2009 RANGER 700

4X4 CREW / 6X6

SERVICE MANUAL
PN 9921885

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 2009 RANGER 700 4X4 CREW / 6X6
SERVICE MANUAL
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with
service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper
tools as specified.

Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc.
2100 Hwy 55 Medina Minnesota 55340.

Publication Printed August 2008 (PN 9921885)

© Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

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 UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or
person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-Vac, Registered Trademark of Neward Enterprises, Inc.

Torx, Registered Trademark of Textron

Hilliard, Trademark of the Hilliard Corporation

Warn, Trademark of Warn Industries

FOX, Registered Trademark of FOX RACING SHOX

RydeFX, Registered Trademark of ArvinMeritor

Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or
by contacting the nearest Polaris dealer.

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 GENERAL INFORMATION 1

MAINTENANCE 2

ENGINE 3

ELECTRONIC FUEL INJECTION 4

BODY / STEERING / SUSPENSION 5

CLUTCHING 6

FINAL DRIVE 7

TRANSMISSION 8

BRAKES 9

ELECTRICAL 10

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 GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . 1.3
TRANSMISSION I.D. NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
RANGER 4X4 CREW / 6X6 (HEIGHT AND WIDTH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
RANGER 6X6 (LENGTH AND WHEEL BASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
RANGER 4X4 CREW (LENGTH AND WHEEL BASE) . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
GENERAL: 2009 RANGER 4X4 CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
DETAILED: 2009 RANGER 4X4 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
GENERAL: 2009 RANGER 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DETAILED: 2009 RANGER 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14

1.1

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 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 09 WH 68 AG

}
}

}
}
Model Year Emissions &
Designation Model Option
Basic Chassis
Designation Engine Designation

Engine Designation Number

EH068OLE046PLE ............................................................Twin, Liquid Cooled, OHV 4 Stroke, Electric Start

VIN Identification
World
Mfg. ID Vehicle Description Vehicle Identifier

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A W H 6 8 A * 9 P 0 0 0 0 0 0
}

Engine Model
Body Style Year Individual Serial No.
Emissions Plant No. * This could be either
Powertrain Check Digit a number or a letter

Engine Serial Number Location

Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be
found on the sticker applied to the cylinder head on the side of engine.

Engine Serial Number A

1.2

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 GENERAL INFORMATION
Vehicle Identification Number (VIN) Location Transmission I.D. Number Location
The machine model number and serial number are important for 1
vehicle identification. The vehicle identification number (A) is The transmission I.D. number is located on the
stamped on the lower LH frame rail close to the front drive right side when installed in the vehicle.
wheel. The model and serial numbers are also located on a
sticker under the hood (B).

1.3

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 GENERAL INFORMATION

VEHICLE DIMENSIONS
RANGER 4x4 CREW / 6X6 (Height and Width)

75 in.
190.5 cm

11.5 in.
29.2 cm

60 in.
152.4 cm

1.4

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 GENERAL INFORMATION
RANGER 6X6 (Length and Wheel Base)
120 in. 1
305 cm

42.5 in.
108 cm

27 in.
69 cm
90 in.
229 cm

RANGER 4x4 CREW (Length and Wheel Base)

145 in.
386 cm

36.5 in.
92.7 cm

108 in.
274 cm

1.5

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 GENERAL INFORMATION

GENERAL SPECIFICATIONS
MODEL: 2009 RANGER 4X4 CREW
MODEL NUMBER: R09WH68AC, AG, AH, AR
ENGINE MODEL: EH68OLE
Category Dimension / Capacity
Length 145 in. / 386 cm
Width 60 in. / 152.4 cm
Height 75 in. / 190.5 cm
Wheel Base 108 in. / 274 cm
Ground Clearance 11 in. / 27.9 cm
Turning Radius 224 in. / 569 cm
Dry Weight 1460 lbs. / 664 kg
Gross Vehicle Weight 3360 lbs. / 1524 kg
Cargo Box Capacity 1000 lbs. / 454 kg
54 x 36.5 x 11.5 in.
Cargo Box Dimensions
(137 x 92.7 x 29.2 cm)
1750 lbs. / 794 kg
Vehicle Payload (Includes driver and five
passengers)
Hitch Towing Capacity 2000 lbs. / 907 kg
Hitch Tongue Capacity 150 lbs. / 68 kg

1.6

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 GENERAL INFORMATION
MODEL: 2009 RANGER 4X4 CREW Drivetrain
MODEL NUMBER: R09WH68AC, AG, AH, AR
ENGINE MODEL: EH68OLE
Transmission Type
Transmission Gear Ratio:
Polaris Automatic PVT 1
Engine Front / Rear
Polaris Domestic Twin Cylinder, High 4.43:1 / 3.83:1
Platform Low 10.08:1 / 8.71:1
Liquid Cooled, 4-Stroke
Reverse 6.87:1 / 5.94:1
Engine Model Number EH068OLE049
Shift Type In Line Shift - H / L / N / R
Engine Displacement 683cc
Polaris Demand Drive Fluid
Number of Cylinders 2 Front Gearcase Oil Requirements
5 oz. (150 ml)
Bore & Stroke (mm) 80 x 68 mm
Polaris Full Synthetic AGL
Compression Ratio 9.40:1 Transmission Oil Requirements
43.6 oz. (1290 ml)
Compression Pressure 150-170 psi Polaris ATV Angle Drive Fluid
Rear Gearcase Oil Requirements
Engine Idle Speed 1150 ± 100 RPM 18 oz. (532 ml)
Lubrication Pressurized Wet Sump Belt 3211118
Oil Requirements PS-4 PLUS 2W-50 Synthetic Clutch Center Distance 10.05” (255 mm)
Oil Capacity 2 qts. / 1.9 L Steering / Suspension
Coolant Capacity n/a Front Suspension MacPherson Strut
Overheat Warning Instrument Cluster Indicator Front Travel 8 in. (20.3 cm)
Exhaust System 2 to 1 Canister Style Rear Suspension Independent Rear Suspension
Fuel System Rear Travel 9 in. (22.9 cm)
Fuel System Type Bosch Electronic Fuel Injection Rear Shock Preload Adjustment Cam Adjustment
Fuel Delivery Electronic Fuel Pump (in tank) Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Fuel Pressure 39 psi Wheels / Brakes
Fuel Filters See Chapter 4 Front Wheel Size 12 x 6
9 gal. (34 L) Rear Wheel Size 12 x 8
Fuel Capacity / Requirement
87 Octane (minimum) Front Tire
Carlisle / PXT / 26 x 9 R12
Electrical Make / Model / Size
Alternator Max Output 500 Watts @ 3000 RPM Rear Tire
Carlisle / PXT / 26 x 11 R12
Lights: Main Headlights 2 - Single Beam 50W / Halogen Make / Model / Size
Tail 5 Watts x 2 Tire Air Pressure - Front / Rear 12 psi / 16 psi
Brake 5 Watts x 2 Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4
Indicator Panel Lights 1 Watt (ea.) Parking Brake Hand Actuated (in dash)
Starting System Electric Start CLUTCH CHART
Ignition System Bosch EFI (ECU Controlled)
Ignition Timing 7° BTDC @ 1200 RPM Driven
Altitude Shift Weight Drive Spring
Spring
Champion RC7YC3 /
Spark plug / Gap 0-1500 21-74 Red/Blue Blk/Almd
.035 in. (0.9 mm)
Meters (0-5000) (5632117) (7043372) (7043167)
Yuasa YB30L-B /
Battery / Model / Amp Hr (Feet) 1500-3700 21-70 Red/Blue Blk/Almd
30 Amp Hr. / 12 Volt
(5000 - 12000) (5632127) (7043372) (7043167)
Instrument Panel Type Multifunction Speedometer
DC Outlet Standard
Relays Fan / Power / Rear Diff Solenoid
Circuit Breakers Fan Motor: 15 Amp
Main Chassis: 20 Amp
Accessory: 20 Amp
Fuses
Power Relay: 15 Amp
ECU: 6 Amp

1.7

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 GENERAL INFORMATION
MODEL: 2009 RANGER 6X6
MODEL NUMBER: R09RF68AF, AR
ENGINE MODEL: EH068OLE
Category Dimension / Capacity
Length 120 in. / 305 cm
Width 60 in. / 152.4 cm
Height 75 in. / 190.5 cm
Wheel Base 90 in. / 229 cm
Ground Clearance 7.2 in. / 18.3 cm
Turning Radius 186 in. / 472 cm
Dry Weight 1410 lbs. / 640 kg
Gross Vehicle Weight 3310 lbs. / 1501 kg
Cargo Box Capacity 1250 lbs. / 567 kg
54 x 42.5 x 11.5 in.
Cargo Box Dimensions
(137 x 108 x 29.2 cm)
1750 lbs. / 794 kg
Vehicle Payload (Includes driver and two
passengers)
Hitch Towing Capacity 2000 lbs. / 907 kg
Hitch Tongue Capacity 150 lbs. / 68 kg

1.8

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 GENERAL INFORMATION
MODEL: 2009 RANGER 6X6 Drivetrain
MODEL NUMBER: R09RF68AF, AR
ENGINE MODEL: EH68OLE
Transmission Type
Transmission Gear Ratio:
Polaris Automatic PVT 1
Engine Front / Rear
Polaris Domestic Twin Cylinder, High 4.43:1 / 3.83:1
Platform Low 10.08:1 / 8.71:1
Liquid Cooled, 4-Stroke
Reverse 6.87:1 / 5.94:1
Engine Model Number EH068OLE048
Shift Type In Line Shift - H / L / N / R
Engine Displacement 683cc
Polaris Demand Drive Fluid
Number of Cylinders 2 Front Gearcase Oil Requirements
5 oz. (150 ml)
Bore & Stroke (mm) 80 x 68 mm
Polaris Full Synthetic AGL
Compression Ratio 9.40:1 Transmission Oil Requirements
43.6 oz. (1290 ml)
Compression Pressure 150-170 psi Polaris ATV Angle Drive Fluid
Mid Gearcase Oil Requirements
Engine Idle Speed 1150 ± 100 RPM 6.75 oz. (200 ml)
Lubrication Pressurized Wet Sump Polaris ATV Angle Drive Fluid
Rear Gearcase Oil Requirements
Oil Requirements PS-4 PLUS 2W-50 Synthetic 10 oz. (300 ml)
Oil Capacity 2 qts. / 1.9 L Belt 3211118
Coolant Capacity 3.25 qts. (3.08 L) Clutch Center Distance 10.05” (255 mm)
Overheat Warning Instrument Cluster Indicator Steering / Suspension
Exhaust System 2 to 1 Canister Style Front Suspension MacPherson Strut

Fuel System Front Travel 8 in. (20.3 cm)

Fuel System Type Bosch Electronic Fuel Injection Center Suspension Progressive Rate / Independent
Fuel Delivery Electronic Fuel Pump (in tank) Center Travel 5.25 in. (13.3 cm)
Fuel Pressure 39 psi Rear Suspension Swing Arm w/Dual Shocks
Fuel Filters See Chapter 4 Rear Travel 6.25 in. (16 cm)
9 gal. (34 L) Rear Shock Preload Adjustment Cam Adjustment
Fuel Capacity / Requirement
87 Octane (minimum) Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Electrical Wheels / Brakes
Alternator Max Output 500 Watts @ 3000 RPM Front Wheel Size 12 x 6 / 10 gauge
Lights: Main Headlights 2 - Single Beam 50W / Halogen Middle / Rear Wheel Size 12 x 8 / 10 gauge
Tail 5 Watts x 2 Front Tire
Titan / AT489 / 25 x 10 R12
Brake 5 Watts x 2 Make / Model / Size
Indicator Panel Lights 1 Watt (ea.) Middle / Rear Tire
Titan / AT489 / 25 x 11 R12
Make / Model / Size
Starting System Electric Start
Tire Air Pressure
Ignition System Bosch EFI (ECU Controlled) 8 - 12 psi
Front / Middle / Rear
Ignition Timing 7° BTDC @ 1200 RPM Brakes / Brake Fluid 4 Wheel Hydraulic Disc / DOT 4
Champion RC7YC3 / Parking Brake Hand Actuated (in dash)
Spark plug / Gap
.035 in. (0.9 mm)

Battery / Model / Amp Hr

Yuasa YB30L-B / CLUTCH CHART
30 Amp Hr. / 12 Volt
Driven
Instrument Panel Type Multifunction Speedometer Altitude Shift Weight Drive Spring
Spring
DC Outlet Standard 0-1500 21-74 Red/Blue Blk/Almd
Relays Fan / Power Meters (0-5000) (5632117) (7043372) (7043167)
Circuit Breakers Fan Motor: 15 Amp (Feet) 1500-3700 21-70 Red/Blue Blk/Almd
Main Chassis: 20 Amp (5000 - 12000) (5632127) (7043372) (7043167)
Accessory: 20 Amp
Fuses
Power Relay: 15 Amp
ECU: 6 Amp

1.9

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 GENERAL INFORMATION

VEHICLE INFORMATION
Publication Numbers
Model Model No. Owner’s Manual PN Parts Manual PN
2009 RANGER 4x4 CREW R09WH68AC, AG, AH, AR 9921882 9921884
2009 RANGER 6x6 R09RF68AF, AR 9921871 9921874
NOTE: When ordering service parts be sure to use the correct parts manual.
NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from
www.purepolaris.com.

Paint Codes
Painted Part Color Description Polaris Number
Main Frame / Cab Frame / Bumpers Medium Gloss Black P-067
Main Frame / Cab Frame / Plastic Gloss Black P-070
Plastic - Hood / Dash Dark Green P-195
Plastic - Hood / Dash Solar Red P-342
Cab Frame / Bumpers Flat Black Wrinkle P-418
Plastic - Hood / Dash Mossy Oak™ P-455
Plastic - Hood / Dash Delta Green P-492
Plastic - Hood / Dash Cherry Metallic P-554

Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original
key and refer to the chart to the right for the proper part number.

Series# Part Number

KEY COVER
20 4010278
P/N 5533534
21 4010278
22 4010321
23 4010321
Key Series 27 4010321
Number 28 4010321
31 4110141
32 4110148
67 4010278
68 4010278

SPECIAL TOOLS
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
product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or
on-line at http://polaris.spx.com/.

1.10

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 GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
1

°C to °F: 9/5(°C + 32) = °F °F to °C: 5/9(°F - 32) = °C

1.11

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 GENERAL INFORMATION
Standard Torque Specifications
The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and
engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.

1.12

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 GENERAL INFORMATION
SAE Tap / Drill Sizes Decimal Equivalents
1

Metric Tap / Drill Sizes

1.13

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 GENERAL INFORMATION
Glossary of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
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.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to
close and grip the drive belt.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers
on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the
cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire
touching the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm²: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in²: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.
Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch system)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
1.14

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 MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
50 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
SERVICE PRODUCTS AND LUBES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . 2.7
MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
MAINTENANCE REFERENCES, CONTINUED..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT LINKAGE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
MIDDLE GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
REAR GEARCASE LUBRICATION (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
REAR GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
RADIATOR COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

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 MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
BATTERY FLUID LEVEL (CONVENTIONAL BATTERY) . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
REAR SUSPENSION ADJUSTMENT (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
REAR SPRING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
PARKING BRAKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
PARKING BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

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 MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use
genuine Pure Polaris parts available from your Polaris dealer. 2
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately
10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or
crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use
and determine the cause or see your dealer.

Break-In Period
The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. Careful treatment
of a new engine and drive components will result in more efficient performance and longer life for these components.

• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.
• Pull only light loads.
• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
• Change both the engine oil and filter after 25 hours or one month.
• See “Owner’s Manual” for additional break-in information.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:
 = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized 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.
Have an authorized Polaris dealer perform these services.

2.3

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 MAINTENANCE
Pre-Ride - 25 Hour Maintenance Interval
Maintenance Interval
(whichever comes first)
Item Remarks
Miles
Hours Calendar
(KM)
 Steering - Pre-Ride -
 Front Suspension - Pre-Ride -
 Rear Suspension - Pre-Ride -
Tires - Pre-Ride -
 Brake Fluid Level - Pre-Ride -
Make adjustments as needed.
 Brake Pedal Travel - Pre-Ride - See Pre-Ride Checklist on Page 2.13.
Brake Systems - Pre-Ride -
Wheels / Fasteners - Pre-Ride -
Frame Fasteners - Pre-Ride -
 Engine Oil Level - Pre-Ride -
E
 Air Filter / Pre-Filter - Daily - Inspect;clean often
E
 Air Box Sediment Tube - Daily - Drain deposits when visible
E
Check level daily, change coolant every 2
Coolant Level - Daily -
years
Check operation; apply dielectric grease if
Head Lamp / Tail Lamp - Daily -
replacing
 Air Filter, - Weekly - Inspect; replace as needed
E Main Element
 Brake Pad Wear / Inspect 10 H Monthly - Inspect periodically
 Parking Brake Pads
Battery 20 H Monthly - Check terminals; clean; test
 Parking Brake Cable 25 H - - Inspect; adjust tension after first 25 hours
 Adjustment
Front Gearcase Oil
 (if equipped) 25 H Monthly - Inspect level; change yearly

 Middle Gearcase Oil 25 H Monthly - Inspect level; change yearly

(if equipped)
Rear Gearcase Oil
 (if equipped) 25 H Monthly - Inspect level; change yearly

 Transmission Oil 25 H Monthly - Inspect level; change yearly

 Engine Breather 25 H Monthly - Inspect; replace if necessary
E Filter (if equipped)
 Engine Oil Change 25 H 1M - Perform a break-in oil change at one month
E (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.

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 MAINTENANCE
50 - 100 Hour Maintenance Interval
Maintenance Interval
(whichever comes first)
Item Remarks
Miles
Hours Calendar
(KM)

 General Lubrication 50 H 3M -
Lubricate all grease fittings, pivots, cables, 2
etc.
Shift Linkage 50 H 6M - Inspect, lubricate, adjust
 Steering 50 H 6M - Lubricate
 Front Suspension 50 H 6M - Lubricate
 Rear Suspension 50 H 6M - Lubricate
 Throttle Cable / Throttle Inspect; adjust; lubricate; replace if
50 H 6M -
E Pedal necessary
Throttle Body Air Intake
E 50 H 6M - Inspect ducts for proper sealing/air leaks
Ducts / Flange
Drive Belt 50 H 6M - Inspect; adjust; replace as needed
Inspect coolant strength seasonally;
Cooling System 50 H 6M -
pressure test system yearly
 Parking Brake Cable 100 H - - Inspect; adjust tension as needed
 Adjustment
 Engine Oil Change Perform a break-in oil change at 25 hours/
100 H 6M -
E one month
 Oil Filter Change 100 H 6M - Replace with oil change
E

 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.

2.5

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 MAINTENANCE
100 - 300 Hour Maintenance Interval
Maintenance Interval
(whichever comes first)
Item Remarks
Miles
Hours Calendar
(Km)
Check for leaks at tank cap, fuel lines, fuel

Fuel System 100 H 12M - pump, and fuel rail.
E
Replace lines every two years.
 Radiator 100 H 12M - Inspect; clean external surfaces
 Cooling Hoses 100 H 12M - Inspect for leaks
 Engine Mounts 100 H 12M - Inspect
Exhaust Muffler / Pipe 100 H 12M - Inspect

Spark Plug 100 H 12M - Inspect; replace as needed
E
Inspect for wear, routing, security; apply
 Wiring 100 H 12M - dielectric grease to connectors subjected to
water, mud, etc.
 Clutches (Drive and Driven) 100 H 12M - Inspect; clean; replace worn parts
 Front Wheel Bearings 100 H 12M - Inspect; replace as needed
Inspect periodically; adjust when parts are
 Toe Adjustment 100 H
replaced
 Brake Fluid 200 H 24M - Change every two years (DOT 4)
Spark Arrestor 300 H 36M - Clean out
 Auxiliary Brake - Inspect daily; adjust as needed

Headlight Aim - Adjust as needed

Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services.

2.6

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 MAINTENANCE
SERVICE PRODUCTS AND LUBES
Polaris Lubricants, Maintenance and Service NOTE: Each item can be purchased separately at
Products your local Polaris dealer.

Part No. Description Part No. Description

Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc. 2

2870791 Fogging Oil (12 oz. Aerosol) 2870585 Loctite™ Primer N, Aerosol, 25 g

PS-4 PLUS Performance Synthetic Loctite™ Thread Sealant 565

2876244 2871956
2W-50 4-Cycle Engine Oil (Quart) (50 ml.) (6 Count)

PS-4 PLUS Performance Synthetic Loctite™ Threadlock 242

2876245 2871949
2W-50 4-Cycle Engine Oil (Gallon) (50 ml.) (10 Count)
Loctite™ Threadlock 242
Gearcase / Transmission Lubricants 2871950
(6 ml.) (12 Count)
Premium Synthetic AGL Gearcase Lube
2873602 Loctite™ Threadlock 262
(12 oz. bottle) (12 Count) 2871951
(50 ml.) (10 Count)
Premium Synthetic AGL Gearcase Lube
2873603 Loctite™ Threadlock 262
(1 Gal.) (4 Count) 2871952
(6 ml.) (12 Count)
Premium ATV Angle Drive Fluid
2871653 Loctite™ Threadlock 271
(8 oz.) (12 Count) 2871953
(6 ml.) (12 Count)
Premium ATV Angle Drive Fluid
2872276 Loctite™ Threadlock 271
(2.5 Gal) (2 Count) 2871954
(36 ml.) (6 Count)
2870465 Oil Pump for 1 Gallon Jug
Loctite™ 680-Retaining Compound
Premium Demand Drive Fluid 2870584
2871654 (10 ml.)
(8 oz.) (12 Count)
Loctite™ 518 Gasket Eliminator / Flange
Premium Demand Drive Fluid 2870587
2872277 Sealant (50 ml.) (10 Count)
(2.5 gal.) (2 Count)
Premium Carbon Clean
2871326
Grease / Specialized Lubricants (12 oz.) (12 Count)
Premium All Season Grease 2870652 Fuel Stabilizer (16 oz.) (12 Count)
2871322
(3 oz. cartridge) (24 Count)
Black RTV Silicone Sealer
Premium All Season Grease 2871957
2871423 (3 oz. tube) (12 Count)
(14 oz. cartridge) (10 Count)
Black RTV Silicone Sealer
2871460 Starter Drive Grease (12 Count) 2871958
(11 oz. cartridge) (12 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count) 2872189 DOT 4 Brake Fluid (12 Count)
2871551 Premium U-Joint Lube (14 oz.) (10 Count) 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
2871312 Grease Gun Kit 2872893 Engine Degreaser (12oz.) (12 Count)
2871329 Dielectric Grease (Nyogel™)
NOTE: The number count indicated by each part
Coolant number in the table above indicates the number of
2871323 60/40 Coolant (Gallon) (6 Count) units that are shipped with each order.

2871534 60/40 Coolant (Quart) (12 Count)

2.7

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 MAINTENANCE
MAINTENANCE REFERENCES
Item Lube Rec. Method Frequency*
Change after 1st month (25 hrs), 6
Polaris PS-4 PLUS
Add oil to proper level months or 100 hours thereafter; Change
1. Engine Oil Performance Synthetic 2W-50
indicated on dipstick. more often in extremely dirty conditions,
4-Cycle Engine Oil (2876244)
or short trip cold weather operation.
Fill reservoir between
2. Brake Fluid DOT 4 (PN 2872189) As required. Change fluid every 2 years.
MAX and Min lines.
Polaris AGL Gearcase Add lube to bottom of fill Change annually. Change more often if
3. Transmission
Lubricant (PN 2873602) plug threads. used in severe conditions.
Premium Demand Drive Fluid Drain completely. Add
4. Front Gearcase Change annually***
(PN 2871654) lube to specified quantity.
Polaris ATV Angle Drive Fluid Drain completely. Add
5. Middle Gearcase Semi-annually**
(PN 2871653) lube to specified quantity.

* More often under severe use, such as operated in water or under severe loads.
**Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)

2. Brake Master Cylinder

1. Engine

Dipstick / Fill Tube

Master
Cylinder

3. Transmission

Fill Plug

4. Front Gearcase
5. Middle Gearcase (6x6)

Fill Plug

Fill Plug
Drain Plug
Drain Plug

2.8

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 MAINTENANCE
Maintenance References, Continued.....

Item Lube Rec. Method Frequency*

Polaris All Season Grease (PN Locate grease fitting on
6. Swing Arm Pivot Semi-annually**
2871423) inside of the swing arm pivot.

7. Rear Prop Shaft Yoke

Polaris Premium U-Joint Lube
(PN 2871551)
Locate fittings and grease
with grease gun.
Semi-annually** 2
Polaris Premium U-Joint Lube Locate fittings and grease
8. Front Prop Shaft Yoke Semi-annually**
(PN 2871551) with grease gun.
Polaris ATV Angle Drive Fluid Drain completely. Add lube
9. Rear Gearcase Change annually***
(PN 2871653) to specified quantity.

* More often under severe use, such as operated in water or under severe loads.
**Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special

Yoke

8. Front Prop Shaft

6. Swing Arm (6x6)

Yoke

Swing Arm Pivot

7. Rear Prop Shaft (6x6)

9. Rear Gearcase 9. Rear Gearcase

(6x6) (4x4 CREW)
Fill Plug

2.9

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 MAINTENANCE

GENERAL VEHICLE INSPECTION Shift Linkage Inspection / Adjustment

AND MAINTENANCE Linkage rod adjustment is necessary when symptoms include:
• No All Wheel Drive light
Pre-Ride / Daily Inspection
• Noise on deceleration
Perform the following pre-ride inspection daily, and when
servicing the vehicle at each scheduled maintenance. • Inability to engage a gear
• Excessive gear clash (noise)
• Tires - check condition and pressures
• Shift selectors moving out of desired range
• Fuel and oil tanks - fill both tanks to their proper level;
Do not overfill oil tank NOTE: Remove necessary components to gain
access to shift linkage cable ends (i.e. exhaust heat
• All brakes - check operation and adjustment (includes shield, exhaust pipe, etc.)
auxiliary brake)

• Throttle - check for free operation and closing

• Headlight/Taillight/Brakelight - check operation of all

indicator lights and switches

• Engine stop switch - check for proper function

• Wheels - check for tightness of wheel nuts and axle

nuts; check to be sure axle nuts are secured by cotter
pins

• Air cleaner element - check for dirt; clean or replace

• Steering - check for free operation noting any unusual 1. Inspect shift linkage cable, clevis pins, and pivot bushings
looseness in any area and replace if worn or damaged.
• Loose parts - visually inspect vehicle for any damaged 2. Be sure idle speed is adjusted properly.
or loose nuts, bolts or fasteners 3. Place gear selector in neutral. Make sure the transmission
bell crank is engaged in the neutral position detents.
• Engine coolant - check for proper level at the recovery
bottle 4. With two wrenches loosen the outside jam nut
counterclockwise. Turn the outside jam nut 1 1/2 turns.
• Check all rear suspension components for wear or Perform this procedure on the shift lever end, also.
damage.
Inside Jam Nut Outside Jam Nut

Frame, Nuts, Bolts, and Fasteners

Periodically inspect the torque of all fasteners in accordance
with the maintenance schedule. Check that all cotter pins are in
place. Refer to specific fastener torques listed in each chapter.

Shift Cable Adjustment

5. After turning the outside jam nut 1 1/2 turns. Hold the
outside jam nut with a wrench and tighten the inside jam
nut clockwise, until it is tight against the bracket.
6. Repeat Step 4 and Step 5 until the proper adjustment is
made for the transmission cable.

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 MAINTENANCE
7. Use this procedure to loosen or tighten the shift linkage Fuel Filter
cable as needed.
The fuel pump on the RANGER 700 EFI is non-serviceable. If
Clockwise Inside Jam Nut the internal fuel pump filters require service, the fuel tank and
fuel pump must be replaced as an assembly.

NOTE: See the “Electronic Parts Catalog” for more

information. 2
NOTE: For all other information related to the EFI
System refer to Chapter 4.

Vent Lines
Counterclockwise Outside Jam Nut
1. Check fuel tank and transmission vent lines for signs of
wear, deterioration, damage or leakage. Replace every
two years.

FUEL SYSTEM AND AIR INTAKE 2. Be sure vent lines are routed properly and secured with
cable ties. CAUTION: Make sure lines are not kinked or
Fuel System pinched

Throttle Pedal Inspection

WARNING

Gasoline is extremely flammable and explosive

under certain conditions.
Always stop the engine and refuel outdoors or in
a well ventilated area.
Do not smoke or allow open flames or sparks in
or near the area where refueling is performed or
where gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately. Throttle Pedal
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water
and change clothing. If the throttle pedal has excessive play due to cable stretch or
Never start the engine or let it run in an enclosed cable misadjustment, it will cause a delay in throttle speed.
area. Engine exhaust fumes are poisonous and Also, the throttle may not open fully. If the throttle pedal has no
can result loss of consciousness or death play, the throttle may be hard to control, and the idle speed may
in a short time. be erratic.
Never drain the fuel when the engine is hot.
Severe burns may result. Check the throttle pedal play periodically in accordance with the
Periodic Maintenance Chart and adjust the play if necessary.

Fuel Lines
1. Check fuel lines for signs of wear, deterioration, damage
or leakage. Replace if necessary.

2. Be sure fuel lines are routed properly and secured with

cable ties. CAUTION: Make sure lines are not kinked or
pinched.

3. Replace all fuel lines every two years.

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 MAINTENANCE
Throttle Freeplay Adjustment Air Filter Service
Inspection It is recommended that the air filter be replaced annually. When
riding in extremely dusty conditions replacement will be
1. Apply the parking brake. required more often.
2. Put the gear shift lever in the N (Neutral) position. The filter should be inspected periodically before each ride,
using the following procedure.
3. Start the engine, and warm it up thoroughly.
1. Lift the box to access the filter box cover.
4. Measure the distance the throttle pedal moves before the
engine begins to pick up speed. Free play should be 1/16”
- 1/8” (1.5 - 3 mm).
Air Box Location
Adjustment
1. Remove the seat.

2. Locate the throttle cable adjuster.

3. Squeeze the end of the rubber boot and slide it far enough
to expose the end of the inline cable adjuster.

2. Remove clips (2) from air box cover and remove cover.
Inspect the gasket. It should adhere tightly to the cover and
Boot seal all the way around.

3. Remove air filter assembly. Do not clean the main filter,

the filter should be replaced.

Lock Nut 4. Inspect main element and replace if necessary. If the filter
Adjuster has been soaked with fuel or oil it must be replaced.

4. Loosen the adjuster lock nut. Breather Filter

5. Rotate the boot to turn the adjuster until 1/16" to 1/8" Cover Seal
(1.5 - 3 mm) of freeplay is achieved at the throttle pedal.

NOTE: While adjusting, lightly flip the throttle pedal

up and down.

6. Tighten the lock nut.

7. Squeeze the end of the rubber boot and slide it over the
cable adjuster to its original position. Filter
Cover

Installation
1. Reinstall the filter into the air box container. Be sure the
filter fits tightly in the air box.

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 MAINTENANCE
NOTE: Apply a small amount of general purpose Air Intake Inspection
grease to the sealing edges of the filter before
installing. 1. Lift the hood.
2. Inspect the foam insert in the engine intake air baffle box.
2. Check air box. If oil or water deposits are found, drain them
If the foam insert is dirty, clean the foam with a high flash
into a suitable container.
point solvent, followed by hot soapy water.
NOTE: Service more frequently if vehicle is operated 2
in wet conditions or at high throttle openings for
extended periods.

3. Install air box cover and secure with clips.

NOTE: The PVT intake air baffle box

does NOT have a foam insert.

3. Rinse and dry the foam thoroughly.

4. Inspect the foam for tears or damage. Replace if necessary.
5. Reinstall the foam insert into the air baffle box.

Air Baffing
Box

Foam
Air Box

Engine Intake Duct

PVT Intake Duct

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 MAINTENANCE

ENGINE Engine Oil Level

The twin cylinder engine is a wet-sump engine, meaning the oil
Compression and Leakdown Test
is contained in the bottom of the crankcase. To check the oil
NOTE: This engine does NOT have decompression level follow the procedure listed below.
components. Compression readings will vary in
proportion to cranking speed during the test.
Average compression (measured) is about 150-200
psi during a compression test.

A smooth idle generally indicates good compression. Low

engine compression is rarely a factor in running condition
problems above idle speed. Abnormally high compression can
be caused by carbon deposits in the combustion chamber or
worn, damaged exhaust cam lobes. Inspect camshaft and Dipstick
combustion chamber if compression is abnormally high.

A cylinder leakdown test is the best indication of engine

condition. Follow manufacturer's instructions to perform a
cylinder leakage test (never use high pressure leakage testers, as
crankshaft seals may dislodge and leak). 1. Set machine on a level surface and set the parking brake.
2. Be sure the machine has sat for awhile before removing the
Cylinder Compression dipstick.
Standard: 150-200 PSI IMPORTANT: Do not run the machine and then check
the dipstick.
Cylinder Leakdown 3. Stop engine and unlock the lever lock. Remove dipstick
Service Limit 15% and wipe dry with a clean cloth.

(Inspect for cause if test exceeds 15%)

Breather Hose Inspection

The engine is equipped with a breather hose (A). Inspect the
breather hose for possible kinks or wear. The hose is form fit-
ted for a proper fit. Follow the breather hose from the side of
the airbox to the engine valve cover.

Lever Lock

Dipstick

NOTE: Make sure lines are not kinked or pinched.

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 MAINTENANCE
4. Reinstall dipstick and push it into place. Do not lock the Engine Oil and Filter Change
dipstick.

NOTE: Make certain the dipstick is inserted all the WARNING

way into the filler tube to keep the angle and depth of
dipstick consistent. When reinstalling the dipstick, Personal injury can occur when handling used
make certain to seat the lever lock. oil. Hot oil can cause burns or skin damage. 2
5. Remove dipstick and check to see that the oil level is in the
normal range. Add oil as indicated by the level on the
dipstick. Do not overfill (see NOTE below!). =
NOTE: Due to the dipstick entry angle into the Recommended Engine Oil:
crankcase, the oil level will read higher on the
bottom side of the dipstick. Proper level indication Polaris PS-4 PLUS Synthetic 2W-50
is determined on the upper surface of the dipstick as (PN 2876244) (Quart)
it is being removed, regardless of the level marks
being on top or on bottom (see the next illustration). Ambient Temperature Range
-40° F to 120° F
Dipstick
1. Place vehicle on a level surface.

2. To ease access to the oil filter, try to access the oil filter from
the front engine cover or remove the storage container
Always read top side of dipstick to located under the driver side seat (refer to Chapter 5 for
properly check oil level in crankcase front engine cover and storage removal).

3. Run engine two to three minutes until warm. Stop engine.

4. Clean area around drain plug at bottom of engine. Drain

plug is accessible through the skid plate.

CAUTION
NOTE: A rising oil level between checks in cool
weather driving can indicate contaminants such as Oil may be hot. Do not allow hot oil to come into
gas or moisture collecting in the crankcase. If the oil contact with skin, as serious burns may result.
level is over the full mark, change the oil
immediately. 5. Place a drain pan beneath crankcase and remove drain plug.

Drain Plug

6. Allow oil to drain completely.

7. Replace the sealing washer on drain plug.

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 MAINTENANCE
NOTE: The sealing surface on the drain plug should Exhaust Pipe
be clean and free of burrs, nicks or scratches.
8. Reinstall drain plug and torque to 16 ± 2 ft. lbs. (21.7 ± 2.7 WARNING
Nm).
9. Place shop towels beneath oil filter. Using Oil Filter Do not perform clean out immediately after the engine
Wrench (PV-43527), turn filter counterclockwise to has been run, as the exhaust system becomes very hot.
remove. Serious burns could result from contact with exhaust
components.
Oil Filter To reduce fire hazard, make sure that there are no
combustible materials in the area when purging the
spark arrestor.
Wear eye protection.
Do not stand behind or in front of the vehicle while
purging the carbon from the spark arrestor.
Never run the engine in an enclosed area. Exhaust
contains poisonous carbon monoxide gas.
Do not go under the machine while it is inclined. Set the
hand brake and block the wheels to prevent roll back.
Failure to heed these warnings could result in serious
personal injury or death.

10. Using a clean dry cloth, clean filter sealing surface on The exhaust pipe must be periodically purged of accumulated
crankcase. carbon as follows:

11. Lubricate O-ring on new filter with a film of fresh engine 1. Remove the clean out plugs located on the bottom of the
oil. Check to make sure the O-ring is in good condition. muffler as shown below.
12. Install new filter and turn by hand until filter gasket contacts
the sealing surface, then turn an additional 1/2 turn.
13. Remove dipstick and fill sump with 2 quarts (1.9 l) of
Polaris PS-4 PLUS 2W-50 Synthetic engine oil
(PN 2876244).
Clean Out Plug
=T
2. Place the transmission in Park and start the engine. Purge
Crankcase Drain Plug Torque: accumulated carbon from the system by momentarily
16 ± 2 ft. lbs. (21.7 ± 2.7 Nm) revving the engine several times.

Oil Filter Torque: 3. If some carbon is expelled, cover the exhaust outlet and
Turn by hand until filter gasket contacts sealing lightly tap on the pipe around the clean out plugs with a
surface, then turn an additional 1/2 turn rubber mallet while revving the engine several more times.

Oil Filter Wrench:

(PV-43527)

14. Place gear selector in neutral and set parking brake.

15. Start the engine and let it idle for one to two minutes.
Stop the engine and inspect for leaks.
16. Re-check the oil level on the dipstick and add oil as
necessary to bring the level to the upper mark on the
dipstick.
17. Dispose of used oil and oil filter properly.

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 MAINTENANCE
4. If particles are still suspected to be in the muffler, back the TRANSMISSION AND GEARCASES
machine onto an incline so the rear of the machine is one
foot higher than the front. Set the hand brake and block the Transmission Lubrication
wheels. Make sure the machine is in Park and repeat Steps
2 and 3. SEE WARNING NOTE: It is important to follow the transmission
maintenance intervals described in the Periodic
Maintenance Chart. Regular fluid level inspections
should be performed as well. 2
The transmission lubricant level should be checked and changed
in accordance with the maintenance schedule.
• Be sure vehicle is positioned on a level surface when
checking or changing the lubricant.
• Check vent hose to be sure it is routed properly and
unobstructed.

Transmission Lubricant Level Check

The fill plug is located on the right side of the transmission.
Access the fill plug from the rear right-hand side of the vehicle.
5. If particles are still suspected to be in the muffler, drive the Maintain the fluid level even with the bottom threads of the fill
machine onto the incline so the front of the machine is one plug hole.
foot higher than the rear. Set the hand brake and block the
wheels. Make sure the machine is in Park and repeat Steps 1. Position vehicle on a level surface.
2 and 3. SEE WARNING
2. Remove the fill plug and check the lubricant level.
6. Repeat steps 2 through 5 until no more particles are
expelled when the engine is revved.

7. Stop the engine and allow the arrestor to cool.

8. Reinstall the clean out plugs.

3. If lubricant level is not even with the bottom threads, add

the recommended lubricant as needed. Do not overfill.

4. Reinstall the fill plug and torque to specification.

=T
Drain / Fill Plug Torque: 14 ft. lbs. (19 Nm)

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 MAINTENANCE
Transmission Lubricant Change Front Gearcase Lubrication
Access the drain plug on the right-hand side of the vehicle The gearcase lubricant level should be checked and changed in
through the skid plate. accordance with the maintenance schedule.

1. Remove the fill plug (refer to “Transmission Lubricant • Be sure vehicle is level with parking brake on before
Level Check”). proceeding.
2. Place a drain pan under the transmission drain plug. • Check vent hose to be sure it is routed properly and
3. Remove the drain plug and allow lubricant to drain unobstructed.
completely. • The correct front gearcase lubricant to use is Polaris
Premium Demand Fluid.
FRONT GEARCASE
Make sure vent is unobstructed

Fill Plug
8-30 ft. lbs.
(11-41 Nm)

Drain Plug: 10 ft. lbs. (14 Nm)

4. Clean the drain plug magnetic surface.

5. Reinstall drain plug with a new O-ring and torque to =

specification.
Front Gearcase Specifications
6. Add the recommended amount of lubricant through the fill
plug hole. Maintain the lubricant level at the bottom of the Specified Lubricant:
fill plug hole when filling the transmission. Do not overfill. Premium Demand Drive Fluid
(PN 2871654)

= Capacity: 5.0 oz. (150 ml.)

Recommended Transmission Lubricant:

Full Synthetic AGL (PN 2873602) (Quart) =T

Capacity: 43.6 oz. (1290 ml) Fill Plug Torque: 8-30 ft. lbs. (11-41 Nm)

7. Reinstall fill plug with a new O-ring and torque to Drain Plug Torque: 10 ft. lbs. (14 Nm)
specification.
To check the lubricant level:

=T The front gearcase lubricant level cannot be checked with a

dipstick. The gearcase must be drained and re-filled with the
Drain / Fill Plug Torque: 14 ft. lbs. (19 Nm) proper amount of lubricant or be filled to the bottom of the fill
plug hole threads. Refer to procedures.
8. Check for leaks. Dispose of used lubricant properly.

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 MAINTENANCE
To change gearcase lubricant: 4. Remove fill plug (8 mm hex) and check the O-ring.
1. Remove gearcase drain plug (B) (11 mm) located on the
bottom of the gearcase and drain oil. (The drain plug is
accessible through the skid plate.) Catch and discard used Fill Plug
oil properly.

A
B

10 ft. lbs (14 Nm) 5. Fill with the recommended fluid amount (5 oz.) or to the
bottom of the fill plug hole threads.
Front Gearcase

2. Clean and reinstall drain plug (B) using a new sealing Plug Threads
washer (A). Torque to 10 ft. lbs. (14 Nm).

3. The fill plug can be accessed through the top hood area by Fill with 5 oz.
removing the storage box or by removing the left side panel
in the left wheel well.

Top View of Hood Area

6. Install fill plug and check for leaks.

Middle Gearcase Lubrication (6x6)

=
LH Side Panel
Middle Gearcase Specifications (6x6)

Specified Lubricant:
ATV Angle Drive Fluid (PN 2871653)
Capacity: 6.75 oz. (200 ml.)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

The gearcase lubricant level should be checked and changed in

accordance with the maintenance schedule.
• Be sure vehicle is level with parking brake on before
proceeding.
• Check vent hose to be sure it is routed properly and
unobstructed.

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 MAINTENANCE
• The correct middle gearcase lubricant to use is ATV Rear Gearcase Lubrication (4x4 CREW)
Angle Drive Fluid

To check the lubricant level:

=
The gearcase must be drained and re-filled with the proper
amount of lubricant. Refer to the procedure below. Rear Gearcase Specifications (4x4 CREW)

To change middle gearcase lubricant: Specified Lubricant:

1. With the RANGER on a level surface, remove the fill plug ATV Angle Drive Fluid (PN 2871653)
and check the lubricant level. Lubricant should be kept at
the specified level, according to the proper gearcase Capacity: 18 oz. (532 ml)
specifications listed.
Lubricant Level Check:
2. Support the vehicle securely with a jack stand and remove
the front tire on the driver’s side. The fill plug is located on the right side of the rear gearcase.
Maintain the fluid level even with the bottom of the threads of
3. Remove gearcase drain plug located on the bottom of the
the fill plug hole.
gearcase and drain oil. (The drain plug is accessible through
the skid plate.) Catch and discard used oil properly. Fill Plug
4. Clean and reinstall drain plug using a new sealing washer. 40-50 ft. lbs.
(54-68 Nm)
5. Remove the fill plug and add the recommended amount of
lubricant.
6. Install fill plug. Check for leaks.
MIDDLE GEARCASE (6X6)
Make sure vent is unobstructed

Side View

Maintain Level at
Bottom of Threads

1. Position the vehicle on a level surface.

2. Remove the fill plug and check the fluid level. The
lubricant level should be even with the bottom of the
threads of the fill plug hole.

Fill to bottom of 3. Add the recommended lubricant as needed.

fill plug hole Fill Plug
threads: 6.75 oz. 14 ft. lbs. (19 Nm) 4. Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm)
Bottom View
=T
Fill Plug Torque: 40-50 ft. lbs. (54-68 Nm)

Drain Plug Torque: 30-45 in. lbs. (3-5 Nm)

Drain Plug
14 ft. lbs. (19 Nm)

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 MAINTENANCE
Lubricant Change: Rear Gearcase Lubrication (6x6)
The drain plug is located on the bottom right side of the rear
gearcase.
=
Fill Plug
Rear Gearcase Specifications (6x6)
2
Specified Lubricant:
ATV Angle Drive Fluid (PN 2871653)

Capacity: 10 oz. (300 ml)

The gearcase lubricant level should be checked and changed in

accordance with the maintenance schedule.

• Be sure vehicle is level before proceeding with parking

brake on.
Drain Plug
• Check vent hose to be sure it is routed properly and
unobstructed.
1. Remove the fill plug.
• The correct rear gearcase lubricant to use is Polaris
2. Place a drain pan under the drain plug. ATV Angle Drive Fluid

3. Remove the drain plug and allow the lubricant to drain To check the lubricant level:
completely. The gearcase must be drained and re-filled with the proper
amount of lubricant. Refer to the procedure below.
4. Clean the drain plug.
To change rear gearcase lubricant:
5. Reinstall the drain plug and torque to 30-45 in. lbs.
(3-5 Nm). 1. With the vehicle on a level surface, remove the fill plug
and check the lubricant level. Lubricant should be kept at
Fill Plug the specified level, according to the proper gearcase
40-50 ft. lbs. specifications listed.
(54-68 Nm)
2. Support the vehicle securely with a jack stand and remove
the front tire on the driver’s side.

3. Remove gearcase drain plug located on the bottom of the

gearcase and drain oil. (The drain plug is accessible through
the skid plate.) Catch and discard used oil properly.

4. Clean and reinstall drain plug using a new sealing washer.

REAR GEARCASE - 6X6
Maintain Level at Make sure vent is unobstructed
Bottom of Threads
Drain Plug
30-45 in. lbs.
(3-5 Nm)
Fill Plug

6. Add the recommended lubricant. Maintain the fluid level

even with the bottom threads of the fill plug hole.

7. Reinstall the fill plug and torque to 40-50 ft. lbs.

(54-68 Nm). Drain Plug

8. Check for leaks. Discard used lubricant properly.

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 MAINTENANCE
5. Remove fill plug (A). Coolant Level Inspection
The recovery bottle, located on the left side of the machine, must
be maintained between the minimum and maximum levels
indicated on the recovery bottle.

A Surge Tank Cap

6. Fill with 10 oz. (300 ml.) or fill to the bottom of the threads
of the fill plug hole.

7. Install fill plug and torque to 14 ft. lbs (19 Nm). Check for
leaks. With the engine at operating temperature, the coolant level
should be between the upper and lower marks on the coolant
reservoir. If not:
=T
1. Remove reservoir cap. Inner splash cap vent hole must be
Drain Plug / Fill Plug Torque: clear and open.
14 ft. lbs. (19.4 Nm)
2. Fill reservoir to upper mark with Polaris Premium 60/40
Anti Freeze / Coolant or 50/50 or 60/40 mixture of
antifreeze and distilled water as required for freeze
COOLING SYSTEM protection in your area.

Liquid Cooling System Overview 3. Reinstall cap.

The engine coolant level is controlled or maintained by the
recovery system. The recovery system components are the
recovery bottle, radiator filler neck, radiator pressure cap and
connecting hose.

As coolant operating temperature increases, the expanding

(heated) excess coolant is forced out of the radiator past the
pressure cap and into the recovery bottle. As engine coolant
temperature decreases the contracting (cooled) coolant is drawn
back up from the tank past the pressure cap and into the radiator. Surge Tank

NOTE: Some coolant level drop on new machines is

normal as the system is purging itself of trapped air.
Observe coolant levels often during the break-in NOTE: If overheating is evident, allow system to
period. cool completely and check coolant level in the
radiator and inspect for signs of trapped air in
Overheating of engine could occur if air is not fully purged from system.
system.

Polaris Premium 60/40 is already premixed and ready to use. Do

not dilute with water.

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 MAINTENANCE
Radiator Coolant Level Inspection • Straight water or antifreeze may cause the system to
freeze, corrode, or overheat.
NOTE: This procedure is only required if the cooling
system has been drained for maintenance and/or
repair. However, if the recovery bottle has run dry, Polaris 60/40 Anti-Freeze / Coolant
or if overheating is evident, the level in the radiator
(PN 2871323)
should be inspected and coolant added if necessary.
2
Radiator Cap Cooling System Pressure Test
Refer to Chapter 3 for cooling system pressure test procedure.

Cooling System Hoses

1. Inspect all hoses for cracks, deterioration, abrasion or
leaks. Replace if necessary.

Coolant Lines

WARNING
Radiator
Never remove the pressure cap when the
engine is warm or hot. Escaping steam can
cause severe burns. The engine must be cool
before removing the pressure cap.

NOTE: Use of a non-standard pressure cap will not

2. Check tightness of all hose clamps.
allow the recovery system to function properly.

To access the radiator pressure cap raise the front hood. CAUTION
The radiator cap is located on the drivers side.
Do not over-tighten hose clamps at radiator, or
Coolant Strength / Type radiator fitting may distort, causing a restriction
Test the strength of the coolant using an antifreeze hydrometer. to coolant flow. Radiator hose clamp torque is
36 in. lbs. (4 Nm).

Antifreeze Hydrometer

• A 50/50 or 60/40 mixture of antifreeze and distilled

water will provide the optimum cooling, corrosion
protection, and antifreeze protection.

• Do not use tap water, straight antifreeze, or straight

water in the system. Tap water contains minerals and
impurities which build up in the system.

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 MAINTENANCE
Radiator 3. Remove the drain plug and drain the coolant from the
radiator. Drain the coolant into a suitable container and
1. Check radiator (A) air passages for restrictions or damage. properly dispose of the coolant.

A 4. Remove the outlet radiator hose, inlet radiator hose, surge

tank hose, and overflow hose from the radiator.

5. Disconnect the fan motor harness and remove the radiator

from the vehicle. Take care not to damage the cooling fins.

6. Remove the radiator.

Inlet Radiator Hose

Outlet Radiator Hose

2. Carefully straighten any bent radiator fins.

3. Remove any obstructions with compressed air or low

pressure water.

Coolant Drain / Radiator Removal

1. Remove the front bumper. Remove three bolts that secure Surge Tank Hose
the bumper to the bottom of the frame. Remove six screws
(both sides) that secure the wheel well panel to the frame. Plug
Remove two bolts that secure the top bumper to the frame.
Remove the darts that attach the plastic to the bumper.

Bolts

Wheel Well

Bolts

2. Remove two mounting screws that secure the top of the

radiator to the frame. Remove the radiator cap. Pull the
radiator out of the frame at an angle.

NOTE: If you have trouble reaching the top radiator

bolts, remove four screws from the top front of the
hood liner. Prop the front of the hood up 1.5 inches
(38.10 mm) to help remove the top bolts that secure
the radiator to the frame.

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 MAINTENANCE
FINAL DRIVE / WHEEL AND TIRE Wheel Removal

Wheel and Hub Torque Table Front & Rear

Wheel Nuts (4)
Item Nut Type Specification

Aluminum Wheels
(Cast)
Lug Nut (1) 90 ft. lbs. (122 Nm) 2
Front Hub Nut
Steel Wheels 60 ft. lbs. (81 Nm)
Flange Nut (2) 35 ft. lbs. (47 Nm)
(Black / Camo)
Front Hub Nut - 60 ft. lbs. (81 Nm)
Rear & Center Hub
- 110 ft. lbs. (150 Nm) Rear Hub Nut
Retaining Nut 110 ft. lbs. (150 Nm)

1. Stop the engine, place the transmission in gear and lock the
parking brake.

2. Loosen the wheel nuts slightly.

#2 3. Elevate the side of the vehicle by placing a suitable stand

#1
under the footrest frame.

4. Remove the wheel nuts and washers and remove the wheel.
Aluminum Wheel Steel Wheel
(LE Models) (Standard Models)
90 ft. lbs. (122 Nm) 35 ft. lbs. (47 Nm) Wheel Installation
1. With the transmission in gear and the parking brake
locked, place the wheel in the correct position on the wheel
CV Shaft Boot Inspection
hub. Be sure the valve stem is toward the outside and
Inspect the CV shaft boots for damage, tears, wear, or leaking rotation arrows on the tire point toward forward rotation.
grease. If the rubber boot exhibits any of these symptoms,
replace the boot. Refer to Chapter 7 for CV boot replacement, 2. Attach the washers (if applicable) and wheel nuts and finger
or have you Polaris dealer replace the boot. tighten them.

3. Lower the vehicle to the ground.

4. Securely tighten the wheel nuts to the proper torque listed

in the torque table at the beginning of this section.

CAUTION

If wheels are improperly installed it could affect

vehicle handling and tire wear. On vehicles with
tapered rear wheel nuts, make sure tapered end
Inspect Boots of nut goes into taper on wheel.

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 MAINTENANCE
Tire Inspection ELECTRICAL AND IGNITION SYSTEM
• Improper tire inflation may affect vehicle
Battery Maintenance
maneuverability.
Keep battery terminals and connections free of corrosion. If
• When replacing a tire always use original equipment cleaning is necessary, remove the corrosion with a stiff wire
size and type. brush. Wash with a solution of one tablespoon baking soda and
• The use of non-standard size or type tires may affect one cup water. Rinse well with tap water and dry off with clean
vehicle handling. shop towels. Coat the terminals with dielectric grease or
petroleum jelly.
Tire Tread Depth
Be careful not to allow cleaning solution or tap water into the
Always replace tires when tread depth is worn to 1/8" (3 mm) or battery
less.

Tread WARNING
Depth 1/8" (3 mm)
Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get

WARNING prompt medical attention.

Batteries produce explosive gases.

Operating a RANGER with worn tires will
Keep sparks, flame, cigarettes, etc. away.
increase the possibility of the vehicle skidding
Ventilate when charging or using in an enclosed
easily with possible loss of control.
space. Always shield eyes when
working near batteries.
Worn tires can cause an accident.
KEEP OUT OF REACH OF CHILDREN.
Always replace tires when the tread depth
NOTE: Batteries must be fully charged before use or
measures 1/8", (.3 cm) or less.
battery life will be reduced by 10-30% of full
potential. Charge battery for 3-5 hours at a current
Tire Pressure equivalent of 1/10 of the battery’s rated amp/hour
capacity. Do not use the alternator to charge a new
CAUTION battery.

Maintain proper tire pressure.

Refer to the warning tire pressure decal
applied to the vehicle.

Tire Pressure Inspection (PSI - Cold)

Model Front / Rear
6x6 8-12 psi / 8-12 psi
4x4 CREW 12 psi / 16 psi

2.26

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 MAINTENANCE
Battery Fluid Level (Conventional Battery) Battery Installation
A poorly maintained battery will deteriorate rapidly. Check the Using a new battery that has not been fully charged can damage
battery fluid level often. Maintain the fluid level between the the battery and result in a shorter life. It can also hinder vehicle
upper and lower level marks. performance. Follow the battery charging procedure before
installing the battery.
Upper Level
1. Ensure that the battery is fully charged. 2
2. Place the battery in the battery holder.

3. Install the battery vent tube.

NOTE: The vent tube must be free of obstructions

and securely installed. Route the tube away from the
frame and vehicle body to prevent contact with
electrolyte.
Lower Level 4. Coat the terminals with dielectric grease or petroleum jelly.

Add only distilled water. Tap water contains minerals that are 5. Connect and tighten the red (positive) cable first.
harmful to a battery.
6. Connect and tighten the black (negative) cable last.
Battery Removal 7. Verify that cables are properly routed.
1. Open the Hood.
Battery Storage
Whenever the vehicle is not used for a period of three months or
more, remove the battery from the vehicle, ensure that it's fully
charged, and store it out of the sun in a cool, dry place. Check
battery voltage each month during storage and recharge as
needed to maintain a full charge.

NOTE: Battery charge can be maintained by using a

Polaris battery tender charger or by charging about
once a month to make up for normal self-discharge.
Battery tenders can be left connected during the
storage period, and will automatically charge the
battery if the voltage drops below a pre-determined
point.
2. Remove the battery vent tube from the battery.
Battery Charging
3. Disconnect the black (negative) battery cable.
1. Remove the battery from the vehicle to prevent damage
4. Disconnect the red (positive) battery cable. from leaking or spilled electrolyte during charging.

5. Lift the battery out of the vehicle, being careful not to tip 2. Charge the battery with a charging output no larger than
it sideways and spill any electrolyte. 1/10 of the battery’s amp/hr rating. Charge as needed to
raise the specific gravity to 1.270 or greater.

CAUTION 3. Reinstall the battery.

To reduce the chance of sparks: Whenever

removing the battery, disconnect the negative
(black) cable first. When reinstalling the battery,
install the negative cable last.

2.27

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 MAINTENANCE
Spark Plug Service 8. Install spark plug and torque to specification.

1. Remove both spark plug high tension leads (A). Clean

plug area so no dirt and debris can fall into engine when Recommended Spark Plug:
plug is removed. Champion RC7YC3

A
=T
Spark Plug Torque:
18 ft. lbs. (24 Nm)

Engine To Frame Ground

B
Inspect engine ground cable connection. Be sure it is clean and
tight. The ground cable runs from the engine to the terminal
block located under the front hood next to the battery.

2. Remove spark plugs (B).

Black Ground
3. Inspect electrodes for wear and carbon buildup. Look for
a sharp outer edge with no rounding or erosion of the
electrodes.

Inspect electrode for Terminal Block

wear and buildup (under hood)

4. Clean with electrical contact cleaner or a glass bead spark

plug cleaner only. CAUTION: A wire brush or coated
abrasive should not be used.

5. Measure gap with a wire gauge. Refer to specifications in

picture below for proper spark plug type and gap. Adjust
gap if necessary by bending the side electrode carefully.
Spark Plug Gap

Gap - .035" (0.90 mm)

6. If necessary, replace spark plug with proper type.

CAUTION: Severe engine damage may occur if the
incorrect spark plug is used.

