner clutch cover-to-engine seal, to ensure a water tight fit between the seal and the cover.
Page 173: Drive Belt
CLUTCHING DRIVE BELT Clean splines inside driven clutch and on the transmission input shaft. Belt Removal Apply a light film of grease to the splines on the shaft. Remove outer clutch cover as described in PVT 10. Install the driven clutch, washer, lock washer, and retaining Disassembly.
Page 174: Belt Inspection
CLUTCHING Belt Inspection Belt Installation NOTE: Be sure to position belt in the same position as when removed or so part number is easily read. Loop belt over the drive clutch and over top of the driven sheave. Projected Belt Width Belt Width New: 1.188”...
Page 175: Drive Clutch Service
CLUTCHING DRIVE CLUTCH SERVICE Spring Specifications The drive clutch spring has two primary functions: To control clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM. To control the rate at which the drive belt moves upward in the drive clutch sheaves.
Page 176: 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 177: Exploded View
CLUTCHING Exploded View Bushing Lock Washer Spring Cover Limiter 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 178: Spider Removal
CLUTCHING NOTE: It is important that the same number and Inspect area on shaft where bushing rides for wear, galling, 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 179: 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 180: 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 181: 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 182: 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 183 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.
Page 184: 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 185: Driven Clutch Service
CLUTCHING DRIVEN CLUTCH SERVICE Place the clutch into the Clutch Compression Tool PN 8700220. Using Compression Extensions PN PS-45909, press down on top of the spider assembly, compressing the Clutch Disassembly spider onto the shaft. Remove snap ring (A) and slowly Remove driven clutch from the transmission input shaft.
Page 186 CLUTCHING Remove the inside spider plate (D) and spider dampener Press out the spring pins (K) in the inner sheave. (E). Inspect the spider dampener (E) for wear and replace if needed. 10. Pull out the clutch roller pins (L) and rollers (M). Remove the E-clips (F), washers (G), and the clutch rollers (H).
Page 187: Bushing Service
CLUTCHING Bushing Service 12. Inspect the bearing for wear. Spin the bearing, if the bearing does not spin smoothly, replace it. To remove the IMPORTANT: Special Tools Required bearing, press the bearing off the shaft. EBS Clutch Bushing Tool Kit - 2201379 Item Qty.
Page 188 CLUTCHING Clutch Bushing Removal Clutch Bushing Installation Install main puller adapter (Item 8) onto puller. Install puller adapter (Item 10) onto puller. Install adapter reducer (Item 9). Install adapter (Item 9) onto puller. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear.
Page 189: Clutch Assembly
CLUTCHING Clutch Assembly Line up the “X” on the moveable sheave with the “X” on the stationary sheave or use the marks previously used. Put Install a new bearing onto the output shaft using a press. the sheaves together. Align X’s Install the shaft/bearing into the outer sheave.
Page 190 CLUTCHING Install the roller pin into the sheave assembly on both sides. Install the spring over the shaft. The flat side of the roller pin faces downward when the shaft side is laying flat on the bench. 10. Install the clutch rollers (D) onto each side of the outside Flat Side Down spider.
Page 191 CLUTCHING 13. Place the clutch into Clutch Compression Tool PN 15. Install the cam (helix) assembly over the shaft. Line up the 8700220. Using Compression Extensions PN PS-45909, “X” on the cam, “X” on spider, and “X” on the stationary press down on the top of the spider assembly, pushing the sheave or use the marks previously made before spider onto the shaft.
Page 192: Exploded View
CLUTCHING Exploded View Screws E-Ring Thrust Spider Washer Dampener Roller Compression Spring (Helix) Retaining Thrust Ring Moveable Washer Sheave Outer Roller Spider Spider Insert Clutch Shaft Slotted Spring Pin Retaining Ring Stationary Ball Sheave Bearing 6.26...
Page 193: 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 194 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 195 FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIAL TOOLS ............7.2 TORQUE SPECIFICATIONS.
Page 196: Special Tools
FINAL DRIVE SPECIAL TOOLS Check bearings for side play by grasping the top and bottom of the tire firmly and checking for movement. The tire should rotate smoothly without binding or rough spots. PART NUMBER TOOL DESCRIPTION 2872608 Roller Pin Removal Tool 8700226 CV Boot Clamp Pliers TORQUE SPECIFICATIONS...
