POLARIS

RANGER

XP 700 4X4

RANGER 6X6

SERVICE

MANUAL
GENERAL INFORMATION 1

MAINTENANCE 2

ENGINE 3

FUEL INJECTION 4

BODY / STEERING / SUSPENSION 5

CLUTCHING 6

FINAL DRIVE 7

TRANSMISSION 8

BRAKES 9

ELECTRICAL 10
 POLARIS

RANGER

XP 700 4X4

RANGER 6X6

SERVICE

MANUAL
 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
UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
TRANSMISSION I.D. NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
VEHICLE DIMENSIONS RANGER 4X4, 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MODEL: RANGER XP 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MODEL: RANGER XP 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MODEL: RANGER XP 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
MODEL: RANGER XP 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

1.1
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 07 RH 68 AG

}
}

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

Engine Designation Number

EH068OLE043PLE ............................................................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 R H 6 8 A * 7 P 0 0 0 0 0 0
}

Body Style
Engine

Powertrain
Emissions
Model
Year

Check Digit
}
Plant No.
Individual Serial No.

* This could be either

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

1.3
GENERAL INFORMATION

VEHICLE DIMENSIONS
RANGER 4X4, 6X6

75 in.
190.50 cm

RANGER 4x4

10 in.
25.4 cm

58 in.
147 cm

1.4
 GENERAL INFORMATION
Vehicle Dimensions RANGER 4X4, 6X6

120 in.
1
305 cm

58 in.
147 cm

27 in.
69 cm
90 in.
229 cm

113 in.
287 cm

58 in.
147 cm

76 in.
193 cm

1.5
GENERAL INFORMATION

GENERAL SPECIFICATIONS

MODEL: RANGER XP 4X4

MODEL NUMBER: R07RH68AD,AG,AH,AK,AL,AW
ENGINE MODEL: EH068OLE
Category Dimension / Capacity
Length 113 in. / 287 cm
Width 60 in. / 152.4 cm
Height 75 in. / 190.5 cm
Wheel Base 76 in. / 193 cm
Ground Clearance 11.5 in. / (29 cm)
Turning Radius 132 in. / 335 cm
Dry Weight 1185 lbs. / 537 kg
Gross Vehicle Weight 2750 lbs. / 1247 kg
Cargo Box Capacity 1000 lbs. / 454 kg
58 x 42 x 10 in.
Cargo Box Dimensions
(147 x 106.7 x 25.4 cm)
1500 lbs. / 681 kg
Vehicle Payload (Includes driver and two
passengers - 500 lbs. / 227kg)
Hitch Towing Capacity 1500 lbs. / 681 kg
Hitch Tongue Capacity 150 lbs. / 68 kg

MODEL: RANGER XP 6X6

MODEL NUMBER: R07RF68AF
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. / (18.25 cm)
Turning Radius 180 in. / 457 cm
Dry Weight 1410 lbs. / 640 kg
Gross Vehicle Weight 2900 lbs. / 1315 kg
Cargo Box Capacity 1250 lbs. / 567 kg
58 x 48 x 10 in.
Cargo Box Dimensions
(147 x 122 x 25.4 cm)
1750 lbs. / 794 kg
Vehicle Payload (Includes driver and two
passengers - 500 lbs. / 227kg)
Hitch Towing Capacity 1750 lbs. / 794 kg
Hitch Tongue Capacity 150 lbs. / 68 kg