7. Apply a small amount of anti-seize compound to the spark

plug threads.
2.28

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 MAINTENANCE
STEERING AND SUSPENSION • If abnormal movement is detected, inspect the hub and
wheel assembly to determine the cause (loose wheel
Steering nuts or loose front hub nut).
• Refer to the Final Drive chapter for more information.
The steering components should be checked periodically for
loose fasteners, worn tie rod ends, and damage. Also check to
Wheel Toe Alignment Inspection
make sure all cotter pins are in place. If cotter pins are removed,
they must not be re-used. Always use new cotter pins. 1. Place machine on a smooth level surface and set steering
2
wheel in a straight ahead position. Secure the steering
Replace any worn or damaged steering components. Steering
wheel in this position.
should move freely through entire range of travel without
binding. Check routing of all cables, hoses, and wiring to be 2. Place a chalk mark on the center line of the front tires
sure the steering mechanism is not restricted or limited. approximately 10” (25.4 cm) from the floor or as close to
the hub/axle center line as possible.
NOTE: Whenever steering components are
replaced, check front end alignment.

WARNING
Measure Here
Due to the critical nature of the procedures
outlined in this chapter, Polaris recommends
steering component repair and adjustment be Mark (A), measure,
performed by an authorized Polaris MSD- then roll forward
certified technician when replacing worn or and measure (B).
damaged steering parts.
Use only genuine Polaris replacement parts.

Tie Rod End / Steering Inspection

• To check for play in the tie rod end, grasp the steering A 10” B
tie rod, pull in all directions feeling for movement.
• Replace any worn steering components. Steering NOTE: It is important the height of both marks be
should move freely through entire range of travel equally positioned to get an accurate measurement.
without binding.
3. Measure the distance between the marks and record the
measurement. Call this measurement “A”.

4. Rotate the tires 180° by moving the vehicle forward.

Position chalk marks facing rearward, even with the hub/
axle center line.

5. Again measure the distance between the marks and record.

Call this measurement “B”. Subtract measurement “B”
from measurement “A”. The difference between
measurements “A” and “B” is the vehicle toe alignment.
The recommended vehicle toe tolerance is 1/8”, to 1/4”, (.3
to .6 cm) toe out. This means the measurement at the front
of the tire (A) is 1/8”, to 1/4”, (.3 to .6 cm) wider than the
measurement at the rear (B).
• Elevate front end of machine so front wheels are off the
ground. Check for any looseness in front hub / wheel
assembly by grasping the tire firmly at top and bottom
first, and then at front and rear. Try to move the wheel
= In. / mm.
and hub by pushing inward and pulling outward.
Wheel Toe-Out: (A) - (B) = 1/8 - 1/4" (.3 to .6 cm)

2.29

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 MAINTENANCE
Toe Adjustment Front Suspension
If toe alignment is incorrect, measure the distance between • Compress and release front suspension. Damping
vehicle center and each wheel. This will tell you which tie rod should be smooth throughout the range of travel.
needs adjusting.
• Check all front suspension components and fasteners
NOTE: Be sure steering wheel is straight ahead for wear or damage.
before determining which tie rod(s) need
adjustment. • Inspect front strut cartridges for leakage.

CAUTION
Bolt Torque
During tie rod adjustment, it is very important that 15 ft. lbs. (20 Nm)
the following precautions be taken when
tightening tie rod end jam nuts.
If the rod end is positioned incorrectly it will not
pivot, and may break.

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both end of the tie rod.

Inspect for leaks
• Shorten or lengthen the tie rod until alignment is as
required to achieve the proper toe setting as specified in
“Wheel Toe Alignment”.

• IMPORTANT: When tightening the tie rod end jam

nuts, the rod ends must be held parallel to prevent rod
end damage and premature wear. Damage may not be
immediately apparent if done incorrectly.

Hold
Rod End

Correctly Incorrectly
Tightened Tightened
Jam Nut Jam Nut

• After alignment is complete, torque jam nuts to 12-14

ft. lbs. (16-19 Nm).

=T
Tie Rod Jam Nut Torque:
12-14 ft. lbs. (16-19 Nm)

2.30

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 MAINTENANCE
Rear Suspension Rear Suspension Adjustment (4x4 CREW)
The rear suspension may be adjusted to provide a stiffer
suspension if necessary.

1. Remove the top shock mounting bolts from the inside

2.
mounting holes.

Reposition the shocks to the outside mounting holes.

2
3. Reinstall the shock mounting bolts. Torque to 30 ft. lbs.
(40 Nm).

Outside Mounting Holes

RANGER 4X4
Independent Rear Suspension

Inside Mounting Holes

Rear Spring Adjustment

The rear shock absorber springs are adjusted by rotating the
adjustment cam either clockwise or counterclockwise to
increase or decrease spring tension.

RANGER 6X6 To adjust the suspension, use the adjustment cam located near
Rear Swingarm Suspension the bottom of the rear shock. This will allow you to increase or
decrease the amount of spring preload.
• Compress and release rear suspension. Damping should
be smooth throughout the range of travel.

• Check all rear suspension components for wear or

damage.
Rear Spring
• Inspect shock for leakage. Adjustment Cam

Shock Spanner Wrench

(PN 2870872)

2.31

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 MAINTENANCE

BRAKE SYSTEM Brake Pad / Disc Inspection

1. Check the brake pads for wear, damage, or looseness.
Brake Fluid Inspection
Always check the brake pedal travel and inspect the brake fluid 2. Inspect the brake pad wear surface for excessive wear.
reservoir level before each operation. If the fluid level is low,
3. Pads should be changed when the friction material is worn
add DOT 4 brake fluid only.
to .040” (1 mm).
Brake fluid should be changed every two years. The fluid
should also be changed anytime the fluid becomes
contaminated, the fluid level is below the minimum level, or if
the type and brand of the fluid in the reservoir is unknown.

The brake fluid master cylinder reservoir can be accessed by

lifting up the front hood.

1. Position the vehicle on a level surface.

Measure Pad Material
Thickness Service Limit:
2. Place the transmission in Neutral (N) and set the parking
brake. .040" (1 mm)

3. View the brake fluid level in the reservoir. The level should
be between the MAX and MIN level lines.
4. Check surface condition of the brake discs.
4. If the fluid level is lower than the MIN level line, add brake
fluid until it reaches the MAX level line. 5. Measure the thickness of the front and rear brake discs.

5. Install the reservoir cap and apply the brake pedal 6. The disc(s) should be replaced if thickness is less than the
forcefully for a few seconds and check for fluid leakage specified service limit (see Chapter 9 for specifications).
around the master cylinder fittings and the brake caliper
Measure Brake Disc Thickness
fittings.

Front Rear
Maximum Disc Disc

Minimum

Parking Brake Cable Adjustment

When the parking brake is fully engaged and the parking brake
Brake Hose and Fitting Inspection indicator is illuminated, engine speed is limited to 1300 RPM in
all gears, including neutral. If throttle is applied, this limiting
Check brake system hoses and fittings for cracks, deterioration,
feature prevents operation, which protects the parking brake
abrasion, and leaks. Tighten any loose fittings and replace any
pads from excessive wear.
worn or damaged parts.
NOTE: Inspect the parking brake cable tension after
the first 25 hours of operation and every 100 hours
of operation afterwards to ensure proper cable
tension.

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 MAINTENANCE
Loss of tension in the parking brake cable will cause
illumination of the parking brake light and activation of the
limiting feature. If this occurs, inspect and adjust parking brake
cable tension. If performing this service is difficult due to
conditions or location, open the hood and temporarily
disconnect the parking brake connector. Reconnect the
connector as soon as practicable and adjust the parking brake
cable to proper tension.
2
1. Pull back on the parking brake lever (located in the dash).

2. After 2 to 3 clicks the “(P)” brake light should illuminate

on the instrument cluster and the wheels of the vehicle
should not rotate when turning by hand. After 8 full clicks
of lever travel, the vehicle should not roll while parked.

3. If the vehicle moves, adjustment is necessary.

4. Adjust the parking brake cable where the cable attaches to

the caliper mount bracket located on the rear gearcase.

Adjustment Procedure: Refer to “Chapter 9 - Brakes”

for complete adjustment procedure.

Parking Brake Pad Inspection

Measure the thickness of the rear caliper parking brake pads.
Replace assembly as needed. See illustration below for proper
readings.
Inboard Pad Thickness
New .304” (7.72 mm)
Limit: 0.24” (6.1 mm)

Inboard Outboard
Pad Pad

Outboard Pad Thickness

New 0.360” (9.14 mm)
Limit: 0.31” (7.87 mm)

Installed Disc to Park Brake

0.375” (0.953 cm)

New Rotor Disc Thickness

0.150” - 0.164”
(3.81 - 4.16 mm)

2.33

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 MAINTENANCE

NOTES

2.34

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 ENGINE
CHAPTER 3
ENGINE
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
CRANKCASE EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
ENGINE FASTENER TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
700 EFI ENGINE SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3
COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
COOLING SYSTEM EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
VALVE COVER REMOVAL - 6X6 MODELS (ENGINE INSTALLED) . . . . . . . . . . . . . . 3.17
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
ENGINE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
CYLINDER HEAD ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
ROCKER ARMS / PUSH RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CYLINDER HEAD INSPECTION / WARP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
VALVE SEAL / SPRING SERVICE (ON ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
VALVE LIFTER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CYLINDER HONE SELECTION AND HONING PROCEDURE . . . . . . . . . . . . . . . . . . . 3.33
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
STARTER DRIVE BENDIX REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
FLYWHEEL / STATOR REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
ENGINE CRANKCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
FLYWHEEL / STATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
OIL PUMP PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
ENGINE BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59

3.1

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 ENGINE
ENGINE SPECIFICATIONS
Crankcase Exploded Views
A. Journal Bearings
B. Camshaft
C. Thrust Plate
D. Balance Shaft
E. Woodruff Key B
F. Flange Seal
G. Crankshaft
H. Oil Pickup C
I. Journal Bearings
J. Baffle A
K. Oil Plug
L. Washer
M. O-ring
N. Crankcase
O. Crankcase Bolts 115 ± 12 in. lbs.
D (13 ± 1.35 Nm)

F E
60 ± 6 in. lbs.
(6.8 ± .68 Nm)

G
I
H
I J
60 ± 6 in. lbs.
(6.8 ± .68 Nm) NOTE: If needed, heat
the oil baffle bolts with a
heat gun to remove.

M
192 ± 24 in. lbs
K (21.7 ± 2.7 Nm)
L

Apply Loctite™ 242 to

bolt threads.
O
Apply White Lithium
Grease

22 ± 2 ft. lbs. (30 ± 3 Nm) Apply Moly

Lube Grease.

3.2

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 ENGINE
Oil Pump / Water Pump / Engine Cover Exploded View
A. Split Gear
B. Washer
C. Bolt
D. Oil Rotor
E. Oil Pump
A F. Mag Gasket Cover
B G. Impeller
C H. Washer
I. Nut
D
E
J. Counterbalance Gear
K. Washer 3
L. Bolt
M. Oil Pump Bolts
N. Engine Cover
F O. Wire Hold down
J P. Stator Housing Bolts
K
L
22 ± 2 ft. lbs. (30 ± 3 Nm)
G
M
H
84 ± 8 in. lbs. (9.5 ± .90 Nm) I

No Grease on this
Portion of the Gasket! N 108 ± 12 in.lbs.
(6.8 ± .68 Nm)
O
Apply corrosion resistant
P
grease to stator grommet area. 96 ± 3 in.lbs.
(10.85 ± 0.35 Nm)
Oil Pump Bolt Tighten Sequence

Mag Cover Bolt Tighten Sequence

Apply Polaris 2W-50

oil to component
Apply White Lithium
Grease

3.3

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 ENGINE
Stator Cover / Starter / Water Pump Exploded View

Apply Polaris 3 5
Starter Grease Water Pump Cover
2
Bolt Tighten Sequence 7
Apply Polaris 2W-50
1
oil to seal
4
Loctite™ Pipe Sealant
(PN 2871956) 6
J
A No Grease or Oil
K
84 ± 8 ft.lbs. (9.5 ± 0.9 Nm)
L
Tighten Top Bolt First B 96 ± 12 in. lbs.
(10.85 ± 1.35 Nm)
1st

2nd
C

E D
108 ± 12 ft.lbs. O
(12 ± 1.35 Nm)
F
N M
65 ± 7 ft. lbs.
(88 ± 9.5 Nm)

I
A. Bolts
B. Starter
C. Washer H
D. Nut
E. Positive Cable
F. Negative Cable
G. Gasket 96 ± 12 in. lbs. (10.85 ± 1.35 Nm) Stator Cover Bolt
H. Clamp
I. Bolts Tighten Sequence
J. Gasket
K. Water Pump Cover
L. Bolts
M. Crank Nut / Washer
N. Flywheel

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 ENGINE
Oil Filter / Pressure Relief / Dipstick Assembly Exploded View

A. Clamp
B. Oil Fill Tube
C
C. Dipstick
D. O-ring
E. Hex Plug
F. Oil Filter Nipple
G. Oil Filter
H. Dowel
I. Galley Plug Asm.
3
J. Screw
K. Relief Spring

50 ± 5 in. lbs.
J (5.65 ± 0.56 Nm)
22 ± 2 ft. lbs.
(30 ± 3 Nm) I
K A

H D

18 ± 2 ft. lbs.
E (24.4 ± 2.71 Nm)

35 ± 4 ft. lbs.
F (47.5 ± 5.4 Nm)

50 ± 5 in. lbs. G
(5.65 ± 0.56 Nm)

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 ENGINE
Cylinder / Cylinder Head / Piston Exploded View

Initial:
Lubricate threads & between 35 ± 4 ft. lbs (47.5 ± 5.5 Nm)
washers and underside of bolt heads
with engine oil. 1 in sequence. Finalize sequence
by tightening an additional 90°
Torque in sequence provided. (Apply each (1/4 turn)
Bolt Threads)
Apply Moly Lube grease to
valve tips. A
22 ± 2 ft. lbs.
Gasket free of oil. Verify tabs are (30 ± 3 Nm) B
visible.
Apply thin film of 2W-50 to 2C Head Bolt Tighten
25-55 mm of cylinder bore. Sequence

Apply 2W-50 to piston pin or pin

bore. D3
Apply 2W-50 to lifters.

Do Not install expansion plug

F
more than 1.5 mm inward.
E
1.5 mm
G

4
Side View 4
A. Head Bolts
B. Rocker Arms H
C. Head Assembly I
D. Gasket 5 J Circlip UP
for Install
E. Pushrods
F. Bushing
G. Expansion Plug 3
H. Cylinder K
I. Piston Assembly L
J. Circlip
K. Gasket 6
L. Hydraulic Lifter

Apply Polaris 2W-50 Oil

Apply Moly Lube Grease

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 ENGINE
Engine Sensors / Valve Cover / General Component Exploded View

A
84 ± 8 in. lbs.
(9.5 ± 0.9 Nm)
B
C

A. Screws
20 ± 5 in. lbs. D
3
B. Rocker Cover
C. Breather (2.5 ± 0.55 Nm) E
D. O-ring Seal 18 ± 2 ft. lbs. F
E. Breather Bolts (24.5 ± 2.7 Nm)
F. Spark Plugs (Apply Dielectric Grease
G. Intake Boot to threads of Spark Plug)
H. Bolts
I. Boot Clamp G
J. Throttle Body 18 ± 2 ft. lbs.
(24.5 ± 2.7 Nm)
K. Crank Position Sensor H
L. Thermistor
M. O-ring 20 ± 5 in. lbs.
N. Thermostat (2.5 ± 0.55 Nm) I
O. Bolts
P. Gasket
Q. Exhaust Manifold
R. Bolts J
S. Thermostat Housing K
Apply Corrosion
Resistant Grease
84 ± 4 in. lbs.
(9.5 ± 0.9 Nm)

17 ± 2 ft. lbs.
P L (23 ± 3 Nm)
Q S

M
O
N 84 ± 8 in. lbs.
(9.5 ± 0.9 Nm)
18 ± 2 ft. lbs.
R (24.5 ± 2.7 Nm)

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 ENGINE
EFI Harness / Fuel Injection Exploded View

A. Fuel Injector
B. Fuel Rail
C. EFI Harness

B A
18 ± 2 ft. lbs.
(24.5 ± 2.7 Nm)

NOTE: See Chapter 4 for more information on the EFI system.

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 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
tighten in sequence 90° (1/4 turn).

35 ± 4 ft. lbs.
(47.5 ± 5.5 Nm) + 90° (1/4 turn)

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 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 ± 24 (24.5-± 2.7) 18 ± 2 (24.5 ± 2.7)
Counterbalance Gear 8 mm 22 ± 2 (30 ± 3)
Crankcase Bolts 8 mm * 22 ± 2 (30 ± 3)
Crankcase Breather 5 mm 20 ± 5 (2.5 ± 0.55) -
Cylinder Head Bolts 11 mm * 35 ± 4 (47.5 ± 5.5)
Exhaust Manifold 8 mm 216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7)
Flywheel 14 mm 65 ± 7 (88 ± 9.50)
Injector Rail 8 mm 216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7)
Magneto Cover 6 mm * 96 ± 3 (10.85 ± 0.35) -
Oil Baffle Weldment 5 mm 60 ± 6 (6.8 ± 0.68) -
Oil Drain Bolt (Crankcase) 12 mm 192 ± 24 (21.7 ± 2.7) 16 ± (21.7)
Oil Fill Tube Bolt 5 mm 50 ± 5 (5.64 ± 0.56) -
Oil Filter Pipe Fitting 20 mm 35 ± 4 (47.5 ± 5.4)
Oil Pick Up 5 mm 60 ± 6 (6.8 ± 0.68) -
Oil Pressure Relief Plug 10 mm 22 ± 2 (30 ± 3) -
Oil Pump Housing Screw 6 mm * 84 ± 8 (9.50 ± 0.90) -
Rocker Arm 8 mm * 22 ± 2 (30 ± 3)
Rocker Cover 6 mm * 84 ± 8 (9.5 ± 0.9) -
Spark Plug 14 mm 216 ± 24 (24.5 ± 2.7) 18 ± 2 (24.5 ± 2.7)
Starter Motor 6 mm * 84 ± 8 (9.5 ± 0.9) -
Stator Assembly 6 mm 96 ± 3 (10.85 ± 0.35) -
Stator Housing 6 mm * 96 ± 3 (10.85 ± 0.35) -
Temperature Switch 3/8 NPT 17 ± 2 (23 ± 3)
Thermostat Housing 6 mm 84 ± 8 (9.5 ± 0.9) -
Timing Plug 3/4-16 7 - 9 (10 - 12)
Trigger Coil/Stator Wire Holddown 5 mm * 96 ± 3 (10.85 ± 0.35) -
Water Pump Housing Cover 6 mm * 96 ± 3 (10.85 ± 0.35) -
Water Pump Impeller Nut 8 mm 108 ± 3 (12 ± 0.35) -

NOTE: * See exploded views for notes or torque sequences.

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 ENGINE
700 EFI Engine Service Specifications

Cylinder Head - Engine Specifications

Main Component: Cylinder Head EH068OLE

Cam Lobe Height - Intake / Exhaust 1.3334" (33.8674 mm)

Camshaft Journal Outer Diameter - Mag 1.654" ± 0.00039" (42 ± 0.010 mm)

Camshaft Journal Outer Diameter - Center 1.634"± 0.00039" (41.50 ± 0.010 mm)

Camshaft Journal Outer Diameter - PTO 1.614" ± 0.00039" (41 ± 0.010 mm) 3
Camshaft Camshaft Journal Bore Inner Diameter - Mag 1.656" ± 0.00039" (42.07 ± 0.010 mm)

Camshaft Journal Bore Inner Diameter - Center 1.637" ± 0.00039" (41.58 ± 0.010 mm)

Camshaft Journal Bore Inner Diameter - PTO 1.617" ± 0.00039" (41.07 ± 0.010 mm)

Camshaft Oil Clearance 0.00276" ± 0.00079" (0.07 ± 0.02 mm)

Camshaft End Play 0.0167" ± 0.0098" (0.425 ± 0.25 mm)

Counter Balance Counter Balance End Play 0.005" (0.127 mm)

Cylinder Head - Surface warp limit 0.00394" (0.1 mm)

Cylinder Head
Cylinder Head - Standard height 3.478" (88.35 mm)

Valve Seat - Contacting Width - Intake 0.0472" ± 0.00787" - 0.0039"

(1.20 ± 0.20 - 0.10mm)
Valve Seat Valve Seat - Contacting Width - Exhaust 0.0591" ± 0.00787" - 0.0039"
(1.50 ± 0.20 - 0.10 mm)
Valve Seat Angle 45.5° ± 0.255°

Valve Guide Inner diameter 0.2367" ± 0.00029" (6.012 ± 0.007 mm)

Valve Guide
Valve Guide Protrusion Above Head 0.807" ± 0.0039" (20.50 ± 0.01 mm)

Valve Margin Thickness - Intake Standard: 0.79" (20.06 mm)

Max- 0.98" (24.89 mm) Min.- 0.59" (14.98 mm)

Valve Margin Thickness - Exhaust Standard: 0.80" (20.32 mm)

Max- 1.0" (25.4 mm) Min.- 0.60" (15.24 mm)
Valve Stem Diameter - Intake 0.2356" ± 0.00039" (5.985 ± 0.01 mm)

Valve Valve Stem Diameter - Exhaust 0.2351" ± 0.00039" (5.972 ± 0.01 mm)

Valve Stem Oil Clearance - Intake 0.00228" ± 0.00098" (0.058 ± 0.025 mm)

Valve Stem Oil Clearance - Exhaust 0.00275" ± 0.00098" (0.0870 ± 0.025mm)

Valve Stem Overall Length - Intake 4.51" ± 0.01476" (114.5550 ± 0.375 mm)

Valve Stem Overall Length - Exhaust 4.5453" ± .01496" (115.45 ± 0.38 mm)

Valve Spring Overall Length - Free Length 1.735" (46.069 mm)

Valve Spring
Valve Spring Overall Length - Installed Height Intake - 1.4638" (37.18 mm)
Exhaust - 1.4736" (37.43 mm)

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 ENGINE
Cylinder / Piston - Engine Specifications
Main Components: Cylinder / Piston / Connecting Rod EH068OLE
Cylinder - Surface warp limit
0.004" (0.10 mm)
(mating with cylinder head)
Cylinder Bore - Standard 3.1495" (80 mm)
Cylinder
Cylinder Taper Limit 0.00031" (0.008 mm)
Cylinder Out of Round Limit 0.00030" (0.0075 mm)
Cylinder to Piston Clearance .0015" ± .00059" (.040 ± .015mm)
Lifter Outer Diameter Standard 0.84245" ± 0.00025" (21.39 8 ± 0.00635 mm)
Lifter
Lifter Block Bore 0.8438" ± 0.00062" (21.4322 ± 0.0157 mm)
Piston - Standard 3.1477" ± .000121" (79.954 ± .003mm)
Piston Piston Standard Inner Diameter of
0.78789" ± .00009" (20.0125 ± 0.003 mm)
Piston Pin Bore
Piston Pin Outer Diameter 0.7874" - 0.7872" (20 - 19.995 mm)
Piston Pin - Standard Clearance - Piston Pin to
Piston Pin 0.00059" ± 0.0002" (0.015 ± 0.005 mm)
Pin Bore
Piston Pin - Degree of Fit Piston pin must be a push fit (by hand) at 68° F (20° C)

Piston / Connecting Rod / Crankshaft - Engine Specifications

Main Components: Piston / Connecting Rod EH068OLE
Top Ring - Standard 0.0059± 0.138" (0.15 ± 0.35mm)
Top Ring - Limit > 15% Leakdown
Installed Second Ring - Standard 0.0098 ± 0.197" (0.25 ± 0.50mm)
Gap Second Ring - Limit > 15% Leakdown
Oil Ring - Standard 0.0196± 0.00984" (0.50 ± 0.25mm)
Piston Ring
Oil Ring - Limit > 15% Leakdown
Top Ring - Standard 0.0024" ± 0.0008" (0.060 ± 0.020 mm)
Ring to Top Ring - Limit > 15% Leakdown
Groove
Clearance Second Ring - Standard 0.0028" ± 0.0008" (0.070 ± 0.020 mm)
Second Ring - Limit > 15% Leakdown
Connecting Rod Small End I.D. 0.789"− 0.78841" (20.030 − 20.015 mm)
Connecting Rod Small End
0.0098"± 0.00039" (0.025 ± 0.010mm)
Radial Clearance
Connecting Rod Connecting Rod Big End
0.01181"± 0.00591" (0.030 ± 0.015mm)
Side Clearance
Connecting Rod Big End
0.0015"± 0.00006" (0.0038 ± 0.0015mm)
Radial Clearance
Crankshaft Crankshaft Runout Limit 0.00236" (0.060mm)

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 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
PU-45497-2
CAM GEAR SPRING INSTALLATION KIT
CAM GEAR TOOTH ALIGNMENT TOOL
3
PU-45498 CAM SPANNER WRENCH
PU-45838 GEAR HOLDER
PA-44995 WATER PUMP MECHANICAL SEAL INSTALLER
PU-45543 UNIVERSAL DRIVER HANDLE
PA-45483 MAIN SEAL INSTALLER
PU-45658 CRANKSHAFT MAIN SEAL SAVER
PA-45401 WATER PUMP SEAL SAVER
2870975 MITY VAC™ PRESSURE TEST TOOL
PU-45778 OIL SYSTEM PRIMING TOOL

GENERAL ENGINE SERVICE Piston Identification

Four stroke engine rings have a rectangular profile. See
Accessible Components
“PISTON RING INSTALLED GAP” for ring installation. Use
Following Components can be serviced or removed with the the information below to identify pistons and rings.
engine installed: (See Page 3.17 for 6x6 Valve Cover R & R)
Engine Model Piston Diameter
• Flywheel
• Alternator (Stator) EH068OLE 80 mm

• Starter Motor/Drive
Cooling System Specifications
• Cylinder Head (6x6: See Page 3.17)
• Cylinder (6x6: See Page 3.17) Condition Specification
• Piston / Rings (6x6: See Page 3.17) Thermostat Open 180° F (82° C)
• Camshaft (6x6: See Page 3.17) Thermostat Full Open Lift 6 mm at 203° F (95° C)
• Rocker Arms (6x6: See Page 3.17) Thermostat Closed 171° F (77° C)
• Oil pump / Water Pump / Oil Pump Drive Gear System Capacity 3.25 Quarts (2.13L)
• Gear Train Components Radiator Cap Pressure Relief 13 PSI
Following Components Require Engine Removal for service:
• Counterbalance Shaft or Bearings Polaris Premium Antifreeze
• Connecting Rod 2871534 - Quart
2871323 - Gallon
• Crankshaft
• Crankshaft Main Bearings
• Crankcase
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 ENGINE
Recommended Coolant Radiator Cap Pressure Test
Use only high quality antifreeze/coolant mixed with distilled
water in a 50/50 or 60/40 ratio, depending on freeze protection WARNING
required in your area.
CAUTION: Using tap water in the cooling system will lead to
Never remove radiator cap when engine is
a buildup of deposits which may restrict coolant flow and reduce
warm or hot. The cooling system is under
heat dissipation, resulting in possible engine damage. Polaris
pressure and serious burns may result.
Premium 60/40 Antifreeze/Coolant is recommended for use in
Allow the engine and cooling system to cool
all cooling systems and comes pre-mixed, ready to use.
before servicing.

1. Remove radiator pressure cap and test using a cap tester

Radiator (commercially available).

2. The radiator cap relief pressure is 13 lbs. Replace cap if it

does not meet this specification.

Thermostat Water
Pump Radiator Cap

Cylinder Cylinder
Head

Cooling System Pressure Test

1. Lift up the front hood.

2. Remove the pressure cap from the radiator and pressure test
the cooling system using a commercially available tester.

3. The system must retain 10 psi for five minutes or longer.

If pressure loss is evident within five minutes, check
radiator, all cooling system hoses and clamps and water
pump seal for leakage.

Coolant Flow Diagram

Surge Tank

From
Thermostat Housing

Radiator
To Water Pump

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 ENGINE
Cooling System Exploded View

Radiator Inlet Hose

Engine Outlet Hose

Engine Inlet Hose

Radiator Outlet Hose

3
Fan Radiator Cap
Surge Tank

Radiator

Shroud

Drain Plug

Cooling System Bleeding Procedure 1. Place the vehicle in Neutral and set the parking brake.

WARNING CAUTION

Always wear safety glasses and proper shop Be sure the engine has cooled and there is no
clothing when performing the procedures in this pressure built up in the cooling system before
manual. Failing to do so may lead to possible removing the radiator cap. The coolant may be
injury or death. hot and could cause severe injury or burns.

2. Remove radiator cap (A) and top off coolant.

CAUTION
3. Remove surge tank fill cap (B) and fill the surge tank to the
Use caution when performing these procedures. full line.
Coolant may be hot and may cause
severe injury or burns.

NOTE: If the coolant level is LOW in the radiator, or

B
if there are leaks in the system, the coolant system A
will not draw coolant from the reservoir tank.

NOTE: Use this procedure when a unit overheats

and no apparent leaks in the cooling system are
found.

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 ENGINE
4. Elevate the driver’s side of the vehicle 20” (50.8 cm) off 8. Add Polaris Premium Antifreeze to the radiator if the level
the ground so the thermostat housing is at the highest point goes down.
on the cylinder head. This will allow any trapped air to
accumulate near the thermostat housing bleed screw. 9. Tighten the bleed screw to 70 ± 10 in.lbs. (8 ± 1.13 Nm) on
the thermostat housing and properly install the radiator cap.

CAUTION
WARNING
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this Be sure to install the radiator cap before
service procedure. shutting off the engine.
Coolant may spit out of the radiator.

10. Stop the engine and let cool, top off the radiator filler neck
with coolant. If you hear or see a “glug” at the filler neck
or there is a dropping of the coolant level, indicating that
coolant has been pulled into the system. Fill the surge tank
only after you have completely filled the cooling system at
the radiator filler neck.

11. Repeat this procedure, if overheating still occurs.

20” (50.8 cm)

5. Start the engine and let it idle for 5-10 minutes or until the
thermostat opens and allows coolant to flow through the
system.

6. Squeeze the coolant lines by hand to help purge the system

of air.

7. Slightly loosen the bleed screw (C) on the thermostat

housing to allow the trapped air to escape. If no air is
present, a steady stream of coolant will stream out. If air
is present, the screw will bubble and sputter as the air
escapes.
Top LH Side
of Engine
C

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 ENGINE

Valve Cover Removal - 6x6 Models 5. Remove the heat shield shown below and loosen the
(Engine Installed) exhaust mounts.

The RANGER 6x6 models have a different engine mounting

system that makes it more difficult to access and remove the Loosen Remove
engine valve cover. Use the procedure provided in this section
of the chapter to remove the valve cover and allow for engine
top-end component service.

1. Remove the seat base.

2. Remove the clamp from the valve cover breather hose and 3
remove the hose and valve cover vent.
Valve Cover
Screws (7)

Breather Hose
6. Remove the upper engine mount.
Vent
7. Loosen the lower engine mount bolts, but DO NOT
completely remove them.

8. Remove the front engine mount bolts from the engine case.

NOTE: You may need to support the engine during

this step by using a jack or by using wooden blocks
between the engine and frame.
3. Remove the 7 screws that retain the valve cover.
Upper Mount
4. Remove the front dog house cover located in the floor panel
of the RANGER. The valve cover will have to be removed
through the dog house.

Floor Panel Dog House Remove

Cover

Remove

Lower Mount

Loosen Front Mount

9. Move the engine to allow the valve cover to be removed

through the dog house cover hole.

10. To reinstall, reverse steps 1-9. Torque all bolts to

specification as listed earlier in this chapter.

NOTE: It may be necessary to use a pry bar to get

the bolts back in during reassembly.

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 ENGINE
Engine Removal 12. Disconnect the air intake hose (D) from the air box and
remove the air intake hose.

WARNING C
B
Always wear safety glasses and proper shop
clothing when performing the procedures in this
manual. Failing to do so may lead to possible A
injury or death.

1. Clean work area.

2. Thoroughly clean the engine and chassis.

D
3. Disconnect battery (-) negative cable.

4. Remove the following parts as required:

13. Disconnect the Throttle Position Sensor at the electrical
• Seat connector (E). Remove the clamps that secure the throttle
body (F) to the air intake boot and engine intake boot.
• Storage unit under driver seat (Refer to chapter 5)
Remove the throttle body (F). Insert a shop towel into the
5. Remove middle dog house cover and remove exhaust pipe engine intake to prevent dirt from entering the intake port.
bolts.
E

14. Relieve the fuel pressure in the fuel rail (refer to Chapter 4,
6. Remove springs from exhaust pipe and remove pipe. “FUEL INJECTION”) for proper procedure. Carefully
remove the fuel rail (G) and injectors.
7. Refer to PVT System in Chapter 6 to remove outer clutch
cover, drive belt, drive clutch, driven clutch, and inner 15. Remove the spark plug high tension leads (H).
cover.

8. Drain coolant and engine oil. G

9. Remove the air breather line (A).

10. Remove PVT exhaust duct (B).

11. Remove the exhaust shield (C).

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 ENGINE
16. Remove the crank position sensor (I) located on the mag NOTE: Use caution when lifting the engine out of
cover. frame. Use an engine lift or other means if the engine
is too heavy to be lifted manually.
I

17. Disconnect the coolant temperature sensor (J) from the left
side of the cylinder.

J 22. For engine installation, reverse procedures.

Engine Installation Notes

After the engine is installed in the frame, review this checklist
and perform all steps that apply:

General Items

1. Install previously removed components using new gaskets,

seals, and fasteners where applicable.

18. Disconnect the coolant hoses. Properly dispose of any NOTE: Properly route all electrical harnesses and
antifreeze from the engine or hoses. re-attach any fasteners or protective tubing. Check
for any possible rubbing points of electrical wires.
19. When removing starter cables, note and mark ground cable
and positive (+) cable mounting angle and locations. 2. Perform regular checks on fluid levels, controls, and all
Remove the cables. important areas on the vehicle as outlined in the daily pre-
ride inspection checklist (refer to Chapter 2 or the Owner's
20. Remove all engine mount nuts and / or engine mount plates. Manual).
21. With all hoses and wires disconnected, the engine can be PVT System
pulled straight out of the chassis.
1. Adjust center distance of drive and driven clutch.
NOTE: Rotating the engine to the left 90 degrees (Chapter 6)
(valve cover facing left), may ease engine removal.
2. Adjust clutch offset, alignment, and belt deflection.
(Chapter 6)

3. Clean clutch sheaves thoroughly and inspect inlet and

outlet ducts for proper routing and sealing. (Chapter 6)

Transmission

1. Inspect transmission operation and adjust linkage if

necessary. Refer to Chapter 2 and Chapter 8.

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 ENGINE
Exhaust Engine Lubrication Specifications
1. Replace exhaust gaskets. Seal connections with high temp
silicone sealant.
=
2. Check to be sure all springs are in good condition.
Capacity - Approximately 2 U.S. Quarts (1.9 l)
Bleed Cooling System
Oil Type - Polaris PS-4 PLUS 2W-50 Synthetic
NOTE: Follow coolant bleeding procedure outlined
earlier in this chapter Filter Wrench - PV-43527 or equivalent
Engine Break-In Period
- Oil Pressure Specification -
The break-in period for a Polaris RANGER engine is defined as 35-39 PSI @ 5500 RPM, Polaris 2W-50
the first 25 hours of operation, or the time it takes to use 2 full Synthetic, Engine at operating temperature.
tanks of gasoline. No single action on your part is as important
as a proper break-in period. Careful treatment of a new engine
will result in more efficient performance and longer life for the
engine. Perform the following procedures carefully: Oil Pressure Test
1. Remove blind plug/sender from left side of crankcase.
CAUTION 2. Insert a 1/8 NPT oil pressure gauge adaptor into the
crankcase and attach the gauge.
Use only Polaris PS-4 PLUS 2W-50 Synthetic
engine oil or an equivalent. 3. Start engine and allow it to reach operating temperature,
Never substitute or mix oil brands. monitoring gauge indicator.
Serious engine damage and voiding of
warranty can result. NOTE: Use only Polaris PS-4 PLUS 2W-50 Synthetic
Do not operate at full throttle or high speeds for Engine Oil.
extended periods during the first three hours of
use. Excessive heat can build up and cause
damage to close fitted engine parts.
Oil Pressure at 5500 RPM (Engine Hot):
Standard: 39 PSI
1. Fill fuel tank with unleaded or leaded fuel which has a Minimum: 35 PSI
minimum pump octane number of 87= (R+ M)/2.

2. Check oil level indicated on dipstick. Add oil if necessary

(Refer to Chapter 2, “Engine Oil Level” ).

3. Drive slowly at first to gradually bring engine up to

operating temperature.

4. Vary throttle positions. Do not operate at sustained idle or

sustained high speed.

5. Perform regular checks on fluid levels, controls and all

important bolt torques.

6. Pull only light loads during initial break-in.

7. Change oil and oil filter after break-in period at 25 hours.

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 ENGINE
Oil Flow Chart
This chart describes the flow of oil through the 700 engine. Beginning in the crankcase sump, the oil is drawn through an oil galley
to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained
in the filter allows oil to bypass the filter element. At this point, the oil is supplied to the main oil galley through a crankcase passage.
Oil is then diverted three ways from the main oil galley, with the first path entering the camshaft bores, onto the rear balance shaft
journal and then draining back into the crankcase sump. The second oil path from the main oil galley feeds the lifter bores and then
drains back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also
to the front balance shaft journal and onto the crankcase sump. The oil pressure switch is fed off the main oil galley.

3.21

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 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

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 ENGINE
Rocker Arms 5. If the push rod (A) is visibly bent, it should be replaced.

1. Mark or tag rocker arms in order of disassembly to keep

them in order for reassembly. A

Cylinder Head Removal

2. Inspect the wear pad at the valve end of the rocker arm for 1. Loosen the six cylinder head bolts evenly 1/8 turn each in
indications of scuffing or abnormal wear. If the pad is a criss-cross pattern until loose.
grooved, replace the rocker arm.
2. Remove bolts (A) and tap cylinder head (B) lightly with a
NOTE: Do not attempt to true this surface by soft face hammer until loose. CAUTION: Tap only in
grinding. reinforced areas or on thick parts of cylinder head casting
to avoid damaging the head or cylinder.
3. Check the rocker arm pad and fulcrum seat for excessive
wear, cracks, nicks or burrs. 3. Remove cylinder head (B) and head gasket (C) from the
cylinder (D).

Push Rods
1. Clean push rods (A) in a suitable solvent. Blow dry push
rods with compressed air.

2. Use compressed air to confirm the oil passage is clear in the

center of the push rod.

A
WARNING

Always wear safety glasses when working with

compressed air to prevent personal injury. B
3. Check the ends of the push rods (A) for nicks, grooves,
roughness or excessive wear.
C
4. The push rods (A) can be visually checked for straightness
while they are installed in the engine by rotating them with
the valve closed. Push rods can also be checked with a dial D
indicator or rolled across a flat surface to check for
straightness.

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 ENGINE
Cylinder Head Inspection Valve Seal / Spring Service (On Engine)
Thoroughly clean cylinder head surface to remove all traces of NOTE: The following procedure is only for servicing
gasket material and carbon. the top end of the valve train when replacing valve
springs or replacing valve seals.

CAUTION In some cases the valve train can be serviced while the cylinder
head is still on the engine. Keep all parts in order with respect
Use care not to damage sealing surface. to their location in the cylinder head.

WARNING
Cylinder Head Warp
1. Lay a straight edge (A) across the surface of the cylinder Wear eye protection or a face shield during
head (B) at several different points and measure warp by cylinder head disassembly and reassembly.
inserting a feeler gauge between the straight edge and the
cylinder head surface. If warp exceeds the service limit, 1. Having already removed the valve cover, rocker arms and
replace the cylinder head. pushrods, align the cylinder to be worked on at top dead
center (TDC). Install the Valve Pressure Hose (PU-
A 45652) into the spark plug hole. Hook the hose to an air
compressor and supply 50 to 100 psi to the hose. This will
seat the valves during valve spring removal. Do not
remove air from the hose at anytime until reassembly is
completed.

2. Using the Valve Spring Compressor (PU-45257),

compress the valve spring and remove the valve keepers.
B
NOTE: A small parts magnet (A) can aid in the
removal of the retainers (B).
Measure at different
points on the surface.
B

= In. / mm.

Cylinder Head Warp Limit: A

.004" (.1016 mm) max

PU-45257
NOTE: To prevent damage to the valve seals, do not
compress the valve spring more than is needed to
remove the valve keepers.

3. Remove spring retainer and spring.

4. The valve seals are now serviceable.

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 ENGINE
Cylinder Head Disassembly 4. Remove valve guide seals.

1. 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.

5. Mark the valves with a white pen. Remove the valves from
the cylinder head. This will ensure that the valves are
properly placed during engine reassembly.

Mark the Valves 3

2. Place the hydraulic lifters (C), pushrods (D), and rocker

arms (E) in a safe, clean area.

C D

3. Measure free length of spring with a Vernier caliper.

Compare to specifications. Replace spring if measurement
is out of specification.

Valve Spring
Free Length

= In. / mm.

Valve Spring Free Length:

Std: 1.735" (44.069 mm)

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 ENGINE
Valve Inspection
1. Remove all carbon from valves with a soft wire wheel or
brush.
= In. / mm.
2. 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. Intake: 0.2356" + 0.00039"
(5.985 + 0.01 mm)
Exhaust: 0.2351" + 0.00039"
(5.972 + 0.01 mm)

6. Measure valve guide (C) inside diameter at the top middle

and end of the guide using a small hole gauge and a
micrometer. Measure in two directions.

3. Check end of valve stem for flaring, pitting, wear or damage

(A).

B
= In. / mm.

4. Inspect split keeper groove for wear or flaring of the keeper Valve Guide I.D.:
seat area (B). 0.23672" + 0.000295"
NOTE: The valves can be re-faced or end ground, if (6.0617 + 0.0075 mm)
necessary. They must be replaced if extensively
worn, burnt, bent, or damaged. 7. Subtract valve stem measurement from the valve guide
measurement to obtain stem to guide clearance. NOTE:
5. Measure diameter of valve stem with a micrometer in three The valve guides cannot be replaced. Be sure to measure
places, then rotate 90 degrees and measure again (six each guide and valve combination individually.
measurements total). Compare to specifications.

Measure valve stem in several places.

Rotate the valve 90 degrees and measure
for wear.

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 ENGINE
Combustion Chamber NOTE: Valve seat width and point of contact on the
valve face is very important for proper sealing. The
1. Clean all accumulated carbon deposits from combustion valve must contact the valve seat over the entire
chamber and valve seat area with carbon cleaner and a soft circumference of the seat, and the seat must be the
plastic scraper. proper width all the way around. If the seat is
uneven, compression leakage will result. If the seat
IMPORTANT: Do not use a wire brush, metal scraper, is too wide, seat pressure is reduced, causing
or abrasive cleaners to clean the bottom of the carbon accumulation and possible compression
cylinder head. Extensive damage to the cylinder head loss. If the seat is too narrow, heat transfer from
may result. Wear safety glasses during cleaning. valve to seat is reduced. The valve may overheat
and warp, resulting in burnt valves.
Combustion Area 3

1. Install pilot into valve guide.

Valve Seat Reconditioning 2. Apply cutting oil to valve seat and cutter.

NOTE: Polaris recommends that the work be done 3. Place 46° cutter on the pilot and make a light cut.
by a local machine shop that specializes in this area.

NOTE: The cylinder head valve guides cannot be

replaced.

WARNING

Wear eye protection or a face shield during

cylinder head disassembly and reassembly.

Valve Seat Inspection

Inspect valve seat in cylinder head for pitting, burnt spots,
roughness, and uneven surface. If any of the above conditions
exist, the valve seat must be reconditioned. If the valve seat is
cracked the cylinder head must be replaced.

Follow the manufacturers instructions provided with the valve

seat cutters in the Cylinder Head Reconditioning Kit (PN
2200634). Abrasive stone seat reconditioning equipment can
also be used. Keep all valves in order with their respective seat.

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 ENGINE
4. Inspect the cut area of the seat: NOTE: When using an interference angle, 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. Look for an even and
seat, rotate the pilot 180° and make another light cut. continuous contact point all the way around the
valve face (A).
* If the cutter now contacts the uncut portion of the seat, check
the pilot. Look for burrs, nicks, or runout. If the pilot is bent it B
must be replaced.

* If the contact area of the cutter is in the same place, the valve
guide is distorted from improper installation
A
* If the contact area of the initial cut is greater than 75%,
continue to cut the seat until all pits are removed and a new seat
surface is evident. NOTE: Remove only the amount of material
necessary to repair the seat surface. Proper Seat Contact
on Valve Face
5. To check the contact area of the seat on the valve face, apply
a thin coating of Prussian Blue™ paste to the valve seat. If
using an interference angle (46°) apply black permanent Bottom 60° Seat 45°
marker to the entire valve face (A). Top 30°

6. Insert valve into guide and tap valve lightly into place a few
times.

7. Remove valve and check where the Prussian Blue™ Seat

indicates seat contact on the valve face. The valve seat Width
should contact the middle of the valve face or slightly
above, and must be the proper width.

* If the indicated seat contact is at the top edge of the valve face
and contacts the margin area (B) it is too high on the valve face.
Use the 30° cutter to lower the valve seat.

* If too low, use the 60° cutter to raise the seat. When contact
area is centered on the valve face, measure seat width.
= In. / mm.
* If the seat is too wide or uneven, use both top and bottom
cutters to narrow the seat. Valve Seat Width:
Intake Std: .028" (.7 mm)
* If the seat is too narrow, widen using the 45° cutter and re- Limit: .055" (1.4 mm)
check contact point on the valve face and seat width after each Exhaust Std: .039I (1.0 mm)
cut. Limit: .071" (1.8 mm)

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 ENGINE
8. Clean all filings from the area with hot soapy water. Rinse Cylinder Head Reassembly
and dry with compressed air.
NOTE: Assemble the valves one at a time to
9. Lubricate the valve guides with clean engine oil, and apply maintain proper order.
oil or water based lapping compound to the face of the
valve. 1. Apply engine oil to valve guides and seats.

NOTE: Lapping is not required with an interference 2. Coat valve stem with molybdenum disulfide grease or
angle valve job. 2W-50 Synthetic engine oil.

10. Insert the valve into its respective guide and lap using a 3. Install valve carefully with a rotating motion to avoid
damaging valve seal.
lapping tool or a section of fuel line connected to the valve
stem.
4. Valve seals should be installed after the valves are in the
3
head to avoid valve seal damage. Install new valve seals
on valve guides.

5. Dip valve spring and retainer in clean engine oil and install.

6. Place retainer on spring and install Valve Spring

Compressor (PU-45257). Install split keepers with the gap
even on both sides.

NOTE: A small magnet can be used to aid in the

installation of the keepers.
PU-45257

11. Rotate the valve rapidly back and forth until the cut sounds
smooth. Lift the valve slightly off of the seat, rotate 1/4
turn, and repeat the lapping process. Do this four to five
times until the valve is fully seated, and repeat process for
the other valve(s).

12. Thoroughly clean cylinder head and valves.

7. Repeat procedure for remaining valves. When all valves

are installed, tap lightly with soft faced hammer on the end
of the valves to seat the split keepers.

NOTE: To prevent damage to the valve seals, do not

compress the valve spring more than necessary to
install the keepers.

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 ENGINE
Valve Sealing Test Valve Lifter Removal / Inspection
1. Clean and dry the combustion chamber area (A). 1. Remove the valve lifters by reaching into the crankcase
and pushing the lifter up through the lifter bore by hand.
A
2. Thoroughly clean the lifters in cleaning solvent and wipe
them with a clean, lint-free cloth.

3. Mark the lifters with a white pen if using the lifters for
reassembly. This will ensure that the lifters are properly
placed during engine reassembly.

Mark Hydraulic Lifter

2. Pour a small amount of clean solvent onto the intake port

and check for leakage around each intake valve. The valve
seats should hold fluid with no seepage.

3. Repeat for exhaust valves by pouring fluid into exhaust

port.

Cylinder Removal 4. Check the lifters for wear or scores.

1. Follow engine disassembly procedures to remove rocker 5. Check the bottom end of lifter to make sure that it has a
cover and cylinder head. slight convex.

2. Tap cylinder (A) lightly with a rubber mallet in the 6. If the bottom surface has worn flat, it may be used with the
reinforced areas only until loose. original camshaft only.

3. Rock cylinder forward and backward while lifting it from

the crankcase, supporting pistons and connecting rods.
Support pistons with Piston Support Block (PN 2870390).

Inspect Hydraulic Lifter

NOTE: Lifters that are scored, worn, or if the bottom

is not smooth should be replaced with new lifters
and cam as an assembly. If replacing the lifters, the
camshaft should also be replaced.

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 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
1. 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. oil ring land of the piston.

To Remove:
A) Remove the top rail first followed by the bottom rail.
B) Remove the expander.

Compression B
Rings 3
Oil Ring

NOTE: If the pistons are to be reused, reassemble

the pistons in the same cylinder and direction from
which they were removed.

NOTE: New pistons are non-directional and can be

placed in either cylinder.

2. Remove piston circlip and push piston pin out of piston. If

necessary, heat the crown of the piston slightly with a
propane torch. CAUTION: Do not apply heat to the piston
rings. The ring may lose radial tension.

3. Remove top compression ring:

*Using a piston ring pliers: Carefully expand ring and lift it off
the piston. CAUTION: Do not expand the ring more than the
amount necessary to remove it from the piston, or the ring may
break.

*By hand: Placing both thumbs as shown, spread the ring open
and push up on the opposite side. Do not scratch the ring lands.

4. Repeat procedure for second ring.

5. Remove the oil control ring.

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 ENGINE
Cylinder Inspection 3. Inspect cylinder for wear, scratches, or damage.

1. Remove all gasket material from the cylinder sealing

surfaces.
2. 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.

4. Inspect cylinder for taper and out of round with a

B telescoping gauge or a dial bore gauge. Measure in two
different directions, front to back and side to side, on three
Measure at different different levels (1/2, down from top, in the middle, and 1/
points on surface. 2, up from bottom). Record measurements. If cylinder is
tapered or out of round beyond .002", the cylinder must be
replaced.

1/2” Down From Top of Cylinder

B

1/2” Up From Bottom

= In. / mm.

Cylinder Warp: .004" (0.1 mm) Max.

= In. / mm.

Cylinder Taper Limit:

.002" (9.05mm) Max.

Cylinder Out of Round:

Limit: .002" (.0 mm) Max.

700 Standard Bore Size

(Both Cylinders): 3.1496" (80 mm)

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 ENGINE
Cylinder Hone Selection And Honing If cylinder wear or damage is excessive, it will be necessary to
Procedure replace the cylinder. The cylinders are lined with a nicasil
coating and are not repairable. Hone only enough to de-glaze
Cylinders may be wet or dry honed depending upon the hone the outer layer of the cylinder bore.
manufacturer’s recommendations. Wet honing removes more
material faster and leaves a more distinct pattern in the bore.

CAUTION

A hone which will straighten as well as remove

material from the cylinder is very important. 3
Using a common spring loaded glaze breaker
for honing is not advised for nicasil cylinders.
Polaris recommends using a rigid hone or arbor
honing machine. Cylinders may be wet or dry Example of Cross Hatch Pattern
honed depending upon the hone manufacturer's
recommendations.
Wet honing removes more material faster and IMPORTANT: Clean the cylinder after honing
leaves a more distinct pattern in the bore.
If cylinder wear or damage is excessive, it will be necessary to
replace the cylinder. The cylinders are lined with a nicasil
coating and are not repairable. Hone only enough to de-glaze
Honing To Deglaze the outer layer of the cylinder bore.
A finished cylinder should have a cross-hatch pattern to ensure
piston ring seating and to aid in the retention of the fuel/oil
mixture during initial break in. Hone cylinder according to hone Cleaning the Cylinder After Honing
manufacturer's instructions, or these guidelines: It is very important that the cylinder be thoroughly cleaned after
honing to remove all grit material. Wash the cylinder in a
• Honing should be done with a diamond hone. Cylinder
solvent, then in hot, soapy water. Pay close attention to areas
could be damaged if the hone is not hard enough to
where the cylinder sleeve meets the aluminum casting (transfer
scratch the nicasil lining.
port area). Use electrical contact cleaner if necessary to clean
• Use a motor speed of approximately 300-500 RPM, run these areas. Rinse thoroughly, dry with compressed air, and oil
the hone in and out of the cylinder rapidly until cutting the bore immediately with Polaris Lubricant.
tension decreases. Remember to keep the hone drive
shaft centered (or cylinder centered on arbor) and to
bring the stones approximately 1/2, (1.3 cm) above and
below the bore at the end of each stroke.

• Release the hone at regular intervals and inspect the

bore to determine if it has been sufficiently de-glazed,
and to check for correct cross-hatch.
NOTE: Do not allow cylinder to heat up during
honing.

• After honing has been completed, inspect cylinder for

thinning or peeling.

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 ENGINE

Piston-to-Cylinder Clearance 2. 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.

Subtract this measurement from the maximum cylinder

measurement obtained in Step 5.

5 mm

Piston Pin Measurement Locations

Piston
Piston Pin
Piston Pin O.D.:
See “700 EFI Engine Service
Piston to Cylinder Clearance: Specifications” on page 3.11
See “700 EFI Engine Service
Specifications” on page 3.11 3. Measure connecting rod small end ID.

Piston O.D.:
See “700 EFI Engine Service
Specifications” on page 3.11

Piston / Rod Inspection

1. Measure piston pin bore.

Connecting Rod Small End I.D.:

See “700 EFI Engine Service
Specifications” on page 3.11

Piston Pin Bore:

See “700 EFI Engine Service
Specifications” on page 3.11

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 ENGINE
4. Measure piston ring to groove clearance by placing the ring 3. 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. specified range.
NOTE: Always check piston ring installed gap after
Piston
re-boring a cylinder or when installing new rings. A
re-bored cylinder should always be scrubbed
Ring thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with oil immediately
to remove residue and prevent rust.

Starter Drive Bendix Removal / Inspection 3

Feeler Gauge 1. Remove stator housing bolts and remove housing.
2. Remove the flywheel nut and washer. Install Flywheel
Puller (PN 2871043) and remove flywheel.

See “700 EFI Engine Service NOTE: Do not thread the puller bolts into the
Specifications” on page 3.11 flywheel more than 1/4, or stator coils may be
damaged.
3. Remove starter bendix assembly (A). Note the thrust
washers located on both sides of the bendix.
Piston Ring Installed Gap
1. Place each piston ring (A) inside cylinder (B) using piston
to push ring squarely into place as shown. A

B 25-50 mm

A
4. Inspect the thrust washer for wear or damage and replace
if necessary.
5. After the bendix is removed, remove the two bolts retaining
Piston Ring Installed Gap the starter. Tap on the starter assembly (B) with a soft faced
See “700 EFI Engine Service mallet to loosen the starter from the crankcase.
Specifications” on page 3.11
B
NOTE: Ring should be installed with the mark facing
upward.
2. Measure installed gap with a feeler gauge (C) at both the
top and bottom of the cylinder.
IMPORTANT: A difference in end gap indicates
cylinder taper. The cylinder should be measured for
excessive taper and out of round.

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 ENGINE
6. Inspect gear teeth on starter drive (A). Replace starter drive
if gear teeth are cracked, worn, or broken.

7. Inspect the bendix bushing (C) in the mag cover for wear.
Replace as needed.

C 2871043 A

4. Use caution when removing the wire holddown (B) and the
stator assembly (D). Do not tap or bump the gear /stator
housing cover or the stator. This could cause the seal
around the gear/stator housing cover and the crankcase to
break, causing a leak.

Flywheel / Stator Removal / Inspection

1. Remove stator housing bolts and remove housing.

E D
B
Remove Stator
Cover 5. Remove the bendix (E) if necessary.

Engine Crankcase Disassembly / Inspection

1. Remove the stator cover (A) and water pump cover (B).
2. Remove flywheel nut and washer.

3. Install Flywheel Puller (PN 2871043) and remove flywheel

(A).
B
CAUTION

Do not thread the puller bolts into the flywheel

more than 1/4, or stator coils may be damaged.

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 ENGINE
2. Remove the nylok nut (C), washer (D), and water pump 5. 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. does not have to be removed at this point.

I
E

3
G
D H
C
6. Remove the gear/stator housing bolts and remove the gear/
3. Remove flywheel nut and washer. stator housing cover (J) and gasket from the crankcase. Be
sure to catch the excess oil from the crankcase.
4. Install Flywheel Puller (PN 2871043) and remove flywheel
(F).

CAUTION

Do not thread the puller bolts into the flywheel

more than 1/4, or stator coils may be damaged.

7. Note the positions of the gears in the photo.

Camshaft Gear
2871043 F

Crank Gear

Counterbalance Gear

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 ENGINE
8. 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.
K Water Pump Gear
The springs could cause injury or become lost
Timing Marks should they pop out.

12. Remove all three springs using one of the tapered pins from
the Tapered Pins (PU-45497-1).

N
M

NOTE: If replacing one of the gears, it is

recommended that all of the gears be replaced. A
gear kit is available.
9. Use the Cam Gear Tooth Alignment Tool (PU-45497-2)
(O) to align the cam split gear assembly. With the split gear
PU-45497-1
aligned, remove the bolt and cam gear assembly.
NOTE: Install the Cam Gear Tooth Alignment Tool
(PU-45497-2) into the assembly hole counter
clockwise from the timing mark as shown. 13. With a white marking pen, accent the timing mark on the
gear that contains the springs.
10. Inspect the cam gear teeth and check to make sure there is
spring tension offsetting the teeth between the two gears.
If there is no tension, check the springs inside of the cam
gear assembly.

