Polaris R16RM257N1 Manuals

Manuals and User Guides for Polaris R16RM257N1. We have 1 Polaris R16RM257N1 manual available for free PDF download: Owner's Manual

Polaris R16RM257N1 Owner's Manual

Polaris R16RM257N1 Owner's Manual (581 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 37.55 MB

Table of Contents

Chapter 1 1 General Information

5
- Table of Contents
  5
- Vehicle Information
  6
- Model Number Designation (2015 +)
  6
- Vehicle Identification Number (Vin) Designation (2015+)
  6
- Vin / Engine Number Location
  7
- General Specifications
  8
- Model: 2015 Ranger Etx
  8
- Model: 2015 Ranger 570
  10
- Model: 2015 Ranger 570 Crew
  12
- Model: 2016 Ranger Etx
  14
- Model: 2016 Ranger 570 4X4
  16
- Model: 2016 Ranger 570 2X4 (Intl.)
  18
- 2016 Ranger 2X4 (Intl.)
  19
- Model: 2016 Ranger 570 Crew
  20
- Misc. Specifications and Charts
  22
- Publication Numbers
  22
- Special Tools
  23
- Replacement Keys
  24
- Master Special Tools Table
  25
- Master Torque Table
  34
- Clutching Chart
  37
- Conversion Table
  38
- Standard Bolt Torque Specification
  39
- Metric Bolt Torque Specification
  39
- Sae Tap / Drill Sizes
  40
- Metric Tap / Drill Sizes
  41
- Decimal Equivalents
  42
Maintenance Chapter 2 Maintenance 2

45
- General Information
  48
- Maintenance
  48
- Special Tools
  48
- Brake System Break-In
  49
- Break-In Period
  49
- Engine and Drivetrain Break-In
  49
- Pvt Break-In (Clutches / Belt)
  49
- Vehicle Break-In Period
  49
- Cold Weather Operation
  50
- Inspection / Maintenance Intervals
  50
- Pre-Ride / Daily Inspection
  50
- Periodic Maintenance Chart
  51
- Periodic Maintenance Chart Key
  51
- Grease Lubrication Points
  54
- Component Quick Reference
  56
- Polaris Lubricants, Maintenance and Service Products
  58
- Service Products and Lubricants
  58
- Frame, Nuts, Bolts, and Fasteners
  59
- General Maintenance
  59
- Shift Cable Adjustment
  59
- Shift Cable Inspection
  59
- Storage Tips
  60
- Air Filter Service
  61
- Fuel Lines
  61
- Fuel Pump / Filter
  61
- Fuel System
  61
- Fuel System and Air Intake
  61
- Throttle Pedal Inspection
  61
- Vent Lines
  61
- Engine Air Intake Inspection
  62
- Pvt Air Intake Inspection
  62
- Compression and Leakdown Test
  63
- Engine Common
  63
- Engine
  64
- Engine Oil Level Check - 325
  64
- Engine Oil Level
  69
- Oil and Filter Change - 570
  69
- Valve Clearance - Dohc
  70
- Breather Hose
  71
- Breather Valve Inspection
  71
- Transmission and Gearcases
  72
- Transmission Lubrication
  72
- Front Gearcase Lubrication
  73
- Coolant Level Inspection
  74
- Cooling System
  74
- Cooling System Overview
  74
- 50/50 Extended-Life Engine Antifreeze
  76
- Coolant Strength / Type
  77
- Cooling System Hoses
  77
- Coolant Drain / Radiator Removal
  78
- Radiator Inspection / Cleaning
  78
- CV Shaft Boot Inspection
  80
- Final Drive / Wheel and Tire
  80
- Wheel and Hub Torque Table
  80
- Wheel Removal
  80
- Tire Inspection
  81
- Tire Pressure
  81
- Wheel Installation
  81
- Battery Fluid Level (Conventional Battery)
  82
- Battery Maintenance
  82
- Battery Removal
  82
- Electrical and Ignition System
  82
- Battery Charging
  83
- Battery Installation
  83
- Battery Storage
  83
- Spark Plug Service
  83
- Main Frame/Engine Ground
  84
- Steering
  85
- Steering Inspection Note
  85
- Tie Rod End / Steering Inspection
  85
- Toe Adjustment
  86
- Wheel Toe Alignment Inspection
  86
- Camber and Caster
  87
- Spring Pre-Load Adjustment
  88
- Stabilizer Bar Pivot Lubrication
  88
- Suspension
  88
- Suspension Inspection
  88
- Suspension Pivot Point Lubrication
  88
- Brake Fluid Inspection
  89
- Brake Hose and Fitting Inspection
  89
- Brake Pad Inspection
  89
- Brake System
  89
- Brake Disc Inspection
  90
- Parking Brake Adjustment
  90
Chapter 3 Engine / Cooling System