1.6
 GENERAL INFORMATION
MODEL: RANGER XP 4X4 Drivetrain
MODEL NUMBER: R07RH68AD,AG,AH,AK,AL,AW
ENGINE MODEL: EH068OLE
Transmission Type
Gear Ratio: Front / Rear
Polaris Automatic PVT 1
Engine High 3.34:1 / 2.89:1
Polaris Domestic Twin Cylinder, Low 8.67:1 / 7.49:1
Platform Rev 5.92:1 / 5.11:1
Liquid Cooled, 4-Stroke
Engine Model Number EH068OLE044 Drive Ratio - Front 3.818:1
Engine Displacement 683cc Drive Ratio - Final 3.70:1
Number of Cylinders 2 Shift Type In Line Shift - H / L / N / R
Bore & Stroke (mm) 80 x 68 mm Trans. Oil Requirements Polaris AGL Gearcase Lube
Compression Ratio 9.40:1 Belt 3211106
Compression Pressure 150-170 psi Drive Belt Deflection 1.125” / 28.57 mm
Engine Idle Speed 1150 ± 100 RPM Center Distance 10” / 254.5 mm
Lubrication Pressurized Wet Sump Clutch Offset 0.365” / 9.27 mm
Oil Requirements 0W-40 Steering / Suspension
Oil Capacity 2 qts. / 1.9 L Front Suspension MacPherson Strut
Coolant Capacity 3.25 qts. / 3.1 L Front Travel 8 in. / 20 cm
Overheat Warning Instrument Cluster Indicator Rear Suspension Independent Rear Suspension
Exhaust System 2 to 1 Canister Style Rear Travel 9 in. / 23 cm
Fuel System Ground Clearance 11.5 in. / 29 cm
Fuel System Type Bosch Electronic Fuel Injection Shock Preload Adjustment Cam Adjustment
Front / Rear 2-2” Twin Tubes
Fuel Delivery Electronic Fuel Pump (in tank)
Turning Radius 132 in. / 335 cm
Fuel Pressure 39 psi
Toe Out 1/8-1/4 in. / 3-6.35 mm
Fuel Filters See Chapter 4
Wheels / Brakes
9 gal. (34 l)
Fuel Capacity / Requirement 12 x 6 / 10 gauge
87 Octane (minimum) Front Wheel Size
L.E. Model AW - 14 x 7
Electrical
12 x 8 / 10 gauge
Alternator Max Output 500 watts @ 3000 RPM Rear Wheel Size
L.E. Model AW - 14 x 8
Lights: Main Headlights 2 - Dual Beam 35 watts / quartz
Carlisle / PXT / 26 x 8 R12
Tail 5 watts x 2 Front Tire
L.E. Model AW - Kenda / Radial
Brake 5 watts x 2 Make / Model / Size
Bounty Hunter / 26 x 10 R14
Indicator Panel Lights 1 watt (ea.) Carlisle / PXT / 26 x 11 R12
Rear Tire
Starting System Electric Start L.E. Model AW - Kenda / Radial
Make / Model / Size
Ignition System Bosch EFI (ECU Controlled) Bounty Hunter / 26 x 12 R14
Ignition Timing 7° BTDC @ 1200 RPM F/R Tire Air Pressure 8-12 psi Front / 8-12 psi Rear
Champion RC7YC3 / Foot Actuated - 4 Wheel
Spark plug / Gap Brake - Front / Rear
.035 in. (0.9 mm) Hydraulic Disc
Yuasa YB30L-B / Parking Brake Foot Actuated (Mechanical)
Battery / Model / Amp Hr
30 Amp Hr. / 12 Volt Brake Fluid DOT 3 or DOT 4
Instrument Type Multifunction Speedometer
DC Outlet Standard CLUTCH CHART
Fan: 20 Amp
Driven
Dash Harness: 20 Amp Altitude Shift Weight Drive Spring
Spring
Circuit Breakers Accessory Terminal: 20 Amp
Power Relay: 15 Amp 0-1500 20-60 Blu/Gray Blk/Almd
ECU Battery Supply: 6 Amp Meters (0-5000) (5631698) (7042202) (7043167)
(Feet) 1500-3700 20-56 Blu/Gray Blk/Almd
(5000 - 12000) (5631215) (7042202) (7043167)