3 Loaded Springs

Accent Timing Marks

11. The cam gear assembly contains three loaded springs. To

open the cam gear assembly:
* Place the cam gear on a flat surface with the timing mark side
facing up.
* While holding both gears together, lightly work a small
flathead screwdriver between the two gears.
* Remove the top gear. The springs should stay in place.

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 ENGINE
14. Inspect the gear teeth and the three tabs on the gears for To Assemble:
wear.
* Hold the spring with one finger.
* Start the pointed end of the tapered pin into the cam gear hole
Inspect Teeth & Tabs and slowly push the dowel through the hole until the end of the
dowel is almost flush with the spring.
* Perform this procedure with all three tapered pins.
* Do not push the pins too far through or the springs will pop
out.
NOTE: Do not remove the tapered pins at this time.
17. Note in the photograph that the Tapered Pins (PU-45497-
3
1) are below flush with end of the springs. This helps to
align the three gear tabs during the next step.

Replace 3 Springs

15. Install the new springs into the grooves of the cam gear.

Install Springs

PU-45497-1

Cam Gear Spring Installation Tool Kit:

(PU-45497)
Tapered Pins:
(PU-45497-1)
16. Insert the pointed dowels from the Tapered Pins (PU- Cam Gear Tooth Align Tool:
45497-1) into the cam gear. (PU-45497-2)

18. Line up the two gears using the timing marks and the three
gear tabs that were referenced earlier. Push the gears back
together, using both hands and hold securely.

Align Timing Marks

PU-45497-1

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 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. rotate the camshaft so the flat side of the camshaft faces the
balance shaft gear.

PU-45498

20. After the tapered pins are removed, be sure the cam gear NOTE: This Cam Spanner Wrench (PU-45498) is
assembly is held together tightly. Place the cam gear only needed to rotate the camshaft when the entire
assembly on a flat surface. Use the Cam Gear Tooth valve train is assembled. If the rocker arms are
Alignment Tool (PU-45497-2) to align the teeth of the cam removed, the cam-shaft can be turned by hand.
gears, as shown in the picture.
22. Remove the bolt and nut from the balance shaft gear. Try
NOTE: Install the Cam Gear Alignment Tool (PU- to remove the balance shaft gear. If the gear does not come
45497-2) into one assembly hole counter clockwise off manually, use the Flywheel Puller (PN 2871043) to
from the timing mark. remove the balance shaft gear.

2871043

PU-45497-2

NOTE: For ease of installing the Cam Gear

Alignment Tool (PU-45497-2), use a twisting motion
when pushing down on the tool.

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 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. If the crankshaft gear is damaged, wrench. Pull out the pump.
remove the crankshaft gear with the Flywheel Puller
(PN 2871043).
S

Q
3

27. Inspect the oil pump rotors for wear. Mark the rotors with
a white pen to ensure, upon reassembly, that the correct
sides of the rotors are installed and mesh with the same
24. Install the two puller bolts (R). Tighten the puller bolts up
edges as previously installed.
so that the bolts are at equal length.
Mark Rotors
R

NOTE: If replacing the old rotors, new replacement

25. Install the Flywheel Puller (PN 2871043) and remove the rotors will fit into the original oil/water pump
crankshaft gear, if needed. housing.
28. Use a feeler gauge to measure the clearance between the
2871043 two rotors. Measure the gap between the two rotor tips as
shown below. The clearance should not exceed 0.006"
(0.15 mm).

Max Tip Clearance

0.006” (0.15 mm)

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 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.

Press Off Gear

CAUTION
30. Reinstall the valve (dowel chamfered end first). Install the
Wear appropriate safety gear during this
spring, washer, and bolt. Torque to specification .
procedure. Protective gloves, clothing and eye
wear are required.
22 ± 2 ft. lbs.
(30 ± 3 Nm). 32. Remove the snap ring from the assembly. Place the housing
in a support and press out the bearing/shaft assembly.

Press out shaft

and bearing
Chamfer
assembly.
End First

Bearing

=T
22 ± 2 ft. lbs. (30 ± 3 Nm)

NOTE: Be sure to place the tapered end of the valve Retaining Ring
(dowel) in first. If the valve is installed incorrectly,
oil pressure and oil priming problems will occur.
33. Place the shaft in a press to remove the bearing.

Press Off Bearing

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 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. Install retaining Tap on the reinforced areas on the cases using soft hammer.
ring. Carefully separate the two crankcase halves.

Press Bearing / Shaft Separate

Assembly using Crankcase Halves
outer race only

36. Press gear onto shaft while supporting the housing. NOTE: Only remove the oil baffle if the baffle is
damaged. When removing the oil baffle bolts, use a
heat gun to heat the bolts and loosen the Loctite™.
This will prevent any possible damage to the bolts or
to the crankcase casting.
39. Remove and clean oil pick up (V) and oil baffle weldment
(W).

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 ENGINE
40. Remove balance shaft and crankshaft. Camshaft Inspection
1. Thoroughly clean the cam shaft.
2. Visually inspect each cam lobe for wear or damage.
3. Measure height of each cam lobe using a micrometer.
Compare to specification.

41. Remove and inspect crankshaft main journal bearings for

abnormal wear. It is recommended to replace the
bearings anytime the engine is disassembled.
Cam Lobe Height

= In. / mm.

Cam Lobe Height

(Intake & Exhaust):
Std: 1.3334" (33.8674 mm)

4. Measure camshaft journal outside diameters (O.D.).

C
B
A

= In. / mm.

Camshaft Journal O.D. :

A. (Mag): 1.654" ± .00039" (42 ± .010 mm)
B. (Ctr.): 1.634" ± .00039" (41.50 ± .010 mm)
C. (PTO): 1.614" ± .00039" (41 ± .010 mm)

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 ENGINE
5. Measure ID of camshaft journal bores. ENGINE REASSEMBLY
Crankcase Reassembly
= In. / mm.

Camshaft Journal Bore I.D.:

CAUTION
(Mag): 1.656" ± 0.00039" (42.07± 0.010 mm)
(Ctr.) 1.637" ± 0.00039" (41.58 ± 0.010 mm) After any reassembly or rebuild, the engine
(PTO) 1.617" ± 0.00039" (41.07 ± 0.010 mm) must be primed using the Oil Priming Adapter
(PU-45778) and a 3/4-full oil filter before initial
start-up (see “Oil Pump Priming”).
6. Calculate oil clearance by subtracting journal O.D.s from
journal bore I.D.s. Compare to specification.
NOTE: Before assembly, clean bolts and bolt holes
3
with Primer N (PN 2874275) to remove any debris.
= In. / mm. This will ensure proper sealing when installing bolts.

1. Install oil pick up (A), if removed. Torque to specification.

Calculated Camshaft Oil Clearance:
Std: 0.0027" (.070mm)
Limit: .0039" (.10 mm)

NOTE: Replace camshaft if damaged or if any part is B

worn past the service limit.

NOTE: Replace engine block if camshaft journal A

bores are damaged or worn excessively.

2. Install oil baffle weldment (B). Torque to specification.

=T
Oil Baffle Weldment &
Oil Pick Up Bolt Torque:
60 ± 6 in. lbs. (6.8 ± 0.68 Nm)

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 ENGINE
3. Install the balance shaft. Inspect balance shaft clearance 6. Apply Crankcase Sealant (PN 2871557) to the top gearcase
(C) in both gearcase halves. Rotate balance shaft to ensure halve.
there is clearance between it and the oil baffle weldment.
NOTE: Do not apply sealant to cam relief hole (E).

7. Assemble the crankcase halves. Apply LocTite™ 242 (PN

NOTE: Always install new balance shaft bearings.
2871949) to the threads and pipe sealant to the bolt flanges.
4. Apply assembly lube to cam journals and balance shaft Torque bolts to specification following torque pattern at
bearing surfaces of the MAG case halve. Install camshaft beginning of this chapter.
and balance shaft.
=T
Crankcase Bolt Torque:
22 + 2 ft. lbs. (30 + 3 Nm)
Torque in sequence

8. Lubricate cam lobes and valve lifters with Moly Lube

Grease.

Apply Moly Lube Cam Lobes

5. Install crankshaft assembly and apply engine oil to crank

pins and rods (D). Apply assembly lube to the main
journals and bearings.

Lifters

9. Lubricate lifters with engine oil and install in the original

order as removed in disassembly. Apply Lubricant or Moly
Lube to the ends of the lifters.

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 ENGINE
NOTE: Always replace the camshaft and lifters as a 12. Orientate the piston rings on the piston before installation
set. into the cylinders. Set the gaps of the rings every 120°
(See Illustration Below).
1
Piston Ring
Orientation 2
3

1. Top Ring 2. Second Ring

3

3. Oil Ring
10. Lubricate connecting rods with 2W-50 synthetic 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. Install new cylinder gasket on crankcase. Align gasket on

the dowel pins for proper gasket alignment.

NOTE: To help align the pistons, slide a rod that is

close to the same diameter as the wrist pin holes to
properly align them in the cylinder.

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 ENGINE
14. Position cylinder and piston assemblies onto the connecting NOTE: New bolts have patch lock on the threads
rods and push the piston pins through the piston and and do not require Loctite™.
connecting rods.

Push in Piston Pins

15. Install the piston pin circlips. The circlip ends should be =T
installed at the 12 O'clock position.
Thrust Plate Screw Torque:
115 ± 12 in.lbs. (13 ± 1.35 Nm)

17. Assemble rotors as marked when disassembled. Use a

cleaner to remove the marks previously made on the rotors.

Line Up Marks

Piston Pin Cirlcip in

12 O’clock position

NOTE: While installing in piston circlips, cover all

engine passages. The clip could fall into the engine
during installation.

18. Apply assembly lube or oil to the rotors on the oil pump
shaft.
NOTE: The application of lubrication aids in priming
the oil pump during initial engine start up.

Lubricate Rotors

16. Install camshaft thrust plate (G) with new bolts. Torque
bolts to specification.

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 ENGINE
19. Align the bolt holes and install oil pump assembly into 21. Apply Loctite™ 242 (PN 2871949) to the crankshaft.
crankcase. Rotate the rotors in the housing during
installation, as this checks for binding if new rotors are
used.
NOTE: For assembly of the gears, the cam gear and
the crankshaft gear are stamped with “This Side
Out." This indicates the side of the gear that faces
outward or away from the case.

22. Before installing the crankshaft gear (I), heat the crankshaft
gear to 250° F (121°C) on a hot plate (J).

NOTE: Before assembly, clean the bolts and bolt

holes with Primer N (PN 2874275) to remove any I J
debris. This will ensure proper sealing when
installing bolts and new Loctite™.
20. Install oil pump housing bolts (H). The new bolts contain
patch lock, so Loctite™ is not needed on the new bolts.
Torque bolts to specification and follow the torque
sequence at beginning of the chapter.

CAUTION

The crankshaft gear is extremely hot! Severe

burns or injury can occur if the gear is not
handled with extreme care and caution. Follow
the procedure below to help ensure safety.

23. Use extreme caution when removing the crankshaft gear

NOTE: Occasionally spin the oil pump when from the hot plate. Use a pair of pliers and leather gloves
installing bolts to check for binding of the rotors. when handling the crankshaft gear.

=T
Oil Pump Bolt Torque:
84 ± 8 in.lbs. (9.50 ± 0.90 Nm)
* Torque in Sequence

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 ENGINE
24. Install the crankshaft gear (I) onto the crankshaft. 26. Use the Cam Gear Alignment Tool (PU-45497-2) to align
the teeth of the cam gear (M). Install the cam gear (M) (with
NOTE: For assembly of the gears, the cam gear and the Cam Gear Alignment Tool still in place) onto the
the crankshaft gear are stamped with This Side Out." camshaft. The timing marks on the camshaft gear should
This indicates the side of the gear that faces outward align with the keyway on the balance shaft gear.
or away from the case.
PU-45497-2

I
NOTE: If the timing mark on the camshaft gear does
not align properly, remove the camshaft gear and
tool. Use the Cam Spanner Wrench (PU-45498) to
rotate the cam to the proper position.
25. Install counter balance shaft gear (J) with new key, aligning
NOTE: Cam Spanner Wrench (PU-45498) is only
timing marks with crankshaft gear (I). Install washer and
needed to rotate the camshaft when the entire valve
bolt. Use the Gear Holder (PU-45838). Torque to
train is assembled.
specification.

J
I PU-45498

PU-45838

27. Reinstall the camshaft gear; so the timing marks are

=T properly aligned. Install the washer and bolt. Torque to
specification.
Balance Shaft Gear Bolt Torque:
22 ± 2 ft. lbs. (30 ± 3 Nm)

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NOTE: Be sure all of the timing marks are properly IMPORTANT: Due to seal design and construction,
aligned. seals MUST be installed DRY (no lubricant) during
assembly. Use of lubricants (oil, soapy water, etc.)
K Water Pump Gear will not allow the seal to wear-in and seal properly. Do
not touch seal surface or allow seal surface to come
Timing Marks in contact with contaminates during installation.
Thoroughly clean parts, tools and hands before
installation.

NOTE: To remove the water pump seal, the gear/

stator housing must be removed. The water pump
seal cannot be removed or installed with the gear/
stator housing attached to the engine. Shaft damage
3
N will occur.
M
NOTE: Install the water pump seal (N) with the seal
lip facing out (towards the crankcase). Use of a
hydraulic press is recommended for this procedure.
Timing Marks
29. Install a new crankshaft seal (P) into the gear/stator housing
cover. Use the Universal Driver Handle (PU-45543) and
the Main Seal Installer (PA-45483) to seat the crankshaft
seal into place.

PU-45543

=T
Counterbalance Gear and Camshaft
Gear Bolt Torque: PA-45483
22 ± 2 ft. lbs. (30 ± 3 Nm)

28. Before installing the gear / stator housing, replace the seals
in the cover. Install a new water pump seal (N) into the gear NOTE: Install the crankshaft seal (P) with the seal lip
/ stator housing. Use the Water Pump Mechanical Seal facing out (towards the crankcase).
Installer (PA-44995) to properly install the seal to the
correct depth in the cover.
P
PA-44995
O
PA
-4 4
99

N
5

Seal lip goes towards the crankcase.

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 ENGINE
30. Once the crankshaft seal is installed into the gear / stator 32. Before installing the gear/stator housing cover, install the
housing cover, set the direction of the paper lip by sliding Water Pump Seal Saver (PA-45401) onto the water pump
the Main Crankshaft Seal Saver (PA-45658) into the shaft.
crankshaft seal from the rubber lipped side to the paper lip
side (back to front). Remove the tool.

Important: Set the direction PA-45401

of the paper lip seal

PU-45658

33. Install a NEW gasket to the gear/stator housing cover and

crankcase. With the tools installed, carefully place the
31. Carefully install the tapered end of the Crankshaft Seal gear/stator housing cover over the protection tools.
Protection Tool (PA-45658) through the paper side of the
crankshaft seal (back to front). Leave the seal protector
installed in the crankshaft seal. Check the crankshaft seal
lips to verify they have not been rolled or damaged.

PU-45658

34. Apply Crankcase Sealant (PN 2871557) to the outside

edges of the crankcase halves (see arrows), where the
crankcases mate (see photos below). This helps to prevent
coolant leakage.

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 ENGINE
NOTE: Before assembly, clean the bolts and bolt
holes with Primer N (PN 2874275) to remove any
debris. This will ensure proper sealing when
installing bolts.

37. Install shaft seal with ceramic surface facing inward.

3
35. Install the gear/stator housing gasket onto he crankcase.

Gear / Stator
Housing Gasket

38. Install water pump impeller (P). Secure the impeller with
the washer and a new nylok nut (Q). Torque the nut to
specification.

36. Secure the gear / stator housing cover to the crankcase with
the cover bolts. Torque bolts in proper sequence to
specification. Remove seal protectors from the shaft ends
once the cover is secure.

=T
PA-45401
Water Pump Impeller Nut Torque:
108 ± 6 in. lbs. (6.8 ± 0.68 Nm)
PA-45658

=T
Gear/Stator Housing Bolt Torque:
96 ± 3 in. lbs. (10.85 ± 0.35 Nm)
*Torque in proper sequence

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 ENGINE
39. Install water pump cover (R) with new O-ring seal. Torque Flywheel / Stator Installation
bolts to specification in proper sequence (See front of this
chapter). NOTE: Before assembly, clean the bolts and bolt
holes with Primer N (PN 2874275) to remove any
debris. This will ensure proper sealing when
Install the O-ring dry, no lubricants
installing bolts.
1. Install stator assembly (S) and bolts. Torque bolts to
specification.
R 2. Install the wire hold down bracket (T). Install two new wire
hold down bolts. New bolts contain patch-lock. Torque
bolts to specification, following the proper bolt torque
sequence. Coat the stator wire grommet (U) with Nyogel™
Grease (PN 2871329).
NOTE: Verify stator wires are routed properly under
the wire hold down bracket.
96 ± 3 in. lbs.
(10.85 ± 1.35 Nm)
Replace 2 bolts with new bolts

=T
Water Pump Housing Bolt Torque:
96 ± 3 in. lbs. (10.85 ± 0.35 Nm)
*Torque in proper sequence

40. Sparingly apply Starter Drive Grease (PN 2871423) to the

starter drive. Install the starter bendix. T S
NOTE: There are thrust washers on both sides of U
starter drive.

=T
Stator Assembly Bolt Torque:
96 ± 3 in.lbs. (10.85 ± 0.35 Nm)

3. Install the flywheel, washer, nut, and key. Torque flywheel

nut to specification.

65 ± 7 ft. lbs.
(88 ± 9.50 Nm)

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 ENGINE
3. Lubricate threads and top of washers underside of bolt head
with engine oil. Install head bolts (C) and torque to
=T specification.

Flywheel Nut Torque

65 ± 7 ft.lbs. (88 ± 9.50 Nm) C

4. Install stator housing with new o-rings. Torque the bolts to

specification and follow proper bolt torque sequence at the
beginning of this chapter.

96 ± 3 in. lbs.
3
(10.85 ± 0.35 Nm)

=T
Cylinder Head Bolt Torque:
Initial setting: 35± 4 ft. lbs. (47.5 ± 5.5 Nm)
Allow to set for 1 minute, then turn
=T additional 90° (1/4 turn)
*Torque Bolts In Sequence
Stator Housing Bolt Torque:
96 ± 3 in. lbs. (10.85 ± 0.35 Nm) 4. Lubricate push rods (D) and install into lifters.

Cylinder Head Reassembly D

NOTE: Before reassembly, clean the bolts and bolt

holes with Primer N (PN 2874275) to remove any
debris. This will ensure proper sealing when
installing bolts.

1. Install the head gasket (A) on the cylinder (B).

2. Install cylinder head on cylinder.

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 ENGINE
5. Lubricate rockers (E) with engine oil.

=T
E
Breather Bolt Toque:
20 ± 5 in. lbs. (2.5± 0.55 Nm)

NOTE: When applying RTV, do not get any RTV

inside the reed assembly.
9. Place a new seal (I) into the bottom of the cover. Be sure
the seal is seated into the cover properly.
IMPORTANT: Before assembly, clean the bolts and
bolt holes with Primer N (PN 2874275) to remove any
debris. This will ensure proper sealing when
installing bolts.
6. Verify pushrods are engaged in lifters.
10. Install rocker cover. Torque bolts to specification.
7. Install rockers. Be sure that tab of fulcrum (F) is seated in
head stand-off. Torque bolts to specification.

=T
=T
Rocker Cover Bolt Torque:
Rocker Arm Bolt Torque 84 ± 8 in.lbs. (9.5 ± 0.9 Nm)
22 + 2 ft. lbs. (30 ± 3 Nm) Torque in Sequence

8. 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. 17 ± 2 ft. lbs.
K
20 ± 5 in.lbs. (23 ± 3 Nm)
(2.5 ± .55 Nm)

G I
84 ± 8 in. lbs.
(9.5 ± 0.9 Nm)

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2. Remove primer plug from the engine. Install Oil System
Priming Adapter (PU-45778) into the oil plug hole. Push
=T 3-5 oz. (approx.) of Polaris PS-4 PLUS 2W-50 Synthetic
into the adapter or until resistance is felt. Remove the
Thermostat Housing Bolt Torque: adapter. Apply sealant to the plug threads. Install the plug
84 ± 8 in. lbs. (9.5± 0.9 Nm) and torque to specification.
12. Install temperature sender (K) and torque to specification.
PU-45778

K
3

=T
Temperature Sender Torque:
17 ± 2 ft.lbs. (23 ± 3 Nm)

Oil Pump Priming =T

1. After the engine is completely assembled and ready for Primer Plug Torque
installation, the engine must be properly primed with 18 ± 2 ft.lbs. (24.4 ± 2.71 Nm)
Polaris PS-4 PLUS 2W-50 Synthetic Oil (PN 2876244).
Fill the oil filter three-quarters full with Polaris PS-4 PLUS
2W-50 Synthetic Engine Oil (PN 2876244). Let the oil CAUTION
soak into the filter for 8-10 minutes. Install the filter onto
the engine. After any reassembly or rebuild, the engine
must be primed using the Oil Priming Adapter
(PU-45778) and a 3/4-full oil filter before initial
start-up. Follow the steps in this section to
properly prime the engine and aid proper engine
break in. Failure to perform this procedure may
cause internal engine damage on initial start-up.

Engine Break-In
Refer to “Engine Break-In Period” under “Engine Installation
Fill 3/4 full Notes” listed earlier in this chapter.
with 2W-50

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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)
• Incorrect spark plug heat range or gap
• Incorrect or restricted carburetor jetting
• PVT system calibrated incorrectly/ components worn or
mis-adjusted • Reverse speed limiter limiting speed
• Incorrect ignition timing
• Fuel quality poor (old) or octane too high
• Restricted exhaust system
• Low compression
• Cam worn excessively
• Restricted exhaust
• Weak ignition (loose coil ground, faulty coil, or stator) Engine Has Low Power
• Spark plug fouled
• Restricted air filter (main or pre-cleaner) or breather
system • Cylinder, piston, ring, or valve wear or damage (check
compression)
• Improperly assembled air intake system
• PVT not operating properly
• Restricted engine breather system
• Restricted exhaust muffler
• Oil contaminated with fuel
• Cam worn excessively
Engine Turns Over But Fails To Start
Piston Failure - Scoring
• No fuel
• Lack of lubrication
• Dirt in fuel line or filter
• Dirt entering engine through cracks in air filter or ducts
• Fuel will not pass through fuel valve
• Engine oil dirty or contaminated
• Fuel pump inoperative/restricted
• Tank vent plugged or pinched Excessive Smoke and Carbon Buildup
• Engine flooded • Excessive piston-to-cylinder clearance

• Low compression (high cylinder leakage) • Wet sumping

• No spark (Spark plug fouled) ignition component • Worn rings, piston, or cylinder
failure • Worn valve guides or seals
Engine Does Not Turn Over • Restricted breather

• Dead battery • Air filter dirty or contaminated

• Starter motor does not turn Piston Failure - Scoring

• Engine seized, rusted, or mechanical failure • Lack of lubrication
Engine Runs But Will Not Idle • Dirt entering engine through cracks in air filter or ducts

• Restricted carburetor pilot system • Engine oil dirty or contaminated

• Low compression
• Crankcase breather restricted

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Excessive Smoke and Carbon Buildup Cooling System
• 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 • Wrong type/mix of coolant
• Restricted breather • Faulty pressure cap or system leaks
• Air filter dirty or contaminated • Restricted system (mud or debris in radiator fins
Low Compression causing restriction to air flow, passages blocked in
radiator, lines, pump, or water jacket, accident damage) 3
• Cylinder head gasket leak
• Lean mixture (restricted jets, vents, fuel pump or fuel
• No valve clearance ( cam wear ) valve)
• Cylinder or piston worn
• Fuel pump output weak
• Piston rings worn, leaking, broken, or sticking
• Electrical malfunction
• Bent valve or stuck valve
• Water pump failure/ Loose impeller
• Valve spring broken or weak
• Thermistor failure
• Valve not seating properly (bent or carbon accumulated
• Cooling fan inoperative or turning too slowly (perform
on sealing surface)
current draw test)
• Rocker arm sticking
• Low oil level
Backfiring • Spark plug incorrect heat range
• Speed limiter system malfunction • Faulty hot light circuit
• Fouled spark plug or incorrect plug or plug gap • Thermostat stuck closed or not opening completely
• Exhaust system air leaks • Radiator is missing its internal diverter plate not
• Exhaust system air leaks allowing coolant to flow through entire radiator

• Ignition system faulty: Temperature Too Low

Spark plug cap cracked / broken
• Thermostat stuck open
Ignition coil faulty
Ignition switch circuit faulty Leak at Water Pump Weep Hole
Poor connections in ignition system
• Faulty water pump mechanical seal (coolant leak)
Ignition timing incorrect
Sheared flywheel key • Faulty pump shaft oil seal (oil leak)

• Valve sticking

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NOTES

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 ELECTRONIC FUEL INJECTION
CHAPTER 4
ELECTRONIC FUEL INJECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
EFI SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
FUEL TANK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
EFI SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
EFI SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FUEL LINES - QUICK CONNECT REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . 4.9
ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
PRINCIPAL COMPONENTS / EFI OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . 4.10
INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
ECU SERVICE / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
4
FUEL SENDER TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL PUMP / TANK ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL PRESSURE REGULATOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
FUEL INJECTOR SERVICE / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
CPS TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP). . . . . . . . . . . . . 4.17
T-BAP TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
TPS TEST PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
TPS INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
TPS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
ECT SENSOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
IGNITION COIL / HT LEAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
GENERAL TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
DIAGNOSTIC “BLINK CODES” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
EFI TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
EFI SYSTEM BREAK-OUT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
FUEL INJECTOR CIRCUIT (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
FUEL INJECTOR CIRCUIT (MAG). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
CRANKSHAFT POSITION SENSOR (CPS) CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . 4.26
FUEL PUMP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26
ENGINE COOLANT TEMPERATURE SENSOR (ECT). . . . . . . . . . . . . . . . . . . . . . . . . 4.27
TEMPERATURE OVERHEAT INDICATOR LAMP CIRCUIT. . . . . . . . . . . . . . . . . . . . . 4.27
THROTTLE POSITION SENSOR (TPS) CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28
AIR TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP) CIRCUIT . 4.28
DIAGNOSTIC CONNECTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29
DIAGNOSTIC INDICATOR LAMP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29

4.1

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 ELECTRONIC FUEL INJECTION
GENERAL INFORMATION Special Tools

PART
WARNING NUMBER
TOOL DESCRIPTION

PU-43506-A Fuel Pressure Gauge Kit

* Gasoline is extremely flammable and explosive
under certain conditions. PV-48656 Fuel Pressure Gauge Adaptor
* EFI components are under high pressure. Verify
PU-47082 Throttle Position Sensor Tester
system pressure has been relieved before
disassembly. 4010264 TPS Tester Regulator
* Never drain the fuel system when the engine is hot.
Severe burns may result . Digital Wrench™ Diagnostic Software
* Do not overfill the tank. The tank is at full capacity PU-47063 (Includes most recent version of software
when the fuel reaches the bottom of the filler neck. and a serial number)
Leave room for expansion of fuel. Digital Wrench™ SmartLink Module Kit
* Never start the engine or let it run in an enclosed PU-47471
(PU-47470, PU-47469, PU-47468)
area. Gasoline powered engine exhaust fumes are
poisonous and can cause loss of consciousness and Digital Wrench™
PU-47470
death in a short time. PC Interface Cable
* Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or where Digital Wrench™
PU-47469
gasoline is stored. Vehicle Interface Cable
* If you get gasoline in your eyes or if you should Digital Wrench™
swallowgasoline,seekmedicalattentionimmediately. PU-47468
SmartLink Module
* If you spill gasoline on your skin or clothing,
immediately wash with soap and water and change IMPORTANT: For the most recent information on
clothing.
Digital Wrench™ software and fileset downloads
* Always stop the engine and refuel outdoors or in a
please visit the website: www.polaris.diagsys.com
well ventilated area.

4.2

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 ELECTRONIC FUEL INJECTION
Fuel Pressure Gauge Kit - PU-43506-A Throttle Position Sensor Tester - PU-47082
IMPORTANT: The EFI fuel system remains under high This tester allows the use of a digital multi-meter to test TPS
pressure, even when the engine is not running. function and perform the TPS Adjustment procedure.
Before attempting to service any part of the fuel
system, pressure must be relieved (if applicable). The
Fuel Pressure Gauge Kit has an integrated pressure
relief valve that can be used to bleed off pressure once
you have completed the fuel pressure test.

Relief Valve

4
NOTE: Voltage Regulator 4010264 is required if
using TPS harness PU-47082. If your dealership
Adaptor shown is
included with kit. 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
SPX at 1-800-328-6657.
Fuel Pressure Gauge Adaptor - PV-48656

Adaptor works with TPS Tester Regulator - 4010264

PU-43506-A
This tester regulator regulates the 9 volt battery voltage to a 5
volt input, required when using the TPS harness PU-47082.

Disconnect here and connect

in-line w/fuel pump outlet

NOTE: 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 SPX at 1-800-328-6657.

4.3

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 ELECTRONIC FUEL INJECTION
Digital Wrench™ Diagnostic Software Digital Wrench™ - Download Website
PU-47063 Located at: www.polaris.diagsys.com
This dealer-only software installs on laptop computers equipped
with a CD drive and serial port connection, and is designed to
replace multiple shop tools often used to test EFI components.
It also includes step-by-step diagnostic procedures to aid
technician repair and troubleshooting.

Digital Wrench™
SmartLink Module Kit - PU-47471
This module kit contains the necessary cables and hardware to
communicate between the vehicle ECU and the Digital
Wrench™ diagnostic software. Polaris dealers can also order
the following separately: SmartLink Module 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 (1-800-328-6657).

PU-47469

PU-47468
PU-47470

Digital Wrench™ - Diagnostic Connector

(Located under the hood as shown below)

4.4

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 ELECTRONIC FUEL INJECTION
EFI Service Notes
• For more convenient and accurate testing of EFI components, it is recommended dealers utilize the
Digital Wrench™ Diagnostic Software (dealer only), or testing may be done manually using the
procedures provided.

• 80% of all EFI problems are caused by wiring harness connections.

• For the purpose of troubleshooting difficult running issues, a known-good ECU from another Polaris
RANGER 700 EFI of the same model may be used without damaging system or engine components.

• Never attempt to service any fuel system component while engine is running or ignition switch is "on."

• Cleanliness is essential and must be maintained at all times when servicing or working on the EFI
system. Dirt, even in small quantities, can cause significant problems.

• Do not use compressed air if the system is open. Cover any parts removed and wrap any open joints
4
with plastic if they will remain open for any length of time. New parts should be removed from their
protective packaging just prior to installation.

• Clean any connector before opening to prevent dirt from entering the system.

• Although every precaution has been taken to prevent water intrusion failure, avoid direct water or
spray contact with system components.

• Do not disconnect or reconnect the wiring harness connector to the control unit or any individual
components with the ignition "on." This can send a damaging voltage spike through the ECU.

• Do not allow the battery cables to touch opposing terminals. When connecting battery cables attach the
positive (+) cable to positive (+) battery terminal first, followed by negative (-) cable to negative (-)
battery terminal.

• Never start the engine when the cables are loose or poorly connected to the battery terminals.

• Never disconnect battery while engine is running.

• Never use a battery boost-pack to start the engine.

• Do not charge battery with key switch "on."

• Always disconnect negative (-) battery cable lead before charging battery.

• Always unplug ECU from the wire harness before performing any welding on the unit.

4.5

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 ELECTRONIC FUEL INJECTION
Fuel Tank Exploded View

PFA Nut

Fuel Sender
Float Arm

Fuel Pump / Regulator

PFA Gasket

Preliminary Filter
Fuel Tank Assembly

NOTE: Fuel Pump is NOT Serviceable

Fuel Flow
Fuel Rail Fuel Injectors

Fuel Tank

Pressure Regulator

Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line

4.6

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 ELECTRONIC FUEL INJECTION
EFI System Exploded View
1. Electronic Control Unit (ECU)
2. Intake Air Temperature / Barometric Air Pressure Sensor (T-BAP)
3. Crankshaft Position Sensor (CPS)
4. Fuel Injectors
5. Fuel Filter
6. Fuel Pump / Regulator / Gauge Sender Asm. (Located in tank as an assembly)
7. Fuel Rail
8. Engine Coolant Sensor (ECT)
9. Throttle Position Sensor (TPS)
10. Throttle Body
11. Wire Harness (Part of main harness)

4.7

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 ELECTRONIC FUEL INJECTION
EFI System Component Locations 4. Fuel Injectors / Fuel Rail
Attached to the fuel rail located in the intake track of the
1. Electronic Control Unit (ECU) cylinder head.
Located under the seat on the driver’s side.

2. Intake Air Temperature and Barometric Air Pressure 5. Fuel Pump / Regulator / Fuel Gauge Sender Assembly
Sensor (T-BAP) Located in fuel tank as an assembly.
Located in the rubber intake boot between the air box and
throttle body.

6. Throttle Body
3. Crankshaft Position Sensor (CPS)
Located in the magneto cover on the right-hand side of the
engine.

Throttle
Body

4.8

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 ELECTRONIC FUEL INJECTION
7. Throttle Position Sensor (TPS) Fuel Lines - Quick Connect
Located on the right-hand side of the throttle body. Removal / Installation
TPS
CAUTION

Verify fuel system has been depressurized

before performing this procedure.

RANGER 700 EFI models use quick connect fuel lines. Refer
to the steps for fuel line removal / installation:

1. Thoroughly clean the connector and place a shop towel

around the fuel line to catch any dripping fuel.

8. Engine Coolant Temperature Sensor (ECT)

Located in the cylinder head.
2. Squeeze the connector tabs together and slide the green
retainer forward. 4

Squeeze Connector Tabs

3. Lift up on the fuel line to remove from the fuel pump outlet.

4. To install the line, verify the connector and fuel pump outlet
are clean and free of debris.

5. Place the connector end over the fuel pump outlet and push
the green retainer and tabs back into place.

6. Repeat this process to remove the fuel line from the fuel rail.

4.9

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 ELECTRONIC FUEL INJECTION
ELECTRONIC FUEL INJECTION The ECU controls the amount of fuel being injected and the
ignition timing by monitoring the primary sensor signals for air
Principal Components temperature, barometric air pressure, engine temperature, speed
(RPM), and throttle position (load). These primary signals are
The Electronic Fuel Injection (EFI) system is a complete engine compared to the programming in the ECU computer chip, and
fuel and ignition management design. This system includes the the ECU adjusts the fuel delivery and ignition timing to match
following principal components: the values.

• Fuel Pump During operation the ECU has the ability to re-adjust
• Fuel Rail temporarily, providing compensation for changes in overall
• Fuel Line(s) engine condition and operating environment, so it will be able
• Fuel Filter(s) to maintain the ideal air/fuel ratio.
• Fuel Injectors
• Pressure Regulator During certain operating periods such as cold starts, warm up,
• Throttle Body / lntake Manifold acceleration, etc., a richer air / fuel ratio is automatically
• Engine Control Unit (ECU) calculated by the ECU.
• Ignition Coils
• Coolant Temperature Sensor
• Throttle Position Sensor (TPS) Initial Priming / Starting Procedure
• Crankshaft Position Sensor (CPS)
• Intake Air Temperature and Barometric Air NOTE: The injection system must be purged of all
Pressure Sensor (T-BAP) air prior to the initial start up, and / or any time the
• Wire Harness Assembly system has been disassembled.
• Check Engine Light
If the EFI system is completely empty of fuel or has been
disassembled and repaired:
EFI Operation Overview 1. Cycle the key switch from “OFF” to “ON” 6 times,
The EFI system is designed to provide peak engine performance waiting for approximately 3 seconds at each “ON” cycle to
with optimum fuel efficiency and lowest possible emissions. allow the fuel pump to cycle and shut down.
The ignition and injection functions are electronically 2. Once step 1 is completed, turn the key switch to “START”
controlled, monitored and continually corrected during until the engine starts or 5 seconds has passed.
operation to maintain peak performance. 3. If the engine failed to start, repeat step 1 for 2 more cycles
and attempt to start the engine.
The central component of the system is the Bosch Engine
Control Unit (ECU) which manages system operation, If the engine fails to start, a problem may still exist, and should
determining the best combination of fuel mixture and ignition be diagnosed.
timing for the current operating conditions.
NOTE: Accurate testing of EFI components is
An in-tank electric fuel pump is used to move fuel from the tank recommended utilizing the Digital Wrench™
through the fuel line and in-line fuel filter. The in-tank fuel Diagnostic Software (dealer only).
pressure regulator maintains a system operating pressure of 39
psi and returns any excess fuel to the tank. At the engine, fuel is
fed through the fuel rail and into the injectors, which inject into
the intake ports. The ECU controls the amount of fuel by varying
the length of time that the injectors are "on." This can range from
1.5-8.0 milliseconds depending on fuel requirements. The
controlled injection of the fuel occurs each crankshaft
revolution, or twice for each 4-stroke cycle. One-half the total
amount of fuel needed for one firing of a cylinder is injected
during each injection. When the intake valve opens, the fuel/air
mixture is drawn into the combustion chamber, ignited and
burned.

4.10

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 ELECTRONIC FUEL INJECTION
ELECTRONIC CONTROL UNIT (ECU) RANGER 700 EFI RPM Limit:
Hard Limit - Injector suppression occurs
Operation Overview
• High: 6200
The ECU is the brain or central processing computer of the
entire EFI fuel/ignition management system. During operation, • Low: 6200
sensors continuously gather data which is relayed through the • Neutral: 6200
wiring harness to input circuits within the ECU. Signals to the
ECU include: ignition (on/off), crankshaft position and speed • Reverse: 6200
(RPM), throttle position, engine coolant temperature, air Soft Limit - Timing suppression occurs
temperature, intake manifold air pressure and battery voltage.
The ECU compares the input signals to the programmed maps • High: None
in its memory and determines the appropriate fuel and spark
• Low: 5900
requirements for the immediate operating conditions. The ECU
then sends output signals to set the injector duration and ignition • Neutral: 5900
timing.
• Reverse: 5900
4
ECU Service
Never attempt to disassemble the ECU. It is sealed to prevent
damage to internal components. Warranty is void if the case is
opened or tampered with in any way.

All operating and control functions within the ECU are pre-set.
No internal servicing or readjustment may be performed. If a
problem is encountered, and you determine the ECU to be
faulty, contact the Polaris Service Department for specific
handling instructions. Do not replace the ECU without factory
authorization.
During operation, the ECU continually performs a diagnostic The relationship between the ECU and the throttle position
check of itself, each of the sensors, and system performance. If sensor (TPS) is very critical to proper system operation. If the
a fault is detected, the ECU turns on the “Check Engine” light TPS is faulty, or the mounting position of the TPS to the throttle
in the speedometer and stores the fault code in its fault memory. body is altered, the TPS must be adjusted.
Depending on the significance or severity of the fault, normal
operation may continue, or "Fail-Safe" operation (slowed speed, For the purpose of troubleshooting, a known-good ECU from
richer running) may be initiated. A technician can determine the another Polaris RANGER 700 EFI of the same model may be
cause of the “Check Engine” light by initiating the “Blink Code” used without system or engine component damage.
sequence or by using Digital Wrench™. The ECU requires a
minimum of 7.0 volts to operate. The memory in the ECU is
operational the moment the battery cables are connected. ECU Replacement
To prevent engine over-speed and possible failure, a rev- 1. Remove the retaining screws (2) holding the ECU.
limiting feature is programmed into the ECU. If the maximum
RPM limit (6200) is exceeded, the ECU suppresses the injection 2. With the Ignition turned off, disconnect the wire harness
signals, cutting off the fuel flow. This process repeats it self in from the ECU.
rapid succession, limiting operation to the preset maximum.
3. To install, reverse the procedures and tighten screws to
specification.

=T
ECU Retaining Screws
10 in. lbs. (1.1 Nm)

4.11

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 ELECTRONIC FUEL INJECTION
FUEL PUMP Fuel Sender Test
If the fuel gauge reading on the instrument cluster is not
Operation Overview
working, or if the display reading differs in large comparison to
NOTE: All EFI units utilize quick connect lines. the fuel in the tank, perform a resistance test on the fuel sender.

An electric fuel pump assembly is used to transfer fuel to the EFI Disconnect the fuel pump / sending unit connection and measure
system from inside the fuel tank. This assembly includes the fuel the resistance between the Purple and Brown wires (see chapter
pump, regulator and fuel gauge sender. The pump is rated for a 10 for further details). If out of specification, replace the fuel
minimum output of 25 liters per hour at 39 psi and has a non- pump / tank assembly.
serviceable internal 60-micron filter.
Fuel pump is not Fuel Sender Resistance Specifications:
serviceable, picture is Full: 90Ω
for reference only. Empty: 5Ω
Fuel Pump

Regulator Fuel Pump Test

Fuel Gauge NOTE: The fuel pump/tank assembly is non-
Sender Float serviceable and must be replaced if determined to be
faulty. If a fuel delivery problem is suspected, make
certain the fuel pump is being activated by the ECU,
all electrical connections are properly secured, the
fuses are good, and a minimum of 7.0 volts is being
supplied. If during starting the battery voltage drops
below 7.0 volts, the ECU will fail to operate the
system.

Internal 60 Micron
Strainer (Bottom) WARNING

Fuel is extremely flammable and may cause

When the key switch is turned to "ON", the ECU activates the
severe burns, injury, or death.
fuel pump, which pressurizes the system for start-up.
Do not use any device that produces a flame or
The ECU switches off the pump preventing the continued electrical devices that may spark around
delivery of fuel in these instances: fuel or fuel vapors.

• If the key switch is not promptly turned to the "start" 1. Cover the fuel line connection with a shop towel and
position. disconnect the fuel line from the fuel pump.

• If the engine fails to start. 2. Install the Fuel Pressure Gauge Adaptor (PV-48656) in-line
between the fuel pump outlet and fuel line.
• If the engine is stopped with the key switch "ON" (as in
the case of an accident).

In these situations, the “check engine” light will go on, but will
turn off after 4 cranking revolutions if system function is OK.
Once the engine is running, the fuel pump remains on.

4.12

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 ELECTRONIC FUEL INJECTION
3. Connect the hose from the Fuel Pressure Gauge Kit (PU- Fuel Pump / Tank Assembly Replacement
43506-A) to the test valve on the Fuel Pressure Gauge
Adaptor. Route the clear hose into a portable gasoline NOTE: All EFI units utilize quick connect fuel lines.
container or the vehicle’s fuel tank.
WARNING
PV-48656
Always wear safety goggles when working with
high pressure or flammable fluids. Failure to do so
could result in serious injury or complications.

NOTE: The fuel pump cannot be replaced as an

individual part, the entire fuel pump and fuel tank is
replaced as an assembly. Refer to your parts book
for the proper part number.
1. Disconnect the negative battery cable.
PU-43506-A 2. Remove the seat. 4
3. Disconnect the fuel line from the fuel pump.
4. Turn on the key switch to activate the pump and check the
system pressure on the gauge. If system pressure of 39 psi Harness
± 3 is observed, the ignition switch, ECU, fuel pump, and
pressure regulator are working properly. Turn the key
switch off and depress the valve button on the tester to
relieve the system pressure.

Fuel Line
Fuel Pump Pressure: 39 psi. ± 3

NOTE: If the pressure is too high or too low, replace

the fuel pump / tank assembly.
5. If the pump did not activate (Step 4), disconnect the plug Vent Hose
from the fuel pump. Connect a DC voltmeter across
terminals “A” and “C” in the plug on the vehicle harness 4. Disconnect the fuel pump electrical harness.
side. Turn on the key switch and observe voltage to ensure
a minimum of 7 volts is present. 5. Remove the fuel tank vent hose
NOTE: If the voltage was below 7 VDC, test battery, NOTE: A small amount of fuel may come out of the
ignition switch, relay(s), wiring harness and ECU. fuel line or tank. Plug the fuel line and tank inlet or
use a shop towel during removal.
6. If the reading is between 7 and 14 volts, turn key switch
off and connect an ohmmeter between the terminals “A” NOTE: Properly drain fuel into a suitable container.
and “C”' in the plug on the pump harness to check for
6. Remove the RH rear fender and fuel cap.
continuity within the fuel pump.
NOTE: If there was no continuity between the pump
terminals, replace the fuel pump / tank assembly.
7. If voltage at the plug was within the specified range, and
there was continuity across the pump terminals, reconnect
the plug to the pump, making sure you have clean
connections. Turn on the key switch and listen for the pump
to activate.
NOTE: If the pump starts, verify you have the
correct amount of fuel pressure.
NOTE: If the pump still does not operate, replace the
fuel pump / tank assembly.

4.13

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 ELECTRONIC FUEL INJECTION
7. Remove the two inner bolts that hold the fuel tank to the Fuel Tank Installation
frame.
1. Reinstall the fuel pump / tank assembly.

2. Reinstall the four fuel tank mounting bolts that were

removed.

3. Reconnect the electrical harness. Install the fuel line and

vent line and verify they are secure.

4. Reinstall the RH rear fender.

5. Reconnect the negative battery cable. Test the fuel pump

by turning on the key and listening for the pump to activate.

FUEL PRESSURE REGULATOR

8. Remove the two outer lower bolts that hold the fuel tank to
the frame. Operation Overview
The fuel pressure regulator maintains the required operating
system pressure of 39 psi + 3psi. A rubber-fiber diaphragm
divides the regulator into two separate sections-, the fuel
chamber and the pressure regulating chamber. The pressure
regulating spring presses against the valve holder (part of the
diaphragm), pressing the valve against the valve seat. The
combination of atmospheric pressure and regulating spring
tension equals the desired operating pressure. Any time the fuel
pressure against the bottom of the diaphragm exceeds the
desired (top) pressure, the valve opens, relieving the excess
pressure, returning the excess fuel back to the tank.

Fuel Pressure Regulator Test

9. Reinstall the fuel cap and carefully pull the fuel tank out the Refer to the “FUEL PUMP TEST” procedure.
RH side of the frame.
See “Fuel Pump Test” on page 4.12.

Fuel Pressure Regulator Replacement

The regulator is a sealed, non-serviceable assembly. If it is
faulty, the pump assembly must be replaced. Refer to the Fuel
Pump / Tank Assembly Replacement procedure.

WARNING

Wear safety goggles while performing this

procedure, failure to do so could result
in serious injuries.

4.14

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 ELECTRONIC FUEL INJECTION
FUEL INJECTORS NOTE: Do not apply voltage directly to the fuel
injector(s). Excessive voltage will burn them out. Do
Operation Overview not ground the injector(s) with the ignition on.
lnjector(s) will open/turn on if relay is energized.
The fuel injectors mount into the intake manifold, and the fuel
rail attaches to them at the top end. Replaceable O-rings on both If an injector is not operating, it can indicate either a bad injector,
ends of the injector prevent external fuel leaks and also insulate or a wiring/electrical connection problem. Check as follows:
it from heat and vibration. Injector leakage is very unlikely, but in rare instances it can be
internal (past the valve needle), or external (weeping around the
injector body). The loss of system pressure from leakage can
cause hot restart problems and longer cranking times.
Injector problems due to dirt or clogging are unlikely due to the
design of the injectors, the high fuel pressure, the use of filters
and the detergent additives in the gasoline. Symptoms that could
be caused by dirty/clogged injectors include rough idle,
hesitation/stumble during acceleration, or triggering of fault
codes related to fuel delivery. Injector clogging is usually caused 4
by a buildup of deposits on the director plate, restricting the flow
of fuel, resulting in a poor spray pattern. Some contributing
factors to injector clogging include; dirty air filters, higher than
normal operating temperatures, short operating intervals and
dirty, incorrect, or poor quality fuel. Cleaning of clogged
When the key switch is on, the fuel rail is pressurized, and injectors is not recommended; they should be replaced.
voltage is present at the injector. At the proper instant, the ECU Additives and higher grades of fuel can be used as a preventative
completes the ground circuit, energizing the injector. The valve measure if clogging has been a problem.
needle in the injector is opened electromagnetically, and the
pressure in the fuel rail forces fuel down through the inside. The Fuel Injector Replacement
“director plate” at the tip of the injector (see inset) contains a 1. Thoroughly clean the area around the throttle body, intake
series of calibrated openings which directs the fuel into the boot and fuel injectors. Allow engine to cool.
intake port in a cone-shaped spray pattern.
2. Disconnect the fuel injector harness(s) as shown below.
The injector is opened and closed once for each crankshaft
revolution, however only one-half the total amount of fuel
needed for one firing is injected during each opening. The
amount of fuel injected is controlled by the ECU and determined
by the length of time the valve needle is held open, also referred
to as the “injection duration” or “pulse width”. It may vary in
length from 1.5-8 milliseconds depending on the speed and load
requirements of the engine.

Fuel Injector Service

Injector problems typically fall into three general categories-
electrical, dirty / clogged, or leakage. An electrical problem
usually causes one or both of the injectors to stop functioning.
Several methods may be used to check if the injectors are
operating.
3. Place a catch-container below the fuel line fitting at the fuel
• With the engine running at idle, feel for operational rail and remove the fuel line.
vibration, indicating that they are opening and closing. 4. Remove the fuel rail mounting screw and carefully loosen
• When temperatures prohibit touching, listen for a / pull the rail away from the injectors.
buzzing or clicking sound with a screwdriver or 5. Reverse the procedures to install the new injector(s) and
mechanic's stethoscope. reassemble. Use a new O-ring any time an injector is
• Disconnect the electrical connector from an injector and removed (replacement injectors include new O-rings).
listen for a change in idle performance (only running on Lubricate O-rings lightly with oil to aid installation. Torque
one cylinder) or a change in injector noise or vibration. the fuel rail mounting screw to 16-20 ft. lbs. (22-27 Nm).

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 ELECTRONIC FUEL INJECTION
CRANKSHAFT POSITION SENSOR CPS Test
(CPS) The crankshaft position sensor is a sealed, non-serviceable
assembly. If fault code diagnosis indicates a problem within this
Operation Overview area, test and correct as follows:

The engine speed sensor is essential to engine operation, 1. Disconnect main harness connector from ECU.
constantly monitoring the rotational speed (RPM) and position
of the crankshaft. 2. Connect an ohmmeter between the pin terminals. A
resistance value of 560Ω ± 10% at room temperature (20°
C, 68° F) should be obtained. If resistance is correct, check
the mounting, air gap, toothed ring gear (damage, runout,
etc.), and flywheel key.

Crankshaft Position Sensor:

560Ω ± 10% (20° C, 68° F)

3. Disconnect speed sensor connector from wiring harness.

(the connector with one heavy black lead) Viewing the
connector with dual aligning rails on top, test resistance
between the terminals. A reading of 560Ω ± 10% should
again be obtained.
A ferromagnetic 60-tooth ring gear with two consecutive teeth NOTE: If the resistance is incorrect, remove the
missing is mounted on the flywheel. The inductive speed sensor screw securing the sensor to the mounting bracket
is mounted 1.0 ± 0.26 mm (0.059 ± 0.010 in.) away from the and replace the sensor. If the resistance in step 2
ring gear. During rotation, an AC pulse is created within the was incorrect, but the resistance of the sensor alone
sensor for each passing tooth. The ECU calculates engine speed was correct, test the main harness circuit between
from the time interval between the consecutive pulses. The two- the sensor connector terminals and the
tooth gap creates an “interrupt” input signal, corresponding to corresponding pin terminals in the main connector.
specific crankshaft position for PTO cylinder. This signal serves Correct any observed problem, reconnect the
as a reference for the control of ignition timing by the ECU. sensor, and perform step 2 again.
Synchronization of the CPS and crankshaft position takes place
during the first two revolutions each time the engine is started.
This sensor must be properly connected at all times. If the sensor CPS Replacement
fails or becomes disconnected for any reason, the engine will
quit running. 1. Disconnect sensor harness connector.

2. Using a 6 mm hex wrench, remove the retaining bolt and

replace the sensor, using a light coating of oil on the o-ring
to aid installation.

3. Torque the retaining bolt to specification.

=T
CPS Retaining Bolt Torque:
25 in. lbs. (2.8 Nm)

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 ELECTRONIC FUEL INJECTION
TEMPERATURE / BAROMETRIC AIR THROTTLE POSITION SENSOR (TPS)
PRESSURE SENSOR (T-BAP) Operation Overview
Operation Overview The throttle position sensor (TPS) is used to indicate throttle
plate angle to the ECU.
Mounted on the throttle body intake, the temperature and
barometric air pressure sensor (T-BAP) performs two functions Mounted on the throttle body and operated directly off the end
in one unit. of the throttle shaft, the TPS works like a rheostat, varying the
voltage signal to the ECU in direct correlation to the angle of the
throttle plate. This signal is processed by the ECU and compared
to the internal pre-programmed “maps” to determine the
required fuel and ignition settings for the amount of engine load.

Stop Screw
(Factory Set)
DO NOT ADJUST 4
Throttle Body

Air passing through the intake is measured by the T-BAP and

relayed to the ECU. These signals, comprised of separate air
temperature and barometric air pressure readings, are processed
by the ECU and compared to its programming for determining TPS
the fuel and ignition requirements during operation.
Yellow
(Output)
T-BAP Test TPS Connector

The temperature and barometric air pressure sensor (T-BAP) is

a non-serviceable item. If it is faulty, it must be replaced. This
sensor requires a 5 Vdc input to operate, therefore the T-BAP
sensor should only be tested using the Digital Wrench™ Blue Black
Diagnostic Software (dealer only). Refer to the EFI Diagnostic (Input) (Ground)
Software Manual for more information.

The correct position of the throttle body

T-BAP Replacement stop screw is established and set at the
1. Disconnect sensor from engine harness. factory. DO NOT loosen the throttle body
stop screw or alter its position in any
2. Using a 10mm wrench, remove the retaining bolt and manner. The stop screw controls the air
replace the sensor, using a light coating of oil on the o-ring flow calibration of the throttle body. If the
to aid installation.
stop screw is repositioned or adjusted, the
3. Torque the retaining bolt to specification. throttle body assembly must be replaced.

=T
TPS Tester / Regulator
T-BAP Retaining Bolt Torque: The throttle position sensor (TPS) reading can be checked by
29 in. lbs. (3.3 Nm) using the TPS Tester Adapter Harness (PU-47082) and TPS
Tester Regulator (4010264).

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 ELECTRONIC FUEL INJECTION
Set-up the TPS Tester Adapter Harness (PU-47082), according Verify TPS Tester Reference Voltage
to the instructions that accompanied the tester. Make sure the 9
A 5 volt reference voltage from the TPS Tester harness is
Volt battery is new.
required for the TPS test to be accurate. Refer to the instructions
provided with the TPS Tester Adapter Harness (PU-47082) or
follow the bullet point steps below to check reference voltage.
Use NEW
9V battery Reference Voltage Test:
PU-47082
TPS Tester • Insert black voltmeter probe into the “Bk” test port.

• Connect the red voltmeter probe into the “R” test port
and verify the voltage is 4.99-5.01 Vdc. If this reading
is low, verify the 9 volt battery is good or try a new 9
volt battery.

As mentioned in the instructions included with the tester, be sure

the TPS Tester Adapter Harness is set up along with the TPS
Tester Regulator (4010264).

4010264
TPS Tester Regulator

NOTE: If your dealership sells Polaris snowmobiles,

you may already have this regulator from TPS Tester
Kit (2201519). If you do not have this regulator, you
must order one from SPX at 1-800-328-6657.

Typical Tester
Set-up

Test Ports
9 Volt Battery TPS Reference Voltage
5 Vdc Input
Regulator

IMPORTANT: Always use a fresh 9 Volt battery.

Cable Ties
Install Regulator
Connections Here

R = RED
P = PINK
Bk = BLACK
Y = YELLOW

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 ELECTRONIC FUEL INJECTION
Checking TPS Reading 8. Allow the throttle foot pedal to rest in the idle position. The
voltmeter should read .660 ± .010 volts.
1. Remove the lower seat base to access the sensor connector.
PU-47082 Tester
2. Assemble the TPS Tester according to the instructions.
Refer to “TPS Tester / Regulator” for proper set-up and
testing. Verify the 9 volt tester battery is new.
Black
3. Disconnect the vehicle chassis harness from the TPS. Red Probe
Probe
Throttle Black
Body Red Pink
Should Read
.660 ± .010 Vdc

.660

4
TPS
TPS
Connector
Figure 4-18
4. Plug the TPS Tester harness into the TPS harness.
TPS Output Reading
5. Set your voltmeter to read Vdc. Connect the red voltmeter
.660 ± .010 Vdc
probe into the “Y” test port and the black voltmeter probe
into the “Bk” test port.
9. If the voltage does not read within the specification,
6. Move the throttle open and closed slowly while reading the proceed to the “TPS Adjustment” procedure. If the
display. The voltage should increase and decrease voltage reading is within specification, no adjustment is
smoothly without any “jumps” when the throttle is applied. required.
PU-47082 Tester
TPS Adjustment
NOTE: This procedure should be performed after
Black you have checked the TPS reading. Refer to
Red Probe “Checking TPS Reading” procedure before making
Probe any adjustments.
Black 1. Make sure the TPS Tester harness is still connected to the
Red Pink
TPS harness.

2. Loosen the mounting screw (B) holding the TPS to the

No “Jumps”
in read out 0.66 ~ 3.7 throttle body (see Figure 4-19).

3. Rotate the TPS until your voltmeter reads .660 ± .010 volts
(see Figure 4-18).

TPS Output Reading

.660 ± .010 Vdc

4. Retighten the mounting screw, and verify the voltage did

not change. If the voltage changed, repeat steps 2 - 4.
7. If voltage varies with throttle movement, continue on to
Step 8. If the sensor did not function correctly, replace it. 5. Reconnect the TPS harness to the vehicle harness.