Page 197: Bearing Replacement
FINAL DRIVE Remove the two brake caliper mounting bolts. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. visually, and by feel.
Page 198: Bearing Carrier Installation
FINAL DRIVE Bearing Installation Install pinch bolts and torque to 17 ft. lbs. (23 Nm). Thoroughly clean the front bearing carrier housing and the outer race on the new bearing. Be sure that all oil residue has been removed from each surface. Support the bottom of the bearing carrier housing.
Page 199 FINAL DRIVE Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a NEW cotter pin. Tighten nut slightly if necessary to align cotter pin holes. Front Caliper Mounting Bolt Torque: 80 ft. lbs. 30 ft. lbs. (40 Nm) (108 Nm) CAUTION New bolts have a pre-applied locking agent...
Page 200: Front Drive Shaft
FINAL DRIVE FRONT DRIVE SHAFT Remove the upper ball joint pinch bolt. Drive Shaft Removal Pinch Bolt 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 201: Drive Shaft / Cv Joint Handling Tips
FINAL DRIVE Drive Shaft / CV Joint Handling Tips It may be necessary to tap the CV joint assembly outward with a soft faced hammer. Care should be exercised during drive shaft removal or when Retaining Ring servicing CV joints. Drive shaft components are precision parts. Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life.
Page 202: Drive Shaft Installation
FINAL DRIVE Drive Shaft Installation Add grease through large end of boot. Install new spring ring on drive shaft. Apply an anti-seize 10. Position large end of boot on CV joint, purge excess air by compound to splines. partially compressing axle into CV bell. Lift one edge of boot to let out excess air.
Page 203 FINAL DRIVE Install the upper pinch bolt and torque to 17 ft. lbs. (23 Nm). 17 ft. lbs. (23 Nm) Wheel Hub Castle Nut Torque: 80 ft. lbs. (108 Nm) Install brake caliper mounting bolts and torque to 30 ft. lbs. (40 Nm).
Page 204: Propshaft Service
FINAL DRIVE PROPSHAFT SERVICE Remove the fasteners retaining the plastic skid plate and remove the skid plate from the vehicle. Removal / Installation Locate the propshaft roll pin and use the Roll Pin Removal Tool (PN 2872608), to remove the roll pin. NOTE: Front wheel can be removed to gain better access to the propshaft roll pin.
Page 205: Assembly
FINAL DRIVE Support inner yoke as shown and drive outer yoke down Tighten vise to force bearing caps in. (bearing cap out) with a soft face hammer. Using a suitable arbor, fully seat the bearing cap in one side. Support U-joint in vise as shown and drive inner yoke down Continually check for free movement of bearing cross as to remove remaining bearing caps.
Page 206: Front Gearcase / Centralized Hilliard
FINAL DRIVE FRONT GEARCASE / CENTRALIZED HILLIARD Centralized Hilliard Exploded View 7-11 ft. lbs. (10-15 Nm) ESCRIPTION ESCRIPTION Cover Screws Roll Cage Assembly with H-Springs Cover Plate Assembly Rollers Thrust Plate Clutch Housing / Ring Gear Armature Plate Gearcase Housing Output Hub Assembly Wire Harness Retainer 7.12...
Page 207: All Wheel Drive Operation
FINAL DRIVE All Wheel Drive Operation 4x4 Engagement: When the AWD switch is turned on, a 12 Vdc current charges the hub coil and creates a magnetic field. Front Gearcase Engagement: The AWD switch may be This magnetic field attracts an armature plate keyed to a roller turned on or off while the vehicle is moving.
Page 208: Awd Diagnosis
FINAL DRIVE AWD Diagnosis Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil Symptom: AWD Will Not Engage should be seated below the U-shaped insert. The U-shaped insert controls the pole gap.
Page 209: Gearcase Removal
FINAL DRIVE Gearcase Removal Remove the gearcase from the front LH wheel well area and slide it between the upper and lower A-arm. Stop engine and place gear selector in Park. Refer to “FRONT DRIVE SHAFT - Drive Shaft Removal” and remove both front drive shafts from the front gearcase.
Page 210 FINAL DRIVE NOTE: The backlash for the centralized hilliard is set Remove the (4) screws retaining the pinion shaft assembly at the factory. No adjustment is required unless the and remove the assembly from the gearcase housing. cover plate assembly is replaced, or the backlash Inspect and clean the gearcase housing and replace the seal.