93
- Engine Special Tools
  98
- General Information
  98
- Engine Lubrication Specifications
  99
- Oil Pressure Test
  99
- Engine Oil Flow Chart
  100
- Engine Specifications
  101
- Engine Detail - Torque Values - Sequences
  103
- Engine Fastener Torque Specifications
  103
- Spark Plug / Throttle Body / Thermostat
  105
- Stator Cover / Valve Cover / Oil Sump Cover
  106
- Camshafts / Cam Carrier / Cam Chain Tensioner
  107
- Cylinder Head / Crankcase
  108
- Crankshaft / Balance Shaft / Cam Chain Guides
  109
- Engine Mounting Torque Specifications
  110
- Engine / Transmission Coupler Bracket Torque Sequence
  111
- Cylinder Head Torque Specification / Sequence
  112
- Stator Cover Torque Sequence
  113
- Oil Sump Cover Torque Sequence
  114
- Lower Crankcase Sealant Pattern
  115
- 325 Exhaust System
  116
- Cooling System Flow
  117
- Engine Cooling System
  117
- Cooling System Assembly View
  118
- Cooling System Pressure Test
  119
- Cooling System Specifications
  119
- Pressure Cap Test
  119
- Coolant Drain / Radiator Removal
  120
- Radiator
  120
- Thermostat Inspection / Replacement
  121
- Cooling System Bleeding Procedure
  122
- Water Pump Service
  123
- Accessible Engine Components
  125
- Engine Removal
  125
- Engine Service
  125
- Top-End Service (Engine in Chassis)
  125
- Engine Installation
  128
- Engine Break-In Period
  131
- Engine Lubrication Specifications
  131
- Engine to Transmission Coupler Service
  132
- Setting Tdc (Top-Dead-Center)
  134
- Engine / Cooling System
  135
- Engine Disassembly / Inspection - Top End
  135
- Valve Cover Inspection
  135
- Valve Cover Removal
  135
- Camshaft / Carrier Removal
  136
- Camshaft Carrier Disassembly
  137
- Camshaft Inspection
  139
- Camshaft Sprocket Inspection
  139
- Camshaft Oil Jet
  141
- Cylinder Head Disassembly
  141
- Cylinder Head Removal
  141
- Cylinder Head Inspection
  142
- Cylinder Head Warp Inspection
  143
- Valve Inspection
  143
- Combustion Chamber Cleaning
  144
- Valve Sealing Test
  144
- Valve Seat Reconditioning
  145
- Cylinder Inspection
  147
- Cylinder Removal
  147
- Piston Removal
  147
- Piston / Rod Inspection
  148
- Piston-To-Cylinder Clearance
  148
- Piston Ring Installed Gap
  149
- Engine Assembly - Top End
  150
- Piston Ring Installation
  150
- Cylinder Installation - Piston Installed on Connecting Rod
  151
- Piston / Connecting Rod Assembly
  151
- Cylinder Installation - Piston in Cylinder
  152
- Cylinder Head Assembly
  154
- Cylinder Head Installation
  155
- Camshaft Installation / Timing
  156
- Camshaft Timing - Quick Reference
  159
- Valve Clearance Adjustment
  160
- Valve Cover Installation
  161
- 325 Intake Valve Lash - Tappet Selection Matrix
  162
- 325 Exhaust Valve Lash - Tappet Selection Matrix
  163
- Crankcase Disassembly
  164
- Engine Disassembly / Inspection - Lower End
  164
- Stator Cover / Flywheel Removal
  164
- Starter One-Way Clutch Inspection
  165
- Stator Removal
  165
- Oil Pump Removal
  166
- Oil Pressure Regulator (Bypass) Valve Inspection
  167
- Stator Cover Oil Seal Inspection
  167
- Balance Shaft Bearing Service
  168
- Balance Shaft Removal / Inspection
  168
- Crankcase Separation
  168
- Crankshaft Inspection
  169
- Crankshaft Removal
  169
- Pto and Mag Side Crankcase Bearing Service
  170
- Crankcase Inspection
  171
- Oil Pickup Assembly Inspection
  171
- Crankcase Assembly
  172
- Engine Assembly - Lower End
  172
- Balance Shaft Installation / Timing
  173
- Flywheel Installation
  174
- Starter One-Way Clutch Installation
  174
- Oil Pump Assembly
  176
- Stator / Stator Cover Installation
  176
- Engine / Cooling System Troubleshooting
  178
- Engine Troubleshooting
  178
- Cooling System Troubleshooting
  179
- General Information
  180