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 ELECTRONIC FUEL INJECTION
TPS Replacement Coolant passes through the cylinder and by the sensor probe,
varying a resistance reading which is relayed to the ECU. This
NOTE: The correct position of the TPS angle on the signal is processed by the ECU and compared to its
throttle body is established and set at the factory. If programming for determining the fuel and ignition
the TPS is replaced, repositioned or loosened it requirements during operation. The ECU also uses this signal
must be recalibrated. Refer to the “TPS Adjustment” to determine when to activate the fan during operation. If for
procedure. any reason the engine temperature sensor circuit is interrupted,
the fan will default to “ON”.
1. Remove the lower seat base to access the TPS.

2. Disconnect the TPS harness connection (A). ECT Sensor Test

A TPS

Engine Coolant Temperature Sensor

To quickly rule out other components and wiring related to the

ECT sensor, disconnect the harness from the ECT sensor. The
fan should turn on. This indicates all other components are
working properly.
Figure 4-19 B
Refer to Chapter 10 for ECT testing. Polaris dealers can also test
3. Remove the mounting screw (B) and replace the sensor. the sensor by using the Digital Wrench™ Diagnostic Software
(dealer only). Refer to the Digital Wrench™ User Guide for
NOTE: If replacing the TPS or throttle body, you more information.
must perform the “TPS Adjustment” procedure.

4. Refer to “TPS Adjustment” for setting the TPS voltage.

ECT Sensor Resistance Readings

Temperature °F (°C) Resistance

ENGINE COOLANT TEMPERATURE 68 °F (20 °C) 2.5 kΩ ± 6%
SENSOR (ECT) 212 °F (100 °C) 186 Ω ± 2%

Operation Overview
Mounted on the cylinder head, the engine temperature sensor
ECT Sensor Replacement
measures coolant temperature. The engine temperature sensor 1. Drain coolant to level below sensor.
is a Negative Temperature Coefficient (NTC) type sensor, as the
temperature increases the resistance decreases. 2. Disconnect sensor from engine harness.

3. Using a wrench, remove and replace the sensor, applying

a light coating of thread sealant to aid installation.

4. Torque the sensor to 17 ft. lbs. (23 Nm).

=T
ECT Retaining Bolt Torque:
17 ft. lbs. (23 Nm)

4.20

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 ELECTRONIC FUEL INJECTION
IGNITION COIL Primary Test

Operation Overview
The ignition coil is used to provide high voltage to fire the spark
plugs. When the ignition key is on, DC voltage is present in
primary side of the ignition coil windings. During engine
rotation, an AC pulse is created within the crankshaft position
sensor for each passing tooth on the flywheel. The two-tooth
gap creates an “interrupt” input signal, corresponding to specific
crankshaft position for PTO cylinder. This signal serves as a
reference for the control of ignition timing. The ECU then
calculates the time interval between the consecutive pulses, and
determines when to trigger the voltage spike that induces the
voltage from the primary to the secondary coil windings to fire
the spark plugs.
4
Storage Box
Measure Between
Connector Pins
0.4 Ω
Ignition Coil

Secondary Test

Ignition Coil Tests

The ignition coil can be tested by using an ohm meter. Use the Measure Between
following illustration and specification table to test the ignition End Caps
coil.
5kΩ
NOTE: The left hand storage compartment must be
removed to properly access the ignition coil harness
Ignition Coil / HT Lead Replacement
for testing purposes.
1. Remove the seat base and left hand storage compartment
Ignition Coil Resistance Readings to access the ignition coil.

Pin 2. Disconnect the ignition coil harness and remove the high
Test Resistance tension leads from the coil.
Connection
3. Remove the fastener retaining the coil and remove the coil
Between 1 & 2
Primary 0.4 Ω from the vehicle. If replacing the high tension lead(s),
Between 3 & 2 remove the other end of the lead(s) from the spark plug.
Between 4. Install the new ignition coil and/or high tension lead(s).
Secondary High Tension 5kΩ
Lead Ends =T
Ignition Coil Retaining Bolt Torque:
75 in. lbs. (8.5 Nm)

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 ELECTRONIC FUEL INJECTION
GENERAL TROUBLESHOOTING 3. Any “blink codes” stored in the ECU will display a
numerical “blink code”, one at a time, in numerical order,
Diagnostic “Blink Codes” on the instrument cluster display.
4. The word “End” will display after all of the codes have been
NOTE: The EFI diagnostic mode is intended to displayed or if no codes are present.
quickly view the cause of the “Check Engine” light.

To recall blink codes (fail codes) from the ECU:

1. Verify the key switch is off and the transmission is in
neutral with the parking brake applied.

2. Turn the key switch ON and OFF 3 times within 5 seconds

and leave the key switch in the ON position on the third
turn. The word “Wait” will appear as the ECU searches for
NOTE: To clear codes manually, disconnect the
blink codes.
positive battery lead for 20 seconds.

DIAGNOSTIC “BLINK CODES” CHART

SAE CODE BLINK CODE NAME CHECK ENGINE
P0335 21 Loss of Synchronization Yes
P0122 22 TPS: Open or Short Circuit to Ground Yes
P0123 22 TPS: Short Circuit to Battery Yes
P0601 23 RAM Error: Defective ECU Yes
P0914 25 Transmission Input: Invalid Gear Yes
P0500 26 Vehicle Speed Sensor: Implausible Yes
P0113 41 Intake Air Temp Sensor: Open or Short Circuit to +Sensor Voltage (ECU) Yes
P0112 41 Intake Air Temp Sensor: Short Circuit to Ground Yes
P0117 42 Engine Temperature Sensor Circuit: Short To Ground Yes
P0118 42 Engine Temperature Sensor Circuit: Open or Short to Battery Yes
P0107 45 Barometric Pressure Sensor: Circuit Low Input Yes
P0108 46 Barometric Pressure Sensor: Circuit High Input Yes
P1260 51 Injector 1: Open Load Yes
P0261 51 Injector 1: Short Circuit to Ground Yes
P0262 51 Injector 1: Short Circuit to Battery Yes
P1263 52 Injector 2: Open Load Yes
P0264 52 Injector 2: Short Circuit to Ground Yes
P0265 52 Injector 2: Short Circuit to Battery Yes
P0655 54 Engine Temperature Lamp: Open Load Yes
P1657 54 Engine Temperature Lamp: Short Circuit to Ground Yes
P1658 54 Engine Temperature Lamp: Short Circuit to Battery Yes
P1651 55 Diagnostic Lamp: Open Load Yes
P1652 55 Diagnostic Lamp: Short Circuit to Ground Yes
P1653 55 Diagnostic Lamp: Short Circuit To Battery Yes
P1231 56 Pump Relay: Open Load Yes
P1232 56 Pump Relay: Short Circuit to Ground Yes
P1233 56 Pump Relay: Short Circuit to Battery Yes
P1480 58 Cooling Fan: Open Load Yes
P1481 58 Cooling Fan: Short Circuit to Ground Yes
P1482 58 Cooling Fan: Short Circuit to Battery Yes

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 ELECTRONIC FUEL INJECTION
EFI Troubleshooting Poor Idle
Symptom: Idle Too High (If greater than 1300 RPM when
Fuel Starvation / Lean Mixture engine is warm)
Symptoms: Hard start or no start, bog, backfire, popping
• Throttle stop screw set incorrect
through intake / exhaust, hesitation, detonation, low power,
spark plug erosion, engine runs hot, surging, high idle, idle • Throttle cable sticking, improperly adjusted, routed
speed erratic. incorrectly

• No fuel in tank Symptom: Idle Too Low (if less than 900 RPM when engine is
warm)
• Restricted tank vent, or routed improperly
• Plugged air filter
• Fuel lines or fuel injectors restricted
• Leaking injector (rich condition)
• Fuel filter plugged

• Fuel pump inoperative

• Belt dragging
4
• Throttle stop screw tampering
• Air leak in system
Symptom: Erratic Idle
• Intake air leak (throttle shaft, intake ducts, airbox or air
cleaner cover) • Throttle cable incorrectly adjusted
• Incorrect throttle stop screw adjustment • Air Leaks, dirty injector

Rich Mixture • TPS damaged or adjusted

Symptoms: Fouls spark plugs, black, sooty exhaust smoke, • Tight valves
rough idle, poor fuel economy, engine runs rough/ misses, poor
performance, bog, engine loads up, backfire. • Ignition timing incorrect

• Air intake restricted (inspect intake duct) • Belt dragging

• Air filter dirty/plugged • Dirty air cleaner

• Poor fuel quality (old fuel) • Engine worn

• Fouled spark plug • Spark Plug fouled

• TPS setting incorrect • Throttle stop screw set incorrectly (out of sync with
ECU)
• Injector failure

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 ELECTRONIC FUEL INJECTION
EFI SYSTEM BREAK-OUT DIAGRAMS
Fuel Injector Circuit (PTO)

Fuel Injector Circuit (MAG)

4.24

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 ELECTRONIC FUEL INJECTION
Crankshaft Position Sensor (CPS) Circuit

Fuel Pump Circuit

4.25

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 ELECTRONIC FUEL INJECTION
Engine Coolant Temperature Sensor (ECT)

Temperature Overheat Indicator Lamp Circuit

4.26

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 ELECTRONIC FUEL INJECTION
Throttle Position Sensor (TPS) Circuit

Air Temperature / Barometric Air Pressure Sensor (T-BAP) Circuit

4.27

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 ELECTRONIC FUEL INJECTION
Diagnostic Connector Circuit

Diagnostic Indicator Lamp Circuit

4.28

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 BODY / STEERING / SUSPENSION
CHAPTER 5
BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
REMOVAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
LOWER BODY, FLOOR AND FENDERS (4X4 CREW). . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
LOWER BODY, FLOOR AND FENDERS (6X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
HOOD / DASH COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
DASH INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
CAB FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
ASSEMBLY / REMOVAL (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
ASSEMBLY / REMOVAL (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
SEAT / HEAD REST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
CHASSIS / MAIN FRAME (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
CHASSIS / MAIN FRAME (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT A-ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.14
5.15
5
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
FRONT STRUT CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
BALL JOINT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
MID AXLE A-ARM (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
REAR A-ARM (4X4 CREW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
REAR STABILIZER BAR (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
SWING ARM (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6X6) . . . . . . . . . . . . . . . . . 5.23
REAR CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
CARGO BOX - PANELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
CARGO BOX - TAILGATE / BOX SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
BOX REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
STORAGE BOX (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27

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 BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS SPECIAL TOOLS
ITEM TORQUE VALUE TOOL DESCRIPTION PART NUMBER
ft.lbs. (Nm)
Strut and Ball Joint Tool Set 2870871
Front A-Arm Attaching Bolt 30 ft. lbs. (41 Nm)
Shock Spanner Wrench 2870872
Front A-Arm Ball Joint Stud Nut 30 ft. lbs. (41 Nm)
Shock Spring Compressor Tool 2870623
Front Wheel Hub Castle Nut 60 ft. lbs. (81 Nm)
Strut Spring Compressor Tool (LH) 2871573
Rear Shock Bolt (upper) 30 ft. lbs. (41 Nm)
Strut Spring Compressor Tool (RH) 2871574
Rear Shock Bolt (lower) 30 ft. lbs. (41 Nm)
Rear Wheel Hub Castle Nut 110 ft. lbs. (150 Nm)
Mid Half Shaft Castle Nut (6x6) 110 ft. lbs. (150 Nm)
Wheel Nuts (Cast Rims) 90 ft. lbs. (122 Nm)
Wheel Nuts (Steel Rims) 35 ft. lbs. (47 Nm)
Upper / Lower Control Arm
30 ft. lbs. (41 Nm)
Mounting Bolt
Mid Axle Upper / Lower Control
35 ft. lbs. (47 Nm)
Arm Mounting Bolt (6x6)
Lower Middle Wheel Bearing 35 ft. lbs. (47 Nm)
Carrier Bolt (6x6)
Lower Rear Wheel Bearing
30 ft. lbs. (41 Nm)
Carrier Bolt
Upper Middle Wheel Bearing 35 ft. lbs. (47 Nm)
Carrier Bolt (6x6)
Upper Rear Wheel Bearing
30 ft. lbs. (41 Nm)
Carrier Bolt
Strut Rod Retaining Nut (Top) 15 ft. lbs. (21 Nm)
Strut Casting Pinch Bolt 17 ft. lbs. (23 Nm)
Tie Rod End Jam Nut 12-14 ft. lbs. (17-19 Nm
Tie Rod End Castle Nut 40 ft. lbs. (54 Nm)
Seat Belt to Seat Base 40 ft. lbs. (54 Nm)
Steering Wheel to Shaft 25-31 ft. lbs. (34-42 Nm)
Upper Steering Shaft to
15-19 ft. lbs. (20-26 Nm)
U-Joint Shaft
Lower Steering Shaft to Box 30 ft. lbs. (41 Nm)
Steering Box 14-18 ft. lbs. (19-24 Nm)

NOTE: Refer to exploded views throughout this

chapter for more torque specifications, component
identification, and location of components.

5.2

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 BODY / STEERING / SUSPENSION
BODY COMPONENT REMOVAL
Removal Procedures
TO REMOVE: PERFORM THESE STEPS:
SEAT Pull up on front of seat and then pull forward
1. Remove the gear selector handle
2. Then remove the 4 screws that attach the hood to the dash
DASH 3. Remove the remaining dash screws that attach the RANGER emblem
4. Disconnect the dash component wires
5. Remove the steering wheel (1 nut)
1. Disconnect headlights
HOOD
2. Remove the 4 hinge screws
1. Remove seat back and seat base
CAB 2. Remove the bolts for the front mounts
3. Remove the bolts for the rear mounts
1. Remove liner darts and screws 5
HOOD LINER 2. Disconnect the wiring harnesses
3. Remove the air baffling boxes
1. Lift the hood
2. Remove the 3 front Torx screws from LH and RH wheel well panels
FRONT BUMPER
3. Remove the 2 top bumper mounting bolts
4. Remove the 3 lower bumper mounting bolts
1. Place box in the dump position
2. Remove the pin and clip from the shock at the cargo box
3. Disconnect light harnesses
CARGO BOX
4. Remove (2) screws holding hinge pins
5. Tap out hinge pins
6. Lift the box off the frame with assistance
1. Raise the cargo box
2. Disconnect the vent and fuel lines (note locations)
3. Disconnect electrical connection
FUEL TANK
4. Remove the RH rear fender and fuel cap
5. Remove the 2 inner bolts and 2 outer bolts that hold the tank to the frame
6. Carefully lift the tank out through the side
1. Raise the cargo box
2. Remove the (2) bottom T27 Torx screws
LH STORAGE BOX 3. Remove the (2) top T27 Torx screws
4. Remove the (3) T27 Torx screws on the front edge
5. Lift the storage box outward from frame

5.3

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 BODY / STEERING / SUSPENSION
Lower Body, Floor and Fenders (4x4 CREW)

Speed
Nut Rear Floor Foam Foil
T-27
Foil
Rear Fender Foam Foil
T-27 Foam
T-27
Floor
T-27 Cover
Mid Fender Foil

Dog House
T-27 Cover
Main Floor

Floor 12V
Bracket Receptacle
Rear Floor Ext. T-27
Storage Speed
Dog House Box
Cover Nut

U-Type Nut

Mid Fender
Front Fender

T-27
T-27

Wheel Well
Panel Front Fender
T-27
T-25
Skid Plate

Wheel Well
Panel T-25
Washer

Self-tapping
Screws

TORQUE SPECIFICATIONS
T-25 Screws: 20-30 in. lbs. (2-3.5 Nm)
T-27 Screws: 4-5 ft. lbs. (5-6 Nm)
Skid Plate Screws: 6-8 ft. lbs. (8-10 Nm)

5.4

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 BODY / STEERING / SUSPENSION
Lower Body, Floor and Fenders (6x6)

Foam Foil
Foil
Main Floor Foil
Floor Foam
T-27
Cover
T-27

Speed Foam

T-27
Nut
U-Type
Foil 5
Rear Nut Dog House
Fender Cover
Front
Fender
T-27
T-27
Speed
Nut
T-27
Rear
Fender

T-25
Front T-27
Fender

Wheel Well Skid Plate T-27

Panel T-25
Washer

Self-tapping
Screws

TORQUE SPECIFICATIONS
T-25 Screws: 20-30 in. lbs. (2-3.5 Nm)
T-27 Screws: 4-5 ft. lbs. (5-6 Nm)
Skid Plate Screws: 6-8 ft. lbs. (8-10 Nm)

5.5

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 BODY / STEERING / SUSPENSION
Hood / Dash Components

T-27 Glove Box Assembly

T-30

Hinges

Cup Holder
T-27

Hood

T-27

Grille
Headlights

Hood Latch Strap Hood Liner

TORQUE SPECIFICATIONS
T-30 Screws: 8-10 in. lbs. (0.9-1 Nm)
T-27 Screws: 4-5 ft. lbs. (5-6 Nm)

5.6

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 BODY / STEERING / SUSPENSION
Dash Instruments and Controls
A. Speedometer
B. Headlight Switch A
C. 2WD/AWD Switch G B C
D. 12 Volt Accessory Receptacle
E. Speedometer “Mode” Button
F. Key Switch
G. Speedometer Mount Plate

F E D

B C
5
G
A

F D
E

5.7

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 BODY / STEERING / SUSPENSION
CAB FRAME
Assembly / Removal (6x6)
1. Assemble the two rear cab frames at the coupler joint and secure with two 3/8" screws and nuts. Assemble the front frame in
same manner. Leave all fasteners finger tight.
2. Assemble the center cross bracket to the rear cab frame and secure with two 5/16”-18 x .75” hex bolts and nuts. Tighten 5/16"
bolts to 16-18 ft. lbs. (20-24 Nm).
3. Assemble the front cab frame to the rear cab frame at both side coupler joints and secure with 3/8" screws and nuts. Leave all
fasteners finger tight.
4. Place the assembled cab frame onto the vehicle and align the rear mount holes. Secure the rear of the frame using the two 5/
16”-18 x 2.25” bolts and nuts on the outer tubes, and the two 5/16”-18 x .75” bolts and nuts on the inner mounts. Tighten all
5/16" bolts to 16-18 ft. lbs. (20-24 Nm). NOTE: Tighten all nuts finger tight, then tighten to specification.
5. Secure the front cab frame flanges to the vehicle with 5/16”-18 x .75” bolts and nuts. Tighten all 5/16" bolts to 16-18 ft. lbs.
(20-24 Nm). NOTE: Tighten all nuts finger tight, then tighten to specification.
6. Tighten all 3/8" cab frame screws to 25-28 ft. lbs. (34-38 Nm).
7. Check all nuts and bolts for proper torque and installation. To remove the cab frame, reverse the installation instructions.

5.8

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 BODY / STEERING / SUSPENSION
Assembly / Removal (4x4 CREW)
1. Assemble the two rear cab frames at the coupler joint and secure with two 3/8" screws and nuts. Assemble the center frame
and the front frame in same manner. Tighten all 3/8" screws to 25-28 ft. lbs. (34-38 Nm).
2. Assemble the center cross bracket to the rear cab frame and secure with two 5/16”-18 x .75” hex bolts and nuts. Tighten the
bolts to 16-18 ft. lbs. (20-24 Nm).
3. Assemble the front cab frame to the center cab frame at both side coupler joints and secure with 3/8" screws and nuts. Attach
the center cab frame to the rear cab frame at both side coupler joints and secure with 3/8” screws and nuts. Tighten all 3/8"
screws to 25-28 ft. lbs. (34-38 Nm).
4. Remove the storage box under the front seat.
5. Place the assembled cab frame onto the vehicle and align the rear and center mounting holes. Secure the rear and center of the
frame using the 5/16”-18 x 2.25” bolts on the outer tubes and the 5/16”-18 x .75” bolts on the inner mounts. Tighten all 5/16"
bolts to 16-18 ft. lbs. (20-24 Nm). NOTE: Tighten all nuts finger tight, then tighten to specification.
6. Secure the front flanges to the vehicle with 5/16”-18 x .75” bolts and nuts. Tighten all 5/16" bolts to 16-18 ft. lbs. (20-24 Nm).
NOTE: Tighten all nuts finger tight, then tighten to specification.
7. Check all nuts and bolts for proper torque and installation. Replace the storage box back into position and fasten with four
screws. To remove the cab frame, reverse the installation instructions.

5.9

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 BODY / STEERING / SUSPENSION
SEAT / HEAD REST
Seat Back / Head Rests
1. Fasten the seat back to the rear cab frame(s) using the Torx-head screws. NOTE: For seats that have staples visible from
the rear, the seat back cover will need to be placed between the rear cab frame and seat back assembly. Tighten all Torx-
head fasteners to 18-20 in. lbs. (2-2.5 Nm).

2. Install the headrests on the cab frame using 1/4”-20 x 1” bolts, washers, and 1/4”-20 Nyloc nuts. Place the washers between
the bolt heads and headrest as shown below. Torque bolts to 10 in. lbs. (1.1 Nm).

3. Check all screws and fasteners for proper torque and installation.

5.10

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 BODY / STEERING / SUSPENSION
CHASSIS / MAIN FRAME (4X4 CREW)
Exploded View

(2) Seat Base

(2) RH Floor Support Main Frame

Front Cab Support

28-32 ft. lbs.

(38-43 Nm)

35 ft. lbs.
(47 Nm)

Bumper

Grills

T-27 13-15 ft. lbs.

4-6 ft. lbs. 28-32 ft. lbs.
(38-43 Nm) (17-20 Nm)
(6-8 Nm) (2) LH Floor Support

5.11

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 BODY / STEERING / SUSPENSION
CHASSIS / MAIN FRAME (6X6)
Exploded View

Seat Base

Frame Extension

Front Cab Support

RH Floor Support
45 ft. lbs.
(61 Nm)

Main Frame

28-32 ft. lbs.

(38-43 Nm)

Bumper
Grills
13-15 ft. lbs.
(17-20 Nm) LH Floor Support
T-27
28-32 ft. lbs.
4-6 ft. lbs.
(38-43 Nm)
(6-8 Nm)

5.12

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 BODY / STEERING / SUSPENSION
STEERING ASSEMBLY
Exploded View

Cap
28 ft. lbs.
(38 Nm) Nut
Rod End & Jam Nut
Steering Wheel
Bushing Wave Washers
17 ft. lbs.
(23 Nm)

16 ft. lbs. 30 ft. lbs.

(22 Nm) (41 Nm)
Upper Steering Shaft
Tie Rod
Lower Steering Shaft
5

Boots 16 ft. lbs.

(22 Nm)
Tie Rod
Steering Box End Bolt

40 ft. lbs.
(54 Nm)

5.13

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 BODY / STEERING / SUSPENSION
STEERING AND SUSPENSION
Exploded View

NOTE: To avoid damage to the tie rod ends and

Always use new other steering components, be sure to install tie
Always use new bolts
cotter pins upon rod end bolts in the proper direction.
upon reassembly
reassembly.

Apply LoctiteTM 242

28 ft. lbs.
(38 Nm)
17 ft. lbs.
(23 Nm)

30 ft. lbs.
(41 Nm)

16 ft. lbs.
(22 Nm)
12-14 ft. lbs.
(16-19 Nm)

16 ft. lbs.
(22 Nm)
30 ft. lbs. 40 ft. lbs.
(41 Nm) (54 Nm)
Front

30 ft. lbs.
(41 Nm)

8 ft. lbs.
(11 Nm)
20-30 ft. lbs.
30 ft. lbs.
(2-3.5 Nm)
(41 Nm)

5.14

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 BODY / STEERING / SUSPENSION
FRONT A-ARM 8. Attach A-arm to hub strut assembly. Tighten ball joint nut
to 30 ft. lbs. (41 Nm). If cotter pin holes are not aligned,
Replacement tighten nut slightly to align. Install a new cotter pin with
open ends toward rear of machine. Bend both ends in
1. Elevate and safely support vehicle with weight removed opposite directions around nut.
from front wheel(s).
2. Remove cotter pin from ball joint stud at wheel end of A- WARNING
arm and loosen nut until it is flush with end of stud.
3. Using a soft face hammer, tap nut to loosen A-arm from Upon A-arm installation completion, test vehicle
bolt. Remove nut and A-arm from hub strut assembly. at low speeds before putting into regular
service.
4. Loosen two bolts on A-arm bushing by alternating each
about 1/3 of the way until A-arm can be removed.
5. Examine A-arm bushing and A-arm shaft. Replace if worn. A-arm Attaching Bolt Torque:
Discard hardware.
6. Insert A arm bushings and A-arm shaft into new A-arm.
30 ft. lbs. (41 Nm)
NOTE: On AWD models, install CV joint shields. See Ball Joint Stud Nut Torque:
Illustration
30 ft. lbs. (41 Nm)
7. Install new A-arm assembly onto vehicle frame. Torque
new bolts to 30 ft. lbs. (41.4 Nm).
5
WARNING
The locking features on the existing bolts were
destroyed during removal. DO NOT reuse old
bolts. Serious injury or death could result if
fasteners come loose during operation.

New Bolt Apply LoctiteTM 242

Vehicle Frame 30 ft. lbs. (41 Nm)

Strut

Ball Joint
New Bolt Stud
30 ft. lbs. (41 Nm)

A-Arm Bushing
A-Arm Shaft

T-20 CV Joint Shield 30 ft. lbs. 8 ft. lbs.

20-30 in. lbs. New Cotter Pin (41 Nm) (11 Nm)
(2-3.5 Nm)

5.15

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 BODY / STEERING / SUSPENSION
FRONT STRUT
Exploded View
Top
Nut Pivot Ball Spring
15 ft. lbs. Retainer
(21 Nm) Spacer Rubber Bottom
Pivot Ball

Washer
Spacer

Front Strut

Clamp

Washer

18 ft. lbs.
(24 Nm)

Spring
Bolt

17 ft. lbs.
Strut Bumper (23 Nm)
Wheel Speed Sensor
(Hall Effect Sensor)
Washer

Bearing

Retaining Ring

5.16

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 BODY / STEERING / SUSPENSION
Front Strut Cartridge Replacement 4. Remove cotter pin (A) from ball joint castlenut.
5. Remove castle nut (B) and separate A-arm (C) from ball
Refer to Front Strut Exploded View.
joint stud.
1. Hold strut rod and remove top nut. 6. Remove screws (D) and ball joint retaining plate (E).
2. Compress spring using strut spring compressor tools. 7. Using ball joint removal/installation tool kit (PN 2870871),
remove ball joint (F) from strut housing.
Strut Spring Compressor Tools
• Install puller guide (G) with extension cap (H).
(PN 2871573) and (PN 2871574) • Apply grease to extension cap and threads of puller bolt
to ease removal.
3. Remove upper strut pivot assembly.
• Thread bolt (K) with nut (J) onto ball joint stud as
4. Remove coil spring and collapse strut cartridge.
shown.
5. Remove two pinch bolts from strut casting.
6. Remove strut cartridge. • Apply heat to ease removal.
7. Install cartridge until bottomed in strut casting. • Hold bolt (K) and turn nut (J) clockwise until ball joint
8. Install pinch bolts with wire clamp(s). Torque pinch bolts is removed from strut housing.
to 17 ft. lbs. (23 Nm).
9. Reassemble spring and top pivot assembly. Be sure all parts
G
are installed properly and seated fully.
10. Torque strut rod nut to specification. Do not over torque H 5
nut.
J
K
Strut Rod Nut Torque
15 ft. lbs. (21 Nm)

Ball Joint Replacement

1. Loosen front wheel nuts slightly.
2. Elevate and safely support machine under footrest/frame 8. To install new ball joint:
area.
• Remove extension cap and attach puller guide using
CAUTION short bolts provided in the kit.

• Insert new ball joint (L) into driver (M).

Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning
this service procedure.

3. Remove wheel nuts and wheels. L

C F
E
• Slide ball joint / driver assembly into guide.
D
B • Apply heat to ease installation.
A
• Drive new joint into strut housing until fully seated.

5.17

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 BODY / STEERING / SUSPENSION
9. Apply Loctite™ 242 (PN 2871949) to threads of retaining
plate screws or install new screws with pre-applied locking
WARNING
agent. Torque screws to 8 ft. lbs. (11 Nm).
The locking features on the existing bolts were
10. Install A-arm on ball joint and torque castle nut to 30 ft. lbs.
destroyed during removal. DO NOT reuse old
(41 Nm).
bolts. Serious injury or death could result if
11. Reinstall cotter pin with open ends toward rear of machine. fasteners come loose during operation.
9. Attach A-arm to wheel bearing carrier. Install the shock to
the upper mid A-arm. Torque bolts as shown.
MID AXLE A-ARM (6X6)
10. Locate grease fitting in center of A-arm tube and pump A-
Replacement arm full of grease.

1. Elevate and safely support the center of the vehicle with WARNING
weight removed from center wheel(s).
2. Remove the hub cap, cotter pin, spindle nut, wheel nuts, and Upon A-arm installation completion, test vehicle
wheel. Refer to Chapter 7 “MID DRIVE BEARING at low speeds before putting into regular
CARRIER / HUB REMOVAL” procedure. service.
3. Remove the bolts that secure the shock to the upper and
lower mid A-arms. RANGER 6X6 Mid Drive
4. Loosen two bolts on A-arm bushing by alternating each
about 1/3 of the way until A-arm can be removed. Perform A-arm Attaching Bolt torque:
this procedure on the upper and lower mid A-arms. 30 ft. lbs. (41 Nm)
5. Examine the A-arm bushing and A-arm shaft. Replace if
worn. Discard hardware.
Upper Bearing Carrier Bolt Torque:
6. Insert A-arm bushings and A-arm shaft into new A-arm.
30 ft. lbs. (41 Nm)
7. Install new lower mid A-arm assembly onto vehicle frame.
Torque new bolts to 30 ft. lbs. (41 Nm).
8. Install a new upper mid A-arm assembly. Torque new bolts
Lower Bearing Carrier Bolt Torque:
to 30 ft. lbs. (41 Nm). 50 ft. lbs. (68 Nm)

Frame New Bolt

Bushing
30 ft. lbs. (41 Nm)

Shaft 30 ft. lbs.

Nut (41 Nm)

Upper Mid
A-arm
Shock

Bushings
Bushing
Mid Axle
A-Arm Assy.

Shaft Wheel Bearing

Carrier
Bushings

Washer
50 ft. lbs.
30 ft. lbs. New Bolt (68 Nm)
Lower Mid A-Arm
(41 Nm)

5.18

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 BODY / STEERING / SUSPENSION
REAR A-ARM (4X4 CREW) 5. Remove the hub and brake disc assembly by sliding it off
of the axle.
Replacement
NOTE: Use the exploded view on the next page as
reference during the procedure.

1. Elevate and safely support vehicle with weight removed

from the rear wheel(s).
2. Remove the wheel nuts, washers, and wheel.

6. Remove the bolt that secures the shock and coil to the upper
A-arm.
7. Remove the bolt that secures the wheel carrier to the upper
A-arm.

Shock Bolt 5
NOTE: To ease the removal of the spindle bolt,
remove the hub cap and loosen the spindle bolts
before removing the wheel.

3. Remove the hub cap, cotter pin, spindle bolt, and washer.
4. Remove the brake caliper. Suspend the brake caliper from
the frame with a wire. Wheel Carrier
Bolt
NOTE: Do not let the brake caliper hang from the
brake line or damage may occur.

8. Loosen two bolts that secure the A-arm to frame by

alternating each about 1/3 of the way until A-arm can be
removed. Perform this procedure on the upper A-arm. See
exploded view, next page.
9. Examine the A-arm bushing and A-arm shaft. Replace if
worn. Discard hardware.
10. To remove the lower control arm, the wheel bearing carrier
needs to be removed. Remove the upper and lower wheel
carrier bolts and slide the rear drive shaft from the carrier.
(See Chapter 7 for more details).

5.19

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 BODY / STEERING / SUSPENSION
11. Remove the bottom stabilizer bar nut. 14. Install new A-arm assembly onto vehicle frame. Torque
new bolts to 30 ft. lbs. (41 Nm).

WARNING
Stabilizer Bar
The locking features on the existing bolts were
destroyed during removal. DO NOT reuse old
bolts. Serious injury or death could result if
fasteners come loose during operation.

15. Attach A-arm to wheel bearing carrier. Torque upper and

lower carrier bolts as shown.
16. Install the shock and tighten shock bolt to 30 ft.lbs. (41
Nm).
12. Loosen two bolts that secure the A-arm bushing to frame 17. Re-install wheel and caliper. Refer to “Chapter 2” for wheel
by alternating each about 1/3 of the way until the A-arm can toque specifications.
be removed. The lower A-arm should now be free to
remove. WARNING
A-Arm Installation Upon A-arm installation completion, test vehicle
13. Insert new A-arm bushings and new A-arm shaft into new at low speeds before putting
A-arm. into regular service.

30 ft. lbs.
30 ft. lbs. (41 Nm)
(41 Nm)
Nuts
A-arm Shaft Coil
Bolts

Bushings Upper A-arm

Shock
Bushings
30 ft. lbs. 30 ft. lbs.
(41 Nm) (41 Nm)
A-arm Bolts
Shaft Caliper
Shaft 18 ft. lbs.
Wheel Bearing
(24 Nm)
Carrier
Nuts

Bushings Lower A-arm Bearing

Carrier Bolt
30 ft. lbs. (41 Nm)
Shaft Snap Ring
Shaft
50 ft. lbs. Bushings
(68 Nm)

5.20

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 BODY / STEERING / SUSPENSION
REAR STABILIZER BAR (4X4 CREW) 4. Remove the two bolts that secure the stabilizer bar to the
main frame, each side.
Removal / Installation
1. Elevate and safely support vehicle with weight removed
from the rear wheel(s).
2. Remove the rear wheel to gain access to the stabilizer bar,
each side.
Stabilizer Bar

Stabilizer
Bar
5. Remove the stabilizer from the frame.
6. Inspect the stabilizer bar for straightness. Inspect the
bushings and replace if needed.
7. Inspect the rubber bushings on the linkage rod and replace
if needed. 5
3. Remove the stabilizer bar nut from the lower A-arm on each 8. Reverse the procedure for installation. Torque the stabilizer
side. bolts to 16-18 ft.lbs. (21-25 Nm).

Inspect Bushings

16-18 ft. lbs.

(21-25 Nm)
Stabilizer Assembly

Inspect Bushings

5.21

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 BODY / STEERING / SUSPENSION
SWING ARM (6X6)
Removal
1. Support machine on a level surface. A
2. Remove rear wheels.
NOTE: The rear axle may be removed to ease the B
removal of the swing arm. Refer to Chapter 7, “REAR
AXLE HOUSING REMOVAL/INSPECTION”.
3. Support swing arm, remove rear axle shocks.
4. Drive spring pin out of rear propshaft at middle angle drive
using the Roll Pin Removal Tool (PN 2872608).

PN 2872608
Installation
1. Raise swing arm assembly and align the drive shaft to
the rear gearcase splined shaft (lube splines).
2. Insert new bushings, check pivot bolts for wear, replace if
necessary, torque bolts to 150 ft. lbs (75.9 Nm). Install
bolt lock brackets and bolts, torque to 30 ft. lbs. (41 Nm).
3. Install rear coil over shocks onto swing arm, torque bolts
to 30 ft. lbs (41 Nm).
4. Install rear wheels, lower machine.
5. Insert new spring pin on rear propshaft.
NOTE: Use jacks and jackstands to help remove the
swing arm assembly. Pivot Bolt and Nut Torque:
5. Remove the pivot bolt lock brackets (A), swing arm pivot 150 ft. lbs. (75.9 Nm)
bolts (B), bolts swing arm bushings, lower swing arm and
rear axle. Rear Shock Mount Bolt Torque:
30 ft. lbs. (41 Nm)

Swing arm

U-Bolt

Shock Coil

Washer & Bolt

30 ft. lbs.
Bushings (41 Nm)
Frame
Pivot Bolt
150 ft. lbs. Bolt Lock
Rear Axle
(203 Nm) Bracket
30 ft. lbs.
(41 Nm) Apply LoctiteTM 271

5.22

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 BODY / STEERING / SUSPENSION
REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6X6)

Retaining Ring
Wheel Axle Tube Screw & Washer
Bearing
60 ft. lbs.
(81 Nm)
Vehicle Frame
Screw & Washer 60 ft. lbs.
(81 Nm)
Swing Arm Axle
Wheel
Bearing

150 ft. lbs. O-Ring

(203 Nm)
Axle Tube
U - Bolt Nut & Washer

5
40 ft. lbs.
(54 Nm)

Washer
Rear Gearcase U- Bolt
Assembly Jam Nut
Grease Fitting
Bolt Lock
Bracket
Swing Arm Bushing

Pivot Bushing

Swing Arm Pivot Bolt 150 ft. lbs.

(203 Nm)

30 ft. lbs.
(40 Nm)
Rubber Pad
Bolt & Washer
Skid Plate 60 ft. lbs.
(81 Nm)

Apply LoctiteTM 242

5.23

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 BODY / STEERING / SUSPENSION
REAR CARGO BOX
Cargo Box - Panels

8-10 in. lbs.

(0.9-1.0 Nm)
Taillight T-20
8-10 in. lbs.
(0.9-1.0 Nm)
T-30 Tailgate Support

T-27
4-6 ft. lbs.
(5-8 Nm)

T-20

T-30
8-10 in. lbs.
(0.9-1.0 Nm)
T-20 Seal Foam
8-10 in. lbs.
(0.9-1.0 Nm) Side Panel
T-20
8-10 in. lbs.
Front Panel (0.9-1.0 Nm)

5.24

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 BODY / STEERING / SUSPENSION
Cargo Box - Tailgate / Box Support

Tailgate Cap

Tailgate
Latch 20-25 in. lbs.
Cable T-20
(2-3 Nm)
T-20
8-10 in. lbs.
Outer Panel
(0.9-1.0 Nm)
Inner Panel Rod

5
Tailgate Tube

Box

Box Support

Box Latch
Assembly

Hinge Pin

Shock Pins
Bolt

Shock Heat
8-10 ft. lbs. Shield
(10-13 Nm)

5.25

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 BODY / STEERING / SUSPENSION
Box Removal
1. Lift the cargo box into the dump position. Slide Hinge Pin Out
2. Disconnect the rear wire harness attached to the tail lights.

3. Remove the upper clip and pin attaching the shock to the
cargo box.

Shock Pin

6. With both hinge pins removed, remove the box from the
frame. Two people maybe needed to remove the box from
the frame.

CAUTION

Use caution when removing the box. It is

recommended to have two people carefully
CAUTION remove the box from the frame.

Safely support the box during the remainder of Box Installation

the removal process. The box is not as stable
with the shock removed. 1. If the shock was replaced, install the lower portion of the
shock to the frame and secure it with the pin and clip.
4. Remove the screw (A) that secures the hinge pin to the
frame on both sides.

A
Lower
Shock Pin

2. Place the cargo box onto the frame. Align the hinges of the
box with the bracket on the frame.
5. Remove the hinge pin from both sides.
3. Install the box hinges on both sides.

CAUTION 4. Secure the box hinges with the hinge screws on both sides.

5. With the hinges installed, attach the shock to the cargo box
Safely support the box during the remainder of by inserting the pin and clip.
the removal process. The box is not as stable
with the hinge pins removed. 6. Lower the box and secure the latch.

5.26

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 BODY / STEERING / SUSPENSION
STORAGE BOX (4X4 CREW) DECAL REPLACEMENT
Plastic polyethylene material must be “flame treated” prior to
Removal
installing a decal to ensure good adhesion. The flame treating
1. Remove the two bottom T-27 torx screws. procedure can often be used to reduce or eliminate the whitish
stress marks that are sometimes left after a fender or cab is bent,
2. Remove the two top T-27 torx screws. flexed, or damaged.

3. Remove the three T-27 torx screws on the front edge.

WARNING

The following procedure involves the use of an

open flame. Perform this procedure in a well
ventilated area, away from gasoline or other
flammable materials.
Be sure the area to be flame treated is clean and
Torque screws to: free of gasoline or flammable residue.
4-5 ft. lbs. (5-6 Nm)
To flame treat the decal area:
1. Pass the flame of a propane torch back and forth quickly
over the area where the decal is to be applied until the
surface appears slightly glossy. This should occur after just
5
a few seconds of flame treating. Do not hold the torch too
close to the surface. Keep the torch moving to prevent
4. Lift the storage box towards the rear of the frame for damage.
removal. 2. Apply the decal.

Installation NOTE: Refer to your parts manual for decal part

number.
1. Install the storage box back into the frame assembly. Align
all screw holes and ensure the storage box is properly fitted
to the frame.

2. Install all of the T-27 torx screws that were removed.

Torque screws to 4-5 ft.lbs. (5-6 Nm).

5.27

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 BODY / STEERING / SUSPENSION

NOTES

5.28

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 CLUTCHING
CHAPTER 6
CLUTCHING
SPECIAL TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT SYSTEM FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
MAINTENANCE / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
OVERHEATING / DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
PVT SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT SEALING, GUARD, AND DUCTING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 6.5
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BELT INSPECTION / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
CLUTCH ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
CLUTCH CENTER DISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
SPRING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
SHIFT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
6
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
ROLLER, PIN, AND THRUST WASHER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6.14
BUTTON TO TOWER CLEARANCE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
MOVEABLE SHEAVE BUSHING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BUSHING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
CLUTCH DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23

6.1

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 CLUTCHING
SPECIAL TOOLS AND SUPPLIES PVT SYSTEM OVERVIEW
TOOL DESCRIPTION PART NUMBER General Operation
Drive Clutch Puller 2870506
Clutch Holding Wrench 9314177 WARNING
Clutch Holding Fixture 2871358
Drive Clutch Spider Removal and All PVT maintenance or repairs should be
Install Tool
2870341 performed only by a certified Polaris Master
Service Dealer (MSD) technician who has
Roller Pin Tool 2870910 received the proper training and understands
Clutch Bushing Replacement Tool Kit 2871226 the procedures outlined in this manual.
Piston Pin Puller 2870386 Because of the critical nature and precision
balance incorporated into the PVT
Clutch Compression Tool 8700220 components, it is absolutely essential that
Clutch Bushing Replacement Tool Kit 2871025 no disassembly or repair be made without
Clutch Alignment Tool PA-49011 factory authorized special tools and
service procedures.

SPECIAL SUPPLIES PART NUMBER The Polaris Variable Transmission (PVT) consists of three
Loctite™ 609 N/A major assemblies:
RTV Silicone Sealer 8560054 1) The Drive Clutch
2) The Driven Clutch
TORQUE SPECIFICATIONS 3) The Drive Belt
The internal components of the drive clutch and driven clutch
PVT System Fastener Torques
control engagement (initial vehicle movement), clutch upshift
and backshift. During the development of a Polaris ATV, the
TORQUE VALUE
ITEM PVT system is matched first to the engine power curve; then to
ft. lbs. (Nm)
average riding conditions and the vehicle’s intended usage.
Drive Clutch Retaining Bolt 47 ft. lbs. (64 Nm) Therefore, modifications or variations of components at random
Driven Clutch Retaining Bolt 17 ft. lbs. (23 Nm) are never recommended. Proper clutch setup and careful
inspection of existing components must be the primary
PVT Inner Cover Bolts 12 ft. lbs. (16 Nm)
objective when troubleshooting and tuning.
PVT Outer Cover Bolts 45-50 in. lbs (5-5.6 Nm)
Drive Clutch Spider 200 ft. lbs. (271 Nm) Drive Clutch Operation
Drive Clutch Cover Plate 90 in. lbs. (10 Nm)
Drive clutches primarily sense engine RPM. The two major
components which control its shifting function are the shift
weights and the coil spring. Whenever engine RPM is
increased, centrifugal force is created, causing the shift
weights to push against rollers on the moveable sheave, which
is held open by coil spring preload. When this force becomes
higher than the preload in the spring, the outer sheave moves
inward and contacts the drive belt. This motion pinches the
drive belt between the spinning sheaves and causes it to rotate,
which in turn rotates the driven clutch.
At lower RPM, the drive belt rotates low in the drive clutch
sheaves. As engine RPM increases, centrifugal force causes the
drive belt to be forced upward on drive clutch sheaves.

6.2

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 CLUTCHING
Driven Clutch Operation Maintenance / Inspection
Driven clutches primarily sense torque, opening and closing Under normal use the PVT system will provide years of trouble
according to the forces applied to it from the drive belt and the free operation. Periodic inspection and maintenance is required
transmission input shaft. If the torque resistance at the trans- to keep the system operating at peak performance. The
following list of items should be inspected and maintained to
mission input shaft is greater than the load from the drive belt,
ensure maximum performance and service life of PVT
the drive belt is kept at the outer diameter of the driven clutch
components. Refer to the troubleshooting checklist at the end of
sheaves. this chapter for more information.
As engine RPM and horsepower increase, the load from the
1. Belt Inspection, Drive to Driven Clutch Alignment, and
drive belt increases, resulting in the belt rotating up toward the
Clutch Center Distance.
outer diameter of the drive clutch sheaves and downward into
the sheaves of the driven clutch. This action, which increases 2. Drive and Driven Clutch Buttons and Bushings, Drive
the driven clutch speed, is called upshifting. Clutch Shift Weights and Pins, Drive Clutch Spider
Rollers and Roller Pins, Drive and Driven Clutch
Should the throttle setting remain the same and the vehicle is
Springs.
subjected to a heavier load, the drive belt rotates back up toward
the outer diameter of the driven clutch and downward into the 3. Sheave Faces. Clean and inspect for wear.
sheaves of the drive clutch. This action, which decreases the
4. PVT System Sealing. Refer to appropriate illustrations on
driven clutch speed, is called backshifting.
the following pages. The PVT system is air cooled by fins
In situations where loads vary (such as uphill and downhill) and on the drive clutch stationary sheave. The fins create a low
throttle settings are constant, the drive and driven clutches are pressure area in the crankcase casting, drawing air into the
continually shifting to maintain optimum engine RPM. At full system through an intake duct. The opening for this intake
throttle a perfectly matched PVT system should hold engine duct is located at a high point on the vehicle (location varies
RPM at the peak of the power curve. This RPM should be by model). The intake duct draws fresh air through a vented
maintained during clutch upshift and backshift. In this respect,
the PVT system is similar to a power governor. Rather than vary
cover. All connecting air ducts (as well as the inner and
outer covers) must be properly sealed to ensure clean air is 6
throttle position, as a conventional governor does, the PVT being used for cooling the PVT system and also to prevent
system changes engine load requirements by either upshifting or water and other contaminants from entering the PVT area.
backshifting. This is especially critical on units subjected to frequent
water forging.

PVT Break-In (Drive Belt / Clutches)

A proper break-in of the clutches and drive belt will ensure a
longer life and better performance. Break in the clutches and
drive belt by operating at slower speeds during the 10 hour
break-in period as recommended (see Chapter 3 “Engine
Break-In Period” for break-in example). Pull only light loads.
Avoid aggressive acceleration and high speed operation during
the break-in period.

6.3

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 CLUTCHING
Overheating / Diagnosis
During routine maintenance, or whenever PVT system overheating is evident, it’s important to check the inlet and outlet ducting
for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures. The
vehicle should be operated in Low when plowing or pulling heavy loads, or if extended low speed operation is anticipated.
CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS
Possible Causes Solutions / What to do
Loading the vehicle into a truck or tall
Shift transmission to Low during loading of the vehicle to prevent belt burning.
trailer when in high range.
Starting out going up a steep incline from When starting out on an incline, use Low, or dismount the vehicle after first
a stopped position. applying the park brake and perform the “K” turn.
Driving at low RPM or low ground speed Drive at higher speed or use Low. The use of Low is highly recommended
(at approximately 3-7 MPH). for cooler PVT operating temperatures and longer component life.
Insufficient warm-up of Utility Task Warm engine at least 5 min., then with transmission in neutral, advance
Vehicles™ exposed to low ambient throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
temperatures. become more flexible and prevent belt burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement.
Towing/Pushing at low RPM/low ground
Use Low only.
speed.
Plowing snow, dirt, etc./utility use. Use Low only.
Shift the transmission to Low, carefully use fast, aggressive throttle
Stuck in mud or snow. application to engage clutch. WARNING: Excessive throttle may cause loss
of control and vehicle overturn.
Shift the transmission to Low, carefully use fast, aggressive, brief throttle
Climbing over large objects from a
application to engage clutch. WARNING: Excessive throttle may cause loss
stopped position.
of control and vehicle overturn.
Shift the transmission to neutral. Using the throttle, vary the engine rpm from
Belt slippage from water or snow idle to full throttle. Repeat several times as required. During this procedure,
ingestion into the PVT system. the throttle should not be held at the full position for more than 10 seconds.
Clutch seals should be inspected for damage if repeated leaking occurs.
For inspection of clutch components, please contact your Polaris dealer. Shift
Clutch malfunction.
transmission to Low during loading of the vehicle to prevent belt burning.
Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Contact
Poor engine performance.
you dealer for further service information.
Low: Heavy pulling, basic operational speeds less than 7 MPH, riding
GENERAL RANGE OPERATION through rough terrain (swamps, mountains, ect.), low ground speeds.
GUIDELINES:
High: High ground speeds, speeds above 7 MPH.

Operating in Low Gear

Low is the primary driving gear. Low should be used in ALL driving applications except for driving on hard packed level surfaces
with light loads. In this circumstance, High may be used.
IMPORTANT: Using High for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance of
drive belt burning.

RANGER 4X4 / 6X6

1. Use Low as the primary driving gear H
for all RANGERs.
L
2. Use High only on hard packed,
N
level surfaces with light loads.
R

6.4

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 CLUTCHING
PVT SYSTEM SERVICE
PVT Sealing, Guard, and Ducting Components

SEALING AND DUCTING COMPONENTS

Clutch Outlet Duct
Inner Cover

Clamps

Inner Cover Seal

Retainer

Outer Cover Seal

6
Cover Bolts
PVT Outer Cover

Disassembly
Some fasteners and procedures will vary. Refer to the 6. Install the Drive Clutch Holder (PN 9314177) (A).
appropriate parts manual for proper fasteners and fastener
placement. 7. Remove drive clutch retaining bolt and remove drive clutch
using the Drive Clutch Puller (PN 2870506) (B).
1. Remove seat.
2. Remove the LH storage box to gain access to PVT outer Drive Clutch Puller (PN 2870506)
cover (see Chapter 5 for removal).
3. Remove PVT air outlet duct hose. Drive Clutch Holder (PN 9314177)
4. Remove outer PVT cover screws.
5. Mark the drive belt direction of rotation and remove drive 8. Remove the driven clutch retaining bolt and driven clutch.
belt. See “Drive Belt Removal”.
Retaining Bolt
A

6.5

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 CLUTCHING
9. Remove driven clutch alignment washer(s) from the 3. Apply RTV silicone sealant to outside edge of inner cover-
transmission input shaft. to-engine seal, to ensure a water tight fit between the seal
and the cover. Surfaces must be clean to ensure adhesion
Note Number of Washers
of silicone sealant.

4. Reinstall cover and tighten rear cover bolts just enough to

hold it in place.

5. Fit lip of inner cover seal (A) to engine. Install seal retainer
plate and tighten screws securely.

B
C

10. Remove screws and retainer plate.

A

Seal outer edge to cover

with RTV silicone sealant

6. Torque rear inner cover bolts (B) to specification.

7. Install clutch alignment washer(s) on transmission input

shaft.

Alignment Washer(s)
11. Remove inner cover retaining bolts at rear of cover.

12. Remove cover along with foam seal on back of cover or

shaft.

Assembly
1. Inspect PVT inner cover-to engine seal. Replace if cracked
or damaged.
Apply RTV Silicone Here

8. Clean splines inside driven clutch and on the transmission

input shaft.

9. Apply a light film of grease to the splines on the shaft.

10. Install the driven clutch, washer, lock washer, and retaining
bolt. Torque to specification.

11. Clean end of taper on crankshaft and the taper bore inside
drive clutch.

12. Install drive clutch and torque retaining bolt to

specification.
2. Place a new foam seal on transmission input shaft.

6.6

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 CLUTCHING
13. Reinstall drive belt noting direction of rotation. If a new belt DRIVE BELT
is installed, install so numbers can be easily read.
Belt Removal
14. Replace PVT outer clutch cover rubber gasket.
1. Remove outer PVT cover as described in PVT
15. Reinstall PVT outer clutch cover and secure with screws. Disassembly.
Torque to 45-50 in. lbs. (5-5.6 Nm).
2. Mark the drive belt direction of rotation so that it can be
16. Install the PVT cover outlet duct and tighten the clamps. installed in the same direction.

NOTE: Belt is normally positioned so that part

numbers are easily read.

Inner Cover Bolt Torque (Rear):

12 ft. lbs. (16.6 Nm)
3. To remove drive belt, put transmission in gear, apply brake,
6
pull upward and rearward on belt to open driven clutch
Outer Cover Bolt Torque: sheaves, pull out and down on belt to slip over the driven
45-50 in.lbs. (5-5.6 Nm) clutch outer sheave.

Driven Clutch Retaining Bolt Torque:

17 ft. lbs. (23.5 Nm)

Drive Clutch Retaining Bolt Torque:

47 ft. lbs. (64 Nm)

6.7

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 CLUTCHING
Belt Inspection PVT Break-In (Drive Belt / Clutches)
1. Inspect belt for hour glassing (extreme circular wear in at A proper break-in of the clutches and drive belt will ensure a
least one spot and on both sides of the belt). Hour glassing longer life and better performance. Break in the clutches and
occurs when the drive train does not move and the drive drive belt by operating at slower speeds during the 10 hour
clutch engages the belt. break-in period as recommended (see Chapter 3 “Engine
Break-In Period” for break-in example). Pull only light loads.
2. Inspect belt for loose cords, missing cogs, cracks, Avoid aggressive acceleration and high speed operation during
abrasions, thin spots, or excessive wear. Compare belt the break-in period.
measurements with a new drive belt. Replace if necessary.

3. Belts with thin spots, burn marks, etc., should be replaced

to eliminate noise, vibration, or erratic PVT operation. See CLUTCH ALIGNMENT
the Troubleshooting Chart at the end of this chapter for
possible causes. Clutch Alignment Tool Use
Clutch alignment is controlled by the number of washers that are
Belt Installation
placed behind the driven clutch on the transmission input shaft.
1. Loop belt over the drive clutch and over top of the driven Adding washers behind the driven clutch will move the drive
sheave. belt toward the moveable sheave of the drive clutch. Removing
washers from behind the driven clutch will move the drive belt
toward the stationary sheave of the drive clutch.

1. Remove the seat.

2. Remove the LH storage box to gain access to the outer PVT

cover (see Chapter 5 for removal).

3. Loosen the hose clamp and remove the PVT air outlet duct
hose from the outer PVT cover.

4. Remove all outer PVT cover screws and remove the cover.

5. Mark the drive belt direction of rotation and remove drive

belt (see “Drive Belt Removal”).
2. While pushing down on top of belt, turn the back or
6. Install the Clutch Alignment Tool.
moveable driven sheave clockwise.

CLUTCH ALIGNMENT TOOL

PA-49011

3. The belt then should be able to be pushed down into and

between the sheaves.

Be sure to position belt so part number is easily read.

6.8

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 CLUTCHING
7. Place the alignment tool in the sheaves of the driven clutch 10. If the alignment tool touches the shaft bearing but has an
and hold firmly as you rotate it down between the sheaves excessive amount of clearance between the tool and
of the drive clutch. stationary sheave, the driven clutch will need to be moved
in to correct the alignment.
PA-49011
• Remove the driven clutch. Remove the required
amount of washers to obtain roughly .020” clearance
between the tool and stationary sheave.

NOTE: The number of washers behind the driven

clutch will vary between vehicles.

IMPORTANT: It may not be possible to achieve

perfect alignment with the tool as previously
described, because of the thickness of the alignment
washers. It is better to have clearance between the
tool and stationary sheave of the drive clutch than to
have the tool touch the stationary sheave before it
touches the shaft bearing.
Clutch Alignment Tool
11. After completing the clutch alignment procedure, the belt
PA-49011 should ride in the drive clutch with an approximate .020”
gap between the belt and stationary sheave and a larger gap
8. As you rotate the tool down between the drive clutch of approximately .130” between the belt and moveable
sheaves, the tool should touch the clutch shaft bearing while sheave.
maintaining a clearance of roughly .020” between the tool
and stationary sheave of the drive clutch. .020” Gap 6
Stationary
Sheave

Shaft Bearing

CLUTCH CENTER DISTANCE

9. If the alignment tool hits the stationary sheave before it
reaches the shaft bearing, the driven clutch will need to be
spaced out to correct the alignment.

• Remove the driven clutch. Add the required amount of

alignment washers to obtain the correct measurement
with the alignment tool. You may need to add more
than one alignment washer.

Alignment Washers
(.030”) PN: 7556454 Center
Distance
(.060”) PN: 7556120 10.05 in. / 255 mm

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 CLUTCHING
DRIVE CLUTCH SERVICE
Spring Specifications
The drive clutch spring has two primary functions:
1. To control clutch engagement RPM. The springs
which have a higher rate when the clutch is in neutral
will increase clutch engagement RPM.
Red/White
2. To control the rate at which the drive belt moves 7043349

upward in the drive clutch sheaves. This is referred Red/Blue

7043372
to as drive clutch upshift.

There are other components which control upshift, but the

spring is one of the primary components in insuring Red/Green
7043382
optimum performance. It is very important that the spring
is of the correct design and is in good condition.

CAUTION

Never shim a drive clutch spring to increase its

compression rate. This may result in complete
stacking of the coils and subsequent clutch
cover failure.

The drive clutch spring is one of the most critical components of the PVT
system. It is also one of the easiest to service. Due to the severe relaxation the
spring is subject to during operation, it should always be inspected for
tolerance limits during any clutch operation diagnosis or repair.

With the spring resting on a flat surface, measure its free length from the outer
coil surfaces as shown. Refer to the spring specification chart for specific free
length measurements and tolerances. Also check to see that spring coils are
parallel to one another. Distortion of the spring indicates stress fatigue,
requiring replacement.