1.7
GENERAL INFORMATION
MODEL: RANGER XP 6X6 Drivetrain
MODEL NUMBER: R07RF68AF Transmission Type Polaris Automatic PVT
ENGINE MODEL: EH068OLE Gear Ratio: Front / Rear
Engine High 3.89:1 / 3.36:1
Polaris Domestic Twin Cylinder, Low 10.08:1 / 8.71:1
Platform Rev 6.87:1 / 5.94:1
Liquid Cooled, 4-Stroke
Engine Model Number EH068OLE044 Drive Ratio - Front 3.818:1
Engine Displacement 683cc Drive Ratio - Mid 3.70:1
Number of Cylinders 2 Drive Ratio - Final 3.70:1
Bore & Stroke (mm) 80 x 68 mm Shift Type In Line Shift - H / L / N / R
Compression Ratio 9.40:1 Trans. Oil Requirements Polaris AGL Gearcase Lube
Compression Pressure 150-170 psi Belt 3211106
Engine Idle Speed 1150 ± 100 RPM Drive Belt Deflection 1.125” / 28.57 mm
Lubrication Pressurized Wet Sump Center Distance 10” / 254.5 mm
Oil Requirements 0W-40 Clutch Offset 0.365” / 9.27 mm
Oil Capacity 2 qts. / 1.9 L Steering / Suspension
Coolant Capacity 3.25 qts. / 3.1 L Front Suspension MacPherson Strut
Overheat Warning Instrument Cluster Indicator Front Travel 8 in. / 20 cm
Exhaust System 2 to 1 Canister Style Center Suspension Progressive Rate / Independent
Fuel System Center Travel 5.25 in. / 13 cm
Fuel System Type Bosch Electronic Fuel Injection Rear Suspension Swing Arm w/Dual Shocks
Fuel Delivery Electronic Fuel Pump (in tank) Rear Travel 6.25 in. / 16 cm
Fuel Pressure 39 psi Ground Clearance 7.2 in. / 18.25 cm
Fuel Filters See Chapter 4 Shock Preload Adjustment Cam Adjustment
Front / Rear 2-2” Twin Tubes
9 gal. (34 l)
Fuel Capacity / Requirement Turning Radius 180 in. / 457 cm
87 Octane (minimum)
Electrical Toe Out 1/8-1/4 in. / 3-6.35 mm
Alternator Max Output 500 watts @ 3000 RPM Wheels / Brakes
Lights: Main Headlights 2 - Dual Beam 35 watts / quartz Front Wheel Size 12 x 6 / 10 gauge
Tail 5 watts x 2 Middle / Rear Wheel Size 12 x 8 / 10 gauge
Brake 5 watts x 2 Front Tire
Titan / AT489 / 25 x 10 R12
Make / Model / Size
Indicator Panel Lights 1 watt (ea.)
Middle / Rear Tire
Starting System Electric Start Titan / AT489 / 25 x 11 R12
Make / Model / Size
Ignition System Bosch EFI (ECU Controlled)
F/M/R Tire Air Pressure 8-12 psi Front / 8-12 psi Rear
Ignition Timing 7° BTDC @ 1200 RPM
Foot Actuated - 4 Wheel
Champion RC7YC3 / Brake - Front / Rear
Spark plug / Gap Hydraulic Disc
.035 in. (0.9 mm)
Parking Brake Foot Actuated (Mechanical)
Yuasa YB30L-B /
Battery / Model / Amp Hr Brake Fluid DOT 3 or DOT 4
30 Amp Hr. / 12 Volt
Instrument Panel Type Multifunction Speedometer CLUTCH CHART
DC Outlet Standard
Fan: 20 Amp Driven
Altitude Shift Weight Drive Spring
Dash Harness: 20 Amp Spring
Circuit Breakers Accessory Terminal: 20 Amp 0-1500 20-60 Blu/Gray Blk/Almd
Power Relay: 15 Amp (0-5000) (5631698) (7042202) (7043167)
Meters
ECU Battery Supply: 6 Amp
(Feet) 1500-3700 20-56 Blu/Gray Blk/Almd
(5000 - 12000) (5631215) (7042202) (7043167)

1.8
 GENERAL INFORMATION
V
P
1
M

20

20

NOTE:

NOTE:
www.purepolaris.com.