- Special Tools
  180
- Engine Lubrication Specifications
  181
- Oil Pressure Test
  181
- Engine Oil Flow Chart
  182
- Engine Specifications
  183
- Engine Detail
  185
- Engine Fastener Torque Specifications
  185
- Torque Sequence
  187
- Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
  188
- Camshafts / Cylinder Head / Flywheel / Stator Cover - Black Head Bolts
  189
- Cylinder / Oil Filter / Oil Pump / Breather
  189
- Cams / Cyl Head / Flywheel / Stator Cover - Silver Head Bolts
  191
- Spark Plug / Starter / Throttle Body / Valve Cover
  192
- Piston / Crankshaft / Balance Shaft
  193
- Cooling System Assembly View and Coolant Flow Diagram
  194
- Engine Cooling System
  194
- Cooling System Pressure Test
  195
- Cooling System Specifications
  195
- Pressure Cap Test
  196
- Radiator
  196
- Coolant Drain / Radiator Removal
  197
- Cooling System Bleeding Procedure
  198
- Thermostat Replacement
  198
- Water Pump Cover and Impeller Service (Stator Cover Remains on Engine)
  199
- Water Pump Mechanical Seal / Oil Seal Replacement
  200
- Accessible Engine Components
  206
- Engine Removal
  206
- Engine Service
  206
- Top-End Service (Engine in Chassis)
  206
- Engine Installation
  209
- Engine Break-In Period
  212
- Engine Lubrication Specifications
  212
- Engine Mounting and Torque Values
  213
- Setting Tdc (Top-Dead-Center)
  214
- Camshaft / Carrier Removal
  216
- Engine Disassembly / Inspection - Top End
  216
- Valve Cover Removal
  216
- Camshaft Sprocket Inspection
  217
- Camshaft Inspection
  218
- Exhaust Camshaft Decompression Mechanism
  218
- Cam Chain and Guide Service
  219
- Cylinder Head Removal
  219
- Cylinder Head Disassembly
  220
- Crankcase Identification
  221
- Cylinder Head Identification
  221
- Cylinder Head Inspection
  222
- Cylinder Head Warp Inspection
  222
- Valve Inspection
  222
- Combustion Chamber Cleaning
  223
- Valve Seat Reconditioning
  224
- Cylinder Inspection
  226
- Cylinder Removal
  226
- Piston Removal
  227
- Piston-To-Cylinder Clearance
  227
- Piston / Rod Inspection
  228
- Piston Ring Installed Gap
  228
- Honing to Oversize
  229
- Camshaft Installation / Timing
  230
- Cleaning the Cylinder after Honing
  230
- Cylinder Hone Selection / Honing Procedure
  230
- Camshaft Timing - Quick Reference
  233
- Engine Assembly - Top End
  234
- Piston Ring Installation
  234
- Piston / Connecting Rod Assembly
  235
- Cylinder Head Assembly
  236
- Cylinder Installation
  236
- Valve Sealing Test
  237
- Crankcase Identification
  238
- Cylinder Head Identification
  238
- Cylinder Head Installation - Black Bolts
  239
- Cylinder Head Installation - Silver Bolts
  240
- Valve Clearance Check / Adjustment
  241
- Valve Lash - Tappet Selection
  244
- Exhaust Valve Lash - Tappet Selection Matrix
  245
- Valve Cover Installation
  246
- Crankcase Disassembly
  247
- Engine Disassembly / Inspection - Lower End
  247
- Starter One-Way Clutch Inspection
  247
- Stator Cover Removal
  247
- Stator Removal
  249
- Oil Pump Removal
  250
- Crankcase Breather Service
  252
- Oil Pump Assembly
  252
- Crankcase Separation
  253
- Balance Shaft Removal / Inspection
  254
- Crankshaft Inspection
  255
- Crankshaft Removal
  255
- Pto Side Crankcase Bearing Service
  256
- Mag Side Crankcase Bearing Service
  257
- Crankcase Inspection
  258
- Oil Pickup Assembly Inspection
  258
- Oil Pressure Regulator (Bypass) Valve Inspection
  258
- Crankcase Assembly - Pto Side
  259
- Engine Assembly - Lower End
  259
- Balance Shaft Installation / Timing
  261
- Final Crankcase Assembly
  261
- Flywheel Installation
  263
- Starter One-Way Clutch Installation
  263
- Stator / Stator Cover Installation
  265
- Engine Cooling System
  266
- Troubleshooting
  266
Chapter 4 Fuel System