Primary Clutch Springs

PART NUMBER COLOR CODE WIRE DIAMETER FREE LENGTH ± .125”
7041021 Plain .157" 4.38"
7041022 Black .140" 4.25"
7041063 Purple .168" 4.37"
7041132 White .177" 2.92"
7041157 Blue / Green .177" 2.53"
7041168 Green .177" 3.05"
7043349 Red / White .200" 2.58"
7043372 Red / Blue .187" 2.56"
7043382 Red / Green .177" 2.63"

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 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.

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 CLUTCHING
Exploded View

Bushing Lock
Washer
Spring

Cover
Bearing
Spider Bolt

Bearing
Non-Braking Flat
Bearing Spacer Washer
Button Cover
Screws

Roller Pin

Button Washers

Nut

Bolt
Washers Shift
Weight

Clutch Disassembly
1. Using a permanent marker, mark the cover, spider, and 3. Inspect cover bushing (A). The outer cover bushing is
moveable and stationary sheaves for reference, as the cast manufactured with a Teflon™ coating. Wear is determined
in X's may not have been in alignment before disassembly. by the amount of Teflon™ remaining on the bushing.

2. Remove cover bolts evenly in a cross pattern and remove

Cover Bushing Inspection:
cover plate.
Replace the cover bushing if more
brass than Teflon™ is visible on
the bushing. Refer to bushing
replacement in this chapter.

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 CLUTCHING
4. Inspect area on shaft where bushing rides for wear, galling, NOTE: It is important that the same number and
nicks, or scratches. Replace clutch assembly if worn or thickness of washers are reinstalled beneath the
damaged. spider during assembly. Be sure to note the number
and thickness of these washers.
Inspect Shaft
To maintain proper clutch balance and
belt-to-sheave clearance, be sure to
reinstall original quantity and thickness
washers

5. Remove and inspect the clutch spring. See “Drive Clutch

Spring Specifications” for spring inspection. Moveable Sheave Bushing Inspection
2. Inspect the Teflon™ coating on the moveable sheave
Spider Removal bushing.

1. Install clutch in holding fixture (PN 2871358) and loosen

the spider (counterclockwise) using Clutch Spider
Removal Tool (PN 2870341).
6

TeflonTM

Moveable Sheave Bushing Inspection:

Replace the cover bushing if more brass

than Teflon is visible on the bushing.
Refer to bushing replacement
Clutch Holding Fixture: in this chapter.
(PN 2871358)

Spider Removal Tool:

(PN 2870341)

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 CLUTCHING
Roller, Pin, and Thrust Washer Inspection Button To Tower Clearance Inspection
1. Inspect all rollers, bushings and roller pins by pulling a flat 1. 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. See “Spider Removal” procedure.
pins and thrust washers in sets of three. Also inspect to see
if roller and bushing are separating. Bushing must fit
tightly in roller. Use the Roller Pin Tool (PN 2870910) to
replace rollers and pins. Take care not to damage roller
bushing or bearing surface of the new pin during
installation.

Button to Tower Clearance:

000-.001”

2. Inspect sheave surfaces. Replace the entire clutch if worn,

damaged or cracked.
2. Rubber backed buttons can be used in all RANGER clutches
if the hollow roller pin is changed to the solid roller pin.
Shift Weight Inspection
NOTE: The rubber side of the button is positioned
toward the solid roller pin.
WARNING

The clutch assembly is a precisely balanced

unit. Never replace parts with used parts from
another clutch assembly!

1. If clutch is not disassembled, inspect as shown, using a

clutch holding tool to compress the moveable sheave. The
contact surface of the weight should be smooth and free of
dents or gall marks.

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 CLUTCHING
2. Remove shift weight bolts and weights. Inspect as shown. Clutch Inspection
The contact surface of the weight should be smooth and free
of dents or gall marks. Inspect the weight pivot bore and NOTE: Remove cover, spring, and spider following
pivot bolts for wear or galling. If weights or bolts are worn instructions for drive clutch removal, then proceed
or broken, replace in sets of three with new bolts. as follows:

1. Remove the moveable sheave spacer (1) and the thrust

washer (2). Visually inspect the washer for damage.

2. Measure the thickness and compare to specification.

Replace if worn or damaged.

Broken Worn Good

NOTE: A damaged shift weight is usually caused by

a damaged or stuck roller in the spider assembly. 2
See “Roller, Pin and Thrust Washer Inspection”.

Bearing Inspection
1. Rotate non-braking clutch bearing in both clockwise and
counter-clockwise directions. The non-braking bearing
should rotate both directions on the shaft with only a slight = In. / mm.
6
amount of drag.

2. Verify there is no binding or rough spots. If problems are Thrust Washer Thickness
noted in either direction, continue with disassembly. Standard: .030” (.76mm)
Service Limit: .025” (.64mm)

3. Remove the moveable clutch sheave.

4. Lift bearing (3) and thrust washer (4) off shaft. Replace as
an assembly if worn, damaged, or if problems were noted.

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 CLUTCHING
5. Inspect surface of shaft for pitting, grooves, or damage. Moveable Sheave Bushing Inspection
Measure the outside diameter and compare to
specifications. Replace the drive clutch assembly if shaft Inspect the Teflon™ coating (arrow) on the moveable sheave
is worn or damaged. bushing. Inspect both sheaves for signs of wear, grooving or
cracking. De-glaze sheave surfaces with a 3M™ Scotch-Brite
Pad if needed.

= In. / mm.
Moveable Sheave Bushing Inspection:
Shaft Diameter: Replace the cover bushing if more brass
Standard: 1.3745 - 1.375 ( than Teflon™ is visible on the bushing.
Service Limit: 1.3730” Refer to bushing replacement
in this chapter.
6. Visually inspect PTFE thrust washer for damage. Measure
the thickness and compare to specification. Replace if
worn or damaged.

= In. / mm.

PTFE Washer Thickness

Standard: .030” (.76mm)
Service Limit: .025” (.64mm)

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 CLUTCHING
Bushing Service
IMPORTANT: Special Tools Required CAUTION

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 1 EBS Puller Tool 5132027
C 1 EBS Puller Nut 5132501 Moveable Sheave - Bushing Removal
D 1 EBS Main Adapter 5132029 1. Remove clutch as outlined previously in this chapter.
E 1 EBS Bushing Removal Tool 5132028
2. Install handle end of the Piston Pin Puller (PN 2870386)
-- 1 Instructions 9915111
securely into bench vise and lightly grease puller threads.
Additional Special Tools
Qty. Part Description Part #
Piston Pin Puller (PN 2870386)
1 Clutch Bushing Replacement Tool Kit 2871226
1 Piston Pin Puller 2870386 3. Remove nut from puller rod and set aside.

*Clutch Bushing Replacement Tool Kit (PN 2871226)

Piston Pin Puller
#2 (PN 2870386)
#3
#5

6
Main Puller Adaptor (#8)
(PN 5020632)

#9
#10 4. Install puller adapter (Item 10 from kit PN 2871226).
#8
5. Install main adapter (Item D) onto puller.
Item Qty. Part Description Part # Puller Tool (A,B) Nut (C)
P-90 Drive/Driven Clutch Side “A” toward
#2 1 5020628
Bushing Install Tool sheave
Drive Clutch Cover
Bushing Removal/
#3 1 5020629
Installation Tool (all
clutches)
P-90 Driven Clutch Cover
#5 1 5020631
Bushing Removal Tool
#8 1 Main Puller Adapter 5020632
Puller
#9 1 Adapter Reducer 5010279 Adapter (10)
Number Two Puller
#10 1 5020633 Main Piston Pin
Adapter Adapter (D) Puller
NOTE: Bushings are installed at the factory using
Loctite™. In order to remove bushings it will be 6. With towers pointing toward the vise, slide sheave onto
puller rod.
necessary to apply heat evenly to the area around
each bushing. Clean all residual Loctite™ from 7. Install removal tool (Item A, B) into center of sheave with
bushing bore prior to installing new bushing. “A side" toward sheave.

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 CLUTCHING
NOTE: Use Bushing Tool PA-47336. Cover Bushing Removal

8. Install nut (C) onto end of puller rod and hand tighten. Turn 1. Install main adapter (Item 8) on puller.
puller barrel to increase tension on sheave if needed. Using Removal Tool Nut (C)
a hand held propane torch, apply heat around outside of (3)
bushing until tiny smoke tailings appear.

9. Turn sheave counterclockwise on puller rod until it comes

free. Lift sheave off puller.

10. Remove nut from puller rod and set aside.

11. Pull bushing removal tool and adapter from puller rod.
Remove bushing from tool and discard.
Adapter Reducer
Drive Clutch Bushing Installation (9)
Main Piston Pin
1. Place main adapter (Item 8) on puller. Adapter (8) Puller
Puller Tool (A,B) Nut (C)
Side “A” toward 2. Install adapter reducer (Item 9).
sheave
3. From outside of clutch cover, insert removal tool (Item 3)
into cover bushing.

4. With inside of cover toward vise, slide cover onto puller.

5. Install nut onto puller rod and hand tighten. Turn puller
barrel to increase tension as needed.
Bushing
Piston Pin 6. Turn clutch cover counterclockwise on puller rod until
Puller bushing is removed and cover comes free.
Main Adapter
(8) 7. Remove nut from puller rod and set aside.

2. Apply Loctite™ 609 evenly to bushing bore inside 8. Remove bushing and bushing removal tool from puller.
moveable sheave. Discard bushing.

3. Set bushing in place on sheave. Cover Bushing Installation

1. Apply Loctite™ 609 evenly to bushing bore in cover.
4. Insert installation puller tool (Item A/B) with “A” side
down, into center of bushing. 2. Working from inside of cover, insert new bushing and
NOTE: 700 EFI Clutch - Use Bushing Tool PA-47336. bushing installation tool into center of clutch cover.
5. With towers pointing upward, slide sheave, bushing and
3. With main adapter on puller, insert cover onto puller rod,
tool onto puller rod.
placing outside of cover toward vise.
6. Install nut on puller rod and hand tighten. Turn barrel to 4. Install nut on rod and hand tighten. Turn puller barrel to
apply additional tension if needed. apply more tension if needed.
7. Turn sheave counterclockwise, making sure bushing is 5. Turn clutch cover counterclockwise on puller rod until
drawn straight into bore. Continue until bushing is seated. bushing is seated.
8. Remove nut from puller rod and set aside.
6. Remove nut from puller rod. Take installation tool and
clutch cover off rod.
9. Remove sheave from puller.

10. Remove installation tool.

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 CLUTCHING
Clutch Assembly 4. 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. The Teflon bushings are
self-lubricating. =T
Spider Torque:
CAUTION 200 ft. lbs. (271 Nm)

Do not apply oil or grease to the bushings.

CAUTION
Reassemble the drive clutch in the following sequence. Be sure
the “X”, or the marks that were made earlier are aligned during Be sure the spider spacer washers are fully
each phase of assembly. seated in the recessed area in the spider.
Any misalignment will alter clutch balance.
Inverting the clutch while initially tightening the
spider will help position the washers.

5. Install shift weights using new lock nuts on the bolts.

6
1. Install moveable sheave onto fixed sheave.

2. Install spider spacers. Use same quantity and thickness as

were removed. Nut on trailing side Rotation

6. Reinstall clutch spring.

7. Reinstall cover, aligning “X” mark with other marks.

8. Torque cover bolts evenly to specification.

=T
Spacer washers
Cover Screw Torque:
3. Compress spider buttons for each tower and install spider, 90 in. lbs. (10.4 Nm)
making sure that “X”, or the marks that were made earlier,
on spider aligns with “X”, or the marks that were made
earlier, in moveable sheave.

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 CLUTCHING
DRIVEN CLUTCH SERVICE
Exploded View

DRIVEN CLUTCH

Compression Spring

Outer Spring Retainer

Secondary Stationary Sheave

Inner Spring Retainer Retaining Ring

Moveable Inner Sheave

Clutch Disassembly / Inspection 3. Place the clutch into the Clutch Compression Tool PN
8700220. Using Compression Extensions PN PS-45909,
apply and hold downward pressure on the outer spring
CAUTION retainer. Carefully remove the snap ring. Remember the
outer spring retainer contains strong spring pressure.
Wear eye protection when removing snap ring to
prevent serious personal injury.
Remove Snap Ring
Use caution when removing, the snap ring
pressure is loaded by the compression spring.

1. Remove driven clutch from the transmission input shaft.

2. Mark the position of the clutch sheaves before disassembly
or use the X’s on the sheaves for reference. This aids in
reassembly and maintains clutch balance after reassembly.

Outer Spring Retainer

NOTE: Spring is compression only and has no

torsional wind.

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 CLUTCHING
4. With the snap ring (A) removed and spring pressure 7. Remove the inner spring retainer from the inner sheave.
relieved, remove the outer spring retainer (B), compression Inspect for wear and replace as needed.
spring (C), and inner spring retainer (D).

A C

Inspect for Abnormal Wear

8. Check the rollers in the stationary sheave for wear. If rollers

are worn, a new driven clutch assembly may be needed.
B

A
D
C

5. Separate the two clutch sheaves.

6

Check Rollers for Wear

9. Inspect the bearings inside the moveable sheave.

Inspect Bearings for Wear

6. Inspect the helix on the moveable sheave.

Inspect for Abnormal Wear

Moveable Sheave Bearing Inspection:

Replace the bearing if more brass than
Teflon™ is visible on the bearing.

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 CLUTCHING
10. Inspect the Teflon™ coating on the moveable sheave
bearings.

11. Inspect driven clutch sheave faces for wear or damage.

12. Clean and inspect splines on helix and transmission input

shaft.

13. Lube splines with a light film of grease. Do not lubricate

the bearings!

Clutch Assembly
1. Install the inner spring retainer if removed. Do not apply Assemble Sheaves
oil or grease to the bearings.
3. Install spring into inner retainer.

4. Install outer retainer on top of spring.

2. Align the “X” marks on each of the sheaves during

reassembly.
5. Place the clutch into Clutch Compression Tool PN
8700220. Using Compression Extensions PN PS-45909,
apply and hold downward pressure on the outer spring
retainer. Carefully install the snap ring.

6. Compress the outer retainer and install the snap ring.

Snap Ring

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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. -Driven clutch spring broken or installed in wrong -Replace spring; refer to proper installation location.
helix location.
-Drive clutch binding. A. Disassemble drive clutch; inspect shift weights for
wear and free operation.
B. Clean and polish stationary shaft hub; reassemble
clutch without spring to determine problem area.
Erratic engine
operating RPM -Belt worn unevenly - thin / burnt spots. Replace belt.
during acceleration or
load variations. -Driven clutch malfunction. A. Replace ramp buttons.
B. Inspect movable sheave for excessive bushing
clearance.

-Sheave face grooved. -Replace the clutch.

-Incorrect drive clutch spring (too high spring rate). -Install correct recommended spring.

-Drive clutch shift weights incorrect for application -Install correct recommended shift weights.
(too light). 6
-Drive clutch binding. -Disassemble and clean clutch, inspecting shift weights
and rollers. Reassemble without the spring and move
Engine RPM above
sheaves through entire range to further determine
specified operating
probable cause.
range.
-Driven clutch binding. -Disassemble, clean, and inspect driven clutch, noting
worn sheave bushing and ramp buttons and helix spring
location.

-Converter sheaves greasy; belt slipage. -Clean sheaves with denatured alcohol or brake cleaner,
install new belt.
-Drive belt worn too narrow. -Replace belt.
Harsh drive clutch
engagement. -Excessive belt / sheave clearance with new belt. -Perform belt / sheave clearance adjustment with shim
washers beneath spider.
-Wrong belt for application. -Replace with correct belt.

Drive belt turns over -Clutch alignment out of spec. -Adjust clutch alignment.

-Engine mount broken or loose. -Inspect / adjust or replace.

-Abuse (continued throttle application when -Caution operator to operate machine within guidelines.
vehicle is stationary, excess load)

Belt burnt, thin spots -Dragging brake -Vehicle operated with park brake on. Inspect brake
system.

-Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement.

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 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. Inform operator.
overheating (melting)
operation.

-High vs. low range. -Instruct operator on guidelines for operation in proper
driving range for different terrain as outlined in Owner’s
Safety and Maintenance Manual.
-Cover seals or ducts leaking -Find leak and repair as necessary.

Water ingestion -Operator error -Instruct operator on guidelines for operation in wet
terrain as outlined in Owner’s Safety and Maintenance
Manual.
-Belt worn out -Replace belt.

Belt slippage -Water ingestion -Inspect and seal PVT system.

-Belt contaminated with oil or grease -Inspect and clean.

-Belt worn or separated, thin spots, loose belt -Replace belt.
PVT noise
-Broken or worn clutch components, cover hitting -Inspect and repair as necessary.
clutches
-Thin spots on belt, worn belt -Replace belt. Refer to belt burnt troubleshooting and
Engagement instruct operator.
erratic or stabby
-Drive clutch bushings stick -Inspect and repair clutches.

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 FINAL DRIVE
CHAPTER 7
FINAL DRIVE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
FRONT HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
HUB REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
HUBSTRUT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
FRONT HUB EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
FRONT PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
6X6 REMOVAL / 4X4 CREW REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
FRONT PROPSHAFT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
FRONT GEARCASE CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
AWD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
GEARCASE DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
GEARCASE REASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
BACKLASH PAD (THRUST PAD) ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
7
MID DRIVE HUB / BEARING CARRIER (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
HUB DISASSEMBLY / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
MID DRIVE EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
MID DRIVE SHAFT (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
DISASSEMBLY / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
MID PROPSHAFT (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
MID DRIVE GEARCASE (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
MID GEARCASE EXPLODED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
REAR HUB / BEARING CARRIER (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
HUB INSPECTION / REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
HUB DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40

7.1

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 FINAL DRIVE
REAR DRIVE SHAFT (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44
DRIVE SHAFT EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.47
REAR PROPSHAFT (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.48
REAR GEARCASE (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
OPERATION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.50
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51
REAR GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.54
REAR GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
REAR GEARCASE EXPLODED VIEW (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . 7.57
REAR AXLE / GEARCASE SERVICE (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.58
REAR AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.58
AXLE TUBE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.59
AXLE TUBE BEARING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.60
GEARCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.60
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.61
GEARCASE / AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62
REAR GEARCASE EXPLODED VIEW (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.65

7.2

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 FINAL DRIVE
SPECIAL TOOLS FRONT HUB
Hub Removal / Inspection
PART NUMBER TOOL DESCRIPTION
1. Elevate front end and safely support machine under
2872608 Roller Pin Removal Tool
footrest / frame area.
8700226 CV Boot Clamp Pliers
PU-48951 Axle Boot Clamp Tool CAUTION

Serious injury may result if machine tips or falls.

TORQUE SPECIFICATIONS Be sure machine is secure before beginning this
service procedure. Wear eye protection when
Wheel, Hub, and Spindle Torque Table removing bearings and seals.

ITEM NUT TYPE SPECIFICATION 2. Check bearings for side play by grasping the tire / wheel
firmly and checking for movement. Grasp the top and
Aluminum Wheels bottom of the tire. The tire should rotate smoothly without
Lug Nut (1) 90 ft. lbs. (122 Nm)
(Cast) binding or rough spots.
Steel Wheels
Flange Nut (2) 35 ft. lbs. (47 Nm)
(Black / Camo)
Front Spindle Nut - 70 ft. lbs. (95 Nm)
Rear & Middle
- 110 ft. lbs. (150 Nm)
Hub Retaining Nut

7
#1 #2

3. Remove wheel nuts, washers, and wheel.

Aluminum Wheel Steel Wheel
(LE Models) (Standard Models) 4. Remove the two brake caliper attaching bolts.
90 ft. lbs. (122 Nm) 35 ft. lbs. (47 Nm) CAUTION: Do not hang the caliper by the brake line. Use
wire to hang the caliper to prevent possible damage to the
brake line.

7.3

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 FINAL DRIVE
5. Remove hub cap, cotter pin, front spindle nut, and washer. 3. Drive bearing out evenly by tapping on outer race only.
Once bearing is at bottom of casting, support casting on
outer edges so bearing can be removed.

6. Rotate each bearing by hand and check for smooth rotation.

Visually inspect bearing for moisture, dirt, or corrosion.
Replace bearing if moisture, dirt, corrosion, or roughness NOTE: Due to extremely close tolerances and
is evident. minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
outer race.

4. Inspect bearing hubstrut housing for scratches, wear or

Rotate Bearing damage. Replace hubstrut housing if damaged.

Bearing Installation
5. Thoroughly clean the hubstrut housing and the outer race
on the new bearing. Be sure that all oil residue has been
removed from each surface.
6. Apply Loctite® 603™ retaining compound to the outer
Hubstrut Bearing Replacement circumference of the new bearing race and carefully install
the new bearing into the strut housing.
Bearing Removal
1. Remove outer snap ring.

Apply Loctite® 603™

NOTE: Use care to not allow any of the Loctite®

compound to get in the bearing.

2. From the back side, tap on the outer bearing race with a drift 7. Wipe the housing clean of any excess compound and install
punch in the reliefs as shown in Step 3. the retaining ring.

7.4

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 FINAL DRIVE
Hub Installation 10. Install brake caliper using new bolts. Tighten bolts to
specified torque.
1. Inspect the hubstrut bearing surface for wear or damage.

2. Apply grease to drive axle spindle.

3. Install spindle through the backside of the hubstrut. Install

the hub onto the spindle.

4. Apply grease to washer and install with domed side out. 18 ft. lbs.
(24 Nm)

Brake Caliper Bolt Torque

18 ft. lbs. (24 Nm)

CAUTION

New bolts have a pre-applied locking agent

which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.
11. Install wheel, washers, wheel nuts, and tighten evenly in a
cross pattern to specified torque.
Out Refer to “Torque Specifications” on Page 7.3 7
Cone Flange Nuts:
Washer Flat side against wheel

5. Install spindle nut and tighten to specification.

Spindle Nut Torque:

70 ft. lbs. (95 Nm)

6. Install a new cotter pin. Tighten nut slightly if necessary

to align cotter pin holes.

7. Rotate wheel and check for smooth operation. Bend both

ends of cotter pin around end of spindle in different
directions.

8. Install hub cap.

9. Rotate hub. It should rotate smoothly without binding or

rough spots or side play.

7.5

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 FINAL DRIVE
Front Hub Exploded View
Disc Brake Stud

Front Hub

Rim

Tire
18 ft. lbs. (24 Nm)
Use new bolts with
pre-applied
locking agent.
Wheel Nut
(Spec on page 7.3)

Dust Cover

Washer

Slotted Nut
70 ft. lbs. (95 Nm) Cotter Pin

7.6

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 FINAL DRIVE
FRONT DRIVE SHAFT 6. Remove the front wheel hub.

Removal
1. 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. Wear eye protection when
removing bearings and seals.

2. Check bearings for side play by grasping tire / wheel firmly

and checking for movement. It should rotate smoothly 7. Remove cotter pin and castle nut from A-arm ball joint.
without binding or rough spots.

8. Remove lower A-arm from ball joint using a tie rod fork.
7
3. Remove the (4) wheel nuts and remove the front wheel.

4. Remove the two brake caliper mounting bolts.

CAUTION: Do not hang the caliper by the brake line. Use
wire to hang the caliper to prevent possible damage to the
brake line.

5. Remove and discard the cotter pin, then remove the front
hub castle nut.

7.7

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 FINAL DRIVE
9. Pull strut assembly out while pivoting front drive shaft • Never use a hammer or sharp tools to remove or to
downward until it clears strut assembly. install boot clamps.

• Be sure joints are thoroughly clean and that the proper

amount and type of grease is used to refill when joint
boots are replaced and when joints are cleaned. Refer
to text for grease capacity of CV joints and CV joint
boots.

Outer CV Joint / Boot Replacement

1. Remove the front drive shaft from the vehicle (see
“FRONT DRIVE SHAFT - Removal”).

2. Remove and discard the boot clamps.

CV Boot Clamp Pliers

10. With short sharp jerks, remove drive shaft from front
gearcase. Earless Type: 8700226

3. Remove the large end of the boot from the CV joint and
slide the boot back.

4. Use a soft-faced hammer or brass drift to separate the CV

joint from the drive shaft.

NOTE: If using a brass drift, be sure to tap on the

inner race of the joint only.

Circlip

Drive Shaft / CV Joint Handling Tips

Care should be exercised during drive shaft removal or when
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. Pull shaft to remove
from CV joint
• The complete drive shaft and joint should be handled by
getting hold of the interconnecting shaft to avoid 5. Make sure the circlip remains on the shaft and not left in
disassembly or potential damage to the drive shaft the joint. Discard the circlip.
joints.
6. Remove the boot from the drive shaft.
• Over-angling of joints beyond their capacity could
result in boot or joint damage.
CAUTION
• Make sure surface-ground areas and splines of shaft are
protected during handling to avoid damage. Complete disassembly of the CV joint is NOT
recommended. The internal components are a
• Do not allow boots to come into contact with sharp
precision fit and develop their own characteristic
edges or hot engine and exhaust components.
wear patterns. Intermixing the internal
• The drive shaft is not to be used as a lever arm to components could result in looseness, binding,
position other suspension components. and/or premature failure of the joint.

7.8

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 FINAL DRIVE
IMPORTANT: If the grease in the joint is obviously 13. Slide the joint onto the drive shaft splines and align the
contaminated with water and/or dirt, the joint should circlip with the lead-in chamfer on the inner race of the
be replaced. joint.

7. Thoroughly clean the joint with an appropriate solvent and 14. Use a soft-faced hammer to tap the joint onto the drive shaft
dry the joint to prevent any residual solvent from being left until it locks into place.
in the joint upon reassembly.
15. Pull on the joint to make sure it is securely locked into place.
8. Visually inspect the joint by tilting the inner race to one side
to expose each ball. Severe pitting, galling, play between 16. Remove excess grease from the CV joint’s external
the ball and its cage window, any cracking or damage to the surfaces and place the excess grease in the boot.
cage, pitting or galling or chips in raceways call for joint
replacement. 17. Pull the boot over the joint and position the boot lips into
the grooves on the joint housing and shaft. Make sure the
NOTE: Shiny areas in ball tracks and on the cage boot is not dimpled or collapsed.
spheres are normal. Do not replace CV joints
because parts have polished surfaces. Replace CV 18. Install and secure the CV boot with the large clamp using
joint only if components are cracked, broken, worn the “earless” clamp pliers.
or otherwise unserviceable.
CV Boot Clamp Pliers
9. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly. Earless Type: 8700226

10. Slide the small boot clamp and boot (small end first) onto
19. While pulling out on the CV shaft, fully extend the CV joint
the drive shaft and position the boot in it’s groove machined
and slide a straight O-ring pick or a small slotted screw
in the shaft.
driver between the small end of the boot and the shaft. This
11. Install a NEW circlip on the end of the shaft. will allow the air pressure to equalize in the CV boot in the
position that the joint will spend most of its life. Before you
12. Grease the joint with the special CV joint grease provided remove your instrument, be sure the small end of the boot
in the boot replacement kit. Fill the cavity behind the balls is in its correct location on the shaft.
and the splined hole in the joint’s inner race. Pack the ball
tracks and outer face flush with grease. Place any
7
remaining grease into the boot.

CAUTION

The grease provided in the replacement kit is

specially formulated for wear resistance and
durability. DO NOT use substitutes
or mix with other lubricants.

NOTE: The amount of grease that’s provided is pre-

measured, so use all the grease.
20. Install and secure the small clamp on the boot using the
“earless” clamp pliers.
Boot Replacement Grease Requirement:

Grease Only Service Kits CV Boot Clamp Pliers

PN 1350059 - 20g Earless Type: 8700226
PN 1350046 - 30g
PN 1350047 - 50g

Outer CV Joint Capacity: 150g

7.9

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 FINAL DRIVE
Inner Plunging Joint / Boot Replacement 12. Grease the joint with the special CV joint grease provided
in the boot replacement kit. Fill the cavity behind the balls
1. Remove the front drive shaft from the vehicle (see and the splined hole in the joint’s inner race. Pack the ball
“FRONT DRIVE SHAFT - Removal”). tracks and outer face flush with grease. Place any
remaining grease into the boot.
2. Remove and discard the boot clamps.

CV Boot Clamp Pliers CAUTION

Earless Type: 8700226
The grease provided in the replacement kit is
specially formulated for wear resistance and
3. Remove the large end of the boot from the plunging joint durability. DO NOT use substitutes
and slide the boot back. or mix with other lubricants.

4. Use a soft-faced hammer or brass drift to separate the NOTE: The amount of grease that’s provided is pre-
plunging joint from the drive shaft. measured, so use all the grease.
NOTE: If using a brass drift, be sure to tap on the
inner race of the joint only. Boot Replacement Grease Requirement:
5. Make sure the circlip remains on the shaft and not left in Grease Only Service Kits
the joint. Discard the circlip.
PN 1350059 - 20g
6. Remove the boot from the drive shaft. PN 1350046 - 30g
PN 1350047 - 50g

CAUTION Inner Plunging Joint Capacity: 150g

Complete disassembly of the plunging joint is

NOT recommended. The internal components 13. Fully compress the joint and push the drive shaft firmly into
are a precision fit and develop their own the inner race.
characteristic wear patterns. Intermixing the
14. Align the circlip with the lead-in chamfer.
internal components could result in looseness,
binding, and/or premature failure of the joint. 15. Use a soft-faced hammer to tap the joint onto the drive shaft
until it locks into place.
IMPORTANT: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint should 16. Pull on the joint to make sure it is securely locked into place.
be replaced.
17. Remove excess grease from the plunging joint’s external
7. Thoroughly clean the joint with an appropriate solvent and surfaces and place the excess grease in the boot.
dry the joint to prevent any residual solvent from being left
in the joint upon reassembly. 18. Pull the boot over the joint and position the boot lips into
the grooves on the joint housing and shaft. Make sure the
8. Visually inspect the joint by tilting the inner race to one side boot is not dimpled or collapsed.
to expose each ball. Severe pitting, galling, play between
the ball and its cage window, any cracking or damage to the 19. Install and secure the small clamp on the boot using the
cage, pitting or galling or chips in raceways call for joint “earless” clamp pliers.
replacement.

9. Clean the splines on the end of the shaft and apply a light CV Boot Clamp Pliers
coat of grease prior to reassembly. Earless Type: 8700226
10. Slide the small boot clamp and boot (small end first) onto
the drive shaft and position the boot in it’s groove machined
in the shaft.

11. Install a NEW circlip on the end of the shaft.

7.10

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 FINAL DRIVE
20. Pull out on the drive shaft to center the joint in the housing. Installation
Slide a straight O-ring pick or a small slotted screw driver
between the large end of the boot and the joint housing and 1. Install new spring ring on drive shaft. Apply an anti-seize
lift up to equalize the air pressure in the boot. compound to splines. Align splines of drive shaft with
front gearcase and install by lightly tapping on drive shaft
21. Position the boot lip in its groove. Install and secure the with rubber faced hammer.
boot with the large clamp using the “earless” clamp pliers.

CV Boot Clamp Pliers

Earless Type: 8700226

Exploded View
NOTE: Refer the “Electronic Parts Catalog” for
required parts to service the drive shaft. Some drive
shafts have “Boot Replacement Kits” that include a
new boot, clamps, and the required amount of
grease.
2. Install drive shaft in strut.
Circlip CV Joint
3. Install the lower A-arm onto the lower ball joint, torque nut
to 25 ft. lbs. (35 Nm) and install new cotter pin.

Large
Clamp
Boot
7
Grease

Small
Clamps Cotter Pin 25 ft. lbs.
(35 Nm)

Grease
4. Install hub and tighten spindle nut to 70 ft. lbs. (95 Nm).

Boot Front Spindle Nut Torque

70 ft. lbs. (95 Nm)
Large
Clamp

Circlip
Plunging
Circlip Joint

7.11

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 FINAL DRIVE
FRONT PROPSHAFT NOTE: Remove the drive shaft floor cover to help
align the roll pin removal tool. The drive shaft can
6x6 Removal be removed through the floor covering.

1. Elevate and safely support vehicle under the frame. The

use of a vehicle hoist is recommended for this procedure.

CAUTION

Serious injury may result if machine tips or falls.

Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.

NOTE: To ease roll pin removal, access the roll pin

through the skid plate hole. Proceed to step 4 if you
are able to access the roll pin through the skid plate.
2. Remove wheel nuts and wheel.
3. Remove cotter pin and nut from the lower A-arm ball joint 4x4 CREW Removal
and then remove the lower A-arm from the ball joint. 1. Follow steps 1-5 of the “6x6 Removal” procedure.
2. Remove the additional drive shaft floor cover located in the
rear passenger floor area.
3. Remove both seats and the storage box from under the front
seat.
4. Remove the RH rear fender and the heat shield mounted on
the exhaust header pipe to allow enough clearance to
remove the propshaft.
5. Remove the propshaft out the rear RH side of the vehicle.

Front Propshaft Components

4. Use the Roll Pin Removal Tool (PN 2872608), to drive out
the roll pin from prop shaft.
6x6 Grease Zerk
Front Yoke
Roll Pin Removal Tool (PN 2872608)

5. Slide prop shaft back and away from front gearcase, then U-Joint Rear Yoke
pull the shaft sharply forward to remove it from the
transmission shaft.
Grease Zerk
4x4 CREW Front Yoke

U-Joint Rear Yoke

Skid Plate
Access Hole

7.12

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 FINAL DRIVE
PROPSHAFT U-JOINT SERVICE 3. Support U-joint in vise as shown and drive inner yoke down
to remove remaining bearing caps.
Disassembly
1. Remove internal or external snap ring from all bearing
caps.

CAUTION

Always wear eye protection.

4. Force U-joint cross to one side and lift out of inner yoke.

NOTE: If yoke or bearing is removed, cross bearing

must be replaced. Note orientation of grease fitting
and mark inner and outer yoke for correct re-
positioning during installation. 7
2. Support inner yoke as shown and drive outer yoke down
(bearing cap out) with a soft face hammer. Assembly
1. Install new bearing caps in yoke by hand. Carefully install
U-joint cross with grease fitting properly positioned
inward toward center of shaft. Take care not to dislodge
needle bearings upon installation of cross joint. Tighten
vise to force bearing caps in.

7.13

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 FINAL DRIVE
2. Using a suitable arbor, fully seat bearing cap in one side. 7. When installation is complete, yokes must pivot freely in
Continually check for free movement of bearing cross as all directions without binding. If the joint is stiff or binding,
bearing caps are assembled. tap the yoke lightly to center the joint until it pivots freely
in all directions.

3. Install snap ring to contain bearing cap just installed.

Repeat procedure for other side.

4. Install outer yoke, aligning marks made before

disassembly.

5. Repeat Steps 1-3 to install bearing caps on outer yoke.

6. Seat all bearing caps against snap rings by supporting cross

shaft and tapping on each corner as shown.

7.14

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 FINAL DRIVE
FRONT GEARCASE / CENTRALIZED HILLIARD
Centralized Hilliard Exploded View
14 19

2 15
17 ft. lbs.
(23 Nm)
22
14
10 ft. lbs. 16
(14 Nm) 18
20 14 14

10 12

13 3 25
8 9
4
1
21 23
11
5 7 8-30 ft. lbs.
14 (11-41 Nm)

2 4
7
12
24
17 ft. lbs.
(23 Nm) 17

REF# DESCRIPTION QTY REF# DESCRIPTION QTY

1 Thrust Button Asm. w/O-ring 1 14 Seal Kit (Includes O-rings and Seals) 1
2 Screw (5/16-18) 11 15 Roller Ball Bearing 1
3 Dowel Pin 1 16 Bushing 1
4 Roller Ball Bearing 2 17 Cover Plate Asm. w/Coil 1
5 Thrust Needle Bearing 1 18 Gearcase LH 1
6 Internal Retaining Ring 1 19 Input Cover 1
7 Clutch Housing / Ring Gear 1 20 Magnetic Drain Plug Asm. 1
8 Thrust Plate 1 21 Bushing 1
9 Roll Cage Asm. (Includes H-Springs) 1 22 Pinion Shaft Asm 1
10 Rollers 14 23 Fill Plug 1
11 Set Screw 1 24 Gear Spacer 1
12 Race / Output Hub Asm. 2 25 Vent Fitting 1
13 Armature Plate 1

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 FINAL DRIVE
All Wheel Drive Operation AWD Engagement: When the AWD switch is activated, the
AWD coil is powered by a 12 Vdc input which creates a
The AWD switch may be turned on or off while the vehicle is magnetic field. This magnetic field attracts an armature plate
moving, however, AWD will not enable until the engine RPM that is keyed to the roll cage. When the ring gear and roll cage
drops below 3100. Once the AWD is enabled, it remains are spinning (vehicle is moving), the energized coil and
enabled until the switch is turned off. armature plate will apply drag to the roll cage that indexes the
rollers inside the ring gear to an engagement position. While in
Engage the AWD switch before getting into conditions where the engagement position, the front drive will be in an “over-
the front wheel drive may be needed. If the rear wheels are running” condition (not engaged), until the rear wheels lose
spinning, release the throttle before switching to AWD. traction. Once the rear wheels begin to lose traction, the front
drive will engage by coupling the output hubs to the ring gear via
CAUTION the rollers. The front drive will remain engaged until the torque
requirement goes away (i.e. rear wheels regain traction).
Switching to AWD while the rear wheels are
Output Hub Rollers
spinning may cause severe drive shaft and
gearcase damage. Always switch to AWD while
the rear wheels have traction or are at rest.

With the AWD switch off, the vehicle drives through the rear
wheels only (2 wheel drive). When the AWD is enabled, the
front drive acts as an on-demand AWD system. This means, the
front drive will engage once the rear wheels have lost traction,
and will remain engaged until the torque requirement goes away
(i.e. rear wheels regain traction).
Ring Roll Cage
Gear & H-springs

CAUTION

If the rear wheels are spinning, release the

throttle before turning the AWD switch on.
If AWD is engaged while the wheels are
spinning, severe drive shaft and clutch
damage could result.

AWD Disengagement: Once the rear wheels regain traction,

the front wheels will return to the “over-running” condition.
The vehicle is now back to rear wheel drive until the next loss
of rear wheel traction occurs.

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 FINAL DRIVE
AWD Diagnosis
Symptom: AWD Will Not Engage Possible
Wear Ring on
1. Check the gearcase coil resistance. To test the coil Armature Plate
resistance, measure between the Grey and Brown/White
wires. The measurement should be within specification.
OK Condition

Bad Condition
(Wear from coil
on armature plate)

5. 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
Front Gearcase Coil Resistance: should be seated below the U-shaped insert. The U-shaped
21.6 - 26.4 Ohms insert controls the pole gap. If the top of the coil is above
the surface of the U-shaped insert it raises the armature
plate, thereby increasing pole gap. If the pole gap increases
2. Turn the ignition and AWD switches on and place gear the coil will not be strong enough to engage the AWD
selector in High or Low gear. Check for minimum battery system. If this is found, replace the cover plate assembly.
voltage at the Gray and Brown/White chassis wires that
power the coil. A minimum of 11 Vdc should be present. Gearcase Cover Plate Asm. 7
3. If electrical tests are within specification, remove gearcase
(see “Gearcase Removal”) and inspect components.
Coil
4. Inspect the armature plate for a consistent wear pattern.
There should be two distinct wear bands (one band inside
the other). If only one band of wear is present (or if there
is wear between the two bands), inspect the coil area as
indicated in Step 5. A wear band with an interrupted wear
mark may indicate a warped plate, which may cause
intermittent operation. See the following illustrations:
U-shaped insert
Side cutaway view of
Centralized Hilliard cover

Armature Plate 6. Inspect the rollers for nicks and scratches. The rollers must
slide up, down, in and out freely within the roll cage sliding
Armature plate design may
differ from what is shown
surfaces and H-springs.

Check for wear bands

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 FINAL DRIVE
8. The front gearcase and drive shafts can be accessed from
Roll Cage both sides of the vehicle and limited access from the top.
Asm.

Rollers

Top View - From under hood

7. Inspect the roll cage assembly for cracks or excessive wear.
If damaged, replace the roll cage assembly.
9. Remove the access panel on the side of the vehicle. T-25
screws secure the panel to the frame.
Gearcase Removal
1. Stop engine, place machine in gear and set parking brake.

2. Loosen right front wheel nuts slightly.

Left
3. Elevate and support machine under footrest/frame area. Side Panel

CAUTION

Serious injury may result if machine tips or falls.

Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing and installing bearings and seals.

4. Remove right wheel nuts and wheel. 10. Remove the roll pin from the front drive shaft.Remove the
front drive shaft from the front gearcase splines.
5. Remove cotter pin, lower ball joint nut, and A-arm from
ball joint. 11. Remove bolts securing bottom of gearcase to frame.
Remove vent line. Remove gearcase from right side of
frame.

Remove 4 Bolts
6. Repeat Step 1 through Step 5 on the opposite side.

7. Pull each axle out from the front gearcase, refer to the
"FRONT DRIVE SHAFT REMOVAL" procedure earlier
in this chapter.

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 FINAL DRIVE
Gearcase Disassembly / Inspection 6. Remove the roll cage assembly, rollers, and H-springs.

1. Drain and properly dispose of used oil. Remove any metal

particles from the drain plug magnet.

2. Remove bolts and output shaft cover.

7. Thoroughly clean all parts. Inspect the rollers (A) for nicks
and scratches. The rollers must slide up and down freely
within the roller cage surfaces (B).

8. Inspect the ring gear (C) for consistent wear patterns. The
3. Check the gearcase coil resistance. The resistance value surfaces should be free of nicks and scratches.
should meet the specifications listed below.

NOTE: To test the gearcase coils resistance, use the

coil harness. The gearcase coils should measure B
between 22.8 ohms and 25.2 ohms.

4. Remove output shaft assembly

7
C
A

9. Inspect roll cage (B) sliding surface. This surface must be

clean and free of nicks, burrs or scratches. Remove and
inspect the H-springs.

H-Spring
NOTE: Be careful not to misplace the thrust bearing B
located between the two output shafts.

5. Clean all parts and inspect spacers for wear. Inspect ring
gear for chipped, broken, or missing teeth.

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 FINAL DRIVE
10. Use a flat head screwdriver to remove the retaining ring 13. Remove the output hub (G) from the cover. remove the
from the output cover. thrust bearing (F) from the output hub (G). Inspect the
thrust bearing (F) and the dowel (H).
Retaining Ring
H G

11. Remove the spacer washer (D), armature plate (E), and
rubber O-ring from the output cover. 14. Inspect the magnetic coil (I) in the output housing.

NOTE: See "FRONT GEARCASE DIAGNOSIS"

D earlier in this chapter for more details on the coil.
O-Ring
15. Inspect the back lash pad (J) for excessive wear.

NOTE: The backlash for the centralized hilliard is set

at the factory. No adjustment is required, unless the
front cover needs to be replaced, or the back lash
E
pad screw is removed. See the "Backlash Pad
Adjustment” procedure later in this chapter for
details on backlash setting.

12. Inspect the armature plate (E) for a consistent wear pattern.
Uneven wear of the armature plate (E) indicates a warped
plate, which may cause intermittent operation.

NOTE: See "FRONT GEARCASE DIAGNOSIS"

earlier in this chapter for more details.

E
I

Armature plate design may

differ from what is shown

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 FINAL DRIVE
16. Remove the other output hub (K) from the main gearcase. 19. Install new seals into the gearcase housing and use new O-
Inspect the inner bearing (L) for wear. If there is excessive rings for the gearcase input and output covers.
wear, replace bearing as needed.

17. Remove the input cover (M), bearing (N), and the pinion
gear (O). Inspect the pinion gear (O) for chipped, broken, Gearcase Reassembly / Inspection
or missing teeth. Replace the input cover O-ring.
1. As mentioned in the disassembly section, replace all O-
rings, seals, and worn components.

2. Press the pinion shaft seal into the pinion cover, until the
seal is flush with the sealing surface.
N
3. Inspect bearings on output and pinion shafts. To replace,
press new bearing on to shaft.

NOTE: Due to extremely close tolerances and

minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
7
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
O
M and minimal movement side to side.

4. Install pinion shaft, bearing, and input cover with new o-

ring and torque bolts to 17 ft. lbs. (23 Nm).
18. Inspect the output shaft bushing. Replace as needed. Clean
the inside surfaces of both gearcase halves.

Input Cover Bolts Torque:

17 ft. lbs. (23 Nm)

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 FINAL DRIVE
5. Install the output hub (A) into the gearcase housing. The 8. Install the retaining ring (F) into the output cover. Be sure
output hub should spin freely. the retaining ring is properly seated into the cover.

6. Install the other output hub (B) and thrust bearing (C) into 9. Install the ring gear (G) onto the output hub on the output
the output cover. Apply a small amount of grease onto the cover.
thrust bearing.
G

10. Install the rollers and roll cage into the ring gear. Insert the
7. Install the armature plate (D) and spacer washer (E) into the rollers as the roll cage is installed.
output cover.

Backlash Plate

NOTE: Be sure backlash plate is in place.

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 FINAL DRIVE
11. Install the output cover assembly onto the main gearcase. Backlash Pad (Thrust Pad) Adjustment
1. Lay the gearcase on the side with the output cover facing
up.
2. The backlash screw has Loctite applied to it. Use a heat gun
to lightly heat up the Loctite on the screw (A).

NOTE: Be sure armature plate tabs are placed into

the slots on roll cage. (See Reference Photo)
Photo for reference only

3. Using a hex wrench, turn the back-lash screw out 3-4 turns.
Armature plate tabs Re-apply red Loctite onto the bottom screw threads.
fit into roll cage slots

Armature plate design may

differ from what is shown

NOTE: This photo is for reference only, the armature 7

plate is actually installed in the output cover.
12. Install output cover with new O-ring and torque bolts to 17
ft. lbs. (23 Nm).
NOTE: Be sure the square O-ring is placed flat on
the cover surface. If the O-ring is twisted fluid 4. Turn the screw in until it is lightly seated, then turn the
leakage may occur. screw out 1/4 turn.
5. Set the gearcase upright. Rotate the pinion shaft at least 4
times. This ensures the ring gear completes one full
rotation.

Cover Bolts Torque:

17 ft. lbs. (23 Nm)

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 FINAL DRIVE
6. If a tight spot is felt during rotation, loosen the backlash MID DRIVE HUB / BEARING CARRIER
screw another 1/8 turn. Perform the previous step again.
Repeat this procedure until the pinion shaft rotates (6X6)
smoothly 4 times (1 revolution of ring gear).
Removal

Gearcase Installation 1. Lock the emergency parking brake. Safely raise the center
of the machine with a floor jack. Raise the machine just
1. To install gearcase, reverse removal procedure.Use new enough to remove the middle wheel.
spring pin in front prop shaft.
2. Remove the four wheel nuts and wheel.
2. Torque mounting bolts to 30 ft.lbs. (41 Nm).
3. Remove the hub cap and cotter pin.

4 Bolts
30 ft. lbs. (41 Nm)

=T 4. Remove the hub nut, domed washer, and flat washer.

Front Housing Mount Bolt Toque:

30 ft. lbs. (41 Nm)

3. Add the proper lubricant to the front gearcase. Check drain

plug for proper torque. Refer to Chapter 2 for fluid fill and
change information.

= Hub Nut & Washers

Premium Demand Drive Fluid

(PN 2871654)

Front Housing Capacity: 5. Remove the hub from the axle shaft.
5 fl. oz. (148 ml)

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 FINAL DRIVE
6. Remove the upper and lower control arm bolts. NOTE: Drive bearing out evenly by tapping on outer
race only. Once bearing is at bottom of casting,
Upper Bolt support casting on outer edges so bearing can be
removed.

Lower Bolt

7. Remove the bearing carrier from the A-arm assembly.

Figure 7.24

3. Inspect the bearing.

NOTE: Due to extremely close tolerances and

minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
outer race.

4. Inspect bearing housing for scratches, wear or damage.

Replace housing if damaged. 7
Hub Disassembly
1. Remove outer snap ring (A). Hub Assembly
A 1. Support bottom of bearing carrier housing. (A) Bearing
Carrier Housing; (B) Bearing; (C) Snap Ring

2. From the back side, tap on the outer bearing race with a drift
punch in the reliefs as shown in Figure 7.24.

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 FINAL DRIVE
2. Start bearing (B) in housing (A). 3. Install upper A-arm bolt and torque both upper and lower
bolts.
B
Lower Control Arm Bolt Torque:
A 35 ft. lbs. (47 Nm)

Upper Control Arm Bolt Torque:

35 ft. lbs. (47 Nm)

4. Pull drive shaft outward and install hub onto drive shaft
splines. Apply Anti-Seize compound to the axle splines.
5. Install the flat washer (A) and cone washer (B) with domed
side facing outward. (Refer to next photo)
3. Press bearing into place until outer race bottoms on
housing.

CAUTION
Use an arbor and press only on the outer race,
as bearing damage may occur. Out
Cone
Washer
6. Install the castle nut (C), wheel, and wheel nuts.

A B C

4. Install snap ring into groove.

Hub Installation 7. Remove jackstand and torque mid hub nut to 110 ft. lbs.
(149 Nm) and wheel nuts to 35 ft. lbs. (47 Nm).
1. Install hub carrier to lower A-arm. Hand tighten lower A-
arm bolt. Mid Hub Nut Torque:
2. Slide mid drive shaft through the hub carrier. 110 ft. lbs. (149 Nm)

Mid Wheel Nut Torque

35 ft. lbs. (47 Nm)

8. Install a new cotter pin. Tighten nut slightly to align holes

if required.
9. Install hub cap.

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 FINAL DRIVE
Mid Drive Exploded View

35 ft. lbs.
(47 Nm) BUSHING

SHAFT
MID UPPER A-ARM

35 ft. lbs.
(47 Nm)
MID DRIVE AXLE

BEARING CARRIER
35 ft. lbs.
(47 Nm)
BEARING
SHAFT
HUB

BUSHING SNAP RING

MID LOWER A-ARM 35 ft. lbs.

(47 Nm) BUSHING

MID DRIVE SHAFT (6X6) 7

Removal 3. Pull the middle axle straight out from the frame. The axle
will slide off the mid gearcase splined output shaft.
1. Repeat Steps 1-7 in the “Mid Drive Hub / Bearing Carrier
Removal” section.

2. Slide the middle axle out of the bearing carrier by pulling

the bearing carrier assembly outward and down.

Disassembly / Assembly
NOTE: For mid drive shaft service information, see
“REAR DRIVE SHAFT (4X4 CREW) - CV Joint / Boot
Replacement”

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 FINAL DRIVE
Installation 5. Install the flat washer (A) and cone washer (B) with domed
side facing outward. (Refer to next photo)
1. Apply Anti-Seize compound onto the mid gearcase output
shaft splines. Slide mid drive shaft (A) onto the mid 6. Install the castle nut (C), wheel, and wheel nuts.
gearcase output shaft (B).

B
A

A B C

7. Remove jackstand and torque mid hub nut to 110 ft. lbs.
(149 Nm) and wheel nuts to 35 ft. lbs. (47 Nm).
2. Install the outer end of the mid drive shaft into the hub
carrier (C). Mid Hub Nut Torque:
110 ft. lbs. (149 Nm)

Mid Wheel Nut Torque

35 ft. lbs. (47 Nm)

8. Install a new cotter pin. Tighten nut slightly to align holes

C if required.

9. Install hub cap.

MID PROPSHAFT (6X6)

Removal
3. Lift hub carrier into place and install bolt to upper control
arm. Torque bolt to 35 ft. lbs. (47 Nm). 1. Use the Roll Pin Removal Tool (PN 2872608), to remove
the roll pin from prop shaft at rear of transmission.
Upper Bolt

4. Pull drive shaft outward and install hub onto drive shaft
splines. Apply Anti-Seize compound to the axle splines.
2. The transmission or middle differential mounting will have
to be loosened to allow the propshaft to slide off of the
transmission output shaft.

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 FINAL DRIVE
MID DRIVE GEARCASE (6X6)
Gearcase Removal 4. Use the Roll Pin Removal Tool (PN 2872608) to remove
the roll pins that secure the rear prop shaft and middle prop
NOTE: To ease the removal of the middle axle shaft to the mid drive gearcase.
gearcase, remove the box from the frame. Refer to
the Box Removal Procedure in Chapter 5. Roll Pin Removal Tool
2872608
1. Remove the vent line clamp and vent line (A) from the top
of the mid drive gearcase (B).
A B

D C
D

NOTE: If the rear drive shaft does not slide off the
mid gearcase output shaft, compress the rear
suspension and the rear drive shaft will move back.

5. Remove the four bolts and washers that secure the gearcase
2. Remove the mid drive shafts (D). Repeat steps 1-3 in the to the frame. The bolts are accessible through the skid plate
“Mid Drive Shaft Removal” section. on the bottom of the frame.
3. Remove the parking brake caliper (C), refer to Chapter 9, 6. With the drive shafts removed from the mid gearcase, lift
“Parking Brake Caliper Service - Caliper Removal”. the gearcase out of the frame.

7
PIN

MID DRIVE GEARCASE

REAR DRIVE SHAFT

PIN

MID DRIVE SHAFT

TRANSMISSION
COUPLER

MOUNTING BOLTS
& WASHERS

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 FINAL DRIVE
Gearcase Disassembly 4. Remove the output shaft and ring gear assembly (E) from
the gearcase. Inspect the ring gear for abnormal wear,
1. Drain the oil from the mid drive gearcase. Properly dispose broken, or chipped teeth. Inspect and spin the bearings (F),
of the oil. the bearings should rotate smoothly.
2. Remove the output cover bolts (A) and the output cover (B).
E

F F
A

5. Remove the wave spring (G) from the gearcase assembly.

3. Remove the O-ring (C) and two shims (D) from the output
cover.

NOTE: The two shims are different of thickness. Be

sure to note the placement of the shims as they are
removed from the output cover for later installation.

6. Remove the bolts from the input cover (H).

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 FINAL DRIVE
7. Remove the input cover bolts (I). Remove the input cover 9. Inspect the pinion gear (K) and 26T output gear (L) for nics
(H) and pinion gear assembly from the gearcase. or uneven wear. Inspect the bearing (M), the bearing should
spin smoothly. Replace the parts as needed.
K L M

I
H

10. Remove the rear output seal (N).

8. Remove the pinion gear assembly (J) from the front cover N
(H). If the pinion gear does not come loose from the front
cover, use the following steps to aid in removal:

• Hold the pinion gear assembly

• Use a rubber mallet to lightly tap around the bearing
cup of the front cover

• Tap the front cover in an X pattern (follow the pattern in

the photo on the right), until the pinion gear assembly
comes loose
J H
1 7
11. Remove the retaining ring (O) and shim (P) from the rear
4 3 output thru shaft.

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 FINAL DRIVE
12. Carefully pull the output thru shaft (Q) through the
gearcase.

15. Replace all O-ring, seals, and worn components. Replace

13. Remove the retaining ring (O), shim (P), and input gear (R) the seals as shown in the photo.
from the output shaft (Q). Inspect the input gear for
abnormal wear, broken, or chipped teeth.

P
O

14. Inspect the two flange bearings (S) inside the gearcase. Gearcase Assembly
Inspect the pinion shaft bushing (T) for wear that is inside
the gearcase. 1. Install the shim (A) and a new retaining ring (B) onto the
output end of the output shaft (C). Install the output thru
shaft into the gearcase.

A&B

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 FINAL DRIVE
2. Install the 26T input gear (D), shim (E), and a new retaining • Hold the pinion gear assembly
ring (F) onto the output shaft.
• Use a rubber mallet to lightly tap on the front of the
input cover, around the bearing cup

• Tap the front cover in an X pattern (follow the pattern in

the photo on the right), until the pinion gear assembly
E comes loose

3
1

D
F 4 2

3. Assemble the pinion shaft assembly (if previously

disassembled). Install the 26T gear (G) and bearing (H)
onto the pinion shaft (I).
NOTE: When replacing the 26T output, be sure the
step of the gear is facing towards the bearing (see
below).
5. Apply Polaris Crankcase Sealant (PN 2871557) to the
Pinion Shaft Assembly inside surface of the input cover (J).
Step Of Gear
J

7
I
G
H

Sealant
Pinion Shaft Assembly Assembled

6. Install the pinion shaft assembly and input cover onto the
gearcase. Install the input cover bolts (K). Torque the bolts
to 18 - 23 ft. lbs. (24 - 31 Nm).

4. Install the pinion shaft assembly into the input cover.

NOTE: Alignment of the pinion shaft bearing into the K

input cover maybe be difficult. If needed, use the
following steps to aid in installation:

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 FINAL DRIVE
7. Install the wave spring (L) into the gearcase assembly. Be 10. Install a new O-ring (O) onto the output cover.
sure the wave spring is fully seated into the bearing cup of
the gearcase.

11. Carefully install the output cover onto the gearcase.

Install the output cover bolts. Torque the bolts to 18 - 23
8. Install the output shaft and ring gear into the gearcase. Be ft. lbs. (24 - 31 Nm).
sure the 10T input pinion gear and the output pinion gear
mesh smoothly.

Input Cover Bolt Torque:

9. Install the shims (M) into the output cover (N). Install the
shims in the order that they were removed during the 18 - 23 ft. lbs. (24 - 31 Nm)
disassembly process.

12. Remove the fill plug (P) and fill the mid gearcase with 6.75
M
oz. (200 ml) of Polaris ATV Angle Drive Fluid
(PN 2871653). Torque the fill plug to 14 ft. lbs. (19 Nm).

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 FINAL DRIVE

Middle Gearcase Specifications:

Capacity: 6.75 oz. (200 ml)

Specified Lubricant: ATV Angle Drive

Fluid (PN 2871653)

Fill Plug Torque: 14 ft. lbs. (19 Nm)

Gearcase Installation
1. Place the middle gearcase in the frame assembly.
A B

D C
D

2. Attach the mid and rear prop shafts to the mid gearcase, but 7
do not install the new roll pins yet.

3. Install the four middle drive gearcase bolts. Torque the

bolts to 30 ft. lbs. (41 Nm) in a cross pattern.