Paint Codes

Painted Part Color Description Polaris Number

Frame / Cab Medium Gloss Black P-067
RANGER XP 4x4 - Plastic - Hood / Dash Black Metallic P-177
RANGER XP 6x6 - Plastic - Hood / Dash Dark Green P-195
RANGER XP 4x4 - Plastic - Hood / Dash Turbo Silver P-402
RANGER XP 4x4 - Plastic - Hood / Dash Mossy Oak™ P-455
RANGER XP 4x4 - Plastic - Hood / Dash Delta Green P-492
RANGER XP 4x4 - Plastic - Hood / Dash Sunset Red Metallic P-520

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
27 4010321
28 4010321
Key Series 31 4110141
Number 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, 1-800-328-6657.

1.9
GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: (°F + 40) ÷ 9 - 40 = °C

1.10
 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
1
engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.

1.11
GENERAL INFORMATION
SAE Tap / Drill Sizes Decimal Equivalents

Metric Tap / Drill Sizes

1.12
 GENERAL INFORMATION
Glossary of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
1
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.
1.13
 GENERAL INFORMATION
CHAPTER 2
GENERAL INFORMATION
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2
50 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
GENERAL COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
RH SIDE AND DASH VIEW (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
LH SIDE AND REAR VIEW (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
LH SIDE AND RH SIDE VIEWS (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
SERVICE PRODUCTS AND LUBES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . 2.10
MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
MAINTENANCE REFERENCES, CONTINUED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.13
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
SHIFT LINKAGE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
FRONT GEARCASE LUBRICATION (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
MIDDLE GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
REAR GEARCASE LUBRICATION (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
REAR GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
RADIATOR COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.1
GENERAL INFORMATION
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
BATTERY FLUID LEVEL (CONVENTIONAL BATTERY) . . . . . . . . . . . . . . . . . . . . . . . 2.29
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BATTERY STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
REAR SUSPENSION ADJUSTMENT (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
REAR SPRING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BRAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
PARKING BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

2.2
 GENERAL INFORMATION
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment
and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement 2
parts, use genuine Polaris parts available from your Polaris dealer.
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.

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 --If vehicle is subjected to severe use, decrease interval by 50%
(Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm
use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required
under these conditions. Fluid changes, cable, chain and chassis lubrication are required more frequently. For
engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising
oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil imme-
diately and monitor level. If oil level begins to rise, discontinue use and determine cause.)
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 with a could

result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.

2.3
GENERAL INFORMATION
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
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.

2.4
 GENERAL INFORMATION
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,
etc.
2
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
 Engine Oil Change 100 H 6M -
Perform a break-in oil change at 25 hours/
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
GENERAL INFORMATION
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.

Fuel Filter 100 H 12M - Replace yearly
E
 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 3 or 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
 GENERAL INFORMATION
GENERAL COMPONENT LOCATIONS
RH Side (4X4) and Dash View

Gas Tank
Rear Gearcase
Front Gearcase
(Behind Radiator)

Engine (under seat)

Dash Components

Instrument AWD / Differential Switch

Cluster Light (if equipped)
Cup
Holder Switch
Cup
Holder

12V
Ignition Accessory
Storage Switch Outlet Storage
Box Compartment
Storage (with lid)
Tray Mode
Button

2.7
GENERAL INFORMATION
LH Side and Rear View (4X4)

Battery

Storage Rear Prop Shaft

Compartment

Front Prop Shaft

Transmission

Tail Gate Latch

Air Cleaner

Muffler

2" Hitch Drive Shafts

2.8
 GENERAL INFORMATION
LH Side and RH Side Views (6X6)

Front Gearcase
(behind radiator)

Rear Gearcase Engine (under seat)