269
- Efi Operation Overview
  272
- General Information
  272
- Initial Priming / Starting Procedure
  272
- Principal Components
  272
- Special Tools
  273
- Digital Wrench® - Diagnostic Connector
  274
- Fuel Pressure Gauge Adapter - Pa-48838
  274
- Fuel Pressure Gauge Kit - Pu-43506-A
  274
- Digital Wrench® - Download Website
  275
- Digital Wrench® Diagnostic Softwarepu-47063-B
  275
- Digital Wrench® Smartlink Module Kitpu-47471
  275
- Efi Component Locations
  276
- Efi Component Locations - Right View
  276
- Efi Component Locations - Left View
  277
- Fuel Line Routing
  278
- Line / Hose Routing
  278
- Air Box / Intake System
  279
- Air Box / Air Filter Assembly View - 325
  280
- Air Box / Air Filter Assembly View - 570
  282
- Air Box Removal / Installation
  283
- Ecu Overview
  284
- Ecu Service
  284
- Electronic Control Unit (Ecu)
  284
- Rpm Limit
  284
- Ecu Replacement
  285
- Electronic Throttle Body (Etc)
  286
- Etc Learn Procedure
  286
- Etc Overview
  286
- Etc Replacement
  286
- Etc Test
  286
- Operation Overview
  287
- Pedal Position Sensor (Pps)
  287
- Pps Replacement
  287
- Pps Test
  287
- Fuel Tank / Pump / Sendor
  288
- Fuel Tank Assembly View
  288
- Fuel Tank Removal
  288
- Fuel Sender Test
  289
- Fuel Tank Installation
  289
- Fuel Pump Test
  290
- Fuel Pump Replacement
  291
- T-Map Overview
  294
- T-Map Sensor Replacement
  294
- T-Map Sensor Test
  294
- Temperature / Manifold Absolute Pressure (T-Map)
  294
- Cps Overview
  295
- Cps Test
  295
- Crankshaft Position Sensor
  295
- Resistance Test
  295
- Air Gap Test
  296
- Encoder Flywheel / Keyway Inspection
  296
- Cps Replacement
  297
- Coil Pack Connections
  298
- Ignition Coil / Wire Overview
  298
- Ignition Coil / Wire Test
  298
- Ignition Coil Overview
  298
- Spark Plug Wire Connections
  298
- Fuel Injector
  299
- Fuel Injector Overview
  299
- Fuel Injector Replacement
  299
- Fuel Injector Test
  299
- Fuel Injector Troubleshooting
  301
- Ect Overview
  302
- Ect Sensor Test
  302
- Engine Coolant Temperature Sensor (Etc)
  302
- Resistance Vs. Temperature Test
  302
- System Operation Test
  302
- Ect Sensor Replacement
  303
- Ect Sensor Replacement - 570
  303
- Efi Diagnosis
  304
- Service Notes - Fuel System
  304
- Trouble Code Display (Dtc)
  305
- Digital Wrench® - Diagnostic Connector
  312
- Digital Wrench® Diagnostic Software Overview
  312
- Digital Wrench® Operation
  312
- Digital Wrench® Version and Update
  313
- Polaris Mobile Digital Wrench (Pmdw)
  313
- Digital Wrench® Updates
  314
- Digital Wrench® Communication Errors
  317
- Guided Diagnostics
  317
- Digital Wrench® Feature Map
  318
- Digital Wrench® Serial Number Location
  318
- Ecu Replacement
  319
- Ecu Reprogramming (Reflash)
  319
- Etc Learn Procedure
  325
- Fuel Starvation / Lean Mixture
  326
- Fuel System Troubleshooting
  326
- Rich Mixture
  326
Chapter 5 Pvt System