4. Install a new roll pins into the mid and rear prop shafts and
middle gearcase input and rear output shafts.

5. Install the mid drive shafts (D) onto the mid gearcase (B).

6. Install the vent tube (A) and clamp.

7. Lift bearing carrier into place and install bolt to upper

control arm. Torque bolt to 35 ft. lbs. (47 Nm). Refer to the
“MID DRIVE SHAFT INSTALLATION” section for
more details.

8. Install hub, flat washer, domed washer (domed side out)

and nut. Torque center nut to 110 ft. lbs. (149 Nm). Install
new cotter pin and hub cap.

9. Install rear wheel and torque wheel nuts to specification.

10. Install the parking brake caliper (C), refer to Chapter 9,

“Parking Brake Caliper Service - Caliper Installation”

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 FINAL DRIVE
Mid Gearcase Exploded

18-23 ft. lbs.

(24-31 Nm) 30 ft. lbs.
18-23 ft. lbs. (41 Nm)
(24-31 Nm)

REF# DESCRIPTION QTY REF# DESCRIPTION QTY

1 Screw (5/16-18 x 1.0) 12 16 Washer, Thrust 2

2 Plug, Square Socket 3 17 Bearing, Plain Flanged 2
3 Seal, Dual Lip 2 18 Gearcase 1
4 Tube, Vent 1/4” Hose 1 19 Bushing 1
5 Cover, Output 1 20 Pinion, 10T 1
6 Shim 1 21 Gear, 26T Output 1
7 Bearing, Ball 1 22 Bearing, Ball 1
8 Gear, Ring 37T 1 23 Shaft, Output Thru 1
9 Shaft, Output 1 24 Gear, 26T Input 1
10 Bearing, Ball 1 25 Cover, Input 1
11 Spring, Wave 1 26 Seal, Triple Lip 1
12 O-Ring 1 30 Bolt, (5/16-18 x 1.25) 3
13 Pipe, Knock 4 31 Bracket, Caliper Mount 1
14 Seal, Triple Lip 1 32 Ring, Hog 2
15 Ring, Retaining 2

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 FINAL DRIVE
REAR HUB / BEARING CARRIER (4X4) 5. Remove hub cap, cotter pin, front spindle nut, and washer.

Hub Inspection
1. Support machine securely with rear wheels elevated.

2. Grasp wheel / hub and check for movement.

3. If movement is detected, inspect hub, hub nut torque and

bearing condition and correct as necessary.

CAUTION

Serious injury may result if machine tips or falls.

Be sure machine is secure before beginning this
service procedure. Wear eye protection when 6. Slide the rear hub from the rear drive axle.
removing bearings and seals.

Hub Removal
1. Elevate rear end and safely support machine under main
frame area.

2. Check bearings for side play by grasping the tire / wheel

firmly and checking for movement. Grasp the top and
bottom of the tire. The tire should rotate smoothly without
binding or rough spots.

3. Remove wheel nuts and wheel.

4. Remove the two brake caliper attaching bolts. 7. Remove the upper and lower control arm bolts from the rear
7
CAUTION: Do not hang the caliper by the brake line. Use hub / bearing carrier.
wire to hang the caliper to prevent possible damage to the
brake line.

8. Remove the bearing carrier. Inspect the bearing again for

smoothness and side to side movement, replace as needed.

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 FINAL DRIVE
Hub Disassembly Hub Assembly
1. Remove outer snap ring (A). 1. Support bottom of bearing carrier housing. (A) Bearing
Carrier Housing; (B) Bearing; (C) Snap Ring
A

2. From the back side, tap on the outer bearing race with a drift
2. Start bearing (B) in housing (A).
punch in the reliefs as shown.

NOTE: Drive bearing out evenly by tapping on outer B

race only. Once bearing is at bottom of casting,
support casting on outer edges so bearing can be A
removed.

3. Press bearing into place until outer race bottoms on

housing.

CAUTION
Use an arbor and press only on the outer race,
3. Inspect the bearing. as bearing damage may occur.

NOTE: Due to extremely close tolerances and

minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
outer race.

4. Inspect bearing housing for scratches, wear or damage.

Replace housing if damaged.

4. Install snap ring into groove.

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 FINAL DRIVE
Hub Installation 6. Install the washer with domed side out. Install the spindle
retainer nut.
1. Start the wheel bearing carrier onto the drive shaft.

2. Align the bottom of carrier housing and lower control arm.

Slide the lower control arm bushings into place. Secure
with the lower control arm bolt.

3. With the drive shaft placed in the wheel bearing carrier,

align the carrier with the top control arm. Secure with the
upper control arm bolt.

NOTE: The lower shock bolt may need to be

removed to allow the upper A-arm to move more
freely.

7. Install the wheel, washers, and wheel nuts. Torque wheel

nuts to specification. See “Torque Specifications” table on
page 7.3.

8. Lower the vehicle. Torque the spindle retaining nut to 110

ft.lbs. (149 Nm). Install a new cotter key and the hub cap.

4. Torque the top and bottom A-arm bolts as shown in the

photo.
7
110 ft. lbs
(149 Nm)

30 ft. lbs.
(41 Nm)

5. Install the hub assembly onto the rear drive axle.

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 FINAL DRIVE
Exploded View

Rear Gearcase
30 ft. lbs.
(41 Nm)

Coil
A-arm bolts

Shaft
Bushings
Shock
Upper A-arm

Bushings

30 ft. lbs.
(41 Nm)
Rear Drive Axle Caliper
18 ft. lbs.
A-arm bolts (24 Nm)

Nuts
Bearing
Bushings Lower A-arm

Carrier Bolt

Shaft Snap Ring

30 ft. lbs.
(41 Nm)
Shaft Bushings

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 FINAL DRIVE
REAR DRIVE SHAFT (4X4 CREW) Outer CV Joint / Boot Replacement
1. Using a side cutters, cut away and discard the boot clamps.
Removal
1. Repeat all steps of the “Rear Hub / Bearing Carrier, Hub
Removal” section.

2. Remove upper carrier bolt. Slide the rear drive shaft out of
the bearing carrier by pulling the bearing carrier assembly
outward and tipping it down to remove the shaft.

2. Remove the large end of the boot from the CV joint and
slide the boot down the shaft.

3. Pull the rear drive shaft straight out of the frame. Use short
sharp jerks to free the circlip from the gearcase. The circlip
holds the drive shaft in the gearcase.

3. Clean the grease from the face of the joint.

4. Place the drive shaft in a soft-jawed vise.
5. Using a soft-faced hammer, or brass drift, strike the inner
race of the joint to drive the joint off the drive shaft. Be
sure to tap evenly around the joint to avoid binding.

Brass Drift Shown

4. Inspect the axle splines and CV boots for any damage.

IMPORTANT: Tap on inner race only!

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6. Make sure the circlip is on the shaft and not left in the joint. NOTE: Shiny areas in ball tracks and on the cage
spheres are normal. Do not replace CV joints
Circlip because parts have polished surfaces. Replace CV
joint only if components are cracked, broken, worn
or otherwise unserviceable.

10. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.

11. Slide the small boot clamp and boot (small end first) onto
the drive shaft and position the boot in it’s groove machined
in the shaft.

12. Install a NEW circlip on the end of the shaft.

13. Grease the joint with the special CV joint grease provided
in the boot replacement kit. Fill the cavity behind the balls
7. Remove the CV boot from the shaft.
and the splined hole in the joint’s inner race. Pack the ball
tracks and outer face flush with grease. Place any
CAUTION remaining grease into the boot.

Complete disassembly of the CV joint is NOT

recommended. The internal components are a CAUTION
precision fit and develop their own characteristic
wear patterns. Intermixing the internal The grease provided in the replacement kit is
components could result in looseness, binding, specially formulated for wear resistance and
and/or premature failure of the joint. durability. DO NOT use substitutes
or mix with other lubricants.
IMPORTANT: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint should NOTE: The amount of grease that’s provided is pre-
be replaced. measured, so use all the grease.

Boot Replacement Grease Requirement:

Grease Only Service Kits

PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g

Outer CV Joint Capacity: 90g

8. Thoroughly clean the joint with an appropriate solvent and

dry the joint to prevent any residual solvent from being left
in the joint upon reassembly.

9. Visually inspect the joint by tilting the inner race to one side
to expose each ball. Severe pitting, galling, play between
the ball and its cage window, any cracking or damage to the
cage, pitting or galling or chips in raceways call for joint
replacement.

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 FINAL DRIVE
14. Slide the joint onto the drive shaft splines and align the 20. While pulling out on the CV shaft, fully extend the CV joint
circlip with the lead-in chamfer on the inner race of the and slide a straight O-ring pick or a small slotted screw
joint. driver between the small end of the boot and the shaft. This
will allow the air pressure to equalize in the CV boot in the
position that the joint will spend most of its life. Before you
remove your instrument, be sure the small end of the boot
is in its correct location on the shaft.

15. Use a soft-faced hammer to tap the joint onto the drive shaft
until it locks into place.

16. Pull on the joint to make sure it is securely locked in place. 21. Install and tighten the small clamp on the boot using the
Axle Boot Clamp Tool (PU-48951).
17. Remove excess grease from the CV joint's external surfaces
and place the excess grease in the boot.

18. Pull the boot over the joint and position the boot lips into
the grooves on the joint housing and shaft. Make sure the
boot is not dimpled or collapsed.

19. Install and tighten the large clamp using the Axle Boot
Clamp Tool (PU-48951).
7

Axle Boot Clamp Tool

PU-48951

Axle Boot Clamp Tool

PU-48951

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 FINAL DRIVE
Inner Plunging Joint / Boot Replacement 6. Make sure the circlip is still on the shaft and not left in the
joint.
1. Using a side cutters, cut away and discard the boot clamps.
Circlip

7. Remove the boot from the shaft.

2. Remove the large end of the boot from the plunging joint
and slide the boot down the shaft.
CAUTION

Complete disassembly of the plunging joint is

NOT recommended. The internal components
are a precision fit and develop their own
characteristic wear patterns. Intermixing the
internal components could result in looseness,
binding, and/or premature failure of the joint.

IMPORTANT: If the grease in the joint is obviously

contaminated with water and/or dirt, the joint should
be replaced.

3. Clean the grease from the face of the joint.

4. Place the drive shaft in a soft-jawed vise.
5. Using a soft-faced hammer, or brass drift, strike the inner
race of the joint to drive the joint off the drive shaft. Be
sure to tap evenly around the joint to avoid binding.

Brass Drift Shown

8. Thoroughly clean the joint with an appropriate solvent and

dry the joint to prevent any residual solvent from being left
in the joint upon reassembly.
9. Visually inspect the joint for damage. Replace if needed.
10. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
11. Slide the small boot clamp and boot (small end first) onto
the drive shaft and position the boot in its groove machined
IMPORTANT: Tap on inner race only! in the shaft.

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 FINAL DRIVE
12. Install a NEW circlip on the end of the shaft. 18. Remove excess grease from the plunging joint’s external
surfaces and place the excess grease in the boot.
13. Grease the joint with the special CV joint grease provided
in the boot replacement kit. Fill the cavity behind the balls 19. Pull the boot over the joint and position the boot lips into
and the splined hole in the joint’s inner race. Pack the ball the grooves on the joint housing and shaft. Make sure the
tracks and outer face flush with grease. Place any boot is not dimpled or collapsed.
remaining grease into the boot.
20. Install and tighten the small clamp using the Axle Boot
Clamp Tool (PU-48951).
CAUTION

The grease provided in the replacement kit is

specially formulated for wear resistance and
durability. DO NOT use substitutes
or mix with other lubricants.

NOTE: The amount of grease that’s provided is pre-

measured, so use all the grease.

Boot Replacement Grease Requirement:

Grease Only Service Kits

PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g Axle Boot Clamp Tool
PU-48951
Inner Plunging Joint Capacity: 100g
21. Pull out on the drive shaft to center the joint in the housing.
14. Fully compress the joint and push the drive shaft firmly into
the inner race.
Slide a straight O-ring pick or a small slotted screw driver
between the large end of the boot and the joint housing and 7
lift up to equalize the air pressure in the boot.
15. Align the circlip with the lead-in chamfer.
22. Position the boot lip in its groove. Install and tighten the
large clamp using the Axle Boot Clamp Tool (PU-48951).

16. Use a soft-faced hammer to tap the joint onto the drive shaft
until you reach the end of the splines and the joint locks in
place. Axle Boot Clamp Tool
PU-48951
17. Pull on the joint to test that the circlip is seated and that the
joint is securely fastened to the shaft.

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 FINAL DRIVE
Drive Shaft Exploded View

REAR SHAFT

Spring Ring

Plunging
Joint

Gear Side
Grease Capacity Boot Kit
100 Grams

Grease Capacity
90 Grams

Wheel Side
Boot Kit

CV Joint

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 FINAL DRIVE
Installation 4. Lift bearing carrier into place and install the bolt into the
upper control arm. Torque bolt to 30 ft. lbs. (41 Nm).
1. Slide the rear drive axle into the bearing carrier hub.

30 ft. lbs.
(41 Nm)

5. Install hub, domed washer (domed side out) and nut.

2. Install a new circlip onto the rear drive shaft. Apply Anti- Torque rear spindle nut to 110 ft. lbs. (149 Nm). Install new
Seize Compound onto the rear drive shaft splines (both cotter pin and hub cap.
ends).

Apply Anti-Seize

New Circlip
7
Rear Hub Nut Torque:
3. Reinstall the rear drive shaft into the rear gearcase. Be sure
the circlip is securely fit into the rear gearcase. Use a rubber 110 ft. lbs. (149 Nm)
mallet to tap on the outboard end of the drive shaft if
necessary.
6. Install rear wheel and torque washers and wheel nuts to
specification. See “Torque Specifications” on page 7.3.
110 ft. lbs.
(149 Nm) Flat washer

Wheel Nut (4)

Cone
Out washer
Cone dome to
Washer outside

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 FINAL DRIVE
REAR PROPSHAFT (4X4 CREW) 4. Slide the propshaft off the transmission shaft and rear
gearcase input shaft. Orientate the shaft so that it’s parallel
Removal with the frame supports as shown below.

1. Remove the pin clips from upper and lower cargo box
shock pins and remove shock. Carefully allow cargo box
to rest in the dump position as you remove the propshaft.

5. Remove the shaft by placing the brake disc over the top of
the rear frame support and under the front frame support.
Rear Frame
Support

WARNING

Support the cargo box while the shock is removed Front Frame
to prevent injury or damage. Support

2. Use the Roll Pin Removal Tool (PN 2872608), to remove

the roll pin from prop shaft at rear of transmission.

Installation
1. When installing the propshaft, ensure that the shaft is
touching the rear frame support and reinstall the shaft the
same way it was removed with the brake disc over the top
of the rear frame support and under the front frame
support.

3. Remove the two bolts that secure the rear parking brake
caliper. Suspend the brake caliper assembly from the frame
with a piece of wire. (Refer to Chapter 9 for more
information on the rear parking brake)

2. Slide the shaft onto the rear gearcase input shaft and then
slide it onto the transmission shaft.
3. Install a new roll pin into the propshaft
4. Install the parking brake caliper and torque mounting bolts
to 18 ft. lbs. (24 Nm).
5. Install cargo box shock, mounting pins and pin clips.

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 FINAL DRIVE
REAR GEARCASE (4X4 CREW)
Differential - Unlock
General Operation
Clutch Gear
The RANGER rear gearcase has three traction operational
modes: AWD, Differential Lock, and Differential Unlock. Shift Yoke
Locking the rear differential is beneficial in low traction and
rough terrain conditions. Unlocking the rear differential makes
maneuvering easier and minimizes damage to turf and sensitive
terrains.

AWD
When “Differential-Lock” is selected on the switch, power is
removed from the electrical solenoid allowing the solenoid
Differential - Lock plunger to retract. Spring tension moves the shift yoke back into
place and engages the clutch gear into the engagement dogs that
are attached to the differential gear assembly, locking the rear
Differential - Unlock differential as a solid rear axle.

When switch position is set

to “Lock”, power is removed
from the solenoid and
the plunger retracts
When “Differential-Unlock” is selected on the switch, the rear to engage the
differential becomes unlocked for tighter turns. An electrical clutch gear
solenoid mounted in the rear gearcase housing actuates the shift and lock the
yoke. The solenoid plunger extends out to move the shift yoke
and slides the clutch gear away from the engagement dogs that
differential.
7
are attached to the differential gear assembly. This unlocks the
rear differential.

When switch position is set

to “Unlock”, the solenoid is
powered and the Differential - Lock
plunger extends
to disengage the Clutch Gear
clutch gear and
unlock the Shift Yoke
differential.

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 FINAL DRIVE
When the clutch gear is unlocked the rear drive shafts are Operation Modes
dependent on the differential allowing tighter turns. When it’s
locked it becomes a solid rear axle increasing traction.
AWD Mode

Differential

Clutch Gear
Rear Wheels rotate at same speed.
Front Wheels rotate at same speed when AWD activated.

Differential Locked
Locked Mode

Clutch Gear

Locked
Axle Shaft Axle Shaft

Both rear wheels rotate at same speed.

Unlocked Mode
Differential Unlocked
Clutch Gear
IRS Axle
Unlocked
Axle Shaft Axle Shaft

Rear wheels can rotate at different speeds.

(Allows for sharper turning)

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Gearcase Removal Gearcase Disassembly
1. Follow “Rear Drive Shaft Removal” procedure to remove IMPORTANT: The pinion gear assembly is NOT
the rear drive shafts from each side of the rear differential. intended to be disassembled from the case, as it
requires special OEM tooling in order to properly
2. Disconnect the differential solenoid 2-wire harness. reassemble. If there is any damage to the pinion gear,
bearings or case, the assembly must be replaced.
3. Completely drain the lubricant from the rear gearcase Pinion and ring gear shimming information is NOT
provided due to OEM manufacturing requirements.

1. Remove the differential solenoid from the gearcase cover

if servicing the solenoid, shift lever, shift lever spring, or
shift yoke. If none of these items are being serviced, the
solenoid can remain installed in the gearcase cover.

Drain Plug

4. Remove the four bolts that secure the rear gearcase to the
frame.

2. Remove the (7) bolts that secure the cover to the housing.
7
Remove Cover Bolts

Remove the (2)

fasteners from
each side.

5. Remove the (3) fasteners retaining the parking brake

caliper bracket to the rear gearcase and carefully pull the
rear gear case assembly from the frame. Allow the rear
propshaft to slide off of the rear gearcase shaft.

Bracket

(3)

Propshaft

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 FINAL DRIVE
3. Remove the differential assembly from the housing. 6. Remove the shims from the differential assembly. Be sure
to keep the shims together for reassembly.

4. Inspect the bevel gear teeth for chipped, worn, or broken

teeth. 7. Remove the large bearing from the differential assembly.
Inspect the bearing for smoothness and wear.

Inspect Teeth

5. Remove the small bearing from the differential assembly.

Inspect the bearing for smoothness and wear. 8. Remove the shims from the differential assembly. Be sure
to keep the shims together for reassembly.

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 FINAL DRIVE
9. If the solenoid was removed for servicing, inspect the tip 12. Loosen the lock assembly pin.
of the solenoid for wear. If the tip of the solenoid is
flattened the solenoid must be replaced.

13. Remove the pin from the gearcase cover.

10. Remove the clutch gear from the gearcase cover.

7
14. Carefully remove the shift yoke assembly from the
11. Inspect the shift lever (A), shift lever spring (B), shift return gearcase cover.
springs (C), and shift yoke (D) for excessive wear or
damage. If disassembly is required proceed to the next step.
If no disassembly is required proceed to “Rear Gearcase
Assembly.”

C
D

B A

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 FINAL DRIVE
15. Inspect the shift lever (A), shift lever spring (B), shift return
springs (C), shift yoke (D), and lock pin bushing (E).
Inspect the components for excessive wear or damage and
replace as needed.

Do Not Disassemble.
Replace as an assembly
D
if damaged or worn.

C
E B

2. Replace the drive shaft oil seals located in the main

gearcase and gearcase cover
Rear Gearcase Assembly
NOTE: Grease all seals and O-rings with Polaris All
Season Grease (PN 2871322) upon assembly.

1. Remove the pinion shaft oil seal using a seal puller and
replace with a new seal.

NOTE: The pinion gear assembly is NOT intended to

be disassembled from the case, as it requires
special OEM tooling in order to properly reassemble.
If there is any damage to the pinion gear, bearings or
case, the assembly must be replaced.

3. Replace all worn components.

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 FINAL DRIVE
4. Install the original shims (A) onto the differential assembly 6. If previously removed; assembly the shift lever (A), shift
(B) on both sides. Install the bearings (C), replace with new lever spring (B), shift return springs (C), shift yoke (D), and
bearings if needed. lock pin bushing (E).

B
C

A
A

C
C
E B

7. Carefully install the shift yoke assembly into the gearcase

B cover.

7
5. Install the differential assembly into the carrier housing.

8. Install the lock assembly pin and tighten.

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 FINAL DRIVE
9. Install the new lightly greased O-ring onto the carrier cover. Rear Gearcase Installation
O-Ring 1. Place the differential assembly into the frame. Slide the
rear propshaft onto the rear gearcase input shaft.

2. Install the (4) gearcase mounting fasteners and torque the

fasteners to 40 ft. lbs. (54 Nm).
3. Install the parking brake caliper bracket fasteners and
torque the fasteners to 17 ft. lbs. (23 Nm).

Bracket

17 ft. lbs.
23 (Nm)
10. Assemble the gearcase halves and install the (7) bolts that
secure the cover to the housing. Torque the bolts in a criss
cross pattern to 25-35 ft. lbs. (34-48 Nm). Propshaft

40 ft. lbs.
25-35 ft. lbs. (54 Nm)
(34-48 Nm)

4. Reverse the removal procedure for the rest of the

installation.

5. Add Polaris ATV Angle Drive Fluid (PN 2871653) to rear

carrier. Refer to maintenance information in Chapter 2 for
more details. Torque drain plug to 30-45 in. lbs. (3-5 Nm).
Torque fill plug to 40-50 ft. lbs. (54-68 Nm).

11. If previously removed, install the differential solenoid into

the carrier cover. Torque solenoid to 30-40 ft. lbs.
(41-54 Nm).

Fill Plug Drain Plug

40-50 ft. lbs. 30-45 in. lbs.
(54-68 Nm) (3-5 Nm)

Rear Gearcase Capacity:

30-40 ft. lbs.
(41-54 Nm)
18 fl. oz. (532 ml)

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 FINAL DRIVE
Rear Gearcase Exploded View (4x4 CREW)

40-50 ft. lbs.

(54-68 Nm)

30-45 in. lbs.

(3-5 Nm)

25-35 ft. lbs.

(34-48 Nm)

30-40 ft. lbs.

(41-54 Nm)
7

REF# DESCRIPTION QTY REF# DESCRIPTION QTY REF# DESCRIPTION QTY

1 Hypoid Gear Assembly 1 15 Bearing Cone - Diff 1 29 Pinion Nut 1
2 Carrier Housing Half 1 16 Bearing Cup - Diff 1 30 Oil Seal - Pinion 1
3 Carrier Cover Half 1 17 Bearing - Roller 1 31 Pinion Thrust-Washer AR
4 Diff Case Half 1 18 Bearing - Cup 1 32 Lock Pin Bushing 1
5 Diff Case Cover Half 1 19 Bearing Assembly - Collar 1 33 Shift Return Spring 2
6 Diff Side Gear 2 20 Clutch Gear 1 34 Drain Plug 1
7 Diff Pinion Mate Gear 2 21 O-Ring - Housing Halves 1 35 Oil Seal - Shaft 2
8 Pinion Mate Thrust-Washer 2 22 Lock Assembly Pin 1 36 Fill Plug 1
9 Diff Cross Pin 1 23 Vent Tube 1 37 Shift Yoke 1
10 Diff Roll Pin 1 24 Flanged Hex Bolt - Housing 7 38 Shift Lever 1
11 Hex Bolt - Ring Gear 8 25 Diff Solenoid 1 39 Shift Lever Spring 1
12 Diff Case Thrust-Washer AR 26 Spacer - Kit AR 40 Pinion Spacer 1
13 Side Gear Thrust-Washer 1 27 Bearing Cup - Pinion 2
14 Diff Case Thrust-Washer AR 28 Bearing Cone - Pinion 2

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 FINAL DRIVE
REAR AXLE / GEARCASE SERVICE 7. Remove the bottom shock bolts and shocks (both sides).
(6X6)
Rear Axle Removal
1. Jack up vehicle and support on frame and swing arm.

CAUTION

Serious injury could occur if machine tips or falls.

2. Remove rear wheels.

3. Remove the brake calipers. Suspend the brake calipers from

the frame with wire (both sides).
8. Remove the two bolts that secure the rear axle housing to
the frame.

Brake Calipers

9. Mark the positions of the four U-bolts that secure the axle
4. Remove the hub cover, cotter pin, spindle nut and washer to the frame. This will aid with proper U-bolt and axle
(both sides). placement during reassembly.

5. Pull the hub off of the axle.

Mark U-bolt Positions

6. Remove the hose clamp from the rear gearcase breather

hose. Remove the breather hose.

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10. Loosen the four U-bolts. Loosen each U-bolt nut a few turns Axle Tube Removal
at a time, this will reduce stress on all of the U-bolts during
U-bolt removal. 1. Place the rear axle assembly on a clean surface.

2. Remove the bolts that secure the rear gearcase to the axle
tubes and remove the rear gearcase skid plate

Loosen U-bolts

11. With the U-bolts removed, carefully lower the rear axle
assembly from the frame. Pull the axle assembly out from
the frame.
NOTE: The drive shaft yolk (A) slides off of the rear 3. Remove the axle and axle tube’s from the rear gearcase.
gearcase. Note the placement of the axle spacer seals for placement
during reassembly.

NOTE: Use caution when removing the rear axle

assembly. Extra jacks maybe needed to lower the 4. Slide the axles out of each axle tube.
rear axle assembly safely.
NOTE: Make note of the side each axle was
removed.

5. Inspect the splines on the axle ends and the splines on rear
gearcase for chips or wear. Replace as needed.

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Axle Tube Bearing Replacement Gearcase Disassembly / Inspection
1. Remove the retaining ring from the axle tube. 1. Drain and properly dispose of used oil.

2. Remove the differential housing cover bolts and the

gearcase housing cover.

2. Remove the bearings from the axle tube with a bearing

puller. Inspect the bearing contact surfaces in the axle tube.

3. Remove the shim and O-ring from the differential cover.

O-Ring

Shim

3. Install the new bearing using a press.

4. Remove the output shaft and ring gear from the differential.
Inspect the ring gear for abnormal wear, broken, or chipped
teeth. Inspect the bearings for wear. Spin the bearings by
hand, the bearings should roll smoothly. Replace the
bearings if needed.

Bearings

NOTE: The bearing should be properly lubricated

before installation.

4. Reinstall the retaining ring.

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 FINAL DRIVE
5. Remove the wave spring from the differential assembly. 8. Inspect the pinion shaft bushing for wear.
Wave Spring

6. Remove the four bolts that secure the pinion gear cover to
the differential. Remove the pinion gear cover and O-ring.

Pinion Gear Cover

Gearcase Assembly
1. Replace all O-rings, seals, and worn components.

4 Bolts

O-Ring
7
7. Remove the pinion shaft from the differential. Inspect for
abnormal wear, broken, or chipped teeth.

2. Install the pinion shaft into the differential housing.

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 FINAL DRIVE
3. Replace the pinion shaft cover O-ring and install the cover. NOTE: The O-ring is a smaller diameter than the
Install the four pinion shaft cover bolts and torque the bolts gearcase. Use two hands to work the O-ring onto the
to 26 ft. lbs. (35 Nm). gearcase lip.
New O-Ring
Pinion Gear Cover

26 ft. lbs.
(35 Nm)

New O-Ring

7. Install the output cover onto the differential assembly.

Pinion Shaft Cover Bolt Torque:
8. The output cover must be properly aligned and installed
26 ft. lbs. (35 Nm) straight with the differential when installed. This will
ensure that the O-ring is not damaged during output cover
installation. This also helps to prevent any gearcase leaks
4. Install the wave spring into the differential assembly. Be after assembly.
sure to properly seat the wave spring into the differential.

9. Torque the output cover bolts to 30 ft. lbs. (41 Nm).

5. Reinstall the output shaft and ring gear.
Output Cover Bolt Torque
30 ft. lbs. (41 Nm)

Gearcase / Axle Installation

1. Lube the splines of the rear gearcase with anti-seize.
2. Reinstall the axle spacer seals. Reinstall the axle onto the
rear gearcase (both sides) Reinstall the axle tube over the
axle and attach it to the gearcase.
3. Install and tighten the four bolts onto the right side of the
gearcase. Install and tighten the two bottom bolts to the left
side of the gearcase. Do not torque the bolts.
6. Install a new O-ring onto the lip of the gearcase housing.

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 FINAL DRIVE
NOTE: The two top gearcase / axle tube bolts (B) on 6. Install the four U-bolts. Align the U-bolts with the white
the left side are installed into the frame later in this marks previously made on the axle tube for proper rear axle
assembly procedure. alignment.

NOTE: Use a floor jack to help align the rear axle

B assembly for the U-bolt installation.

2 Bolts 4 Bolts

4. Fit the rear axle assembly up to the frame. Slide the rear U-bolt Alignment Marks
drive shaft yoke (A) onto the rear gearcase input shaft.

7. Install the U-bolt nuts, but do not tighten the nuts.

A 8. Install the two frame to gearcase bolts (B). Torque the
gearcase bolts on both sides of the gearcase to 60 ft. lbs.
(81 Nm).

7
5. Fit the rear axle assembly up to frame. Attach the rear axle
assembly to the shocks. Leave the shock bolts finger tight
until assembly is complete. B
NOTE: Use a jack or another person to assist with
the rear axle assembly installation.

NOTE: Use caution when removing the rear axle

assembly. Extra jacks maybe needed to raise the Axle Tube to Gear Case Bolt Torque:
rear axle assembly safely. 60 ft. lbs. (81 Nm)

7.63

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 FINAL DRIVE
9. Torque the U-bolts nuts to 40 ft. lbs. (54 Nm). 13. Install the brake caliper. Torque the bolts to 18 ft. lbs. (24.8
Nm).

U-Bolt Nut Torque:

40 ft. lbs. (54 Nm)
Brake Caliper Torque:
10. Torque the rear shock bolts to 25 ft. lbs. (35 Nm).
18 ft. lbs. (24.8 Nm)

25 ft. lbs. (35 Nm) 14. Install the tire and four wheel nuts. Torque the castle nut
and the wheel nuts to specifications.

Rear Coil Over Shock Bolt Torque

25 ft. lbs. (35 Nm)

11. Reinstall the vent hose and clamp to the rear gearcase
housing.
12. Apply anti-seize to the splines of the axle. Reinstall the hub Rear Hub Nut Torque
onto the axle. Reinstall the domed washer, and spindle nut 110 ft. lbs. (149 Nm)
onto the axle.
Rear Wheel Nut Torque
35 ft. lbs. (47 Nm)

15. Install a new cotter pin. Tighten nut slightly to align holes
if required. Install the hub cap.

7.64

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 FINAL DRIVE
Rear Gearcase Exploded View (6x6)

26 ft. lbs.
(35 Nm)

30 ft. lbs.
(41 Nm)

7
REF# DESCRIPTION QTY REF# DESCRIPTION QTY

1 Seal, Triple Lip 1 12 O-Ring 1

2 Screw (5/16-18 x 1.0) 12 13 Spring, Wave 1
3 Cover, Input 1 14 Bearing, Ball 1
4 O-Ring 1 15 Shaft, Output 1
5 Bearing, Ball 1 16 Gear, Ring 37T 1
6 Pinion, 10T 1 17 Bearing, Ball 1
7 Bearing, Plain 1 18 Shim 1
8 Plug, Square Socket 2 19 Plug, Expansion 1
9 Seal, Dual Lip 2 20 Tube, Vent 1/4” Hose 1
10 Gearcase, Rear Housing 1 21 Cover, Output 1
11 Pipe, Knock 1

7.65

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 FINAL DRIVE

NOTES

7.66

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 TRANSMISSION
CHAPTER 8
TRANSMISSION
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
TROUBLESHOOTING CHECKLIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
TRANSMISSION EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16

8.1

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 TRANSMISSION
TORQUE SPECIFICATIONS 3. Remove the shift lever cover and then remove the screw.
Pull off the shifter knob.

ITEM TORQUE VALUE Shift Lever

10-14 ft. lbs.
Transmission Fill Plug
(14-19 Nm)
10-14 ft. lbs.
Transmission Drain Plug
(14-19 Nm)
27-34 ft. lbs.
Transmission Case Bolts
(37-46 Nm)
12-18 ft. lbs.
Bell Crank Nut
(16-24 Nm)
Shift Lever Location
7-9 ft. lbs.
Bell Crank Gear Cover
(10-12 Nm)
4. Lift the gear shift selector out of mounting bracket and
Transmission Mounting
25 ft. lbs. (35 Nm) away from frame.
Bolts
Transmission AGL Gearcase Lube Installation
Lubricant / Amount 43.6 oz. (1290 ml)
1. Repeat the steps in reverse order to install the gear shift
selector.

SHIFT LEVER
Removal SHIFT LINKAGE
1. Disconnect linkage cable from shifter. Inspection
2. Remove one bolt attaching the gear shift selector mount to Linkage rod adjustment is necessary when symptoms include:
machine frame.
• No All Wheel Drive light
Cover
• Noise on deceleration
Screw
Cable
Shifter knob • Inability to engage a gear
• Excessive gear clash (noise)
Bearing
• Shift selectors moving out of desired range
NOTE: Remove necessary components to gain
access to shift linkage cable ends (i.e. exhaust heat
shield, exhaust pipe, etc.).

1. Inspect shift linkage cable, clevis pins, and pivot bushings

and replace if worn or damaged.
Shifter Bolt
2. Be sure idle speed is adjusted properly.
Grommet

Shift Lever Breakdown

8.2

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 TRANSMISSION
Adjustment TRANSMISSION SERVICE
1. Place gear selector in neutral. Make sure the transmission
Transmission Removal
bell crank is engaged in the neutral position detents.
1. Remove the PVT system from the left side of the
transmission.
2. Drive roll pin from rear driveshaft yoke.
4x4 Shown
Neutral Position
Roll Pin
Removal Tool

2. With two wrenches loosen the outside jam nut

counterclockwise. Turn the outside jam nut 1 1/2 turns.
Perform this procedure on the shift lever end, also.

Inside Jam Nut

Roll Pin Removal Tool (PN 2872608)

NOTE: The front output shaft yolk slides off during

the transmission removal.

3. Remove the air intake hose from the air box that is located
above the transmission. Place the hose to the side, this eases
the transmission removal. Remove the vent hose from the
top of the transmission.
Outside Jam Nut Vent Tube & Air Intake Hose

3. After turning the outside jam nut 1 1/2 turns. Hold the 8
outside jam nut with a wrench and tighten the inside jam
nut clockwise, until it is tight against the bracket.
4. Repeat Step 4 and Step 5 until the proper adjustment is
made for the transmission cable.
5. Use this procedure to loosen or tighten the shift linkage
cable as needed.
Clockwise
Inside Jam Nut

Outside Jam Nut

Counterclockwise

8.3

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 TRANSMISSION
4. Disconnect the transmission switch. 7. Remove the mounting bolts from the transmission
mounting on both sides of the transmission.
General Transmission Mounting

Transmission Switch

5. Remove the cotter pin from the shift linkage rod. Remove
the shift linkage rod and a washer from the bellcrank.
8. Remove the four bottom transmission to frame bolts.

9. Remove the rear transmission to frame bolt.

10. Remove front transmission-to-engine mount bolt.

11. Remove transmission from right side of frame.

6. Loosen the jam nuts for the transmission cable. Remove the
cable from the mounting bracket.
Jam Nuts

8.4

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 TRANSMISSION
Transmission Disassembly 5. Mark the detent gear with a white pen. Remove the detent
gear from the case.
NOTE: Refer to the exploded view at the end of this
chapter. NOTE: It may be helpful to place a mark just above
the keyed spline.
1. Place the bellcrank in neutral position.
Detent Gear
2. Remove the nut, and washer that secure the bell crank.
Remove the bellcrank.

6. Mark the lockout disc, this will indicate which side of the
disc faces outward during assembly. Remove the disc.

NOTE: It may be helpful to place a mark just above

3. Remove the five bolts that secure the cover and remove the the keyed spline. Note the raised edge on the detent.
cover from the transmission.

Cover

Lockout Disc

4. Remove the detent spring. 7. Remove the shift shaft and detent lever.

Spring

8.5

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 TRANSMISSION
8. Note the transmission gear position and mark the two shift 11. Remove the shift drum.
gears before removing them to aid with reassembly.
Remove the shift gears from the case. NOTE: You may have to tap the shift drum from the
backside of the case to aid in removal.

NOTE: Depending on what gear the transmission is

in upon disassembly, the stamped timing marks may
not be lined up. To avoid confusion, mark the two 12. Remove the upper gear cluster and shift forks. You may
gears as described in Step 8. need to move the assembly back and forth to aid in removal

9. Remove the bolts on the LH transmission case cover. Tap

the cover off with a soft face hammer if necessary.

13. Set the upper gear cluster on a flat surface and inspect the
components.

10. Lift shift rail 0.5”-1” (12.70-25.40 mm). Then rotate the
shift rail / forks and shift drum, so the forks’ pins disengage
from the drum.

8.6

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 TRANSMISSION
14. Remove the shift forks from the assembly. Note the correct 17. Remove the bearing from the input shaft with a puller.
position of each fork.
Shift Fork

18. Remove the snap ring and washer from the reverse shaft.
NOTE: The picture above depicts a transmission
with a “Park” engagement dog on the end of the
shaft instead of a regular engagement dog. The
transmission will have a regular engagement dog in
the location indicated by the arrow in the photo.

15. Remove the bearing from the reverse shaft with a puller.

19. Remove low gear (33T) and the needle bearing.

16. Remove the engagement dog. Remove the wave spring and
reverse engagement dog.

Engagement 20. Remove the reverse gear shaft.

Dogs

8.7

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 TRANSMISSION
21. Remove the rest of the bearings from the shafts. 24. Remove the gear, split bearing, and washer from the reverse
shaft.

22. Use a press to remove the gear from the shaft.

25. Slide off the shift dogs and wave springs.

23. Make note of the direction of the gear and hub location.
26. Remove the snap ring, washer, gear, and split bearing.

8.8

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 TRANSMISSION
27. Remove bearing and the helical gear. 30. Remove the front housing cover, shim, thrust button, and
thrust button shim.

28. Remove the pinion shaft retainer plate and the pinion shaft.
31. Remove the shafts as an assembly.

29. Remove the front housing cover screws.

32. Remove the silent chain from the assembly for shaft
inspection.

33. Clean all components in a parts washer and inspect for 8

wear.

34. Inspect engagement dogs of gears and replace if edges are

rounded.

35. Inspect gear teeth for wear, cracks, chips or broken teeth.
Note the location of the hubs on the gear.

Note Location of Hubs

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 TRANSMISSION
36. Remove seals from transmission case. 3. Before installing the cover make sure the sealing surfaces
are clean and dry, and shafts are fully seated in the
IMPORTANT: New seals should be installed after the transmission case. Apply Polaris Crankcase Sealant to the
transmission is completely assembled. mating surfaces.

37. Inspect bearings for smooth operation. Check for excessive

play between inner and outer race.

Transmission Assembly
1. Reinstall the chain onto the front output shaft and rear
output shaft.

Crankcase Sealant
(PN 2871557)

4. Reinstall the thrust button shim, thrust button, and other

shims into the cover. Reinstall cover and torque bolts in a
criss-cross pattern in 3 steps to 27-34 ft. lbs. (37-46 Nm).
2. Install front and rear output shafts into the case. NOTE: Make sure that the case locating pins (knock
pipes) are in place.

Front Cover Bolt Torque:

27-34 ft. lbs. (37-46 Nm)

5. Apply grease to the seal lips. Apply electricians tape or

somehow cover the splines of the shaft to protect the seal
lips during installation. Install new front and rear output
shaft seals.

6. Install pinion shaft with bearing.

7. Install retainer plate with flat side toward bearing.

8.10

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 TRANSMISSION
8. Apply Loctite™ 262 (Red) (PN 2871951) to screw threads 11. Slide the reverse shaft assembly through the silent chain.
and torque screws to 6-12 ft. lbs. (8-16 Nm).

12. Install a new needle bearing, the low gear, the thrust washer
and the snap ring. Use of a new snap ring is recommended.
Pinion Retainer Plate Bolt Torque: 13. Install the engagement dogs, wave springs, and bearing.
14. Install the ball bearing onto the end of the input shaft.
6-12 ft. lbs. (8-16 Nm)

9. Install a new needle bearing, the 24T reverse sprocket,

washer, and a new snap ring. Install the shift dogs and wave
spring. Install the washer, a new needle bearing and the high
gear. Install the press fit gear and ball bearing.

10. Install a new snap ring at this time. When installing the new
snap ring, open the snap ring just far enough to go over the
shaft, to avoid stressing the snap ring. If the snap ring is
overstressed it could come off the shaft and cause internal
damage to the transmission.

15. As the engagement dogs are installed onto the shaft, place
the wave springs into the spring groove. Keep the spring in
place while the fork is being installed on the shaft and while 8
placing the shafts into the case.
NOTE: Use caution when installing the fork, the
spring can easily fall out.

NOTE: Installing the shift rail will aid in keeping the

shift forks, shift dogs, and the springs in place.

8.11

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 TRANSMISSION
16. Carefully install the shaft assembly and gear cluster as a 20. Lift the shift rail slightly and rotate the rail/fork assembly
unit into their respective bearing case recesses. Tap with a so it meshes with the tracks on the shift drum. Be sure the
soft face hammer to seat shaft assemblies. wave springs are properly in place and that the shift rail is
seated into the pocket on the backside of the case.

17. Position the shift forks up and so the pins point toward the
9 o’clock position, before installing the shift drum 21. Install the helical gear and bearing onto the pinion shaft.
assembly.
22. Clean the mating surfaces of the case and cover. Apply
Crankcase Sealant (PN 2871557) to the mating surfaces. Be
sure the locating pins (knock pipes) are in place. Reinstall
cover and torque bolts in a criss-cross pattern in 3 steps to
27-34 ft. lbs. (37-46 Nm).

23. Reinstall the mounting bracket if previously removed.

18. Replace and grease the O-ring’s on the shift drum before
installation.

Front Cover Bolt Torque:

27-34 ft. lbs. (37-46 Nm)

24. Grease the seal lips of the input shaft seal. Apply
electricians tape or somehow cover the splines of the shaft
to protect the seal lips during installation. Install new input
shaft seal.

19. Install the shift drum into the case.

NOTE: Make sure shift shaft pins are properly

positioned in the slot on selector arms.

8.12

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 TRANSMISSION
25. Install drain plug with a new sealing washer. Torque drain 28. Install the lockout disc with the raised edge facing outward.
plug to 10-14 ft. lbs. (14-19 Nm). Use the white mars that was previously applied for
reference.

Lockout Disc

29. Install the detent gear with the raised edge facing outward.
Note the keyed spline on the end of the shaft.
30. Install the detent lever spring. Install a new o-ring onto the
shift shaft after the detent lever is assembled to the shaft.
Place a small amount of grease on the small O-ring on the
Drain Plug Torque: shift shaft and on the detent gear. Grease the o-ring on the
end of the shift drum.
10-14 ft. lbs. (14-19 Nm)
Detent Gear

26. Place a small amount of grease (PN 2871551) into the

pocket before installing the sector gear. Install the shift gear
(16T) on the shift drum shaft. Install the sector gear in the
bushing pocket on the left side. Align the timing marks you
made on the gears during disassembly.

Detent Lever 8
Spring

31. Install the cover and hand tighten all of the bolts. Tighten
the bolt indicated in the picture below first and torque the
bolt to 7-9 ft. lbs. (10-12 Nm). This helps to align the cover
and shaft to ensure smoother shifting.
7-9 ft. lbs.
(10-12 Nm)
IMPORTANT: Note the location of the skip tooth on
the splines. Apply a light coating of grease on the
gear teeth.

27. Install the shift shaft along with the detent lever.

Tighten This Bolt First

8.13

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 TRANSMISSION
32. Torque the remaining bolts to 7-9 ft.lbs. (10-12 Nm). Transmission Installation
1. Install transmission from right side of vehicle.
Cover Bolt Torque:
2. Align the front input shaft to the front propshaft yoke on
7-9 ft. lbs. (10-12 Nm) the vehicle and install the propshaft.

3. Align the rear output shaft to the mid or rear propshaft yoke
33. Install a new bellcrank onto the shift shaft. Note the keyed
and roll pin hole.
spline on the bellcrank and shaft. Install the washer and nut.
Torque the bellcrank nut to 12-18 ft. lbs. (16-24 Nm). 4. Slide the mid or rear propshaft onto the rear output shaft and
drive a NEW roll pin into the propshaft yoke.

5. Position transmission in frame.

Keyed Spline
6. Loosely install the front transmission to frame bolts.

7. Loosely install the rear transmission to frame bolt.

8. Loosely install the three bottom transmission to frame

bolts.

9. Tighten mounting fasteners in order A-D as shown.

Bellcrank Nut Torque:

12-18 ft. lbs. (16-24 Nm)

34. Install transmission and add Polaris AGL Gearcase

Lubricant (PN 2873602).

Transmission Mounting Bolts Torque

25 ft. lbs. (34.5 Nm)

NOTE: Be sure to tighten the lower transmission

bolts first, this ensures that the transmission is tight
against the lower frame and helps to properly align
the transmission.

10. If torque stop was removed, set clearance to .060-.080 in.

(1.52-2.03 mm).

11. Reinstall the shift linkage rod, the air intake hose, and the
vent hose on top of the transmission.

= NOTE: Align clutches as outlined in Chapter 6.

12. Refer to Chapter 6 for PVT installation.

AGL Gearcase Lube
43.6 oz. (1290 ml)

8.14

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 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
• Loose fasteners on rod ends
• Loose fasteners on selector box
• Worn rod ends, clevis pins, or pivot arm bushings
• Linkage rod adjustment and rod end positioning
• Shift selector rail travel
• *Worn, broken or damaged internal transmission components

NOTE: To determine if shifting difficulty or problem is caused by an internal transmission problem, isolate
the transmission by disconnecting linkage rod from transmission bellcrank. Manually select each gear range
at the transmission bellcrank, and test ride vehicle. If it functions properly, the problem is outside the
transmission.

If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding),
damage. Inspect all bearings, circlips, thrust washers and shafts for wear.

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 TRANSMISSION
TRANSMISSION EXPLODED VIEW
Exploded View

27-34 ft. lbs.

(37-46 Nm)

6-12 ft. lbs.

(8-16 Nm)

10-14 ft. lbs.

(14-19 Nm)

GREASE

7-9 ft. lbs.

(10-12 Nm)
15-19 ft. lbs.
(20-26 Nm)

10-14 ft. lbs.

(14-19 Nm)
27-34 ft. lbs.
(37-46 Nm)
12-18 ft. lbs.
(16-24 Nm)

FOR REASSEMBLY
Apply White Lithium
Based Grease.

Apply Polaris
Crankcase Sealant.

Apply LoctiteTM 262 to

the bolt threads.

8.16

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 TRANSMISSION
Exploded View, Continued
Ref. Qty. Description Ref. Qty. Description
1. 1 Plug, Fill 36. 1 Sprocket, 22T
2. 1 Plug, Drain, Magnetic 37. 1 Lockout Disc
3. 5 Screw, Self-Tapping 1/4-20 38. 1 Detent Pawl
4. 2 Screw, 5/16-18 39. 1 Detent Star
5. 4 Screw, 1/4-20 40. 1 Bellcrank, Shift Drum
6. 15 Screws, Self-Tapping 5/16-18 41. 1 Output Shaft, Front Main
7. 1 Nut, Nylon Lock 42. 1 Thrust Button
8. 2 Nut, Nylon Lock 43. 1 Rail, Shift Shaft
9. 1 Washer 44. 1 Shift Shaft
10. 1 Washer 45. 1 Output Shaft, Rear Main
11. 1 Washer 46. 1 Gear, 33T
12. 4 Dowel Pin 47. 1 Sprocket, 19T
13. 1 Retaining Ring, External 48. 4 Engagement Dog, 6 Face
14. 1 Retaining Ring, External 49. 1 Reverse Shaft
15. 2 Retaining Ring, External 50. 1 Gear, 33T
16. 1 Spacer 51. 1 Gear, Mid-Output, 47T
17. 1 Thrust Washer 52. 1 Gear, Mid-Output, 60T
18. 1 Shim 53. 1 Vent Tube
19. 1 Shim 54. 1 Sprocket, 38T
20. 1 Needle Bearing 55. 1 Gear Set, 10T/31T
21. 4 Ball Bearing 56. 2 Shift Fork w/Pin
22. 4 Ball Bearing 57. 1 Input Shaft, 37/19/15
23. 1 Needle Bearing 58. 1 Cover, Center Drive Bearing
24. 1 Plain Bearing 59. - N/A 8
25. 1 Needle Bearing 60. 1 Silent Chain, 11W/40P
26. 1 Ball Bearing 61. 1 Chain
27. 1 Spring, Compression 62. 1 Switch, 6-Pin Rotary
28. 2 Spring, Wave 63. 1 Seal, Dual Lip
29. 1 Cover, Sector Gear 64. 2 Seal, Triple Lip
30. 1 Cover, LH Input 65. 1 O-Ring
31. 1 Gearcase, Main 66. 1 O-Ring
32. 1 Shift Drum 67. 1 O-Ring
33. 1 Cover, Output 68. - N/A
34. 1 Sector Gear, 16T 69. 1 Bracket, Torque Stop
35. 1 Sector Gear, 31T 70. 1 Bracket, Transmission Mount

8.17

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 TRANSMISSION

NOTES

8.18

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 BRAKES
CHAPTER 9
BRAKES
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
BRAKE SYSTEM SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
BRAKE SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
FOOT BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
EXPLODED VIEW (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
EXPLODED VIEW (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
INSPECTION / CABLE TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
PARKING BRAKE CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
NEW BRAKE PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
PARKING BRAKE DISC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
PAD REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
PAD ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
REAR BRAKE PADS (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
PAD REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
REAR BRAKE PADS (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
PAD INSPECTION / ASSEMBLY / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
REAR CALIPER SERVICE (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CALIPER ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
REAR CALIPER SERVICE (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33

9.1

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 BRAKES
GENERAL SPECIFICATIONS
FRONT BRAKE SYSTEM
Item Standard Service Limit
Front Brake Pad Thickness .298 ± .007" / 7.56 ± .178 mm .180" (4.6 mm)
Front Brake Disc Thickness .158" ( 4.01mm) .140" (3.56mm)
Front Brake Disc Runout - .010" (.254mm)

REAR BRAKE SYSTEM

Item Standard Service Limit
Rear Brake Pad Thickness .298 ± .007"/ 7.56 ± .178 mm .180" (4.6 mm)
Rear Brake Disc Thickness .188" (4.78 mm) .170" (4.32 mm)
Inboard - .304” (7.72 mm) .240" (6.1 mm)
Park Brake Pad Thickness
Outboard - .360” (9.14 mm) .310” (7.87 mm)
Park Brake Disc Thickness 0.150” - 0.164” (3.81 - 4.16 mm) .140" (3.56 mm)
Rear Brake Disc Runout - .010" (.254 mm)

TORQUE SPECIFICATIONS SPECIAL TOOLS

Torque Torque Part Number Tool Description

Item
ft. lbs. Nm 2870975 Mity Vac™ Pressure Test Tool

Front Caliper Mounting Bolts 18 24

Rear Caliper Mounting Bolts 18 24

Parking Brake Mounting Bolts 18 24

Parking Brake Assembly Bolts 25 34

Brake Line Flare Fittings 12-15 16-20

Brake Line Banjo Bolts

15 20
(All)

Front Brake Disc to Hub Bolts 18 24

Rear Brake Disc to Hub Bolts 28 38

Brake Switch 12-15 16-20

Master Cylinder Clevis Nut 9-13 12-18

9.2

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 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.

• Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment.
• Do not over-fill the master cylinder fluid reservoir.
• Make sure the brake pedal returns freely and completely.
• Adjust stop pin on front caliper after pad service.
• Check and adjust master cylinder reservoir fluid level after pad service.
• Make sure atmospheric vent on reservoir is unobstructed.
• Test for brake drag after any brake system service and investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins (where applicable).
• Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.
• Perform a brake burnishing procedure after installing new pads to maximize service life.
• DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake cleaning
products.

BRAKE NOISE TROUBLESHOOTING

Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning
does not reduce the occurrence of brake noise, Permatex™ Disc Brake Quiet (PN 2872113) can be applied to the back of the pads.
Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance of squeaks caused by
dirt or dust.

Brake Noise Troubleshooting

Possible Cause Remedy
Spray disc and pads with CRC Brakeleen™ or an equivalent
Dirt, dust, or imbedded material on pads or disc non-flammable aerosol brake cleaner. Remove pads and/or disc
hub to clean imbedded material from disc or pads.
Pad(s) dragging on disc (noise or premature pad wear) because Adjust pad stop (front calipers)
of improper adjustment
Master cylinder reservoir overfilled Set to proper level
9
Master cylinder compensating port restricted Clean compensating port
Master cylinder piston not returning completely Inspect. Repair as necessary
Caliper piston(s) not returning Clean piston(s) seal
Operator error (riding the brake) Educate operator
Loose wheel hub or bearings Check wheel and hub for abnormal movement.
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
If noise does not change when brake is applied check other
Noise is from other source (axle, hub, disc or wheel)
sources. Inspect and repair as necessary
Wrong pad for conditions Change to a softer or harder pad

9.3

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 BRAKES
HYDRAULIC BRAKE SYSTEM OPERATION
The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines,
brake calipers, brake pads, and brake discs, which are secured to the drive line.

When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master cylinder
piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure within the brake
system. As the pressure within the system is increased, the pistons located in the brake calipers move outward and apply pressure
to the moveable brake pads. These pads contact the brake discs and move the calipers in their floating bracket, pulling the stationary
side pads into the brake discs. The resulting friction reduces brake disc and vehicle speed.

The friction applied to the brake pads will cause the pads to wear. As these pads wear, the piston within the caliper moves further
outward and becomes self adjusting. Fluid from the reservoir fills the additional area created when the caliper piston moves outward.

Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause the brakes to feel
spongy. Too much fluid could cause brakes to drag due to fluid expansion.

Located within the master cylinder is the compensating port which is opened and closed by the master cylinder piston assembly. As
the temperature within the hydraulic system changes, this port compensates for fluid expansion or contraction. Due to the high
temperatures created within the system during heavy braking, it is very important that the master cylinder reservoir have adequate
space to allow for fluid expansion. Never overfill the reservoir! Do not fill the reservoir beyond the MAX LEVEL line!

When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened,
use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid. Brake
fluid is hygroscopic, meaning it rapidly absorbs moisture. This causes the boiling temperature of the brake fluid to drop, which can
lead to early brake fade and the possibility of serious injury.

9.4

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 BRAKES
BRAKE SYSTEM EXPLODED VIEW
6x6

Master Cylinder Top View LH Front Caliper

LH Front 2
Brake Line
Master Cylinder
1
15 ft. lbs.
LH Rear Line (20 Nm) RH Front Caliper
LH Rear Caliper 3 2
1 Cross
2
Cross Fitting Fitting

1
1
3
MC Rear RH Front
2 1 Brake Line Brake Line
Brake
Switch Caliper Banjo Style Fittings:
1
MC Front 15 ft. lbs. (20 Nm).
Brake Line All Caliper Bleed Screws:
2 47 in. lbs. (5.3 Nm)
All Flare Style Fittings:
RH Rear Caliper RH Rear Line 3 12-15 ft. lbs. (16-20 Nm)

4x4 CREW
Master Cylinder Top View LH Front Caliper
LH Front 2
Brake Line
Master Cylinder
1
15 ft. lbs.
LH Rear Line (20 Nm) RH Front Caliper
LH Rear Caliper 3 2
9
1 Cross
2 Fitting
Cross Fitting
1
1
3
MC Rear RH Front
Brake Line Brake Line
2 1
Brake
Switch Caliper Banjo Style Fittings:
1
MC Front 15 ft. lbs. (20 Nm).
Brake Line All Caliper Bleed Screws:
2 47 in. lbs. (5.3 Nm)
All Flare Style Fittings:
RH Rear Caliper RH Rear Line 3 12-15 ft. lbs. (16-20 Nm)

9.5

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 BRAKES
MASTER CYLINDER FOOT BRAKE PEDAL
Removal Pedal Removal
1. Open the hood. Locate the master cylinder. 1. Open the hood. Locate the master cylinder.
2. Remove the retaining clip (A) from the clevis pin (B) that 2. Remove the nut, bushing, tube, and bolt from the brake
attaches the master cylinder to the brake pedal lever. pedal.

D Master Cylinder

Bolt
Bushing

Clevis Pin

Tube
Clip
15 ft. lbs. Nut
B
(20 Nm)
Bushing
Brake Pedal
A 9-13 ft. lbs.
(12-18 Nm)

3. Remove the retaining clip and clevis pin from the master
cylinder to remove the brake pedal.

15 ft. lbs.
C
Pedal Installation
(20 Nm)
1. Reverse Steps 1-3 for foot brake installation. Torque the
3. Place a container to catch brake fluid under the master clevis nut to 9-13 ft. lbs. (12-18 Nm). After installing the
cylinder brake line banjo bolts (C). foot brake check pedal freeplay. Pedal freeplay should not
NOTE: Dispose of brake fluid properly and do not exceed .090” (2.29 mm).
re-use.
Brake Pedal Freeplay:
CAUTION
.090” (2.29 mm)
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact
with finished surfaces.