Transmission

Mid Gearcase

Battery

Drive Shafts
Front Prop Shaft
Rear Prop Shaft

2.9
GENERAL INFORMATION

SERVICE PRODUCTS AND LUBES NOTE: Each item can be purchased separately at
your local Polaris dealer.
Polaris Lubricants, Maintenance and Service
Part No. Description
Products
Additives / Sealants / Thread Locking Agents / Misc.
Part No. Description 2870585 Loctite™ Primer N, Aerosol, 25 g
Engine Lubricant Loctite™ Thread Sealant 565
2871956
2870791 Fogging Oil (12 oz. Aerosol) (50 ml.) (6 Count)
Premium 2 Cycle Engine Oil (Quart) (12 Loctite™ Threadlock 242
2871098 2871949
Count) (50 ml.) (10 Count)
Engine Oil (Quart) Premium 4 Synthetic Loctite™ Threadlock 242
2871281 2871950
0W-40 (4-Cycle) (12 Count) (6 ml.) (12 Count)
Engine Oil (Gallon) Premium 4 Synthetic Loctite™ Threadlock 262
2871844 2871951
0W-40 (4-Cycle) (4 Count) (50 ml.) (10 Count)
Engine Oil (16 Gallon) Premium 4 Loctite™ Threadlock 262
2871567 2871952
Synthetic 0W-40 (4-Cycle) (6 ml.) (12 Count)
Gearcase / Transmission Lubricants Loctite™ Threadlock 271
2871953
(6 ml.) (12 Count)
Premium Synthetic AGL Gearcase Lube
2873602 Loctite™ Threadlock 271
(12 oz. bottle) (12 Count) 2871954
(36 ml.) (6 Count)
Premium Synthetic AGL Gearcase Lube
2873603 Loctite™ 680-Retaining Compound
(1 Gal.) (4 Count) 2870584
(10 ml.)
Premium ATV Angle Drive Fluid
2871653 Loctite™ 518 Gasket Eliminator / Flange
(8 oz.) (12 Count) 2870587
Sealant (50 ml.) (10 Count)
Premium ATV Angle Drive Fluid
2872276 Premium Carbon Clean
(2.5 Gal) (2 Count) 2871326
(12 oz.) (12 Count)
2870465 Oil Pump for 1 Gallon Jug
2870652 Fuel Stabilizer (16 oz.) (12 Count)
Premium Demand Drive Hub Fluid
2871654 Black RTV Silicone Sealer
(8 oz.) (12 Count) 2871957
(3 oz. tube) (12 Count)
Premium Demand Drive Hub Fluid
2872277 Black RTV Silicone Sealer
(2.5 gal.) (2 Count) 2871958
(11 oz. cartridge) (12 Count)
Grease / Specialized Lubricants
2870990 DOT 3 Brake Fluid (12 Count)
Premium All Season Grease
2871322 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
(3 oz. cartridge) (24 Count)
Premium All Season Grease 2872893 Engine Degreaser (12oz.) (12 Count)
2871423
(14 oz. cartridge) (10 Count)
NOTE: The number count indicated by each part
2871460 Starter Drive Grease (12 Count)
number in the table above indicates the number of
2871515 Premium U-Joint Lube (3 oz.) (24 Count) units that are shipped with each order.
2871551 Premium U-Joint Lube (14 oz.) (10 Count)
2871312 Grease Gun Kit
2871329 Dielectric Grease (Nyogel™)
Coolant
2871323 60/40 Coolant (Gallon) (6 Count)
2871534 60/40 Coolant (Quart) (12 Count)

2.10
 GENERAL INFORMATION
MAINTENANCE REFERENCES
Item Lube Rec. Method Frequency*
Change after 1st month (25 hrs), 6 months
Polaris 0W-40 or 100 hours thereafter; Change more often
1. Engine Oil Add oil to proper level.
Synthetic (PN 2871281) in extremely dirty conditions, or short trip
cold weather operation. 2
Fill reservoir between MAX
2. Brake Fluid DOT 3 (PN 2870990) or Dot 4 As required. Change fluid every 2 years.
and Min lines.
Polaris AGL Gearcase Add lube to bottom of fill plug Change annually. Change more often if
3. Transmission
Lubricant (PN 2873602) threads. used in severe conditions.
Polaris Demand Drive Hub Drain completely. Add lube to
4. Front Gearcase Change annually***
Fluid (PN 2871654) specified quantity.
ATV Angle Drive Fluid Drain completely. Add lube to
5. Middle Gearcase Semi-annually**
(PN 2871653) 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