Page 211: Gearcase Assembly / Inspection
FINAL DRIVE 12. Remove the roll cage assembly and rollers from the clutch 16. Inspect both output hub assemblies. Inspect the bearings housing. Use a shop towel to cover the housing in order to and replace if needed. retain all the rollers. Thrust Bearing NOTE: Rollers are spring loaded.
Page 212 FINAL DRIVE Carefully install the rollers into the roll cage assembly Install the RH output hub into the clutch housing assembly. while installing the assembly into the clutch housing. RH Hub Clutch Housing 10. While holding the hub in the clutch housing, flip the clutch housing over and install the armature plate.
Page 213: Backlash Thrust Plate Adjustment
FINAL DRIVE Backlash Thrust Plate Adjustment 12. Line up the gearcase housing with the cover plate assembly. Set the gearcase housing on top of the assembled cover NOTE: Ring gear backlash is set from the factory. plate. Take care not to damage the new seal when installing No adjustment is required unless the cover plate, the gearcase housing.
Page 214: Gearcase Installation
FINAL DRIVE Set the gearcase upright. Install the vent line. Install Back the adjustment screw out while rotating the pinion Vent Line shaft. The pinion shaft should rotate freely during four Connect complete rotations. The four pinion shaft rotations ensures Harness that the ring gear completes one full rotation.
Page 215: Rear Bearing Carrier
FINAL DRIVE REAR BEARING CARRIER Remove the rear wheel hub assembly. Bearing Carrier Inspection / Removal Elevate rear of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.
Page 216: Bearing Replacement
FINAL DRIVE NOTE: Due to extremely close tolerances and Bearing Installation minimal wear, the bearings must be inspected Thoroughly clean the rear bearing carrier housing and the visually, and by feel. While rotating bearings by outer race on the new bearing. Be sure that all oil residue hand, inspect for rough spots, discoloration, or has been removed from each surface.
Page 217: Bearing Carrier Installation
FINAL DRIVE Bearing Carrier Installation Install brake caliper mounting bolts and torque to 18 ft. lbs. (24 Nm). Install drive shaft axle through the backside of the bearing carrier. Be sure bushings and pivot tubes are installed. 18 ft. lbs. 24 (Nm) Install the fasteners that attach the rear bearing carrier to the Rear Caliper Mounting Bolt Torque:...
Page 218: Rear Drive Shaft
FINAL DRIVE Install wheel and (4) wheel nuts. Torque wheel nuts to Remove the two brake caliper attaching bolts. specification. CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. Wheel Nut Torque: Steel Wheels: 27 ft.
Page 219: Cv Joint / Boot Replacement
FINAL DRIVE CV Joint / Boot Replacement Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it Remove clamps from rubber boot(s) using the CV Boot down to remove the shaft. Clamp Pliers (PN 8700226) (A).
Page 220 FINAL DRIVE NOTE: When replacing a damaged boot, check the Refit CV joint on the shaft by tapping with a plastic hammer grease for contamination by rubbing it between two on the joint housing. Take care not to damage threads on fingers.
Page 221: Installation
FINAL DRIVE Installation 11. While pulling out on the CV shaft, fully extend the CV joint and slide a straight O-ring pick or a small slotted screw Install new spring ring on drive shaft. Apply anti-seize driver between the small end of the boot and the shaft. This compound to splines.
Page 222 FINAL DRIVE Lift bearing carrier into place and install the bolt attaching the bearing carrier to the upper A-arm. Torque fastener to 37 ft. lbs. (50 Nm). Rear Caliper Mounting Bolt Torque: 18 ft. lbs. (24 Nm) CAUTION 37 ft. lbs. New bolts have a pre-applied locking agent 50 (Nm) which is destroyed upon removal.
Page 223: Rear Gearcase
FINAL DRIVE REAR GEARCASE Remove the fasteners and bracket that secure the rear gearcase to the transmission. Gearcase Removal Drain the fluid from the rear gearcase. Remove the rear drive shafts from each side of the rear gearcase. See “REAR DRIVE SHAFT” on page 7.24 Remove the exhaust pipe and exhaust silencer to allow for gearcase removal.
Page 224: Gearcase Disassembly
FINAL DRIVE Gearcase Disassembly IMPORTANT: Due to the manufacturing process, the pinion and ring gear assembly are NOT intended to be disassembled and replaced. Pinion and ring gear shimming information is NOT provided. The components are matched at the factory which requires special OEM tooling in order to properly assemble and shim the gears.