4. Loosen the banjo bolts (C) for the brake lines and allow
fluid to drain.
NOTE: Make note of front and rear brake line
locations to master cylinder.
5. Remove the two mounting bolts (D) that secure the master
cylinder to the frame.

Installation
1. Reverse Steps 1-5 for master cylinder installation.
Refer to the torque specifications in the illustration.
After installing the foot brake check pedal freeplay. Pedal
freeplay should not exceed .090” (2.29 mm).
9.6

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 BRAKES
BRAKE BLEEDING / FLUID CHANGE 6. Have an assistant slowly pump foot pedal until pressure
builds and holds.

NOTE: When bleeding the brakes or replacing the 7. Hold brake pedal on to maintain pedal pressure, and open
fluid always start with the furthest caliper from the bleeder screw. Close bleeder screw and release foot pedal.
master cylinder.
NOTE: Do not release foot pedal before bleeder
screw is tight or air may be drawn into master
CAUTION cylinder.

8. Repeat procedure until clean fluid appears in bleeder hose

Always wear safety glasses.
and all air has been purged. Add fluid as necessary to
maintain level in reservoir.
CAUTION
CAUTION
Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished Maintain at least 1/2"(1.27 cm) of brake fluid in
surfaces. This procedure should be used to the reservoir to prevent air from
change fluid or bleed brakes during entering the master cylinder.
regular maintenance.
9. Tighten bleeder screw and torque to 47 in. lbs. (5.3 Nm)
1. Clean master cylinder reservoir cover thoroughly. and remove bleeder hose.
2. Remove cover from reservoir. 10. Repeat procedure Step 5 through Step 9 for the remaining
3. If changing fluid, remove old fluid from reservoir with a calipers.
Mity Vac™ pump or similar tool. 11. Add brake fluid to MAX level inside reservoir.

Mity Vac™ (PN 2870975)

4. Add brake fluid to the indicated MAX level of reservoir.

Maximum

Polaris DOT 4 Brake Fluid

(P/N 2872189) Minimum

5. Begin bleeding procedure with the caliper that is farthest

from the master cylinder. Install a box end wrench on
caliper bleeder screw. Attach a clean, clear hose to fitting
and place the other end in a clean container. Be sure the
hose fits tightly on fitting. 9
Master Cylinder Fluid Level

Bleeder Between the MIN and MAX line shown

Screw
on the reservoir.

12. Install master cylinder reservoir cover.

13. Field test machine at low speed before putting into service.
Check for proper braking action and pedal reserve. With
pedal firmly applied, pedal reserve should be no less than
1/2"(1.3 cm).

14. Check brake system for fluid leaks.

9.7

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 BRAKES
PARKING BRAKE
Exploded View (4x4 CREW)

Parking Brake
Lever

Nuts

Clevis
Pin
Washers

Parking Brake
Caliper
Clevis Screw
Pin Nut
Clip Clip

Washer
Bolt
Mount Bracket
Cable

Nut

Rear Propshaft Bolts

w/Parking Brake Disc

Rear Gearcase

9.8

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 BRAKES
Exploded View (6x6)

Parking Brake Clevis

Lever Pin

Nut
Parking Brake
Caliper

Nuts Clip

Bolt
Mount Bracket
Washers

Clevis
Pin
Parking Brake Disc
Clip
Screw

Washer

Middle Gearcase

Cable

9.9

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 BRAKES
Inspection Adjustment Procedure

1. Inspect the parking brake cable and brake pads on the 1. Place the vehicle in neutral on a flat level surface.
caliper assembly located on the rear propshaft.
See “Parking Brake Caliper Service” for brake pad 2. Carefully lift the rear of the vehicle off the ground and
replacement information. stabilize on jack stands.

3. Locate the parking brake cable adjustment area where the

Inboard Pad
Outboard Pad cable attaches to the caliper mount bracket on the rear
gearcase.

Front

Parking Brake
Cable Adjustment

Cable Tension Adjustment

When the parking brake is fully engaged and the parking brake
indicator is illuminated, engine speed is limited to 1300 RPM in 4. Use two open-end wrenches and loosen the outer jam nut
all gears, including neutral. If throttle is applied, this limiting (D). Back out the outer jam nut (D) 1 1/2 turns.
feature prevents operation, which protects the parking brake To Parking
pads from excessive wear. Brake Caliper
NOTE: Inspect the parking brake cable tension after
the first 25 hours of operation and every 100 hours
of operation afterwards to ensure proper cable
tension. C D

Loss of tension in the parking brake cable will cause

illumination of the parking brake light and activation of the
limiting feature. If this occurs, inspect and adjust parking brake
cable tension. If performing this service is difficult due to
conditions or location, open the hood and temporarily
disconnect the parking brake connector. Reconnect the
Mount Bracket
connector as soon as practicable and adjust the parking brake
cable to proper tension.
5. Now hold the outer jam nut (D) and turn in the inner jam
1. Pull back on the parking brake lever (located in the dash). nut (C) clockwise, until the jam nut is tight against the
bracket.
2. After 2 to 3 clicks the “(P)” brake light should illuminate
on the instrument cluster and the wheels of the vehicle 6. Repeat Step 4 and Step 5 until the proper adjustment is
should not rotate when turning by hand. After 8 full clicks obtained for the parking brake.
of lever travel, the vehicle should not roll while parked.
NOTE: See Chapter 10 for more information on the
3. If the vehicle moves, adjustment is necessary. parking brake switch.
4. Adjust the parking brake cable where the cable attaches to
the caliper mount bracket located on the rear gearcase (mid
gearcase on 6x6 models).

9.10

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 BRAKES
PARKING BRAKE CALIPER SERVICE
Exploded View

Hex Nut
Pad & Holder
Pad & Holder Plain Washer

18 ft. lbs.
(24 Nm)
Sleeve Thrust Washer
Hex Head
Mount Bolt

Shim Pack Lever

Nut (4 Shims)
Asm. Bolt
25 ft. lbs.
(34 Nm)
Stationary Actuator
Spring Pin
Compression Spring Steel Balls (3) Figure 9.10

Caliper Removal
NOTE: Do not get oil, grease, or fluid on the parking 2. If replacing the brake pads, slightly loosen the caliper
brake pads. Damage to or contamination of the pads assembly bolts before removing the complete caliper
may cause the pads to function improperly. assembly. This will ease the caliper disassembly procedure
later.
1. Remove the clip pin and pin (A) from the parking brake
cable.

NOTE: Be sure the parking brake is not engaged.

9.11

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 BRAKES
3. Loosen the two brake caliper mounting bolts (B) in equal 10. Measure the thickness of the rear caliper parking brake
increments. pads. Replace assembly or pads as needed. See illustration
below for proper readings.
B Inboard pad thickness
New .304” (7.72 mm)
Limit: 0.24” (6.1 mm)

Inboard Outboard
Pad Pad

Outboard Pad Thickness

New 0.360” (9.14 mm)
Limit: 0.31” (7.87 mm)

Installed Disc to Park Brake

4. Remove the mounting bolts from the mount bracket and lift 0.375” (0.953 cm)
the parking brake caliper assembly out of the vehicle.

New Rotor Disc Thickness

Caliper Disassembly / Inspection 0.150” - 0.164”
(3.81 - 4.16 mm)
NOTE: The parking brake caliper is replaced as an
assembly. Refer to the “Electronic Parts Catalog”
for information.

5. Remove the two caliper assembly nuts (C) that were

previously loosened during Step 2 of “Caliper Removal”.

6. Slide the brake pads and springs from the assembly.

NOTE: Retain the lever and ball bearings for

reassembly.

7. Inspect the brake pads linings for excessive wear. Replace

as needed.

8. Check the three steel balls for any signs of cracking.

Replace as needed.

9. Check ball seats in lever and stationary actuator. If

excessively worn, replace parts as needed.

9.12

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 BRAKES
New Brake Pad Installation Caliper Installation
NOTE: Parking Brake Pads can be replaced by 1. Install the parking brake assembly into place. Tighten the
ordering one of the following kits: two mounting bolts in increments for proper installation.
PN 2203148 - Brake Pad and Shim Kit
PN 2203147 - Brake Pad Kit 18 ft. lbs.
There may be more parts in the service kit than your
(24 Nm)
brake requires. Check the parts list included with
the kit for the exact quantities.

1. Using the stationary actuator, assemble the caliper

components as shown below. Do not install the springs or
shims yet. Measure the gap for the brake disc.
Disassemble and add shims between thrust washer and the
inside brake pad as needed to close the gap to 0.203”-
0.193” (5.156-4.902 mm). For shim location, see Figure
9.10 on page 11.

Add shims until gap

measures 0.203”- 0.193”
(5.156 - 4.902 mm) 2. Torque the two mounting bolts to 18 ft. lbs. (24 Nm).

=T
Parking Brake Caliper - Mounting Bolts:
18 ft. lbs. (24 Nm)

3. Install the cable, pin, and clip pin. Test the park brake for
proper function.
2. Once you have determined the correct amount of shims to
use, install the assembly bolts through the sleeves. Install PARKING BRAKE DISC SERVICE
the nuts and the correct amount of shims, the inner brake
pad, springs, and outer brake pad. Torque the assembly Disc Inspection / Removal
nuts to 25 ft. lbs. (34 Nm).
1. Measure the parking brake disc with a micrometer. If the
thickness of the disc is less than specified, replace the rear
=T propshaft / disc assembly.

Parking Brake Caliper - Assembly Bolts: 2. Follow the appropriate rear prop shaft removal procedure
25 ft. lbs. (34 Nm) listed in Chapter 7 to remove the rear prop shaft / disc
assembly. 9
3. Ensure the parking brake assembly functions properly by
actuating the lever before reinstallation. New Disc: 0.164” - 0.173” (4.17 - 4.39 mm)
Disc Service Limit: 0.140” (3.56 mm)
Remove Bolts

6X6 Shaft Shown

9.13

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 BRAKES
FRONT BRAKE PADS 5. Push mounting bracket inward and slip outer brake pad past
edge. Then remove inner pad.
Pad Removal
1. 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.

2. Remove the wheel nuts, washers and front wheel. Loosen

pad adjuster screw 2-3 turns.

Pad Inspection
Pad 1. Measure the thickness of the pad material. Replace pads if
Adjuster worn beyond the service limit.

3. Remove the upper and lower caliper mounting bolts and

remove the caliper from the front hub.
NOTE: When removing caliper, use care not to
damage brake line. Support caliper so to avoid
kinking or bending brake line.
4. Push caliper piston into caliper bore slowly using a
C-clamp or locking pliers with pads installed.

Measure
Thickness

Front Brake Pad Thickness

NOTE: Brake fluid will be forced through New: .298 ± .007” (7.56 ± .178 mm)
compensating port into master cylinder fluid Service Limit: .180” (4.6 mm)
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.

9.14

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 BRAKES
Pad Assembly / Installation 5. Install the pad adjuster set screw and turn clockwise until
stationary pad contacts disc, then back off 1/2 turn
1. 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

Pad
Adjuster

6. Verify fluid level in reservoir is up to MAX line inside

reservoir and install reservoir cap.
2. Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
other.
Master Cylinder Fluid
Up to MAX line inside reservoir
WARNING
7. Install wheel and torque wheel nuts to specification (see
If brake pads are contaminated with grease, oil, “Chapter 2 - Maintenance”).
or liquid soaked do not use the pads.
Use only new, clean pads.
Brake Burnishing Procedure
3. Install caliper onto front hub and torque mounting bolts.
It is required that a burnishing procedure be performed after
installation of new brake pads to extend service life and reduce
noise.
Start machine and slowly increase speed to 30 mph. Gradually
apply brakes to stop machine. Allow pads and disc to cool
sufficiently during the procedure. Do not allow pads or disc to
become hot or warping may result. Repeat this procedure 10
times.
18 ft. lbs.
(24 Nm) 9

=T
Front Caliper Mount Bolt Torque:
18 ft. lbs. (24 Nm)

4. Slowly pump the brake pedal until pressure has been built
up. Maintain at least 1/2, (12.7 mm) of brake fluid in the
reservoir to prevent air from entering the brake system.

9.15

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 BRAKES
FRONT CALIPER SERVICE
Caliper Exploded View

Apply Polaris DOT 4 Brake Fluid C 47 in. lbs.

B A
to Component (5.3 Nm)
E
Apply Polaris All Purpose
Grease

H D

A. Socket Set Screw

B. Bleeder Screw
C. Caliper Assy.
D. Boot
E. Square O-rings
F. Piston
G. Caliper Mount
H. Brake Pads

Caliper Removal
1. Elevate and safely support the front of the vehicle. 5. Loosen brake pad adjustment set screw 2-3 turns to allow
brake pad removal after the caliper is removed.
2. Remove the (4) wheel nuts and the front wheel.

CAUTION

Use care when supporting vehicle so that it does not

tip or fall. Severe injury may occur.
Pad
3. Clean caliper area before removal. Adjuster
4. Place a container below the caliper to catch brake fluid
when removing the line. Remove brake line from caliper.

Remove
Brake Line

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 BRAKES
6. Remove the two caliper mounting bolts and remove the 3. Remove mounting bracket, pin assembly and dust boot.
caliper assembly from the front strut.

NOTE: Image shown with

brake line attached. Be sure
to remove prior to this step.

Remove

4. Thoroughly clean the brake caliper before disassembly and

prepare a clean work area to disassemble the caliper.
Caliper Disassembly 5. Use low pressure compressed air to remove the pistons
1. Push brake pad retainer pin inward and slip brake pads past from the caliper.
the edge.
CAUTION

Use caution and always wear safety glasses

when working with compressed air.

6. While holding the caliper and covering the pistons with a

shop towel, carefully apply compressed air to the brake line
inlet to force the pistons out from the caliper.

IMPORTANT: Do not remove the caliper pistons with

a pliers. The piston sealing surfaces will become
damaged if a pliers is used.

7. Once the pistons are removed, use a pick to carefully

remove the square O-rings from the caliper. O-rings should
2. Remove both brake pads from the caliper. be replaced during caliper service.

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 BRAKES
8. Clean the caliper body, piston, and retaining bracket with 2. Inspect piston for nicks, scratches, pitting or wear. Measure
brake cleaner or alcohol. piston diameter and replace if damaged or worn beyond
service limit.

Clean
Components

NOTE: Be sure to clean seal grooves in caliper

body.
= In. / mm.
Caliper Inspection
Caliper Piston O.D.:
1. Inspect caliper body for nicks, scratches, pitting or wear. Std: 1.370” (34.80 mm)
Measure bore size and compare to specifications. Replace Service Limit: 1.368” (34.75 mm)
if damaged or worn beyond service limit.
3. Inspect the brake disc and pads as outlined in this chapter.

Caliper Assembly
1. Install new O-rings in the caliper body. Be sure the
grooves are clean and free of residue or brakes may drag
upon assembly.

Seal
Grooves

= In. / mm.
New
Caliper Piston Bore I.D.: O-Rings
Std: 1.373” (34.87 mm)
Service Limit: 1.375” (34.93 mm)

2. 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.

9.18

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 BRAKES
3. Lubricate the mounting bracket pins with Polaris Premium 2. Install brake line and torque the banjo bolt to the proper
All Season Grease (PN 2871423), and install the rubber torque specification.
dust seal boots.

15 ft. lbs.
(20 Nm)

3. Install the pad adjustment screw and turn until stationary

4. Compress the mounting bracket and make sure the dust seal pad contacts disc, then back off 1/2 turn.
boots are fully seated. Install the brake pads. Clean the disc
and pads with brake parts cleaner or denatured alcohol to 1/2 Turn
remove any dirt, oil or grease.

Caliper Installation
1. Install caliper and torque mounting bolts to specification. Pad
Adjuster

4. Perform brake bleeding procedure as outlined earlier in this

chapter.
18 ft. lbs.
(24 Nm) 5. Install wheel and torque wheel nuts to specification (see
Chapter 2).

NOTE: If new brake pads are installed, brake

burnishing is recommended (see “FRONT BRAKE
PADS - Brake Burnishing Procedure”).
9
=T
Front Caliper Mount Bolt Torque:
18 ft. lbs. (24 Nm)

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 BRAKES
FRONT BRAKE DISC Disc Replacement
1. Remove front brake caliper (see “Front Caliper Service”).
Disc Inspection
2. Remove dust cap, cotter pin, castle nut and washers.
1. Visually inspect disc for scoring, scratches, or gouges. 3. Remove the wheel hub assembly from the vehicle and
Replace the disc if any deep scratches are evident. remove the (4) bolts retaining the disc to the hub.
2. Use a 0-1” micrometer and measure the disc thickness at
eight different points around the pad contact surface. (4) Bolts
Replace disc if worn beyond service limit.
Measure
Thickness
Dust
Cap
Front
Disc

Washers
Nut
Cotter
Pin
4. Clean the wheel hub mating surface and install new disc on
wheel hub. Torque new bolts to 18 ft. lbs. (24 Nm).
Brake Disc Thickness 18 ft. lbs.
New .158” (4.01 mm) (24 Nm)
Service Limit .140” (3.56 mm)

Brake Disc Thickness Variance

Service Limit: .002” (.051 mm)
difference between measurements

3. Mount dial indicator as shown to measure disc runout.

Slowly rotate the disc and read total runout on the dial
indicator. Replace the disc if runout exceeds specification. 60 ft. lbs.
(81 Nm)

CAUTION

Always use new brake disc mounting bolts. The

bolts have a pre-applied locking agent which is
destroyed upon removal.
5. Install wheel hub assembly, washers, and castle nut.
Torque castle nut to 60 ft. lbs. (81 Nm) and install a new
cotter pin before installing the dust cap.
6. Install front brake caliper (see “Front Caliper Service”).
Follow bleeding procedure outlined earlier in this chapter.
Brake Disc Runout 7. Field test unit for proper braking action before putting into
service. Inspect for fluid leaks and firm brakes. Make sure
Service Limit .010” (.254 mm)
the brake is not dragging when pedal is released. If the brake
drags, re-check assembly and installation.

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 BRAKES
REAR BRAKE PADS (6X6) Pad Inspection
1. Push caliper piston into caliper bore slowly with pads
Pad Removal
installed.
1. Elevate and support rear of machine.
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
CAUTION reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
Use care when supporting vehicle so that it does
not tip or fall. Severe injury may occur 2. Remove the brake pads.
if machine tips or falls.

2. Remove the rear wheel. Loosen pad adjuster screw 2-3

turns.
Adjuster Screw

3. Clean the caliper with brake cleaner or alcohol.

4. Measure the thickness of the pad material. Replace pads if

worn beyond the service limit.
3. Clean caliper area before removal.

4. Remove caliper mounting bolts and lift caliper off of disc.

NOTE: When removing caliper, be careful not to

damage brake line. Support caliper so as not to kink
or bend brake line.

Remove Caliper Bolts Measure

Thickness
9
Rear Brake Pad Thickness
New .298 + .007” (7.56 + .178 mm)
Do not bend or kink Service Limit .180” (4.6 mm)

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 BRAKES
Pad Installation REAR BRAKE PADS (4X4 CREW)
1. Install new pads in caliper body.
Pad Removal
1. 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.

2. Remove the wheel nuts, washers and rear wheel. Loosen

pad adjuster screw 2-3 turns.

2. Install caliper and torque mounting bolts.

18 ft. lbs. (24 Nm)

Pad
Adjuster

3. Remove the upper and lower caliper mounting bolts and

remove the caliper from the front hub.

Rear Brake Caliper Mounting Bolt: NOTE: When removing caliper, use care not to
damage brake line. Support caliper so to avoid
Torque 18 ft. lbs. (24 Nm) kinking or bending brake line.
4. Push caliper piston into caliper bore slowly using a
3. Turn adjuster screw back in finger tight using a hex wrench. C-clamp or locking pliers with pads installed.
4. Slowly pump the brake pedal until pressure has been built
up. Maintain at least 1/2"(12.7 mm) of brake fluid in the
reservoir to prevent air from entering the master cylinder.

NOTE: Brake fluid will be forced through

compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.

9.22

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 BRAKES
5. Push mounting bracket inward and slip outer brake pad past Pad Assembly / Installation
edge. Then remove inner pad.
1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease (PN 2871423), and
install rubber dust boots.

Pad Inspection 2. Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
1. Measure the thickness of the pad material. Replace pads if other.
worn beyond the service limit.

WARNING

If brake pads are contaminated with grease, oil,

or liquid soaked do not use the pads.
Use only new, clean pads.

3. Install caliper onto rear hub and torque mounting bolts.

18 ft. lbs.
(24 Nm)

Measure
Thickness
=T
Front Caliper Mount Bolt Torque:
18 ft. lbs. (24 Nm)
Front Brake Pad Thickness
New: .298 ± .007” (7.56 ± .178 mm) 4. Slowly pump the brake pedal until pressure has been built
Service Limit: .180” (4.6 mm) up. Maintain at least 1/2, (12.7 mm) of brake fluid in the
reservoir to prevent air from entering the brake system.

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 BRAKES
5. Install the adjustment set screw and turn clockwise until
stationary pad contacts disc, then back off 1/2 turn
(counterclockwise).

1/2 Turn

Pad
Adjuster

6. Verify fluid level in reservoir is up to MAX line inside

reservoir and install reservoir cap.

Master Cylinder Fluid

Up to MAX line inside reservoir

7. Install wheel and torque wheel nuts to specification (see

“Chapter 2 - Maintenance”).

Brake Burnishing Procedure

It is required that a burnishing procedure be performed after
installation of new brake pads to extend service life and reduce
noise.
Start machine and slowly increase speed to 30 mph. Gradually
apply brakes to stop machine. Allow pads and disc to cool
sufficiently during the procedure. Do not allow pads or disc to
become hot or warping may result. Repeat this procedure 10
times.

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 BRAKES
REAR CALIPER SERVICE (6X6)
Rear Caliper Exploded View

Apply Polaris DOT 4 Brake Fluid G

to Component

Apply Polaris All Purpose

Grease
E F

D
H

A. Socket Set Screw B E

B. Bleeder Screw 47 in. lbs.
C. Caliper Assy. (5.3 Nm)
D. Boot
E. Square O-rings
F. Piston
G. Caliper Mount
H. Brake Pads C

Caliper Removal 3. After the fluid has drained into the container, remove the
two caliper mounting bolts and remove caliper.
1. Safely support the rear of the machine.

CAUTION
Remove Caliper Bolts
Use care when supporting vehicle so that it does
not tip or fall. Severe injury may occur
if machine tips or falls.

2. Use a wrench to remove the brake line. Place a container

9
to catch brake fluid draining from brake lines.

Remove Banjo Bolt

4. Clean disc, caliper body, and pistons with brake cleaner or

alcohol.

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 BRAKES
Caliper Disassembly Caliper Inspection
1. Remove brake pad adjuster screw (A). Inspect caliper body for nicks, scratches or wear. Measure bore
size and compare to specifications. Replace if damage is evident
2. Push upper pad retainer pin inward and slip brake pads past or if worn beyond service limit.
edge, if pads are still installed.

3. Remove mounting bracket (B) and dust boot (C).

B Pads
C
F D

A = In. / mm.
4. Remove piston (D) and square O-rings (E) from the caliper Caliper Piston Bore I.D.:
body (F). Std: 1.505” (38.23 mm)
Service Limit: 1.507” (38.28 mm)

6. Inspect piston for nicks, scratches, wear or damage.

Measure diameter and replace if damaged or worn beyond
service limit.

5. Clean the caliper body, piston, and retaining bracket with

brake cleaner or alcohol.

NOTE: Be sure to clean seal grooves in caliper

body.

= In. / mm.

Caliper Piston O.D.:

Std: 1.500” (38.10 mm)
Service Limit: 1.498” (38.05 mm)

7. Inspect the brake disc and pads as outlined for brake pad
replacement in this chapter.

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 BRAKES
Caliper Assembly Caliper Installation
1. Install new square O-rings (A) in caliper body. Be sure the 1. Install the rear caliper with the mounting bolts. Torque
grooves are clean and free of residue or brakes may drag. mounting bolts to 18 ft.lbs. (24 Nm).

2. Install brake line banjo bolt. Torque banjo bolt to 15 ft. lbs.
A (20 Nm).

18 ft. lbs.
(24 Nm)

15 ft. lbs.
(20 Nm)

2. Coat the piston with clean DOT 4 Brake Fluid 3. Install rear wheel and wheel nuts. Carefully lower vehicle.
(PN 2872189). Install piston (B) with a twisting motion
while pushing inward. Piston should slide in and out of bore
smoothly, with light resistance.

3. Lubricate the mounting bracket pins with Polaris Premium

All Season Grease, and install the rubber dust seal boots.

Polaris Premium All Season Grease 9

(PN 2871423)

4. Compress the mounting bracket and make sure the dust

seals are fully seated. Install the brake pads. Clean the disc
and pads with brake parts cleaner or denatured alcohol to
remove any dirt, oil or grease.

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 BRAKES
REAR CALIPER SERVICE (4X4 CREW)
Rear Caliper Exploded View

Apply Polaris DOT 4 Brake Fluid 47 in. lbs.

C B A
to Component (5.3 Nm)
E
Apply Polaris All Purpose
Grease E

G
H D

A. Socket Set Screw

B. Bleeder Screw
C. Caliper Assy.
D. Boot
E. Square O-rings
F. Piston
G. Caliper Mount
H. Brake Pads

Caliper Removal
1. Elevate and safely support the rear of the vehicle. 5. Loosen brake pad adjustment set screw 2-3 turns to allow
brake pad removal after the caliper is removed.
2. Remove the (4) wheel nuts, (4) washers and rear wheel.

CAUTION

Use care when supporting vehicle so that it does not

tip or fall. Severe injury may occur.
Pad
3. Clean caliper area before removal. Adjuster
4. Place a container below the caliper to catch brake fluid
when removing the line. Remove brake line from caliper.

Remove
Brake Line

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 BRAKES
6. Remove the two caliper mounting bolts and remove the 3. Remove mounting bracket, pin assembly and dust boot.
caliper assembly from the rear hub.

Remove

4. Thoroughly clean the brake caliper before disassembly and

prepare a clean work area to disassemble the caliper.

Caliper Disassembly 5. Use low pressure compressed air to remove the pistons
from the caliper.
1. Push brake pad retainer pin inward and slip brake pads past
the edge. CAUTION

Use caution and always wear safety glasses

when working with compressed air.

6. While holding the caliper and covering the pistons with a

shop towel, carefully apply compressed air to the brake line
inlet to force the pistons out from the caliper.

IMPORTANT: Do not remove the caliper pistons with

a pliers. The piston sealing surfaces will become
damaged if a pliers is used.

7. Once the pistons are removed, use a pick to carefully

remove the square O-rings from the caliper. O-rings should
be replaced during caliper service.
2. Remove both brake pads from the caliper.

9.29

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 BRAKES
8. Clean the caliper body, piston, and retaining bracket with 2. Inspect piston for nicks, scratches, pitting or wear. Measure
brake cleaner or alcohol. piston diameter and replace if damaged or worn beyond
service limit.

Clean
Components

NOTE: Be sure to clean seal grooves in caliper

body.
= In. / mm.
Caliper Inspection
Caliper Piston O.D.:
1. Inspect caliper body for nicks, scratches, pitting or wear. Std: 1.186” (30.12 mm)
Measure bore size and compare to specifications. Replace Service Limit: 1.184” (30.07 mm)
if damaged or worn beyond service limit.
3. Inspect the brake disc and pads as outlined in this chapter.

Caliper Assembly
1. Install new O-rings in the caliper body. Be sure the
grooves are clean and free of residue or brakes may drag
upon assembly.

Seal
Grooves

= In. / mm.
New
Caliper Piston Bore I.D.: O-Rings
Std: 1.192” (30.28 mm)
Service Limit: 1.194” (34.33 mm)

2. 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.

9.30

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 BRAKES
3. Lubricate the mounting bracket pins with Polaris Premium 2. Install brake line and tighten securely with a line wrench.
All Season Grease (PN 2871423), and install the rubber Torque the banjo bolt brake line(s) to the proper torque
dust seal boots. specification.

15 ft. lbs.
(20 Nm)

4. Compress the mounting bracket and make sure the dust seal 3. Install the pad adjustment screw and turn until stationary
boots are fully seated. Install the brake pads. Clean the disc pad contacts disc, then back off 1/2 turn.
and pads with brake parts cleaner or denatured alcohol to
remove any dirt, oil or grease. 1/2 Turn

Caliper Installation
1. Install caliper and torque mounting bolts to specification.
Pad
Adjuster

18 ft. lbs.
(24 Nm)
4. Perform brake bleeding procedure as outlined earlier in this
chapter.

5. Install wheel and torque wheel nuts to specification (see

Chapter 2).

NOTE: If new brake pads are installed, brake

burnishing is recommended (see “REAR BRAKE
9
=T PADS - Brake Burnishing Procedure”).

Rear Caliper Mount Bolt Torque:

18 ft. lbs. (24 Nm)

9.31

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 BRAKES
REAR BRAKE DISC 3. Remove the wheel hub assembly from the vehicle and
remove the (4) bolts retaining the disc to the hub.
Disc Inspection (4) Bolts
1. Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident.
2. Use a 0-1"micrometer and measure disc thickness at 8
different points around perimeter of disc. Replace disc if Dust
worn beyond service limit. Cap

Washers
Nut

Cotter
Rear Pin
Disc
4. Clean the wheel hub mating surface and install new disc on
wheel hub.

Measure 5. Install new bolts and torque to 28 ft. lbs. (38 Nm).
Thickness 28 ft. lbs.
(38 Nm)
Brake Disc Thickness
New .188” (4.78 mm)
Service Limit .170” (4.32 mm)

Brake Disc Thickness Variance

Service Limit .002” (.051 mm)

difference between measurements 110 ft. lbs.
(150 Nm)

3. Mount a dial indicator and measure disc runout. Slowly

rotate the disc and read total runout on the dial indicator.
Replace the disc if runout exceeds specification.
CAUTION
Brake Disc Runout
Service Limit .010” (.254 mm) Always use new brake disc mounting bolts. The
bolts have a pre-applied locking agent which is
destroyed upon removal.

6. Install wheel hub assembly, washers, and castle nut.

Disc Replacement Torque castle nut to 110 ft. lbs. (150 Nm) and install a new
1. Remove rear brake caliper (see “REAR CALIPER cotter pin before installing the dust cap.
SERVICE”). 7. Install rear brake caliper (see “REAR CALIPER
2. Remove dust cap, cotter pin, castle nut and washers. SERVICE”). Follow the bleeding procedure outlined
earlier in this chapter.
8. Field test unit for proper braking action before putting into
service. Inspect for fluid leaks and firm brakes. Make sure
the brake is not dragging when pedal is released. If the brake
drags, re-check assembly and installation.

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 BRAKES
TROUBLESHOOTING
Brakes Squeal / Poor Brake Performance
• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Damaged break pad noise insulator

Pedal Vibration
• Disc damaged
• Disc worn (runout or thickness variance exceeds
service limit)

Caliper Overheats (Brakes Drag)

• Compensating port plugged
• Pad clearance set incorrectly
• Parking brake lever incorrectly adjusted
• Brake pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes

Brakes Lock
• Alignment of caliper to disc
• Caliper pistons sticking 9
• Improper assembly of brake system components

9.33

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 BRAKES

NOTES

9.34

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 ELECTRICAL
CHAPTER 10
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
UNDER-HOOD COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
HEADLIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
AWD / 2WD / TURF SWITCH (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
DIFFERENTIAL SOLENOID (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
STANDARD DISPLAY MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
DIAGNOSTIC DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
VIEWING DIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
INSTRUMENT CLUSTER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 10.11
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . . . . . . . 10.12
TEST 1 - NO ALL WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
TEST 2 - NO DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
TEST 3 - WHEEL SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
TEST 4 - NO AWD HUB SAFETY LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
TEST 5 - FUEL GAUGE DISPLAY NOT WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
TEST 6 - SHIFT INDICATOR NOT WORKING (TRANSMISSION SWITCH) . . . . . . . 10.15
ALL WHEEL DRIVE (AWD) COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
GEAR POSITION INDICATOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
HEADLIGHT ADJUSTMENT / BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 10.17
HEADLIGHT HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
HEADLIGHT HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
TAIL LIGHT / BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
FAN CONTROL CIRCUIT OPERATION / BYPASS TEST. . . . . . . . . . . . . . . . . . . . . . 10.20
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
EFI DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
FUSES / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
CHARGING SYSTEM ALTERNATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
10
CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
BATTERY TERMINALS / BOLTS / TERMINAL BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 10.26
BATTERY ACTIVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
BATTERY INSPECTION / REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 10.27
BATTERY TESTING / OCV - OPEN CIRCUIT VOLTAGE TEST. . . . . . . . . . . . . . . . . 10.27
SPECIFIC GRAVITY TEST / LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
OFF SEASON STORAGE / CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 10.28

10.1

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 ELECTRICAL
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
STARTER MOTOR REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
BRUSH INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
ARMATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
STARTER REASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
STARTER SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
STARTER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
STARTING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
ELECTRIC BOX LIFT ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
DIAGNOSIS (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
ELECTRICAL BREAK-OUT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
STARTING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
KEY-ON POWER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
TRANSMISSION SWITCH CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
AWD CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
SPEED SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
CHARGING SYSTEM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
COOLING FAN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
FUEL DISPLAY / FUEL PUMP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40

10.2

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 ELECTRICAL
GENERAL INFORMATION Under-Hood Components
The following components can be accessed under the hood.
Special Tools
• Voltage Regulator
Part Number Tool Description • Battery
PV-43568 Fluke™ 77 Digital Multimeter • Battery Cables
2870630 Timing Light • Terminal Block
2870836 Battery Hydrometer • Starter Solenoid
2460761 Hall Sensor Probe Harness • Starter Diode
2871745 Static Timing Light Harness • Relays
PU-47063 Digital Wrench™ Diagnostic Software • Fuses
PU-47471 Digital Wrench™ SmartLink Module Kit • Digital Wrench Diagnostic Connector
• Speedometer
Electrical Service Notes • Speedometer Mode Switch
Keep the following notes in mind when diagnosing an electrical • AWD/2WD/TURF Switch
problem:
• Headlight Switch
• Refer to wiring diagram for stator and electrical • 12 VDC Accessory Power Point
component resistance specifications.
• Ignition Switch
• When measuring resistance of a component that has a
resistance value under 10 Ohms, remember to subtract • Parking Brake Switch
meter lead resistance from the reading. Connect the
leads together and record the resistance. The resistance
of the component is equal to tested value minus the lead
resistance.

• Become familiar with the operation of your meter. Be

sure leads are in the proper jack for the test being
performed (i.e. 10A jack for current readings). Refer to
the Owner’s Manual included with your meter for more
information.

• Voltage, amperage, and resistance values included in

this manual are obtained with a Fluke™ 77 Digital
Multimeter (PV-43568). This meter is used when
diagnosing electrical problems. Readings obtained with
other meters may differ.

• Pay attention to the prefix on the multimeter reading (K,

M, etc.) and the position of the decimal point.
10
• For resistance readings, isolate the component to be
tested. Disconnect it from the wiring harness or power
supply.

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 ELECTRICAL
SWITCHES / CONTROLS 4. Inspect the switch connections and test the switch for
continuity at the appropriate pin terminals as shown in the
Headlight Switch following illustration.

1. Lift the front hood.

2. The wires are located on the back side of the instrument

panel.

3. Disconnect the headlight switch harness (Brown, Green,

and Red/White), by depressing the connector lock and
pulling on the connector. Do not pull on the wiring.

4. Inspect the switch connections and test the switch for

continuity at the appropriate pin terminals as shown in the
following illustration.

Differential Solenoid (4x4 CREW)

The differential solenoid is located on the rear gear case. The
solenoid actuates an engagement dog, which locks and unlocks
the rear carrier. (Refer to Chapter 7 for more information on rear
carrier operation.)

AWD / 2WD / TURF Switch (4x4 CREW)

1. Lift the front hood.

2. The wires are located on the back side of the instrument

panel.

3. Disconnect the switch harness (Grey, Orange/White,

Brown, White/Green), by depressing the connector lock
and pulling on the connector. Do not pull on the wiring. Solenoid

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 ELECTRICAL
Differential Solenoid Circuit Operation If the rear carrier fails to switch from operational modes:
The rear differential solenoid relay is located under the hood. • Check the connector located under the left rear fender.
Look for loose wires or bad connections.
Power is present at the AWD / 2WD / Turf Switch when the
ignition key is turned “ON”. • Check for power from the connector, to ensure the
solenoid has power to be activated.
When the switch is pushed to activate “Turf” mode, power is
sent from the AWD / 2WD / Turf Switch to the ECU. • Check the AWD / 2WD / TURF Switch wires for loose
connections.
Depending on vehicle speed, gear position criteria and parking
brake input, the ECU provides a ground path for the Rear Diff • Remove solenoid from carrier and ensure the solenoid
Solenoid Relay allowing it to enable the differential solenoid. plunger is actuating.
NOTE: The Rear Differential will not unlock if the parking
brake is set.
CAUTION
Rear Differential Solenoid Circuit
Do not power the solenoid with 12 Volts for more
than 1 second, or damage may occur
to the solenoid.

Brake Light Switch

1. The brake light switch is located near the steering gearbox
along the frame. The brake pressure switch is installed into
this block.

Brake Switch

2. Disconnect wire harness from switch.

3. Connect an ohmmeter across switch contacts. Reading

should be infinite (OL).
10
4. Apply foot brake and check for continuity between switch
contacts. If there is no continuity or greater than .5 ohms
resistance when the brake is applied with slight pressure,
first clean the switch contacts and re-test. Replace switch
if necessary.

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 ELECTRICAL
Parking Brake Switch Testing The Parking Brake Switch

The parking brake switch is located within the parking brake 1. Disconnect the harness connector at the parking brake
lever. Follow the parking brake lever under the dash to locate switch (Orange/Red and Red/White wires).
the internally mounted switch.
2. Place the ohmmeter leads onto terminal leads A and C. The
reading should be infinite (•).

Switch
Contact
3. Apply the parking brake. Continuity should now exist
between the switch terminals A and C. If no continuity
exists when the parking brake is applied, try to clean the
switch terminals and re-test. Replace switch if necessary.

Switch
Park Brake
Indicator
Harness
Connector P

The switch remains in the “open” position when the park brake
lever is not applied.

When the parking brake lever is applied, the switch makes

contact and sends voltage to the ECU and Speedometer to
illuminate the “Park Brake Indicator” near the top-center of the
instrument cluster.

NOTE: If the parking brake is applied the ECU will

rev limit the engine at 1300 RPM until the parking
brake is released. This feature has been added to
prevent drive-away with the parking brake applied.

If trying to perform an engine diagnostic running test

with the parking brake applied, disconnect the
switch harness connector to allow the engine to rev
higher than 1300 RPMs.

10.6

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 ELECTRICAL
INSTRUMENT CLUSTER Rider Information Display
The rider information display is located in the instrument
Overview
cluster. All segments will light up for 2.5 seconds at start-up.
The RANGER instrument cluster senses vehicle speed from the
NOTE: If the instrument cluster fails to illuminate, a
right front wheel. The instrument cluster measures distance in
battery over-voltage may have occurred and the
miles as well as time, hours of operation and engine RPM.
instrument cluster may have shut off to protect the
electronic speedometer.
Park Brake 3 4 5 6
Indicator 7
Speedometer
8
Speedometer
Needle

1. Gear Indicator - This indicator displays gear shifter

position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
Rider
Information
Display 2. AWD Indicator - This indicator illuminates when the
AWD switch is in the AWD position.

3. Engine Hour Display Indicator

NOTE: In addition to showing vehicle speed, the
speedometer needle flashes when a low fuel 4. Service Interval / Diagnostic Mode Indicator
condition exists.
5. Low Battery and Over Voltage - This warning usually
NOTE: Use the “Mode Button” shown below to indicates that the vehicle is operating at an RPM too low to
toggle between Instrument Cluster display screens. keep the battery charged. It may also occur when the engine
is at idle and high electrical load (lights, cooling fan,
Instrument accessories) is applied. Drive at a higher RPM or recharge
Cluster the battery to clear the warning.

6. Odometer/Tachometer/Tripmeter/ Hour Meter/Clock

7. Fuel Gauge - The segments of the fuel gauge show the level
of fuel in the fuel tank. When the last segment clears, a low
fuel warning is activated. All segments will flash, FUEL 10
will display in the LCD, and the speedometer needle will
blink. Refuel immediately.
Ignition
Switch 8. Check Engine Warning Indicator - This indicator serves
Mode two purposes. The word HOT displays if the engine
Button overheats. It also appears if an EFI-related fault occurs. Do
not operate the vehicle if this warning appears. Serious
engine damage could result.

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 ELECTRICAL
Standard Display Modes Clock Screen

Use the yellow mode button located under the speedometer to

toggle through the mode options.

Odometer Mode
The odometer records the miles traveled by the vehicle.
Trip Meter Mode
The trip meter records the miles or kilometers traveled by the
vehicle on each trip if it's reset before each trip. To reset the trip
meter, select the trip meter mode. Press and hold the mode
button until the display reads 0. To reset the clock:

NOTE: In the Rider Information Display, the trip 1. Enter the diagnostic mode.
meter display contains a decimal point, but the 2. Toggle to the clock screen.
odometer displays without a decimal point. 3. Press and hold the mode button until the hour display
flashes. Release the button.
Hour Meter Mode 4. Press and release the mode button once to advance the
This mode logs the total hours the engine has been in operation. setting by one hour. Press and hold the mode button to
advance the hours quickly.
Tachometer Mode 5. When the desired hour is displayed, wait approximately
The engine RPM is displayed digitally. four seconds, until the minute display flashes.
6. When the display stops flashing, the mode has been set.
NOTE: Small fluctuations in the RPM from day to
7. Use the same procedure to reset the minutes.
day may be normal because of changes in humidity,
temperature and elevation.
Battery Voltage Screen
Clock Mode View this screen to check battery voltage level.
The clock displays time in a 12-hour format. To reset the clock,
see “Clock Screen” in the “Diagnostic Display Mode” section.

Diagnostic Display Mode

The wrench icon will display when the gauge is in the diagnostic
mode. To exit the diagnostic mode, turn the key switch off and
on. Any movement of the tires will also cause the gauge to exit
the diagnostic mode.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds. Tachometer Screen
View the tachometer to check engine speed.
2. Lock the parking brake.

3. Place the transmission in neutral.

4. Hold the mode button and turn the key switch to the “ON”
position. Release the mode button as soon as the display is
activated.

5. Use the mode button to toggle through the diagnostic

screens.

10.8

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 ELECTRICAL
AWD Diagnostic Screen
The gauge indicates whether or not current is flowing through
the AWD coil.

NOTE: A 10 - 20% variance from these readings is

within normal parameters.

Programmable Service Interval

Gear Circuit Diagnostic Screen
When the hours of engine operation equal the programmed
This screen displays the resistance value (in ohms) being read at service interval setting, the wrench icon will flash for 5 seconds
the gear switch input of the gauge. each time the engine is started. When this feature is enabled, it
provides a convenient reminder to perform routine
maintenance.

10
NOTE: The service interval is programmed to 50
hours at the factory.

10.9

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 ELECTRICAL
To enable or disable the service interval:
1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for about seven (7) seconds,
until either ON or OFF appears in the Rider Information
Display, depending on your preference.

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

Viewing Diagnostic Codes
3. Press and hold the mode button for 2-3 seconds, until the
wrench icon flashes. Release the button. Use the following procedure to view diagnostic blink codes
(failure codes) from the EFI module:
4. Press and release the mode button once to advance the
setting by one hour. Press and hold the mode button to NOTE: Refer to Chapter 4 “Electronic Fuel Injection”
advance the hours quickly. for a complete list of Diagnostic Blink Codes.

NOTE: If you scroll past the intended number, press 1. Engage the parking brake.
and hold the button until the hours cycle back to
zero. 2. Stop the engine.

5. When the desired setting is displayed, wait until the wrench 3. Turn the key switch to the ON position.
icon stops flashing. The new service interval is now
4. Turn the key switch off and on three times in less than five
programmed.
seconds, then leave the switch on. The word “Wait” will
appear on the screen along with a flashing “Check Engine”
Miles / Kilometers Toggle light.
The display in the tripmeter and odometer can be changed to
display either standard or metric units of measurement.

1. Enter the diagnostic mode.

2. Toggle to the screen that displays either kilometers (KM)

or miles (MP).

3. Press and hold the mode button until the letters flash, then
press and release the button once. When the display stops
flashing, the mode has been set.

10.10

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 ELECTRICAL
5. Any blink code numbers stored in the EFI module will 2. Push the instrument cluster out from the back side of the
display, one at a time, on the screen. dash panel, while securely holding the panel and rubber
Example below shows a Blink Code of “42”. mount.

Dash Panel

Push Instrument
Cluster Outward

6. The number “61” and/or the word “End” displays after all
codes have been transmitted.

Rubber Mount

Instrument Cluster
Bezel
NOTE: Do not remove the rubber mount from the
dash panel. Only remove the rubber mount if
necessary. The bezel is a snap-on assembly and is a
serviceable part.

Instrument Cluster Installation

Instrument Cluster Removal 1. Spray a soap and water mixture onto the outer surface area
NOTE: Do not allow alcohol or petroleum products of the instrument cluster. This will help the instrument
to come in contact with the instrument cluster lens. cluster slide into the rubber mount more easily.

1. Lift the hood and disconnect the wire connectors from the
back side of the instrument cluster.

10

2. Be sure the rubber mount inside the pod is fully installed

and that the indexing key on the rubber mount is lined up
with the keyway in the dash panel.
3. Hold the dash panel securely and insert the instrument
cluster into the dash panel. Twist the instrument cluster
gently in a clockwise motion to properly seat the instrument
cluster into the pod assembly. Apply pressure on the bezel
while pressing down on the instrument cluster.

10.11

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 ELECTRICAL
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS
Test 1 - No All Wheel Drive

.OTE )F !7$ ICON COMES ON INSTRUMENT

34!24 (%2% CLUSTER IS /+ 0ROCEED TO MECHANICAL TESTS
OUTLINED IN #HAPTER  #HECK THE !7$ ICON
ON INSTRUMENT CLUSTER TO VERIFY ITS OPERATION
30%%$ . #(%#+ 4HE !7$ SWITCH IS DIRECTLY POWERED BY
2%!$/54 30%%$/-%4%2 SWITCHED  VOLTS ORANGEWHITE  4HE GEAR
/+
0%2&/2- SWITCH ONLY INTERFACES WITH THE INSTRUMENT
4%34  CLUSTER 4O ENABLE !7$ THE CLUSTER MUST BE
DISPLAYING LOW HIGH OR REVERSE GEAR
9
+%9 37)4#( /.
42!.3-)33)/. ).
'%!2  0IN #ONNECTOR
 2ED 6 #ONSTANT  "LUE  7HITE %NGINE /VERHEAT 3WITCH
!7$ 37)4#( /.
 2ED  7HITE 6 3WITCHED  /RANGE  2ED 0ARK "RAKE )NDICATOR
 'REY  /RANGE -ODE BUTTON  "LK  7HITE -ALFUNCTION )NDICATOR
 6IOLET  7HITE &UEL 'AUGE
9 

.#
'REEN  "ROWN  2ED 'ROUND
 "LUE  7HITE 'EAR )NDICATOR )NPUT
 9ELLOW 20- )NPUT  .#
 "ROWN  7HITE !7$ #ONTROL
 "ROWN  2ED 'ROUND

/. (5" #/),
#/..%#4/2 ./4 !. ).3425-%.4
,%!6% )4 #/..%#4%$ . #,534%2 02/",%-
-%!352% &/2 6 &2/- #(%#+ !7$ 37)4#(
"2/7.7()4% 4/ 4(% !.$ 7)2).'
#/), "/$9
'2/5.$

.OTE 2EVERSING POLARITY WHEN CONNECTING

THE BATTERY OR OTHER $# POWER SOURCE
9 BACKWARDS WILL FAIL THE !7$ CONTROL AND
THE INSTRUMENT CLUSTER IF THE KEY SWITCH
AND THE !7$ SWITCH ARE TURNED ON
,%!6% !7$
37)4#( /.
452. +%9 37)4#( /&& . 7)2).'
$)3#/..%#4  0).
02/",%-
#/..%#4/2 &2/- #,534%2
452. +%9 37)4#( /. 2%0,!#%
#(%#+ &/2 6 ).3425-%.4
&2/- "2.7()4% #,534%2
4/ '2/5.$
9
02/#%%$ 4/
9 -%#(!.)#!, !7$
. #/-0/.%.43
452. +%9 37)4#( /&& )& !7$ 02/",%-
2%#/..%#4 #,534%2 0%23)343

3()&4 4/ ,/7 /2 ()'(

,%!6% !7$ /.

10.12

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 ELECTRICAL
TEST 2 - No Display
1RWH %HIRUH VWDUWLQJ GLDJQRVLV WXUQ RII VSHHGRPHWHU DQG ZDLW  VHFRQGV
6
WKHQ WXUQ RQ DJDLQ WR VHH LI SUREOHP FOHDUV
< &+(&. )25
1 5(3/$&(
0,1,080 9'&
63(('2
21 3,1 % 72
67$57 +(5(  3LQ &RQQHFWRU 3,1 &
5(3/$&(
.(< 6:,7&+ 21 63(('2 $ '& 3RZHU
% 6LJQDO < 0($685(
6 %$&. 2)
& *URXQG
63(('2
<
5(3/$&( &+(&. 6
&+(&.
:+((/
63(('2 1 63(('
6(1625
$7 %$&. 2) 63(('2
32,17(5
6(1625
32:(5 < &+(&. )25 
029(" 6833/<
6((7(67 9'& 21 3,1 $ 72 3,1
3,1 $
& 21 7+(  3,1
< &211(&725"

3,1 0($
685( 9'& 1 5(3$,5
21 3,16  :,5,1* 1
 $1'   5(3/$&(
63(('2
5(3/$&(
63(('2
1 1
1
< 7(67
2'20(7(5 '5,9( 2'20(7(5 < 32,17(5 < 63(('2
',63/$< 9(+,&/( 2.
&+$1*(" 029("

TEST 3 - Wheel Speed Sensor

7(%%, 30%%$ 3%.3/2
4OOLS 2EQUIRED 4O 3ENSOR 2ED
"RN
3TATIC 4IMING ,IGHT (ARNESS 0. 
(ALL 3ENSOR 0ROBE (ARNESS 0.  7
7HT
OR EQUIVALENT JUMPER WIRES
4O 3ENSOR
4O TEST WHEEL SPEED SENSOR ,%$ 7HITE
 $ISCONNECT  0IN CONNECTOR FROM SPEEDOMETER 6 4O 3ENSOR
 #ONNECT WIRES FROM TEST LIGHT TO SENSOR  0IN "LACK
"LK
CONNECTOR AS SHOWN AT RIGHT USING THE (ALL 3ENSOR
0ROBE (ARNESS 0.  OR JUMPER LEADS
 %LEVATE FRONT RIGHT SIDE OF VEHICLE UNTIL TIRE IS OFF THE
GROUND
 3LOWLY TURN RIGHT FRONT WHEEL WHILE OBSERVING THE
TEST LIGHT
3TATIC 4IMING ,IGHT (ARNESS
10
 )F LIGHT FLASHES SENSOR IS /+ "E SURE CONNECTIONS
ARE GOOD AND  VOLT BATTERY IS IN GOOD CONDITION 0. 

7(%%, 30%%$
3%.3/2 ,/#!4)/.
2)'(4 7(%%,

10.13

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 ELECTRICAL
TEST 4 - No AWD Hub Safety Limiter

127( ,) 7+( $:' ,&21 '2(6 127 &20( 21 25 ,) 

9'& ,6 127 5(*,67(5,1* $1' $:' ,6 (1*$*,1*
$%29(  530,7 0$< %( $ 0(&+$1,&$/ 352%/(0
67$57 +(5(

,6
63(('2
< )81&7,21,1* 1 &+(&.
,1 1(875$/ 63(('2
&255(&7/<"
72**/( 72 7$&+20(7(5
< 6(77,1* 5(9 (1*,1( 7(67  
+2/' 817,/ ',63/$< 67$%,/,=(6

'2(6 ,7 $33($5
$&&85$7("
5(67$57
1
(1*,1( ,'/,1*
7851 .(< 6:,7&+ 2)) 0($685( $& 92/7$*(
< 5(3/$&(
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5(029(  3,1
 5$,6( $79 :+((/6 2)) *5281' $1' &211(&725 )520 3,1 
6833257 ,1 $ 6$)( 0$11(5 %$&. 2) 29(5  9$&"
,167580(17
 021,725 92/7$*( $7 +8% &2,/ &/867(5
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&+(&. &+$5*,1* 6<67(0

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$1' :,5,1*

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$:' 2))  3LQ &RQQHFWRU
67$57 7+( (1*,1(  5HG 9 &RQVWDQW  %OXH  :KLWH (QJLQH 2YHUKHDW 6ZLWFK
5(9 $1' +2/' 7+( 1  5HG:KLWH 9 6ZLWFKHG  2UDQJH5HG3DUN%UDNH,QGLFDWRU
530·6 $%29(  12 352%/(0  %ON  :KLWH 0DOIXQFWLRQ ,QGLFDWRU
7851 $:' 21  *UH\2UDQJH 0RGHEXWWRQ
 1&  9LROHW  :KLWH )XHO *DXJH
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 %OXH
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 <HOORZ 530 ,QSXW
 %URZQ  :KLWH $:' &RQWURO
 %URZQ5HG *URXQG

<

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1 <

0(&+$1,&$/ 352%/(0 5(3$,5 +8% &2,/ :,5,1*

10.14

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 ELECTRICAL
TEST 5 - Fuel Gauge Display Not Working

 3LQ &RQQHFWRU
67$57 +(5(  5HG 9 &RQVWDQW  %OXH  :KLWH (QJLQH 2YHUKHDW 6ZLWFK
 5HG:KLWH 9 6ZLWFKHG  2UDQJH5HG3DUN%UDNH,QGLFDWRU
 *UH\2UDQJH 0RGHEXWWRQ  %ON  :KLWH 0DOIXQFWLRQ ,QGLFDWRU
 1&  9LROHW  :KLWH )XHO *DXJH
&+(&.  *UHHQ  %URZQ  5HG *URXQG
,167580(17 63(('20(7(5
&/867(5
1  %OXH  :KLWH*HDU,QGLFDWRU,QSXW
3(5)250 7(67   <HOORZ 530 ,QSXW  1&
)81&7,212."  %URZQ  :KLWH $:' &RQWURO
 %URZQ5HG *URXQG

< 7851 .(< 6:,7&+ 2))

*$,1 $&&(66 72 )8(/
6(1'(5 :,5,1*
&+(&. )25 &217,18,7< 21 5(3$,5
*$,1 $&&(66 72 :,5(6 $6
%$&. 2) *$8*(
9,2/(7:+,7( 1 5(48,5('
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1 &+(&. )25 &217,18,7< 352%/(0 5(0$,16 "
&+(&. &211(&7,21 $1'
)520 %51 72 *5281' 5(7(67 <
$7 *$8*( 3,1 
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'2(6 )8(/ ,1',&$725
:25."

<
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< 7(67 6(1'(5 )25 3523(5 23(5$7,21 63(('20(7(5
5()(5 72 ´)8(/6(1'(57(67µ,6 ,7 2."
&/($1 &211(&725 7(50,1$/6
&+(&. 5(/$7(' :,5,1*
1
5(3/$&( )8(/3803$60

TEST 6 - Shift Indicator Not Working (Transmission Switch)

2SHUDWLRQ
7KH ,QVWUXPHQW FOXVWHU VHQGV D VLJQDO WKURXJK WKH :KLWH ZLUH
WR WKH UHVLVWRU PRGXOH 7KLV VLJQDO FRPSOHWHV LW·V SDWK RQ WKH
%URZQ5HG ZLUH WKURXJK WKH WUDQVPLVVLRQ VZLWFK 'HSHQGLQJ
RQ WKH WUDQVPLVVLRQ VZLWFK SRVLWLRQ WKH ,QVWUXPHQW &OXVWHU
LQWHUSUHWV WKH UHVLVWDQFH UHDGLQJ DQG GLVSOD\V WKH
FRUUHVSRQGLQJ VKLIW SRVLWLRQ RQ WKH /&' VFUHHQ

7HVWLQJ
8VH WKH GLDJUDP SURYLGHG WR WHVW WKH FRQWLQXLW\ ORRS DW HDFK
RI WKH VKLIW SRLQWV ZLWK D PXOWLPHWHU 127( 7KH ,QVWUXPHQW
FOXVWHU FRQWDLQV WKLV GLDJQRVWLF IHDWXUH
10
 3LQ &RQQHFWRU
 5HG 9 &RQVWDQW  %OXH  :KLWH (QJLQH 2YHUKHDW 6ZLWFK
 5HG:KLWH 9 6ZLWFKHG  2UDQJH5HG3DUN%UDNH,QGLFDWRU
 *UH\2UDQJH 0RGHEXWWRQ  %ON  :KLWH 0DOIXQFWLRQ ,QGLFDWRU
 1&  9LROHW  :KLWH )XHO *DXJH
 *UHHQ  %URZQ  5HG *URXQG
 %OXH  :KLWH*HDU,QGLFDWRU,QSXW
 <HOORZ 530 ,QSXW  1&
 %URZQ  :KLWH $:' &RQWURO
 %URZQ5HG *URXQG

10.15

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 ELECTRICAL
ALL WHEEL DRIVE (AWD) COIL GEAR POSITION INDICATOR SWITCH
Operation Overview Test Diagram
• When the AWD switch is “ON”, 12 VDC power is NOTE: Also see “INSTRUMENT CLUSTER
present at the hub coil. TROUBLESHOOTING” for switch circuit.
• If the criteria is met, the instrument cluster provides a TRANSMISSION SWITCH
ground path at pin #16 (Brown/White wire). When this
High / Low / Neutral / Reverse Switch
occurs the AWD icon should display in the instrument
cluster.