3. Transmission

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

Fill Plug

Fill Plug
Drain Plug
Drain Plug

2.11
GENERAL INFORMATION
Maintenance References, Continued.....

Item Lube Rec. Method Frequency*

Locate grease fitting on the
6. Hubstrut Assembly Polaris All Season Grease (PN underside of the hubstrut
Semi-annually**
(Both Sides) 2871423) assembly and grease with
grease gun.
Polaris All Season Grease (PN Locate grease fitting on inside
7. Swing Arm Pivot Semi-annually**
2871423) of the swing arm pivot.
Polaris Premium U-Joint Lube Locate fittings and grease with
8. Rear Prop Shaft Yoke Semi-annually**
(PN 2871551) grease gun.
Polaris Premium U-Joint Lube Locate fittings and grease with
9. Front Prop Shaft Yoke Semi-annually**
(PN 2871551) grease gun.
ATV Angle Drive Fluid Drain completely. Add lube to
10. Rear Gearcase Change annually***
(PN 2871653) 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

6. Hubstrut Assembly

9. Front Prop Shaft

Yoke

7. Swing Arm (6x6)

8. Rear Prop Shaft (6x6)

Swing Arm Pivot

10. Rear Gearcase

10. Rear Gearcase Fill Plug (4x4)
(6x6)

2.12
 GENERAL INFORMATION
GENERAL VEHICLE INSPECTION Shift Linkage Inspection / Adjustment
AND MAINTENANCE Linkage rod adjustment is necessary when symptoms include:
Pre-Ride / Daily Inspection • No All Wheel Drive light
Perform the following pre-ride inspection daily, and when • Noise on deceleration
servicing the vehicle at each scheduled maintenance. • Inability to engage a gear 2
• Tires - check condition and pressures • Excessive gear clash (noise)

• Fuel and oil tanks - fill both tanks to their proper level; • Shift selectors moving out of desired range
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

looseness in any area 1. Inspect shift linkage cable, clevis pins, and pivot bushings
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.

2.13
GENERAL INFORMATION
7. Use this procedure to loosen or tighten the shift linkage Fuel Filter
cable as needed.
The RANGER XP 4x4 and 6x6 EFI engines use a non-
Clockwise Inside Jam Nut serviceable, high-volume, high-pressure, 60-micron internal
fuel pump filter and an internal 10-micron filter located before
the pump regulator. Neither filter is servicable.

Counterclockwise Outside Jam Nut

FUEL SYSTEM AND AIR INTAKE Fuel filter in tank is not serviceable

Fuel System NOTE: For all other information related to the EFI
fuel system refer to Chapter 4.
WARNING
Vent Lines
Gasoline is extremely flammable and explosive 1. Check fuel tank and transmission vent lines for signs of
under certain conditions. wear, deterioration, damage or leakage. Replace every
Always stop the engine and refuel outdoors or in two years.
a well ventilated area. 2. Be sure vent lines are routed properly and secured with
Do not smoke or allow open flames or sparks in cable ties. CAUTION: Make sure lines are not kinked or
or near the area where refueling is performed or pinched
where gasoline is stored.
Do not overfill the tank. Do not fill the tank neck. Throttle Pedal Inspection
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately.
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water
and change clothing.
Never start the engine or let it run in an enclosed
area. Engine exhaust fumes are poisonous and
can result loss of consciousness or death
in a short time.
Never drain the fuel when the engine is hot.
Severe burns may result.
Throttle Pedal

If the throttle pedal has excessive play due to cable stretch or

Fuel Lines cable misadjustment, it will cause a delay in throttle speed.
1. Check fuel lines for signs of wear, deterioration, damage Also, the throttle may not open fully. If the throttle pedal has no
or leakage. Replace if necessary. play, the throttle may be hard to control, and the idle speed may
2. Be sure fuel lines are routed properly and secured with be erratic.
cable ties. CAUTION: Make sure lines are not kinked or
pinched. Check the throttle pedal play periodically in accordance with the
Periodic Maintenance Chart and adjust the play if necessary.
3. Replace all fuel lines every two years.

2.14
 GENERAL INFORMATION
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.
3.
4.
Start the engine, and warm it up thoroughly.
Measure the distance the throttle pedal moves before the
The filter should be inspected periodically before each ride,
using the following procedure. 2
engine begins to pick up speed. Free play should be 1/16”
1. Lift the box to access the filter box cover.
- 1/8” (1.5 - 3 mm).