Page 225 FINAL DRIVE Inspect the ring gear teeth for chipped, worn, or broken Remove the input shaft seal using a seal puller or other teeth. If damaged, replace the ring gear and pinion gear as suitable method. a set. Inspect Inspect the input shaft by rotating the assembly in the NOTE: In the event damage to the gears or housing gearcase housing while checking for any looseness or requires replacement, the entire assembly must be...
Page 226: Gearcase Assembly
FINAL DRIVE Gearcase Assembly If removed, install each axle spool bearing race using standard bearing installation tools and a shop press. Install a new input shaft seal using a standard seal installer or other suitable method. Install new seals on each side of the gearcase housing using a standard seal installer or other suitable method.
Page 227: Gearcase Installation
Install the gearcase cover. Verify the o-ring is in position. Install the cover screws onto the rear gearcase. Torque to specification. Add Polaris ATV Angle Drive Fluid to rear gearcase. Refer to maintenance information in Chapter 2 for more details. Torque drain and fill plugs to specification.
Page 228: Gearcase Exploded View
FINAL DRIVE Gearcase Exploded View 23-27 ft. lbs. (31-37 Nm) 70-80 ft. lbs. (95-108 Nm) 23-27 ft. lbs. (31-37 Nm) 23-27 ft. lbs. 40 ft. lbs. (31-37 Nm) (54 Nm) 30-45 in. lbs. (3-5 Nm) ESCRIPTION ESCRIPTION Screw Axle, Spool Screw O-Ring Bracket, Rear Mount, RH...
Page 229: Wheel Hubs
FINAL DRIVE WHEEL HUBS Front Hub Exploded View Sealed Ball Bearing Bolts Stud Wheel Hub Cone Washers Cotter Pin Bearing Carrier Castle Nut Retaining Ring 80 ft. lbs. (108 Nm) Brake Disc Front Rim Front Tire Flanged Nuts See Page 7.2 for Torque Value Valve Rear Hub Exploded View...
Page 230 FINAL DRIVE NOTES 7.36...
Page 231 TRANSMISSION CHAPTER 8 TRANSMISSION TORQUES / SPECIFICATIONS ..........8.2 SHIFT LEVER .
Page 232: Torques / Specifications
TRANSMISSION TORQUES / SPECIFICATIONS SHIFT LEVER Removal Maintain and check/change these items in accordance with the maintenance schedule in Chapter 2 or during service repairs. Pry the shift lever cover using a suitable tool and remove the screw. Pull knob off the shifter. ITEM TORQUE VALUE Transmission Fill Plugs...
Page 233: Shift Cable Inspection / Adjustment
TRANSMISSION Shift Cable Inspection / Adjustment Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH (H) Shift cable adjustment may be necessary if symptoms include: gear and PARK (P). •...
Page 234: Transmission Service
TRANSMISSION TRANSMISSION SERVICE Remove the (7) bolts retaining the transmission support bracket. Transmission Removal / Service Notes The engine, transmission and rear differential are bolted together as a unit. Removal of the transmission is not possible without removing the engine and differential. The shift housing cannot be removed without first disassembling the transfer case.
Page 235 TRANSMISSION After removing the cover, remove the intermediate shaft 10. Remove the intermediate pinion shaft assembly from the bearing cup and shims from the cover. Bearing cup is a housing. Check bearings and gear teeth for wear or damage slip-fit. Note and record the number and thickness of shims and replace as needed.
Page 236 TRANSMISSION 13. Remove the front output pinion shaft assembly. The shaft 15. Remove the lower snap ring from under the gear. can be disassembled as shown using a press and standard bearing removal tools. 16. Remove the intermediate shaft seal using a seal puller or other suitable method.
Page 237: Transfer Case Reassembly
TRANSMISSION Transfer Case Reassembly Install the shims, bearing cup and alignment dowels into the retaining bracket. Install the intermediate shaft seal (circled) flush or slightly below the case. Install circlips and gear onto the input intermediate shaft as shown. Install a new output shaft seal flush with the case. Install the output pinion shaft assembly and bearing cup/bracket assembly as shown.
Page 238 TRANSMISSION Reinstall the intermediate pinion shaft assembly and Install the transfer case cover. Align the dowels (#1 & #7) bearing cup. and insert the cover screws (note position of the longest screw #4). Torque the screws evenly to specification in sequence as shown.