327
- General Information
  328
- Pvt System Fastener Torques
  328
- Special Tools
  328
- Clutching Chart
  329
- General Operation
  329
- Pvt System Overview
  329
- Drive Clutch Operation
  330
- Driven Clutch Operation
  330
- Maintenance / Inspection
  330
- Pvt Break-In (Drive Belt / Clutches)
  330
- Operating in Low Gear
  331
- Overheating / Diagnosis
  331
- Pvt Sealing, Guard, and Duct Components
  332
- Pvt System Service
  332
- Pvt Disassembly
  333
- Pvt Assembly
  334
- Belt Inspection
  335
- Belt Removal
  335
- Drive Belt
  335
- Belt Installation
  336
- Pvt Break-In (Drive Belt / Clutches)
  336
- Clutch Alignment / Offset / Center Distance
  337
- Inspection
  337
- Adjustment
  338
- Engine to Transmission Coupler Service
  339
- Drive Clutch Assembly View
  342
- Drive Clutch Service
  342
- Clutch Disassembly
  343
- Shift Weight Inspection
  344
- Spider Removal
  345
- Bearing Inspection
  346
- Button to Tower Clearance Inspection
  346
- Clutch Inspection
  346
- Bushing Service
  348
- Clutch Assembly
  350
- Assembly View
  352
- Driven Clutch Service
  352
- Clutch Disassembly / Inspection
  353
- Clutch Assembly
  354
- Troubleshooting
  355
Chapter 6 Transmission