Adjustment
Air Box Location
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.

Boot
2. Remove clips (2) from air box cover and remove cover.
Inspect the gasket. It should adhere tightly to the cover and
seal all the way around.
3. Remove air filter assembly. Do not clean the main filter,
Lock Nut the filter should be replaced.
Adjuster
4. Inspect main element and replace if necessary. If the filter
4. Loosen the adjuster lock nut. has been soaked with fuel or oil it must be replaced.
5. Rotate the boot to turn the adjuster until 1/16" to 1/8"
Breather Filter
(1.5 - 3 mm) of freeplay is achieved at the throttle pedal.

NOTE: While adjusting, lightly flip the throttle pedal Cover Seal
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.

NOTE: Apply a small amount of general purpose

grease to the sealing edges of the filter before
installing.

2.15
GENERAL INFORMATION
2. Check air box. If oil or water deposits are found, drain them Air Intake Inspection
into a suitable container.
1. Lift the hood.
NOTE: Service more frequently if vehicle is operated 2. Inspect the foam inserts in the air baffle boxes. If the foam
in wet conditions or at high throttle openings for inserts are dirty, clean the foam with a high flash point
extended periods. solvent, followed by hot soapy water.
3. Install air box cover and secure with clips.

3. Rinse and dry the foam thoroughly.

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

Air Baffing
Box

Foam
Air Box

Engine Intake Duct

PVT Intake Duct

2.16
 GENERAL INFORMATION
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 2
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,
1. Set machine on a level surface and set the parking brake.
as crankshaft seals may dislodge and leak).
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.

2.17
GENERAL INFORMATION
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
way into the filler tube to keep the angle and depth of WARNING
dipstick consistent. When reinstalling the dipstick,
make certain to seat the lever lock. Personal injury can occur when handling used
oil. Hot oil can cause burns or skin damage.
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!) Recommended Engine Oil:
NOTE: Due to the dipstick entry angle into the
crankcase, the oil level will read higher on the Polaris Premium Synthetic OW-40
bottom side of the dipstick. Proper level indication (PN 2871281) (Quart)
is determined on the upper surface of the dipstick as
it is being removed, regardless of the level marks Ambient Temperature Range
being on top or on bottom. (See the next illustration)
-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
located under the driver side seat (refer to Chapter 5 for
Always read top side of dipstick to front engine cover and storage removal).
properly check oil level in crankcase
3. Run engine two to three minutes until warm. Stop engine.
4. Clean area around drain plug at bottom of oil engine. Drain
plug is accessible through the skid plate.

CAUTION

Oil may be hot. Do not allow hot oil to come into

NOTE: A rising oil level between checks in cool contact with skin, as serious burns may result.
weather driving can indicate contaminants such as
gas or moisture collecting in the crankcase. If the oil 5. Place a drain pan beneath crankcase and remove drain plug.
level is over the full mark, change the oil
immediately. Drain Plug

6. Allow oil to drain completely.

7. Replace the sealing washer on drain plug.
NOTE: The sealing surface on the drain plug should
be clean and free of burrs, nicks or scratches.

8. Reinstall drain plug and torque to 192 ± 24 in. lbs. (21.7 ±

2.7 Nm).

2.18
 GENERAL INFORMATION
9. Place shop towels beneath oil filter. Using Oil Filter Exhaust Pipe
Wrench (PV-43527), turn filter counterclockwise to
remove.
WARNING
Oil Filter
Do not perform clean out immediately after the engine
has been run, as the exhaust system becomes very hot.
Serious burns could result from contact with exhaust
2
components.
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.
10. Using a clean dry cloth, clean filter sealing surface on
Do not go under the machine while it is inclined. Set the
crankcase.
hand brake and block the wheels to prevent roll back.
11. Lubricate O-ring on new filter with a film of fresh engine Failure to heed these warnings could result in serious
oil. Check to make sure the O-ring is in good condition. personal injury or death.
12. Install new filter and turn by hand until filter gasket contacts
the sealing surface, then turn an additional 1/2 turn. The exhaust pipe must be periodically purged of accumulated
13. Remove dipstick and fill sump with 2 quarts (1.9 l) of carbon as follows:
Polaris Premium 4 Synthetic Oil (PN2871281)
1. Remove the clean out plugs located on the bottom of the
muffler as shown below.
Crankcase Drain Plug Torque:
192 ± 24 in. lbs. (21.7 ± 2.7 Nm)