Page 239: Transmission Shift Housing Disassembly
TRANSMISSION Transmission Shift Housing Disassembly Place the transmission shift housing onto a flat surface as shown. Lift the transmission case half straight up and IMPORTANT: Shift housing repairs are not possible remove. without performing transfer case disassembly. Read and understand all instructions before beginning disassembly.
Page 240 TRANSMISSION Remove the (5) screws retaining the park flange. Inspect the Remove the input shaft seal and clutch intermediate shaft park flange dogs for wear or damage. Replace as required. seal using a seal puller or punch. Inspect the shaft bearing. Use a standard bearing puller to Remove the (2) screws that attach the shift switch to the remove the shaft bearing if required.
Page 241 TRANSMISSION Remove the plate, pins, springs, drum gear and thrust 11. Remove the park flange sleeve from the clutch shaft. washer from the shift housing. Replace any worn or damaged components. 12. Pull back fully on gear selector arm to bring shift collar up and disengage the shift collar from the clutch yoke.
Page 242 TRANSMISSION 14. Remove the sliding shoes from the clutch yoke. 17. From the back side of the high gear assembly, separate the high and low gear assemblies by tapping the gear retaining plate from the roll pins using a brass punch. Note the order of disassembly on the entire gear assembly (plate, thrust washer, bearing, thrust washer).
Page 243 TRANSMISSION 20. Remove the clutch yoke from the gear selector shaft and 22. Remove the screw from the end of the gear selector shaft spring. assembly and remove the assembly from the housing. Note the clips, spring and plate orientation. 23.
Page 244: Transmission Shift Housing Reassembly
TRANSMISSION Transmission Shift Housing Reassembly Install the input shaft assembly. Install a new shift lever seal flush with the case. Apply lubricant to the seal lip. Press new bearings (if required) into the housing. Install clutch yoke into the gear selector shaft and spring. Align the pivot pin holes and install clutch yoke pivot pin.
Page 245 TRANSMISSION Assemble the high and low gear assemblies as shown. Install the clutch shaft into the housing. Note that the Complete the assembly by aligning the roll pin holes and forward gear assembly is loose in the housing and that tapping the roll pins through the retaining plate and into the alignment of the shaft, gear assembly, thrust washer and high gear using a brass punch.
Page 246 TRANSMISSION 11. Install the outer sleeve screws and inner shift detent screws, With the transmission in neutral, lubricate and install the thrust washer, drum gear, plate, springs, pins and the shift position springs, and balls from each side of the shift housing. Use sensor/o-ring assembly into the shift housing.
Page 247 TRANSMISSION 13. Install the reverse idler lower washer, needle bearing, gear, 16. Install the reverse clutch/gear assembly onto the park upper washer and snap ring onto the idler shaft of the flange. Note the orientation of the (2) thrust washers (top / transmission case half.
Page 248 TRANSMISSION 18. Place the transmission shift housing onto a flat surface as 20. Install the (2) shift housing case screws to the backside as shown. Apply a bead of crankcase sealant onto the mating shown. Torque to specification. surfaces. Align the dowels and install the transmission case NOTE: Shift cable bracket installation is required.
Page 249: 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 250: Transmission Exploded Views
TRANSMISSION TRANSMISSION EXPLODED VIEWS Shift Housing / Transfer Case Exploded View Shift Housing Transfer Case 8.20...
Page 251 BRAKES CHAPTER 9 BRAKES GENERAL SPECIFICATIONS..........9.2 TORQUE SPECIFICATIONS.
Page 252: General Specifications
BRAKES GENERAL SPECIFICATIONS FRONT BRAKE SYSTEM Item Standard Service Limit Front Brake Pad Thickness .300 ± .007" (7.62 ± .178 mm) .180" (4.6 mm) Front Brake Disc Thickness .188" (4.76 mm) .170" (4.32 mm) Front Brake Disc Runout .010" (.254mm) REAR BRAKE SYSTEM Item Standard...
Page 253: 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 254: Hydraulic Brake System Operation
MAX LEVEL line! resulting friction reduces brake disc and vehicle speed. When servicing Polaris brake systems use only Polaris DOT 4 The friction applied to the brake pads will cause the pads to Brake Fluid (PN 2872189). WARNING: Once a bottle is wear.