• The AWD system must be grounded to operate.

Diagnosing System Failures

• Verify the AWD switch is functional and that a
minimum of 11 volts is present at the hub coil. High Range
Low Range
• Verify the AWD hub coil is functional. Test the AWD Neutral
hub coil using an ohm meter. See specifications below: Reverse

Green/White Brown/Red
Violet White/Blue
Blue/Red
7HVW5HVLVWDQFH
5HDGLQJVVKRXOGEH
*<WR%1:+a2KPV
*<WR*URXQG1R&RQQHFWLRQ

AWD Hub Coil Resistance:

24 Ω ± 5%

• Verify the wiring harness, wiring, connectors,

connector pins and grounds are undamaged, clean and
connected properly.

• Verify continuity of wire connections with a volt/ohm

meter.

IMPORTANT: Verify all wires and wiring connections

have been tested properly with a known good volt/
ohm meter before suspecting a component failure.
80% of all electrical issues are caused by bad/failed
connections and grounds.

10.16

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 ELECTRICAL
HEADLIGHTS 6. Adjust the beam to desired position. Repeat the procedure
to adjust the other headlight.
Headlight Adjustment
WARNING
The headlight beam is adjustable.
1. Place the vehicle on a level surface with the headlight Due to the nature of light utility vehicles and
approximately 25 ft. (7.6 m) from a wall. where they are operated, headlight lenses
become dirty. Frequent washing is necessary to
maintain lighting quality. Riding with poor
lighting can result in severe injury or death.
25 ft.
X (7.6 m) X
8 in. (20 cm)
Headlight Bulb Replacement
1. Open the hood.

2. Unplug the headlight bulb (A) from the wiring harness. Be

sure to pull on the connector, not on the wiring.

3. Turn the lamp counterclockwise to remove it.

2. Measure the distance from the floor to the center of the
headlight and make a mark on the wall at the same height.

3. With the machine in Neutral and parking brake applied,

start the engine and turn the headlight switch to high beam.

4. The most intense part of the headlight beam should be

aimed 8 in. (20 cm) below the mark placed on the wall in
Step 2.

NOTE: Rider weight must be included in the seat

while performing this procedure.

5. Adjust the beam to the desired position by loosening the A

adjustment screw (A) and moving the lamp to the
appropriate height.
4. Insert new bulb. Reinstall the harness assembly into the
headlight assembly.
A
NOTE: Make sure the tab on the lamp locates
properly in the housing.

Headlight Housing Removal

1. Open the hood.
10
2. Unplug the headlight from the wiring harness. Be sure to
pull on the connector, not on the wiring.

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 ELECTRICAL
3. Remove the O-ring (A) from the headlight brackets (both TAIL LIGHT / BRAKE LIGHT
sides).
Lamp Replacement
A
Before replacing the tail light, use a digital multi-meter to test
the harness to ensure the lamp is receiving 12 volts and that a
ground path is present.

B If the tail light / brake light does not work the lamp assembly
may need to be replaced.

1. From the rear of the tail light remove two screws holding
lens cover in place and remove lens cover. (T-20 Torx)

4. After the O-rings are removed from the headlight, remove

the adjustment screw (B) and pull the headlight from the
brackets.
Tail Light Screws

2. Remove lamp by turning the rubber base 1/4 turn and

pulling the bulb out. Replace it with recommended lamp.
Apply Dielectric Grease (PN 2871329).

Headlight Housing Installation

1. To install the headlight housing, press the headlight tabs
back into the brackets.
2. Secure the headlight housing with the rubber O-rings on
each side (A). Install the adjustment screw (B).
Tail Light
Brake Light
RD and BN
A OG and RD

Replacement Bulbs
PN 4030040
B

3. Reinstall the lens cover removed in Step 1.

4. Test the tail light / brake light to see it is working.

3. Reconnect wire harness or re-insert bulb if previously
removed.
4. Adjust headlights using the “High Beam Headlight
Adjustment” procedure on the previous page.

10.18

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 ELECTRICAL
COOLING SYSTEM
Cooling System Break-Out Diagram

+EY /N
 6OLT 0OWER

10

10.19

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 ELECTRICAL
Fan Control Circuit Operation EFI DIAGNOSTICS
Power is supplied to the fan via the Orange/Black wire when the
EFI Component Testing
relay is ON. The ground path for the fan motor is through the
Brown harness wire. Refer to “RELAYS” later in this chapter All EFI component information and diagnostic testing
for more information on fan functions. procedures are located in Chapter 4.

Refer to Chapter 4 “Electronic Fuel Injection System (EFI)”

CAUTION when diagnosing an EFI System.

Keep hands away from fan blades during FUEL SENDER

operation. Serious personal injury could result.
Testing
NOTE: The fan may not function or operation may
be delayed if coolant level is low or if air is trapped in 1. Drain the fuel tank and remove it from the chassis.
the cooling system. Be sure cooling system is full 2. Set the fuel tank on a flat surface.
and purged of air. Refer to Maintenance Chapter 2
for cooling system information. 3. Hook up an ohm meter to the fuel sender harness Violet/
White wire (B) and Brown wire (C).
Fan Control Circuit Bypass Test 4. With the sender float in the empty position and compare
to specification.
1. Disconnect harness from coolant temperature sensor on
engine.
Fuel Sender - Empty: 5 Ω ± 5%
2. With the parking brake applied, turn the ignition key (and
engine stop switch) “ON”. The fan should start running.
5. Slowly tilt invert the tank so that gravity moves the sender
3. If the fan does not run or runs slowly, check the fan motor float to the full position and compare to specification.
wiring, ground, motor condition and mechanical relay for
proper operation. Repair or replace as necessary. If the fan
runs with the sensor harness disconnected, but will not turn Fuel Sender
on when the engine is hot, check the coolant temperature
sensor and connector terminals.

Coolant Temperature Sensor

The coolant temperature sensor can be tested using an ohmmeter
or voltmeter.
Empty: 5Ω ± 5%
1. With the engine and temperature sensor at room
temperature (68°F = 20°C), disconnect the harness Half: 57Ω ± 5%
connector. Full: 90Ω ± 5%
2. With the meter in the ohms mode, place the meter leads
onto the sensor contacts.
Fuel Sender - Full: 90 Ω ± 5%
3. Use the table Temperature / Resistance table to determine
if the sensor needs to be replaced.
6. If the readings are not to specification, or if the reading is
erratic or LCD display “sticks”, check the following before
TEMPERATURE °F (°C) RESISTANCE replacing the fuel pump assembly.
68 °F (20 °C) 2.5 k Ω ± 6% • Loose float
212 °F (100 °C) 186 Ω ± 2% • Float contact with tank
• Bent Float Rod
NOTE: If the coolant temperature sensor or circuit
malfunctions the radiator fan will default to 'ON'. If none of the conditions exists, the sender assembly is faulty.
Fuel pump/tank assembly replacement is required.

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 ELECTRICAL
RELAYS REAR DIFF SOLENOID RELAY

Operation COLOR FUNCTION

The relays, located under the hood, assist with component Key-On battery power supply, switched on
Red / White
operation like the fan, fuel pump, and rear differential. by key switch, enables power to relay.
Brown Ground path for relay.
The differential relay, controlled by the AWD switch and ECU,
operates the differential solenoid. Key-On power supply, switched by relay,
Orange / White
provides power to Rear Diff Solenoid.
The fan relay, controlled by the ECU and Temp Sensor, operates
the fan. ECU ground input to connect relay Key-On
Brown / White
power to Rear Diff Solenoid output.
The power relay, controlled by the ECU, turns on power for
components such as the fuel pump, injectors, etc.
FAN RELAY
COLOR FUNCTION
+EY /N 6 0OWER Key-On battery power supply, switched on
Red / White
'ROUND by key switch, enables power to relay.
2EAR $IFF 0OWER /UPUT Fused 15-Amp power, switched by relay,
Orange / Black
%#5 )NPUT provides power to Fan Motor.
ECU input to connect relay Fused 15-Amp
Yellow / Black
power to Fan Motor output.
+EY /N 6 0OWER Fused 15-Amp, constant battery power IN
Red
supply for EFI component operation.
&AN 0OWER /UTPUT

%#5 )NPUT POWER RELAY

 !MP 0OWER 3UPPLY
COLOR FUNCTION

Fused 15-amp, constant battery power IN

Orange
 !MP 0OWER 3UPPLY supply for EFI component operation.

+EY /N 0OWER )NPUT Key-On battery power supply, switched on

Red / White
by key switch, enables power to relay.
EFI power output. Switched by relay when
+EY /N 0OWER /UTPUT ECU sends a signal on the GRY/W wire,
Red / Black closing the relay. Supplies 15-amp power
%#5 )NPUT for ECU-controlled operation of EFI
components.
ECU input to enable relay. The ECU 10
supplies a ground which closes the relay,
Gray / White
supplying power to run the fuel pump,
injectors, etc.

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 ELECTRICAL
FUSES / CIRCUIT BREAKER
Operation
The fuse panel, located under the hood, provides component protection for components such as the Instrument Cluster, ECU, EFI
system, Chassis Power and Accessories.

A 15-amp circuit breaker protects the fan motor circuit.

6 0OWER TO 3PEEDOMETER

6 0OWER TO &AN 2ELAY

!CCESSORY 0OWER 4ERMINAL "LOCK

6 0OWER TO +EY 3WITCH
6 0OWER TO 0OWER 2ELAY

 !MP 0ROTECTION FOR %#5

6 0OWER FROM &USIBLE ,INK

 !MP 0ROTECTION FOR +EY /N 0OWER

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 ELECTRICAL
CHARGING SYSTEM Charging System “Break Even” Test

Current Draw - Key Off

CAUTION

CAUTION Do not allow the battery cables to become

disconnected with the engine running. Follow the
Do not connect or disconnect the battery cable steps below as outlined to reduce the chance of
or ammeter with the engine running. Damage will damage to electrical components.
occur to electrical components.
The “break even” point of the charging system is the point at
Connect an ammeter in series with the negative battery cable. which the alternator overcomes all system loads (lights, etc.)
Check for current draw with the key off. If the draw is excessive, and begins to charge the battery. Depending on battery condition
loads should be disconnected from the system one by one until and system load, the break even point may vary slightly. The
the draw is eliminated. Check component wiring as well as the battery should be fully charged before performing this test.
component for partial shorts to ground to eliminate the draw.

Current Draw Inspection WARNING

Key Off
Never start the engine with an ammeter
connected in series. Damage to the meter or
meter fuse will result.
Do not run test for extended period of time.
Do not run test with high amperage accessories.

1. Using an inductive amperage metering device, (set to DC

30 Amp amps) connect to the negative battery cable

2. With engine off, and the key switch and lights in the ON
position, the ammeter should read negative amps (battery
discharge). Reverse meter lead if a positive reading is
indicated.

Current Draw - Key Off: 3. Shift transmission into neutral with the parking brake
Maximum of .01 DCA (10 mA) applied and start the engine. With the engine running at idle,
observe meter readings.

4. Increase engine RPM while observing ammeter and

tachometer.

5. Note RPM at which the battery starts to charge (ammeter

indication is positive).

6. With lights and other electrical loads off, the “break even”
point should occur at approximately 1500 RPM or lower.
10
7. With the engine running, turn the lights on and engage
parking brake to keep brake light on.

8. Repeat test, observing ammeter and tachometer. With

lights on, charging should occur at or below 2000 RPM.

10.23

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 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). 1. Set the selector dial to measure AC Voltage.

2. Start the engine and let it idle.

3. While holding the engine at a specified RPM, separately

Y1 measure the voltage across each ‘leg’ of the stator by
Y2 connecting the meter leads to the wires leading from the
alternator (Y1 to Y2, Y1 to Y3, Y2 to Y3).

4. Refer to the following table for approximate AC Voltage

Y3 readings according to RPM. Test each leg at the specified
RPM in the table.

Example: The alternator current output reading should be

approximately 18 VAC at 1300 RPM between each ‘leg’.

NOTE: If one or more of the stator leg output AC

TEST 1: Resistance Value of Each Stator Leg voltage varies significantly from the specified value,
the stator may need to be replaced.
1. Measure the resistance value of each of the three stator
legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3.
Each test should measure: 0.19Ω ± 15% RPM Reading AC Voltage (VAC) Reading
1300 18 VAC ± 25 %
Connect Meter 3000 42 VAC ± 25 %
Test Ohms Reading
Leads To:
5000 64 VAC ± 25 %
Battery Charge Coil Y1 to Y2 0.19Ω ± 15%
Battery Charge Coil Y1 to Y3 0.19Ω ± 15%
Battery Charge Coil Y2 to Y3 0.19Ω ± 15%

NOTE: If there are any significant variations in ohm

readings between the three legs it is an indication
that one of the three stator legs maybe weak or
failed.

TEST 2: Resistance Value of Each Stator Leg to Ground

1. Measure the resistance value of each of the stator legs to
ground: Y1 to Ground, Y2 to Ground, Y3 to Ground.
Each test should measure: Open Line (OL)

Connect Meter
Test Ohms Reading
Leads To:

Y1, Y2, or Y3 Open Line

Battery Charge Coil
to Ground (Infinity)

NOTE: Any measurement other than Infinity (open)

will indicate a failed or shorted stator leg.

10.24

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 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.:

Using a multitester set on D.C. volts, mea- Remove the battery and properly ser-
sure the battery open circuit voltage (See No vice. Reinstall the fully charged battery
earlier test). It should be 12.4 volts or more. or a fully charged shop battery.
Is it?
Yes

Meter Setting: DC Volts

With the transmission in Neutral, start the
engine and increase RPM to between 3000
and 4000. Read battery voltage with the Yes Check Key off Current Draw.
multitester. Readings should increase to
between 13.0 and 14.6 V D.C. Do they?

No
Check for owner modification, and
Meter Setting: DC Amps discuss operating habits. The battery
Perform system “Break Even Amperage” will continually discharge if operated
test outlined in this chapter. Yes below the “Break Even” RPM. Con-
tinued problems would call for battery
Does charging occur as specified? inspection.
No

Ohm stator wires, if bad replace stator, if good, Inspect the wiring harness between
continue with alternator output test.
the panel and the stator for
Meter Setting: AC Volts
damage. If no damage is found,
Disconnect the Yellow wires from the regulator /
rectifier. Using a multitester, perform an Alternator No remove the recoil and flywheel.
Output test. See test procedure on Page 10.24. Inspect the flywheel magnets, stator
coils and stator wires for damage.
Does output meet specification? Repair or replace any damaged
components.
Yes

Meter Setting: DC Volts

Reconnect the alternator wires. Note: Red
wire must be connected to harness. Battery
Check stator, regulator, ground, battery
voltage must be present on red wire terminal
and battery connections. Also check
on harness side of voltage regulator connector. No wire connections and wire condition.
Is voltage present? Repair or replace faulty wiring or 10
components.
Yes

If all of the previous tests indicate a good

condition, but the charging voltage does not
rise above battery voltage at the connector
or wire harness, replace the voltage regulator.

10.25

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 ELECTRICAL
BATTERY SERVICE Battery Activation

Battery Terminals / Bolts CONVENTIONAL BATTERY

Use Polaris corrosion resistant Nyogel™ grease (PN 2871329)
Removable
on battery terminal bolts.
Caps

Top View

Electrolyte Level
Indicator

Apply
Nyogel™ Side View

Battery Terminal Block WARNING

The terminal block is located under the front hood next to the
battery. The terminal block provides easy access to the main Battery electrolyte is poisonous. It contains
battery and starting cables. The terminal block also provides sulfuric acid. Serious burns can result from
easy hookup for accessories. contact with skin, eyes or clothing. Antidote:

TERMINAL BLOCK External: Flush with water.

Orange/White
Internal: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
Orange/White
Black
(Accessories) vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get

Red Black prompt medical attention.
(Ground)

Batteries produce explosive gases. Keep

sparks, flame, cigarettes etc. away. Ventilate
Red when charging or using in an enclosed space.
(Battery+)
Always shield eyes when working
near batteries.
KEEP OUT OF REACH OF CHILDREN.

WARNING
=T
The gases given off by a battery are explosive.
Terminal Block Nuts:
Any spark or open flame near a battery can
20-25 in. lbs. (2.3-2.8 Nm)
cause an explosion which will spray battery acid
on anyone close to it. Should there be contact
with battery acid, wash the affected area with
large quantities of cool water and seek
immediate medical attention.

10.26

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 ELECTRICAL
To ensure maximum service life and performance from a new Inspect the battery fluid level. When the battery fluid nears the
battery, perform the following steps. NOTE: Do not service the lower level, remove the battery and fill with distilled water only
battery unless it will be put into regular service within 30 days. to the upper level line. To remove the battery:
After initial service, add only distilled water to the battery.
Never add electrolyte after a battery has been in service.

NOTE: New Battery: Battery must be fully charged

before use or battery life will be significantly Maintain
reduced 10-30% of the battery’s full potential. between upper
and lower level
To activate a new battery: marks
1. Remove vent plug from vent fitting. Remove cell caps.

2. Fill battery with electrolyte to upper level marks on case.

3. Set battery aside to allow for acid absorption and

stabilization for 30 minutes.
Battery Removal / Installation
4. Add electrolyte to bring level back to upper level mark on
See Chapter 2 “Maintenance” for battery service procedures.
case.

NOTE: This is the last time that electrolyte should Battery Testing
be added. If the level becomes low after this point,
add only distilled water. Whenever a service complaint is related to either the starting or
charging systems, the battery should be checked first.
5. Charge battery at 1/10 of its amp/hour rating. Examples: 1/
10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4 Following are three tests which can easily be made on a battery
amp; 1/10 of 18 amp battery = 1.8 amp (recommended to determine its condition: OCV Test, Specific Gravity Test and
charging rates). Load Test.

6. Check specific gravity of each cell with a hydrometer to

OCV - Open Circuit Voltage Test
assure each has a reading of 1.270 or higher.
Battery voltage should be checked with a digital multitester.
Readings of 12.6 volts or less require further battery testing and
Battery Inspection charging. See the following chart and Load Test.
IMPORTANT: Proper servicing and upkeep of the
battery is very important in maintaining long battery NOTE: Lead-acid batteries should be kept at or near
life. a full charge as possible. Electrolyte level should be
kept between the low and full marks. If the battery is
The battery is located under the hood. stored or used in a partially charged condition, or
with low electrolyte levels, hard crystal sulfation will
form on the plates, reducing the efficiency and
service life of the battery.

OPEN CIRCUIT VOLTAGE

10
Conventional
State of Charge YuMicron™ Type
Lead-Acid
100% Charged 12.60 V 12.70 V
75% Charged 12.40 V 12.50 V
50% Charged 12.10 V 12.20 V
25% Charged 11.90 V 12.0 V
less than less than
0% Charged
11.80 V 11.9 V

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Specific Gravity Test A battery may indicate a full charge condition in the OCV test
and the specific gravity test, but still may not have the storage
A tool such as a Battery Hydrometer (PN 2870836) can be used capacity necessary to properly function in the electrical system.
to measure electrolyte strength or specific gravity. As the battery For this reason, a battery capacity or load test should be
goes through the charge/discharge cycle, the electrolyte goes conducted whenever poor battery performance is encountered.
from a heavy (more acidic) state at full charge to a light (more
To perform this test, hook a multitester to the battery in the same
water) state when discharged. The hydrometer can measure
state of charge and differences between cells in a multi-cell manner as was done in the OCV test. The reading should be 12.6
battery. Readings of 1.270 or greater should be observed in a volts or greater. Engage the starter and observe the battery
fully charged battery. Differences of more than .025 between the voltage while cranking the engine. Continue the test for 15
lowest and highest cell readings indicate a need to replace the seconds. During cranking the observed voltage should not drop
battery. below 9.5 volts. If the beginning voltage is 12.6 volts or higher
and the cranking voltage drops below 9.5 volts during the test,
replace the battery.

Off Season Storage

Battery Hydrometer (PN 2870836)
See Chapter 2 “Maintenance” for battery service procedures.
1.10

1.15 Charging Procedure

Detail A 1.20
1. Remove the battery to prevent damage from leaking or
1.25 spilled acid during charging.
1.30
2. Charge the battery with a charging output no larger than 1/
10 of the battery’s amp/hr rating. Charge as needed to raise
the specific gravity to 1.270 or greater.
SPECIFIC GRAVITY
Conventional 3. Install battery in vehicle with positive terminal toward the
State of Charge* YuMicron™ Type front. Coat threads of battery bolt with a corrosion resistant
Lead-Acid
dielectric grease.
100% Charged 1.265 1.275
75% Charged 1.210 1.225 Dielectric Grease
50% Charged 1.160 1.175 (PN 2871329)
25% Charged 1.120 1.135
4. Connect battery cables.
0% Charged less than 1.100 less than 1.115
* At 80° F WARNING
NOTE: Subtract .01 from the specific gravity reading at 40° F.
To avoid the possibility of explosion, connect
Load Test positive (+) cable first and negative (-) cable last.

5. After connecting the battery cables, install the cover on the

CAUTION battery and attach the hold down strap.

6. Install clear battery vent tube from vehicle to battery vent.

To prevent shock or component damage, WARNING: Vent tube must be free from obstructions and
remove spark plug high tension leads and kinks and securely installed. If not, battery gases could
connect securely to engine ground accumulate and cause an explosion. Vent should be routed
before proceeding. away from frame and body to prevent contact with
electrolyte. Avoid skin contact with electrolyte, as severe
NOTE: This test can only be performed on machines burns could result. If electrolyte contacts the vehicle frame,
with electric starters. This test cannot be performed corrosion will occur.
with an engine or starting system that is not working
properly. 7. Route cables so they are tucked away in front and behind
battery.

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 ELECTRICAL
STARTER SYSTEM Voltage Drop Test
The Voltage Drop Test is used to test for bad connections. When
Troubleshooting
performing the test, you are testing the amount of voltage drop
Starter Motor Does Not Run through the connection. A poor or corroded connection will
appear as a high voltage reading. Voltage shown on the meter
• Battery discharged - Low specific gravity when testing connections should not exceed .1 VDC per
• Loose or faulty battery cables or corroded connections connection or component.
(see Voltage Drop Tests)
To perform the test, place the meter on DC volts and place the
• Related wiring loose, disconnected, or corroded meter leads across the connection to be tested. Refer to the
voltage drop tests on the starter system in this chapter.
• Poor ground connections at battery cable, starter motor
or starter solenoid (see Voltage Drop Tests)
Voltage should not exceed
• Faulty key switch
.1 DC volts per connection
• Faulty Start Diode. Use a digital multi-meter to test
diode operation. Unplug the diode from the harness
and measure between the Orange and Orange/Green
diode connections. Continuity should flow one Starter Motor Removal / Disassembly
direction only.
NOTE: Use electrical contact cleaner to clean starter
motor parts. Some solvents may leave a residue or
damage internal parts and insulation.

• Faulty starter solenoid or starter motor

• Engine problem - seized or binding (can engine be
rotated easily)

Starter Motor Turns Over Slowly

• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections (see
Voltage Drop Test)

• Engine problem - seized or binding (can engine be

rotated easily)
1. Remove the starter from the engine.
• Faulty or worn brushes in starter motor
Starter Motor Turns - Engine Does Not Rotate 2. Remove the two bolts, washers, and sealing O-Rings.
Inspect O-Rings and replace if damaged.
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel 10

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 ELECTRICAL
NOTE: Note the alignment marks on both ends of 2. Measure resistance between insulated brush and starter
the starter motor casing. These marks must align housing. Reading should be infinite (OL). Inspect
during reassembly. insulation on brush wires for damage and repair or replace
as necessary.
3. Remove the front bracket assembly and the rear bracket
assembly. Remove the shims from the armature shaft and
inspect the O-rings located on the armature housing.
O-Rings

Shims
3. Slide positive brush springs to the side, pull brushes out of
their guides and remove brush plate. Slide brush end frame
off end of starter.
NOTE: The shims will be replaced during
reassembly. NOTE: The electrical input post must stay with the
field coil housing.

Brush Inspection / Replacement 4. Measure resistance between ground brush and brush plate.
Resistance should be .3 ohms or less.
1. Measure resistance between starter input terminal and
insulated brushes. The reading should be .3 ohms or less.
Remember to subtract meter lead resistance.

Brush Inspection
1. Measure length of each carbon brush. Replace brush
assembly when worn to 5/16” (8 mm) or less. The brushes
must slide freely in their holders.
Brush Length

Limit 5/16” (8 mm)

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 ELECTRICAL
Brush Replacement 4. Measure the resistance between each commutator segment
and the armature shaft. The reading should be infinite (no
1. Remove terminal nut with lock washer, flat washer, large continuity).
phenolic washer, the small phenolic spacers, and sealing
O-ring. Inspect O-ring and replace if damaged.

2. Slide positive brush springs to the side, pull brushes out of

their guides and remove brush plate.
5. Check commutator bars for discoloration. Bars discolored
CAUTION in pairs indicate shorted coils, requiring replacement of the
starter motor.
Some cleaning solvents may damage the 6. Place armature in a growler. Turn growler on and position
insulation in the starter. Care should be a hacksaw blade or feeler gauge lengthwise 1/8” (.3 cm)
exercised when selecting an appropriate above armature coil laminates. Rotate armature 360°. If
solvent. If the commutator needs cleaning use
hacksaw blade is drawn to armature on any pole, the
only electrical contact cleaner.
armature is shorted and must be replaced.

Armature Testing CAUTION

1. Remove armature from starter casing. Note order of shims
Use care when handling starter housing. Do not
on drive end for reassembly.
drop or strike the housing as magnet damage is
possible. If magnets are damaged, starter must be
replaced.

Starter Reassembly / Installation

1. Install brush plate to field magnet housing aligning index
tab.

10
2. Inspect surface of commutator. Replace if excessively
worn or damaged.

3. Using a digital multitester, measure the resistance between

each of the commutator segments. The reading should be
.3 ohms or less.

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 ELECTRICAL
2. Install O-ring, two small phenolic spacers, large phenolic NOTE: It is important to tighten the bottom starter
washer, flat washer, lock washer, and terminal nut. bolt first (circle), as the bottom hole acts as a pilot
hole to properly align the starter drive (bendix) with
3. While holding brush springs away from brushes, push the flywheel. This helps to prevent binding and
brushes back and hold in place. starter damage.

4. Slide armature into field magnet housing. Release brushes.

5. Lightly grease the drive roller bearing and reinstall drive

end frame on armature. Inspect seal for wear or damage.
Replace drive end cap if necessary.
Roller Bearing

Seal

Starter Drive
If the garter spring is damaged, the overrun clutch may fail to
return properly. Use either of the following methods to remove
and install a new garter spring:
6. Be sure wire insulation is in place around positive brush
wire and pushed completely into slot on phenolic plate.

7. Using Dielectric Grease (PN 2871329), lubricate brush end

bushing and install shims. H
G
8. Align brush plate and install cover and screws. A F
D
9. Lightly grease pinion shaft and install pinion, spring
stopper, and snap ring.
B

A. Gear Assembly E
B. Thrust Washer C
C. Busing
D. Retaining Ring
E. Thrust Washer
F. Stopper
G. Cover
H. Spring

Set Bolt Torque: 35-52 in. lbs. (3.9-5.9 Nm)

1. Screw the overrun clutch out to the engaged position on the
pinion shaft assembly. Use a small piece of wire with the
10. Completely assemble starter motor and torque set bolts to end bent in a hook and pick the old spring out of its
35 - 52 in. lbs. (3.9 - 5.9 Nm). channel. Slide it off the end of the shaft. Slide the new
spring over the overrun clutch and into the spring groove.
11. Install the starter onto the engine case. Hand tighten each Make sure that the spring is positioned between the shoe
of the starter bolts. Torque the bottom bolt first to 9 ft.lbs. alignment pins and the back flange of the anti kick-out
(12 Nm). Then torque the top bolt to the same specification. shoes.

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 ELECTRICAL
2. Remove the retaining ring, thrust washer, spring retainers
and clutch return spring. Screw the overrun clutch off the
end of the pinion shaft. Remove the old spring and install
a new one. Lightly grease the pinion shaft and reinstall the
clutch, spring, retainers, end washer and lock ring in the
reverse order. Make sure the end washer is positioned
properly so that it will hold the lock ring in its groove.

Starter Solenoid Bench Test

Test the start solenoid by powering the solenoid using battery
voltage for a maximum of 5 seconds. With the solenoid
energized, resistance should read about 0.5Ω ± 10% between
terminal (A) and (B). If resistance measurement is out of
specification, replace the starter solenoid.

Energize
Here

A B

Starter Solenoid Operation

To energize the Starter Solenoid the following must occur:
• The brake must be applied to provide a ground path via
the Orange / Green wire.
• The key switch must be turned to the “start” position to
provide 12V power via the White / Red wire.
• Once the pull-in coil is energized, the solenoid provides
a current path for 12V power to reach the starter motor.

10

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 ELECTRICAL
Starter Exploded View

* Indicates - Do not reuse. 1. Rubber Ring* 10. Gear Assembly

Replace with new parts. 2. Brush Spring 11. Through Bolt
3. Thrust Washer 12. Cover
4. Gear Assembly 13. Stopper
5. O-Ring* 14. Snap Ring
6. Brush Complete 15. Washer
7. O-Ring* 16. Flange Bolt
8. Thrust Washer 17. Thrust Washer
9. Shaft Complete 18. Flange Bushing

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 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 No
fully charged shop battery to continue test.
be 12.4 V D. C. or greater.

Yes

Disconnect 2-wire connector at the solenoid. Check for voltage at the chassis 20 Amp fuse
Using a multi-meter, connect the black meter lead and then check for voltage entering the
to the Orange/Green harness wire and the red No ignition switch. Battery voltage should be
meter lead to the White/Red harness wire. Apply present. If battery voltage is present at the
the brake and turn ignition switch to the “start” ignition switch, but not the solenoid, replace
position. Meter should read battery voltage. the switch. NOTE: The brake MUST be
applied when performing these tests.
Test the start solenoid by powering the solenoid via the 2-wire connection.
Yes With the solenoid energized, resistance should read about 0.5Ω ± 10%
between the two terminals. If resistance measurement is out of specification,
Voltage Drop replace the starter solenoid (see “Starter Solenoid Bench Test”)
Testing
Reconnect the solenoid. Connect the tester black lead No Clean the battery-to-solenoid cable ends
to the battery positive and the red lead to the solenoid or replace the cable.
end of the battery-to-solenoid wire. Turn the ignition
key to the “start” position. Reading should be less
than .1 V D.C.

Yes

Connect the black tester lead to solenoid end of

battery-to-solenoid cable. Connect red tester lead No
to solenoid end of solenoid-to-starter cable. Turn Replace the starter solenoid.
the ignition key to the “start” position. Reading
should be less than .1 V D.C.

Yes

Connect the black tester lead to the solenoid end of

the solenoid-to-starter cable. Connect the red Clean the solenoid-to-starter cable ends or
tester lead to the starter end of the same cable. No
replace the cable. 10
Turn the ignition key to the “start” position. The
reading should be less than .1 V D.C.

Yes

If all of these indicate a good condition, yet the starter still fails to
turn, the starter must be removed for static testing and inspection.

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 ELECTRICAL
ELECTRIC BOX LIFT ACTUATOR
DIAGNOSIS (if equipped)

1. Disconnect the wiring harness to the

box lift actuator. Disconnect Harness

2. Connect a multimeter across the

box lift actuator harness connection.

3. Actuate the box lift switch in both

directions. Verify that there is 12 Volts
reaching the box lift actuator. Follow
the diagram below for diagnosis.

NO
YES

(Not 12 Volts at actuator)

YES - (12 Volts at actuator) Lift the hood. Locate the box lift switch.
Check for 12 Volts between the RED/BLACK
wire terminal on the back of the switch and
the BROWN wire terminal.

NO YES

(Not 12 Volts between wires) (12 Volts between wires)

On the main connector behind the dashboard, Check the switch. Check the
measure for 12 Volts between RED/BLACK wires between the switch
wire terminal and ground. and the actuator motor.

NO YES

(Not 12 Volts between wires) (12 Volts between wires)

Test the accessory and wiring circuit Test wiring between the main
breaker located under the seat. connector and the circuit
(Refer to Wiring Schematic) breaker.
Test the wiring between the main
connector and the circuit breaker.

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 ELECTRICAL
ELECTRICAL BREAK-OUT DIAGRAMS
Starting Circuit

Key-On Power Circuit

10

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 ELECTRICAL
Transmission Switch Circuit

AWD Circuit

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 ELECTRICAL
Speed Sensor Circuit

Charging System Circuit

10

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 ELECTRICAL
Cooling Fan Circuit

Fuel Display / Fuel Pump Circuit

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 A C
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Air Intake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
Cab Frame, Assembly / Removal (4x4 CREW) . . . . . . . . 5.9
Cargo Box, Installation . . . . . . . . . . . . . . . . . . . . . . . . . .5.26
IX
All Wheel Drive (AWD) Coil . . . . . . . . . . . . . . . . . . . 10.16 Cargo Box, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
AWD Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 Centralized Hilliard, Exploded View . . . . . . . . . . . . . . . 7.15
AWD, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
AWD, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16 Charging System, Alternator Tests . . . . . . . . . . . . . . . . 10.24
B Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Clock, Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Ball Joint, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 Coolant Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.22
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 Coolant Strength and Type . . . . . . . . . . . . . . . . . . . . . . . 2.23
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26 Cooling System Bleeding Procedure . . . . . . . . . . . . . . . . 3.15
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 Cooling System Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
Battery Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . 10.26 Cooling System Pressure Test . . . . . . . . . . . . . . . . . . . . . 2.23
Body Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Cooling System Specifications . . . . . . . . . . . . . . . . . . . . 3.13
Brake Burnishing . . . . . . . . . . . . . . . . . . . . . . . . . 9.15, 9.24 Cooling System, Pressure Test . . . . . . . . . . . . . . . . . . . . 3.14
Cooling System, Troubleshooting . . . . . . . . . . . . . . . . . . 3.59
Brake Caliper Assembly, Front . . . . . . . . . . . . . . 9.16, 9.18
Crankshaft Gear, Removal . . . . . . . . . . . . . . . . . . . . . . . 3.40
Brake Caliper Assembly, Rear (4x4 CREW) . . . . 9.28, 9.30
Crankshaft Position Sensor (CPS) . . . . . . . . . . . . . . . . . . 4.16
Brake Caliper Inspection, Front . . . . . . . . . . . . . . . . . . . 9.18
CV Shaft Boot Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.25
Brake Caliper Inspection, Rear (4x4 CREW) . . . . . . . . 9.30
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3.29
Brake Caliper Installation, Front . . . . . . . . . . . . . . . . . . 9.19
Cylinder Head Assembly Exploded View . . . . . . . . . . . 3.22
Brake Caliper Installation, Rear (4x4 CREW) . . . . . . . . 9.31
Cylinder Honing To De-glaze . . . . . . . . . . . . . . . . . . . . . 3.33
Brake Caliper Removal, Front . . . . . . . . . . . . . . . . . . . . 9.16
Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
Brake Caliper Removal, Rear (4x4 CREW) . . . . . . . . . . 9.28
Brake Caliper, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16 D
Brake Caliper, Rear (4x4 CREW) . . . . . . . . . . . . . . . . . 9.28 Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
Brake Caliper, Rear (6x6) . . . . . . . . . . . . . . . . . . . . . . . . 9.25 Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Brake Disc, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20 Diagnostic Codes, Instrument Cluster . . . . . . . . . . . . . . 10.10
Brake Disc, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32 Diagnostics, AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Brake Hose and Fitting Inspection . . . . . . . . . . . . . . . . . 2.32 Diagnostics, Gear Circuit . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Brake Pad Assembly, Front . . . . . . . . . . . . . . . . . . . . . . 9.15 Drive Belt, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
Brake Pad Assembly, Rear (4x4 CREW) . . . . . . . . . . . . 9.23 Drive Belt, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
Brake Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 Drive Belt, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Brake Pad Thickness, Front . . . . . . . . . . . . . . . . . . . . . . 9.14 Drive Clutch, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
Brake Pad Thickness, Rear (4x4 CREW) . . . . . . . . . . . . 9.23 Drive Clutch, Bushing Service . . . . . . . . . . . . . . . . . . . . 6.17
Brake Pads, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14 Drive Clutch, Button to Tower Clearance . . . . . . . . . . . . 6.14
Brake Pads, Rear (4x4 CREW) . . . . . . . . . . . . . . . . . . . 9.22 Drive Clutch, Cover Bushing Remove/Install . . . . . . . . . 6.18
Brake Pads, Rear (6x6) . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21 Drive Clutch, Disassembly . . . . . . . . . . . . . . . . . . . . . . . 6.12
Brake Pads, Removal, Front . . . . . . . . . . . . . . . . . . . . . . 9.14 Drive Clutch, Exploded View . . . . . . . . . . . . . . . . . . . . . 6.12
Brake Pads, Removal, Rear (4x4 CREW) . . . . . . . . . . . 9.22 Drive Clutch, Moveable Sheave Inspection . . . . . . . . . .6.16
Brake Pedal, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 Drive Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Brake Pedal, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 Drive Clutch, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Brake System Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.32 Drive Clutch, Shift Weights . . . . . . . . . . . . . . . . . . . . . . 6.11
Brake System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 Drive Clutch, Spider Removal . . . . . . . . . . . . . . . . . . . . 6.13
Brake System, Exploded View (4x4 CREW) . . . . . . . . . . 9.5 Drive Clutch, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Brake System, Exploded View (6x6, 4x4 CREW) . . . . . . 9.5 Drive Shaft / CV Joint, Handling Tips . . . . . . . . . . . . . . . 7.8
Brake System, Operation . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 Drive Shaft, Mid Drive (6x6) . . . . . . . . . . . . . . . . . . . . . 7.27
Brake System, Troubleshooting . . . . . . . . . . . . . . . . . . . 9.33 Driven Clutch, Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6.22
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Driven Clutch, Disassembly / Inspection . . . . . . . . . . . . 6.20
Breather Hose Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.14 Driven Clutch, Exploded View . . . . . . . . . . . . . . . . . . . . 6.20
Driven Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Driven Clutch, Service . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
IX.1

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 E Engine, Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Engine, Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . 3.41
EFI Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24
Engine, Oil Pump Installation . . . . . . . . . . . . . . . . . . . . 3.48
EFI Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . .4.10
Engine, Oil Pump Priming . . . . . . . . . . . . . . . . . . . . . . . 3.57
EFI Priming / Starting Procedure . . . . . . . . . . . . . . . . . .4.10
Engine, Oil Pump Reassembly . . . . . . . . . . . . . . . . . . . . 3.42
EFI Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.23
Engine, Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . 3.41
EFI, Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . .4.22
Engine, Piston Identification . . . . . . . . . . . . . . . . . . . . . 3.13
Electric Box Lift Actuator . . . . . . . . . . . . . . . . . . . . . . .10.36
Engine, Piston Installation . . . . . . . . . . . . . . . . . . . . . . . 3.47
Electrical Breakout Diagrams (EFI) . . . . . . . . . . . . . . .10.37
Engine, Piston Removal and Inspection . . . . . . . . . . . . 3.31
Electrical, Cooling System Breakout Diagram . . . . . . .10.19
Engine, Piston Ring Installed Gap . . . . . . . . . . . . . . . . . 3.35
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . .4.11
Engine, Piston to Cylinder Clearance . . . . . . . . . . . . . . 3.34
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . 3.13, 3.14
Engine, Piston to Rod Clearance . . . . . . . . . . . . . . . . . . 3.34
Engine Designation Number . . . . . . . . . . . . . . . . . . . . . . .1.2
Engine, Pushrod Inspection . . . . . . . . . . . . . . . . . . . . . . 3.23
Engine Exploded Views . . . . . . . 3.2, 3.3, 3.4, 3.5, 3.7, 3.8
Engine, Rocker Arm Inspection . . . . . . . . . . . . . . . . . . . 3.23
Engine Fastener Torques . . . . . . . . . . . . . . . . . . . . . . . . . .3.9
Engine, Starter Drive Removal . . . . . . . . . . . . . . . . . . . 3.35
Engine Flywheel / Stator Removal . . . . . . . . . . . . . . . . .3.36
Engine, Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . 3.37
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . . . .3.19
Engine, Stator Gear Cover Seal(s) Installation . . . . . . . 3.51
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
Engine, Stator Installation . . . . . . . . . . . . . . . . . . . . . . . 3.54
Engine Oil and Filter Change . . . . . . . . . . . . . . . . . . . . .2.15
Engine, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 3.58
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
Engine, Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . 3.26
Engine Removal / Install Procedure . . . . . . . . . . . . . . . .3.18
Engine, Valve Lifter Removal and Inspection . . . . . . . . 3.30
Engine Serial Number Location . . . . . . . . . . . . . . . . . . . .1.2
Engine, Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . 3.30
Engine Service Specifications . . . . . . . . . . . . . . . . . . . . .3.11
Engine, Valve Seat Reconditioning . . . . . . . . . . . . . . . . 3.27
Engine Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Engine Temperature Sensor . . . . . . . . . . . . . . . . . . . . . .4.20
Engine Temperature Sensor Replacement . . . . . . . . . . .4.20 F
Engine Temperature Sensor Test . . . . . . . . . . . . . . . . . .4.20 Fan Control Circuit Bypass Test . . . . . . . . . . . . . . . . . 10.20
Engine Torque Specifications . . . . . . . . . . . . . . . . . . . . .3.10 Fan Control Circuit Operation . . . . . . . . . . . . . . . . . . . 10.20
Engine Valve Seal/Spring Service . . . . . . . . . . . . . . . . .3.24 Flywheel / Stator Removal . . . . . . . . . . . . . . . . . . . . . . . 3.36
Engine, Accessible Components . . . . . . . . . . . . . . . . . . .3.13 Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
Engine, Balance Shaft Gear Removal . . . . . . . . . . . . . . .3.40 Front A-arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . 5.15
Engine, Balance Shaft Removal . . . . . . . . . . . . . . . . . . .3.44 Front Caliper, Piston Bore I.D. . . . . . . . . . . . . . . . . . . . 9.18
Engine, Cam Gear Reassembly . . . . . . . . . . . . . . . . . . . .3.39 Front Drive Shaft, Installation . . . . . . . . . . . . . . . . . . . . 7.11
Engine, Cam Gear Removal . . . . . . . . . . . . . . . . . . . . . .3.38 Front Drive Shaft, Outer CV Joint / Boot Replacement . 7.8
Engine, Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . .3.44 Front Drive Shaft, Removal . . . . . . . . . . . . . . . . . . . . . . . 7.7
Engine, Camshaft Installation . . . . . . . . . . . . . . . . . . . . .3.46 Front Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . 2.18
Engine, Combustion Chamber . . . . . . . . . . . . . . . . . . . .3.27 Front Gearcase, Assembly . . . . . . . . . . . . . . . . . . . . . . . 7.21
Engine, Crankcase Assembly . . . . . . . . . . . . . . . . . . . . .3.45 Front Gearcase, Backlash Pad Adjustment . . . . . . . . . . 7.23
Engine, Crankshaft Gear Removal . . . . . . . . . . . . . . . . .3.41 Front Gearcase, Centralized Hilliard . . . . . . . . . . . . . . . 7.15
Engine, Crankshaft Installation . . . . . . . . . . . . . . . . . . . .3.46 Front Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.19
Engine, Cylinder Head Assembly . . . . . . . . . . . . . . . . . .3.29 Front Gearcase, Installation . . . . . . . . . . . . . . . . . . . . . . 7.24
Engine, Cylinder Head Disassembly . . . . . . . . . . . . . . . .3.25 Front Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.18
Engine, Cylinder Head Inspection . . . . . . . . . . . . . . . . . .3.24 Front Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Engine, Cylinder Head Removal . . . . . . . . . . . . . . . . . . .3.23 Front Propshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . 7.12
Engine, Cylinder Head Warp . . . . . . . . . . . . . . . . . . . . .3.24 Front Propshaft, U-Joint Service . . . . . . . . . . . . . . . . . . 7.13
Engine, Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . .3.33 Front Strut, Cartridge Replacement . . . . . . . . . . . . . . . . 5.17
Engine, Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . .3.32 Front Strut, Exploded View . . . . . . . . . . . . . . . . . . . . . . 5.16
Engine, Cylinder Installation . . . . . . . . . . . . . . . . . . . . . .3.47 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Engine, Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . .3.30 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Engine, Flywheel and Stator Installation . . . . . . . . . . . .3.54 Fuel Injection, Component Locations . . . . . . . . . . . . . . . 4.8
Engine, Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . .3.37 Fuel Injection, Exploded View . . . . . . . . . . . . . . . . . . . . 4.7
Engine, Gear / Stator Housing Seal Replacement . . . . . .3.51 Fuel Injection, Service Notes . . . . . . . . . . . . . . . . . . . . . . 4.5
Engine, Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . .3.49 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Engine, Gear(s) Removal . . . . . . . . . . . . . . . . . . . . . . . .3.37 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Engine, Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . .3.55 Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Engine, Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . .3.21 Fuel Pump / Tank Assembly . . . . . . . . . . . . . . . . . . . . . 4.12

IX.2

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 Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . . . 4.12, 10.20 Parking Brake Caliper, Removal . . . . . . . . . . . . . . . . . . . 9.11
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Parking Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Parking Brake Pad Inspection . . . . . . . . . . . . . . . . . . . . . 2.33 IX
G Parking Brake, Adjustment . . . . . . . . . . . . . . . . . . 2.32, 9.10
Parking Brake, Exploded View (4x4) . . . . . . . . . . . . . . . . 9.8
Gear Circuit Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Parking Brake, Exploded View (6x6) . . . . . . . . . . . . . . . . 9.9
Gear Position Indicator Switch Test . . . . . . . . . . . . . . . 10.16
Parking Brake, Inspection . . . . . . . . . . . . . . . . . . . . . . . . 9.10
General Specifications, Brakes . . . . . . . . . . . . . . . . . . . . . 9.2
Periodic Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . 2.3
H Piston Ring Installed Gap . . . . . . . . . . . . . . . . . . . . . . . . 3.35
Head Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 Piston to Cylinder Clearance . . . . . . . . . . . . . . . . . . . . . . 3.34
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 Piston to Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
Hub / Bearing Carrier, Mid Drive (6x6) . . . . . . . . . . . . . 7.24 Pre-Ride / Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . 2.10
Hub / Bearing Carrier, Rear (4x4) . . . . . . . . . . . . . . . . . 7.37 Programmable Service Interval . . . . . . . . . . . . . . . . . . . . 10.9
I Propshaft, Mid Drive (6x6) . . . . . . . . . . . . . . . . . . . . . . . 7.28
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21 Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Ignition Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . 4.21 PVT System, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
Ignition Coil Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21 PVT System, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6.5
Indicator, Service Interval . . . . . . . . . . . . . . . . . . . . . . . 10.9 PVT System, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 PVT System, Overview . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
PVT System, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
K PVT Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24
Keys, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Kilometers to Miles Toggle . . . . . . . . . . . . . . . . . . . . . 10.10
R
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
L Radiator Coolant Level Inspection . . . . . . . . . . . . . . . . . 2.23
Leakdown Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 Rear A-arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 5.19
M Rear Axle Service (6x6) . . . . . . . . . . . . . . . . . . . . . . . . . 7.58
Maintenance, Brake System . . . . . . . . . . . . . . . . . . . . . . 2.32 Rear Axle, Exploded View (6x6) . . . . . . . . . . . . . . . . . . 5.23
Maintenance, Cooling System . . . . . . . . . . . . . . . . . . . . 2.22 Rear Caliper, Piston Bore I.D. (4x4 CREW) . . . . . . . . . 9.30
Maintenance, Electrical and Ignition . . . . . . . . . . . . . . . 2.26 Rear Cargo Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
Maintenance, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 Rear Drive Shaft, CV Joint / Boot Replacement . . . . . . . 7.41
Maintenance, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . 2.25 Rear Drive Shaft, Installation . . . . . . . . . . . . . . . . . . . . . 7.47
Maintenance, Fuel System . . . . . . . . . . . . . . . . . . . . . . . 2.11 Rear Drive Shaft, Plunging Joint / Boot Replacement . . 7.44
Maintenance, General Vehicle Inspection . . . . . . . . . . . 2.10 Rear Drive Shaft, Removal . . . . . . . . . . . . . . . . . . . . . . . 7.41
Maintenance, References . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 Rear Gearcase (4x4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
Maintenance, Service Products and Lubricants . . . . . . . . 2.7 Rear Gearcase Lubrication (4x4) . . . . . . . . . . . . . . . . . . 2.20
Maintenance, Steering and Suspension . . . . . . . . . . . . . 2.29 Rear Gearcase Lubrication (6x6) . . . . . . . . . . . . . . . . . . 2.21
Maintenance, Transmission and Gearcases . . . . . . . . . . 2.17 Rear Propshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . . 7.48
Master Cylinder, Installation . . . . . . . . . . . . . . . . . . . . . . 9.6 Rear Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
Master Cylinder, Removal . . . . . . . . . . . . . . . . . . . . . . . . 9.6 Rear Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
Mid Axle A-arm, Replacement . . . . . . . . . . . . . . . . . . . 5.18 Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
Mid Drive Gearcase (6x6) . . . . . . . . . . . . . . . . . . . . . . . 7.29 Rear Suspension Adjustment (4x4) . . . . . . . . . . . . . . . . . 2.31
Middle Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . 2.19 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
Miles to Kilometers Toggle . . . . . . . . . . . . . . . . . . . . . 10.10 S
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Service Interval Indicator . . . . . . . . . . . . . . . . . . . . . . . . 10.9
O Shift Lever, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 Shift Lever, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Oil Pump Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57 Shift Linkage Inspection and Adjustment . . . . . . . . . . . . 2.10
Oil Pump, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41 Shift Linkage, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 8.3
P Shift Linkage, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Solenoid, Rear Differential . . . . . . . . . . . . . . . . . . . . . . . 10.4
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Spark Plug Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
Parking Brake Caliper, Disassembly / Inspection . . . . . 9.12
Special Tool, Cam Gear Installation Kit . . . . . . . . . . . . . 3.39
Parking Brake Caliper, Exploded View . . . . . . . . . . . . . 9.11
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Parking Brake Caliper, Installation . . . . . . . . . . . . . . . . 9.13
Special Tools, Body/Steering/Suspension . . . . . . . . . . . . . 5.2
Parking Brake Caliper, Pad Installation . . . . . . . . . . . . . 9.13
Special Tools, Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
IX.3

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 Special Tools, Clutching . . . . . . . . . . . . . . . . . . . . . . . . . .6.2 Switch, Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
Special Tools, EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Switch, Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Special Tools, Electrical . . . . . . . . . . . . . . . . . . . . . . . . .10.3 T
Special Tools, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Special Tools, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .7.3
Tail Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
Specification, Balance Shaft Gear Bolt Torque . . . . . . .3.50
Tap/Drill Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Specification, Cam Lobe Height . . . . . . . . . . . . . . . . . . .3.44
Temperature / Barometric Air Pressure Sensor (T-BAP) 4.17
Specification, Cam Thrust Plate Fastener Torque . . . . . .3.48
Throttle Freeplay Adjustment . . . . . . . . . . . . . . . . . . . . 2.12
Specification, Camshaft Gear Bolt Torque . . . . . . . . . . .3.51
Throttle Pedal Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Specification, Coolant Temperature Sensor Resistance 10.20
Throttle Position Sensor (TPS) . . . . . . . . . . . . . . . . . . . 4.17
Specification, Cylinder Head Warp . . . . . . . . . . . . . . . . .3.24
Throttle Position Sensor Initialization . . . . . . . . . . . . . . 4.19
Specification, Cylinder Taper Limit . . . . . . . . . . . . . . . .3.32
Throttle Position Sensor Replacement . . . . . . . . . . . . . . 4.20
Specification, Cylinder Warp Limit . . . . . . . . . . . . . . . .3.32
Tie Rod End Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
Specification, Oil Pump Bolt Torque . . . . . . . . . . . . . . .3.49
Timing Gear Mark Alignment . . . . . . . . . . . . . . . . . . . . 3.37
Specification, Oil Pump Rotor Clearance . . . . . . . . . . . .3.41
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Specification, Timing Gear Alignment . . . . . . . . . . . . . .3.37
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Specification, Valve Seat Contact Width . . . . . . . . . . . .3.28
Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Specification, Valve Spring Free Length . . . . . . . . . . . .3.25
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Specification, Valve Stem Diameter . . . . . . . . . . . . . . . .3.26
Torque Specifications, Body/Steering/Suspension . . . . . 5.2
Specification, Valve Stem Guide I.D. . . . . . . . . . . . . . . .3.26
Torque Specifications, Brakes . . . . . . . . . . . . . . . . . . . . . 9.2
Specification, Wheel Toe-Out . . . . . . . . . . . . . . . . . . . . .2.29
Torque Specifications, Clutching . . . . . . . . . . . . . . . . . . . 6.2
Specifications, Cam Shaft . . . . . . . . . . . . . . . . . . . . . . . .3.44
Torque Specifications, Engine . . . . . . . . . . . . . . . . . . . . 3.10
Specifications, Cooling System . . . . . . . . . . . . . . . . . . . .3.13
Torque Specifications, Final Drive . . . . . . . . . . . . . . . . . 7.3
Specifications, Crankcase Fastener Torque . . . . . . . . . . .3.46
Torque Specifications, Transmission . . . . . . . . . . . . . . . . 8.2
Specifications, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2
Torque Specifications, Wheel and Hub . . . . . . . . . . . . . 2.25
Specifications, Engine Lubrication . . . . . . . . . . . . . . . . .3.20
Transmission I.D. Number Location . . . . . . . . . . . . . . . . 1.3
Specifications, Engine Oil Pressure . . . . . . . . . . . . . . . .3.20
Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . . . 2.17
Specifications, General . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6
Transmission, Assembly . . . . . . . . . . . . . . . . . . . . . . . . 8.10
Specifications, Oil Baffle Bolt Torque . . . . . . . . . . . . . .3.45
Transmission, Disassembly . . . . . . . . . . . . . . . . . . . . . . . 8.5
Specifications, Oil Pick-up Bolt Torque . . . . . . . . . . . . .3.45
Transmission, Exploded View (4x4) . . . . . . . . . . . . . . . 8.16
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7
Transmission, Installation . . . . . . . . . . . . . . . . . . . . . . . 8.14
Speedometer Troubleshooting Tests . . . . . . . . . . . . . . .10.12
Transmission, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Speedometer, Installation . . . . . . . . . . . . . . . . . . . . . . .10.11
Trip Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Speedometer, Removal . . . . . . . . . . . . . . . . . . . . . . . . .10.11
Troubleshooting, Brake Noise . . . . . . . . . . . . . . . . . . . . . 9.3
Starter Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.32
Troubleshooting, Clutching . . . . . . . . . . . . . . . . . . . . . . 6.23
Starter Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35
Troubleshooting, No AWD . . . . . . . . . . . . . . . . . . . . . 10.12
Starter Motor Assembly, Exploded View . . . . . . . . . . .10.34 Troubleshooting, No AWD Hub Safety Limiter . . . . . 10.14
Starter Motor, Armature Testing . . . . . . . . . . . . . . . . . .10.31
Troubleshooting, No Fuel Gauge Display . . . . . . . . . . 10.15
Starter Motor, Brush Inspection / Replacement . . . . . .10.30
Troubleshooting, No Gear Indicator Display . . . . . . . . 10.15
Starter Motor, Reassembly / Installation . . . . . . . . . . . .10.31
Troubleshooting, No Instrument Display . . . . . . . . . . . 10.13
Starter Motor, Removal . . . . . . . . . . . . . . . . . . . . . . . . .10.29
Troubleshooting, Transmission . . . . . . . . . . . . . . . . . . . 8.15
Starter Solenoid, Operation . . . . . . . . . . . . . . . . . . . . . .10.33
Troubleshooting, Wheel Speed Sensor . . . . . . . . . . . . 10.13
Starter Solenoid, Test . . . . . . . . . . . . . . . . . . . . . . . . . .10.33
Starter System, Troubleshooting . . . . . . . . . . . . . . . . . .10.29 V
Starting System Testing Flow Chart . . . . . . . . . . . . . . .10.35 Valve Seal/Spring Service . . . . . . . . . . . . . . . . . . . . . . . 3.24
Stator, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36 Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29 Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . . . . 3.27
Steering, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . .5.13 Vehicle Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Storage Box, Installation . . . . . . . . . . . . . . . . . . . . . . . . .5.27 Vent Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Storage Box, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27 VIN Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Swing Arm, Exploded View (6x6) . . . . . . . . . . . . . . . . .5.23 VIN Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Swing Arm, Installation . . . . . . . . . . . . . . . . . . . . . . . . .5.22 Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
Swing Arm, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22 W
Switch, AWD / 2WD / TURF (4x4) . . . . . . . . . . . . . . . .10.4 Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
Switch, Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5 Wheel, Removal / Installation . . . . . . . . . . . . . . . . . . . . 2.25

IX.4

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 PN 9921885
Printed in USA

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 WIRE DIAGRAM

2009 RANGER 700 4X4 CREW (CHASSIS/BOX) PAGE 1 OF 2

WD-1

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 WIRE DIAGRAM

2009 RANGER 700 4X4 CREW (CHASSIS/BOX) PAGE 2 OF 2

WD-2

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 WIRE DIAGRAM

2009 RANGER 700 6X6 (CHASSIS) PAGE 1 OF 2

WD-3

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 WIRE DIAGRAM

2009 RANGER 700 6X6 (CHASSIS) PAGE 2 OF 2

WD-4

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 WIRE DIAGRAM

2009 RANGER 700 4X4 CREW / 6X6 (DASH)

WD-5

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 WIRE DIAGRAM

2009 RANGER 700 4X4 CREW / 6X6 (BREAKOUTS)

5$1*(5;&5(:;%5($.2876

WD-6

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