357
- General Information
  358
- Special Tools, Transmission
  358
- Torque Specifications
  358
- Special Tools
  359
- Lubrication
  360
- Transmission Gears
  360
- Transmission Mounting and Torque Values
  360
- Installation
  361
- Removal
  361
- Shift Lever
  361
- Adjustment
  362
- Inspection
  362
- Shift Cable
  362
- Transmission Removal
  363
- Transmission Installation
  368
- Differential Operation
  374
- Transmission Service
  374
- Transmission Disassembly
  375
- Planetary Differential Bushing Replacement
  380
- Planetary Differential Disassembly
  380
- Planetary Differential Assembly
  382
- Gear / Shaft / Bearing Inspection
  383
- Snorkel Gear Backlash Procedure
  384
- Troubleshooting
  391
- Troubleshooting Checklist
  391
- Transmission
  392
- Transmission Assembly View
  392
Chapter 7 Final Drive

395
- Final Drive Torque Table
  397
- General Information
  397
- Special Tools
  397
- Front Hub / Bearing
  398
- Hub Removal / Inspection
  398
- Hubstrut Bearing Replacement
  398
- Hub Installation
  399
- Front Hub/Wheel Exploded View
  401
- Front Drive Shaft
  402
- Front Drive Shaft Removal
  402
- Front Drive Shaft Installation
  403
- Front Gearcase Removal and Installation
  404
- Gearcase Installation
  404
- Gearcase Removal
  405
- All Wheel Drive Operation
  407
- Awd Diagnosis
  408
- Gearcase Disassembly / Inspection
  409
- Gearcase Assembly
  412
- Exploded View, Front Gearcase (4Wdc)
  415
- Front Gearcase (Adc)
  415
- Operation, Front Gearcase (4Wdc)
  417
- Disassembly / Inspection, Front Gearcase (Adc)
  418
- Reassembly, Front Gearcase (Adc)
  421
- Troubleshooting, Front Gearcase (Adc)
  424
- Inspection
  427
- Rear Bearing Carrier
  427
- Removal
  427
- Assembly
  428
- Disassembly
  428
- Installation
  429
- Rear Drive Shaft
  431
- Rear Drive Shaft Installation
  431
- Rear Drive Shaft Removal
  431
- Drive Shaft / CV Joint Handling Tips
  432
- Drive Shaft Service
  432
- Outer CV Joint / Boot Replacement
  432
- Inner Plunging Joint / Boot Replacement
  435
- Drive Shaft Assembly View
  437
Chapter 8 Steering / Suspension

443
- Torque Specifications
  444
- Special Tools
  445
- Steering Assembly
  446
- Steering Assembly View (Non-Eps)
  446
- Steering Assembly View (Eps)
  448
- Steering Shaft Bearing Replacement
  450
- Steering Wheel Removal (Non-Eps Models)
  450
- Steering Shaft / Steering Rack Removal (Non-Eps Models)
  451
- Steering Wheel / Upper Steering Shaft Removal (Eps)
  452
- Power Steering Unit Installation
  453
- Power Steering Unit Removal
  453
- Assembly View
  455
- Front Strut
  455
- Front Strut Cartridge Replacement
  455
- Ball Joint Replacement
  456
- Rear A-Arms
  458
- Removal / Replacement
  458
- Installation
  459
- Assembly View
  460
- Rear Stabilizer Bar / Linkage
  461
- Removal / Installation
  461
- Assembly View
  462
- Shock Removal / Installation
  462
- Shock Replacement
  462
- Shocks / Springs
  462
Chapter 9 Brake System

463
- Brake Service Specifications
  465
- General Information
  465
- Special Tools
  465
- Torque Specifications
  465
- Brake Noise Troubleshooting
  466
- Brake System Notes
  466
- Brake System Service Notes
  466
- Hydraulic Brake System Operation
  467
- Brake System Assembly View
  468
- Ranger Crew
  469
- Brake Pressure Switch
  470
- Installation
  470
- Master Cylinder
  470
- Removal
  470
- Foot Brake Pedal
  471
- Pedal Installation
  471
- Pedal Removal
  471
- Brake Bleeding / Fluid Change
  472
- Brake Procedures
  472
- Brake Burnishing Procedure
  473
- Brake Pad Inspection
  474
- Front Brake Pads - Ranger
  474
- Pad Removal / Disassembly
  474
- Pad Adjustment- Ranger
  475
- Pad Assembly / Installation- Ranger
  475
- Front Caliper - Ranger
  476
- Front Caliper Assembly View
  476
- Front Caliper Disassembly - Ranger
  477
- Front Caliper Removal- Ranger
  477
- Front Caliper Assembly
  478
- Front Caliper Inspection- Ranger
  478
- Front Caliper Installation
  479
- Front Brake Pads - Crew
  480
- Pad Removal - Crew
  480
- Pad Assembly / Installation- Crew
  481
- Pad Inspection
  481
- Front Caliper - Crew
  483
- Front Caliper Assembly View
  483
- Front Caliper Removal- Crew
  483
- Front Caliper Disassembly - Crew
  484
- Front Caliper Inspection - Crew
  485
- Front Caliper Assembly - Crew
  486
- Front Caliper Installation - Crew
  486
- Disc Inspection
  488
- Front Brake Disc
  488
- Disc Removal / Replacement
  489
- Pad Removal
  490
- Rear Brake Pad Service
  490
- Brake Pad Inspection
  491
- Rear Pad Installation
  491
- Caliper Assembly View
  492
- Rear Caliper
  492
- Caliper Removal
  493
- Rear Caliper Disassembly
  493
- Rear Caliper Assembly
  494
- Rear Caliper Inspection
  494
- Rear Caliper Installation
  495
- Brake Disc Inspection
  496
- Disc Runout
  496
- Rear Brake Disc
  496
- Disc Removal / Replacement
  497
- Parking Brake Assembly View
  498
- Parking Brake System
  498
- Caliper Removal
  500
- Parking Brake Adjustment
  500
- Parking Brake Caliper Exploded View
  500
- Parking Brake Caliper Service
  500
- Caliper Disassembly / Inspection
  501
- New Brake Pad Installation
  502
- Parking Brake Caliper Installation
  503
- Disc Inspection / Removal
  505
- Parking Brake Disc Service
  505
- Brakes Lock
  506
- Caliper Overheats (Brakes Drag)
  506
- Pedal Vibration
  506
- Troubleshooting
  506
Chapter 10 Body / Frame