Page 255: Master Cylinder
BRAKES MASTER CYLINDER CAUTION Removal Brake fluid will damage finished surfaces. Locate the master cylinder above the LH front tire in the Do not allow brake fluid to come in contact wheel well area. with finished surfaces. Master Cylinder NOTE: Make note of front and rear brake line locations to master cylinder.
Page 256: Brake Bleeding / Fluid Change
Mity Vac™ pump or similar tool. 1/2"(1.3 cm). Mity Vac™ (PN 2870975) 13. Check brake system for fluid leaks. Add brake fluid to the indicated MAX level of reservoir. Polaris DOT 4 Brake Fluid (P/N 2872189)
Page 257: 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 258: Pad Assembly / Installation
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. 1/2 Turn Verify fluid level in reservoir is up to MAX line inside Compress mounting bracket and make sure dust boots are reservoir and install reservoir cap.
Page 259: Front Caliper Service
BRAKES FRONT CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid 47 in. lbs. to Component (5.3 Nm) Apply Polaris All Purpose Grease A. Socket Set Screw B. Bleeder Screw C. Caliper Assy. D. Boot E. Square O-ring (thick) F.
Page 260: 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 hub. Remove Thoroughly clean the brake caliper before disassembly and prepare a clean work area to disassembly the caliper. Caliper Disassembly Use low pressure compressed air to remove the pistons Push brake pad retainer pin inward and slip brake pads past...
Page 261: Caliper Inspection
Caliper Piston Bore I.D.: Std: 1.004” (25.5 mm) Service Limit: 1.006” (25.55 mm) Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
Page 262: 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.
Page 263: Front Brake Disc
BRAKES FRONT BRAKE DISC Remove the 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”...
Page 264: Rear Brake Pad
BRAKES REAR BRAKE PAD Push caliper piston into the caliper bore slowly using a C- clamp or locking pliers with pads installed. 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.
Page 265: Pad Inspection
Lubricate mounting bracket pins with a light film of Install the adjustment set screw and turn clockwise until the Polaris Premium All Season Grease (PN 2871423), and stationary pad contacts the disc, then back off 1/2 turn install rubber dust boots.
Page 266: Rear Caliper Service
BRAKES REAR CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Component 47 in. lbs. Apply Polaris All Purpose (5.3 Nm) Grease A. Brake Pad B. Mount Bracket C. Piston D. Caliper Assy. E. Square Ring (thick) F.
Page 267: Caliper Disassembly
BRAKES Caliper Disassembly Caliper Inspection Remove brake pad adjustment set screw (K). Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage Push upper pad retainer pin inward and slip brake pads past is evident or if worn beyond service limit.
Page 268: Caliper Assembly
18 ft. lbs. (24 Nm) Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance.
Page 269: Rear Brake Disc
BRAKES REAR BRAKE DISC Remove the 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. Cotter Use a 0-1”...
Page 270: Troubleshooting
BRAKES TROUBLESHOOTING Brakes Squeal / Poor Brake Performance • Air in system • Water in system (brake fluid contaminated) • Caliper or disc misaligned • Caliper dirty or damaged • Brake line damaged or lining ruptured • Worn disc and/or friction pads •...
Page 271 ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION ..........10.3 SPECIAL TOOLS .
Page 272 ELECTRICAL CHARGING SYSTEM ..........10.21 CURRENT DRAW - KEY OFF .
Page 273: General Information
ELECTRICAL GENERAL INFORMATION Under-Dash Components The following switches and components can be accessed Special Tools underneath the instrument / dash panel: Part Number Tool Description • Speedometer PV-43568 Fluke™ 77 Digital Multimeter • Speedometer Mode Switch 2870630 Timing Light • Digital Wrench Diagnostic Connector 2870836 Battery Hydrometer •...
Page 274: Switches / Controls
ELECTRICAL SWITCHES / CONTROLS AWD SWITCH Headlamp Switch Disconnect the headlamp switch harness (Brown, Green, and Red/Yellow), by depressing the connector lock and pulling on the connector. Do not pull on the wiring. Test the switch connections and check for continuity at the following pins as shown in the illustration.
Page 275: 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 instrument cluster senses vehicle speed from the right NOTE: If the instrument cluster fails to illuminate, a front wheel.
Page 276: Standard Display Modes
ELECTRICAL Standard Display Modes Clock Screen Use the mode button (location shown in the illustration on page 10.5) to toggle through the mode options. Odometer Mode The odometer records the miles or kilometers 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 277 ELECTRICAL AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil. Gear Circuit Diagnostic Screen This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. NOTE: A 10 - 20% variance from these readings is within normal parameters.
Page 278: Viewing Diagnostic Codes
ELECTRICAL NOTE: If you scroll past the intended number, press Programmable Service Interval and hold the button until the hours cycle back to When the hours of engine operation equal the programmed zero. service interval setting, the wrench icon will flash for 5 seconds each time the engine is started.
Page 279: Instrument Cluster Removal
ELECTRICAL Turn the key switch to the ON position. Push the instrument cluster out from the back side of the dash while securely holding the dash and rubber mount. Turn the key switch off and on three times in less than five Push Instrument Dash Panel seconds, then leave the switch on.
Page 280: Instrument Cluster Troubleshooting Tests
ELECTRICAL INSTRUMENT CLUSTER TROUBLESHOOTING TESTS TEST 1 - No All Wheel Drive 10.10...
Page 281: Test 2 - No Display
ELECTRICAL TEST 2 - No Display TEST 3 - Vehicle Speed Sensor 10.11...
Page 282: Test 4 - No Awd Hub Safety Limiter
ELECTRICAL TEST 4 - No AWD Hub Safety Limiter 10.12...
Page 283: Test 5 - Fuel Gauge Display Not Working
ELECTRICAL TEST 5 - Fuel Gauge Display Not Working TEST 6 - Gear Indicator Not Working (Transmission Switch) 10.13...
Page 284: All Wheel Drive Coil
ELECTRICAL ALL WHEEL DRIVE COIL GEAR POSITION INDICATOR SWITCH Operation Overview Test Diagram • When the AWD switch is “ON”, 12 VDC power is Continuity Table present at the hub coil. • If the criteria is met, the instrument cluster provides a HIGH ground path at pin #16.
Page 285: Head Lights
ELECTRICAL HEAD LIGHTS 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 286: Tail / Brake / Work Lights
ELECTRICAL Headlamp Housing Removal TAIL / BRAKE / WORK LIGHTS Disconnect the headlamp from the wiring harness. Be sure Bulb Replacement to pull on the connector, not on the wiring. Before replacing the bulb, use a digital multi-meter to test the Remove the O-rings (A) from the headlamp brackets on harness to ensure the lamp is receiving 12 volts and that a ground both sides of the headlamp.
Page 287: Cooling System Schematic
ELECTRICAL COOLING SYSTEM SCHEMATIC Cooling System Break-Out Diagram 10.17...
Page 288: Fan Control Circuit Operation / Testing
ELECTRICAL Fan Control Circuit Operation / Testing EFI DIAGNOSTICS Power is supplied to the fan via the Orange/Black wire when the EFI Component Testing relay is ON. The ground path for the fan motor is through the Brown harness wire. Refer to “RELAYS” later in this chapter All EFI component information and diagnostic testing for more information on fan functions.
Page 289: Relays
ELECTRICAL RELAYS FAN RELAY Operation OLOR UNCTION Key-On battery power supply, switched on Located in the fuse box under the dash, the relays assist with Red / White by key switch, enables power to relay. component operation like the fan, fuel pump, and EFI system. Fused 20-Amp power, switched by relay, The fan relay, controlled by the ECU and Temp Sensor, operates Orange / Black...
Page 290: Fuses / Circuit Breaker
ELECTRICAL FUSES / CIRCUIT BREAKER Operation Located in the fuse box under the dash, the fuse panel provides current protection for components such as the Instrument Cluster, ECU, EFI system, Chassis Power and Accessories. A separate 20-amp circuit breaker protects the fan motor circuit (see wire diagram for details). 10.20...
Page 291: Charging System
ELECTRICAL CHARGING SYSTEM Charging System “Break Even” Test Alternator Output CAUTION AMPS VOLTS Do not allow the battery cables to become 2500 13.2 Vdc disconnected with the engine running. Follow the steps below as outlined to reduce the chance of Current Draw - Key Off damage to electrical components.
Page 292: 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 293: 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 294: Battery Service
NOTE: New Battery: Battery must be fully charged before use or battery life will be significantly reduced 10-30% of the battery’s full potential. Polaris Sticker To activate a new battery: Remove vent plug from vent fitting. Remove cell caps. Fill battery with electrolyte to upper level marks on case.