507
- Special Tools
  508
- Torque Specifications
  508
- Chassis / Body
  509
- Frame Assembly View
  509
- Crew Frame Assembly View
  510
- Crew Cab Frame
  512
- Dash Instruments / Controls
  513
- Hood / Dash / Front Fascia
  514
- Floor / Rear Fenders
  515
- Seat Mounting / Seat Belts
  516
- Crew Floor / Rear Fenders
  517
- Crew Seat Mounting / Seat Belts
  518
- Cargo Box - Tailgate / Box Support
  519
- Rear Cargo Box
  519
- Box Installation
  521
- Box Removal
  521
- Body Component Removal
  522
- Fenders / Foot Pads
  522
- Front Bumper
  522
- Lower Seat Base
  522
- Hood / Dash
  523
- Floors
  524
- Decal Replacement
  525
Chapter 11 Electrical

527
- Battery Conductance Analyzer
  529
- Electrical Service Notes
  529
- General Information
  529
- Special Tools
  529
- Components under Hood
  530
- Awd / 2Wd / Turf Switch
  531
- Ignition / Headlight Switch
  531
- Switches / Controls
  531
- Brake Pressure Switch
  532
- Differential Solenoid
  532
- Rear Differential Solenoid Operation
  532
- All Wheel Drive (Awd) Coil
  533
- Diagnosing System Failures
  533
- Operation Overview
  533
- Speed Sensor Location
  534
- Speed Sensor Testing
  534
- Vehicle Speed Sensor
  534
- Instrument Cluster
  535
- Overview
  535
- Rider Information Display
  536
- Information Display Area
  537
- Diagnostic Mode
  539
- Instrument Cluster Installation
  540
- Instrument Cluster Pinouts
  540
- Instrument Cluster Removal
  540
- Headlight Adjustment
  542
- Headlights
  542
- Headlight Bulb Replacement
  543
- Headlight Housing Installation
  543
- Headlight Housing Removal
  543
- Led Lamp Replacement
  544
- Tail Light / Brake Light
  544
- Cooling System
  545
- Fan Control Circuit Bypass Test
  545
- Fan Control Circuit Operation
  545
- Ignition Coil
  546
- Ignition Coil Tests
  546
- Operation Overview
  546
- Primary Test
  546
- Secondary Tests
  546
- Ignition Coil and Ht Lead Replacement
  547
- Operation
  548
- Relays
  548
- Fuses / Circuit Breaker
  550
- Operation
  550
- Charging System
  551
- Charging System "Break Even" Test
  551
- Charging System Alternator Tests
  551
- Current Draw - Key off
  551
- Charging System Testing Flow Chart
  553
- Battery Activation
  554
- Battery Service
  554
- Battery Terminal Block
  554
- Battery Terminals / Bolts
  554
- Battery Inspection
  555
- Battery Removal / Installation
  556
- Conventional Battery Testing
  556
- Ocv - Open Circuit Voltage Test
  556
- Voltage Drop Test
  556
- Charging Procedure
  557
- Load Test
  557
- Off Season Storage
  557
- Specific Gravity Test
  557
- Starter Drive
  558
- Starter Motor Does Not Run
  558
- Starter Motor Turns - Engine Does Not Rotate
  558
- Starter Motor Turns over Slowly
  558
- Starter System
  558
- Troubleshooting
  558
- Starter Solenoid Bench Test
  559
- Starter Solenoid Operation
  560
- Starting System Testing Flow Chart
  561

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