Page 295: Battery Inspection
ELECTRICAL Battery Removal Add electrolyte to bring level back to upper level mark on case. Remove the battery holder strap. NOTE: This is the last time that electrolyte should Disconnect battery negative (-) (black) cable first, followed be added. If the level becomes low after this point, by the positive (+) (red) cable.
Page 296 ELECTRICAL OCV - Open Circuit Voltage Test SPECIFIC GRAVITY Battery voltage should be checked with a digital multitester. Conventional YuMicron™ State of Charge* Readings of 12.6 volts or less require further battery testing and Lead-Acid Type charging. See the following charts and Load Test. 100% Charged 1.265 1.275...
Page 297: Off Season Storage
ELECTRICAL Off Season Storage Charging Procedure (Conventional) To prevent battery damage during extended periods of non-use, Remove the battery to prevent damage from leaking or the following basic battery maintenance items must be spilled acid during charging. performed: Charge the battery with a charging output no larger than •...
Page 298: Low Maintenance Battery
ELECTRICAL LOW MAINTENANCE BATTERY To service a Low Maintenance battery: Remove battery from the vehicle. General Battery Information Test battery with a voltage meter or load tester to determine NOTE: All Low Maintenance batteries are fully battery condition. This will determine the length of time charged and tested at the factory before installation.
Page 299: Battery Testing
ELECTRICAL Battery Testing Load Test Whenever a service complaint is related to either the starting or CAUTION charging systems, the battery should be checked first. Following are two tests which can easily be made on a Sealed To prevent shock or component damage, Low Maintenance battery to determine its condition: OCV Test remove spark plug high tension leads and and a Load Test.
Page 300: Charging Procedure (Low Maintenance)
ELECTRICAL Charging Procedure (Low Maintenance) STARTING SYSTEM If battery voltage is 12.8 V or less, the battery may need Troubleshooting recharging. When using an automatic charger, refer to the charger manufacturer’s instructions for recharging. When using Starter Motor Does Not Run a constant current charger, use the following guidelines for •...
Page 301: Voltage Drop Test
ELECTRICAL Voltage Drop Test NOTE: Note the alignment marks on both ends of the starter motor casing. These marks must align The Voltage Drop Test is used to test for bad connections. When during reassembly. performing the test, you are testing the amount of voltage drop through the connection.
Page 302: Armature Testing
ELECTRICAL Brush Replacement Measure resistance between insulated brush and starter housing. Reading should be infinite (OL). Inspect Remove terminal nut with lock washer, flat washer, large insulation on brush wires for damage and repair or replace phenolic washer, the small phenolic spacers, and sealing as necessary.
Page 303: Starter Reassembly / Installation
ELECTRICAL Measure the resistance between each commutator segment Install O-ring, two small phenolic spacers, large phenolic and the armature shaft. The reading should be infinite (no washer, flat washer, lock washer, and terminal nut. continuity). While holding brush springs away from brushes, push brushes back and hold in place.
Page 304: Starter Drive
ELECTRICAL NOTE: It is important to tighten the bottom starter Remove the retaining ring, thrust washer, spring retainers bolt first (circle), as the bottom hole acts as a pilot and clutch return spring. Screw the overrun clutch off the hole to properly align the starter drive (bendix) with end of the pinion shaft.
Page 305: Starter Exploded View
ELECTRICAL Starter Exploded View Indicates Do not reuse. 10. Gear Assembly 1. Rubber Ring* Replace with new parts. 11. Through Bolt 2. Brush Spring 12. Cover 3. Thrust Washer 13. Stopper 4. Gear Assembly 14. Snap Ring 5. O-Ring* 15. Washer 6.
Page 306: 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 307: Electrical Breakout Diagrams
ELECTRICAL ELECTRICAL BREAKOUT DIAGRAMS 12V Key-On Power Circuit Starting System Circuit 10.37...
Page 308: Instrument Cluster Circuit
ELECTRICAL Instrument Cluster Circuit Transmission Switch Circuit 10.38...
Page 309: Wheel Speed Sensor Circuit
ELECTRICAL Wheel Speed Sensor Circuit AWD Circuit 10.39...
Page 310: Fuel Gauge Display Circuit
ELECTRICAL Fuel Gauge Display Circuit Cooling Fan Circuit 10.40...
Page 311: Charging System Circuit
ELECTRICAL Charging System Circuit 10.41...
Page 312 ELECTRICAL NOTES 10.42...

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