Oil Filter Torque:

Turn by hand until filter gasket contacts
sealing surface, then turn an
additional 1/2 turn Clean Out Plug
2. Place the transmission in Park and start the engine. Purge
Oil Filter Wrench: accumulated carbon from the system by momentarily
(PV-43527) revving the engine several times.
3. If some carbon is expelled, cover the exhaust outlet and
14. Place gear selector in neutral and set parking brake. lightly tap on the pipe around the clean out plugs with a
rubber mallet while revving the engine several more times.
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.

2.19
GENERAL INFORMATION
4. If particles are still suspected to be in the muffler, back the The transmission lubricant level should be checked and changed
machine onto an incline so the rear of the machine is one in accordance with the maintenance schedule.
foot higher than the front. Set the hand brake and block the
wheels. Make sure the machine is in Park and repeat Steps • Be sure vehicle is level with the parking brake on
2 and 3. SEE WARNING before proceeding.
5. If particles are still suspected to be in the muffler, drive the
• Check vent hose to be sure it is routed properly and
machine onto the incline so the front of the machine is one
unobstructed.
foot higher than the rear. Set the hand brake and block the
wheels. Make sure the machine is in Park and repeat Steps To check the level:
2 and 3. SEE WARNING
1. Remove the fill plug on the backside of the transmission.

Fill Plug

1 ft.

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. 2. The fluid should be at the bottom of the fill plug hole
8. Reinstall the clean out plugs. threads.
Figure 7-26

TRANSMISSION AND GEARCASES

Transmission Lubrication
NOTE: It is very important to follow a regular Fill Plug Threads
transmission fluid check/change schedule. The
service manual of the RANGER recommends the
Proper
level be checked every twenty-five (25) hours of Fluid
operation, and changed once (1) a year. Level

TRANSMISSION SPECIFICATIONS

Specified Lubricant:
AGL Synthetic Gearcase Lubricant
(PN 2873602) (32 oz.)

Approximate Capacity at Change:

15.2 oz. (450 ml.)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19 Nm)

2.20
 GENERAL INFORMATION
To change lubricant: • The correct front gearcase lubricant to use is Polaris
Premium Demand Hub Fluid.
1. Remove skid plate (if necessary).

2. Place a drain pan beneath the transmission oil drain plug Front Gearcase Specifications
area.

3. Remove the drain plug and wipe the magnetic end clean to
Specified Lubricant:
Premium Demand Drive Hub Fluid
2
remove accumulated metallic filings.
(PN 2871654)
TRANSMISSION
Capacity: 5.0 oz. (150 ml.)

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

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

FRONT GEARCASE
Drain Plug Make sure vent is unobstructed
14 ft. lbs.
(19 Nm)

4. After the oil has drained completely, install the drain plug.
Torque to 14 ft. lbs. (19 Nm). Fill Plug
8-30 ft. lbs.
5. Add the proper lubricant through the fill plug hole until the (11-41 Nm)
oil level is at the bottom of the fill plug threads (see figure
7-26). Do not overfill.

6. Torque fill plug to 14 ft. lbs. (19 Nm)

Drain Plug: 10 ft. lbs. (14 Nm)
7. Check for leaks.

Front Gearcase Lubrication

To check the lubricant level:
The gearcase lubricant level should be checked and changed in
accordance with the maintenance schedule. The front gearcase lubricant level cannot be checked with a
dipstick. The gearcase must be drained and re-filled with the
• Be sure vehicle is level with parking brake on before proper amount of lubricant or be filled to the bottom of the fill
proceeding. plug hole threads. Refer to procedures.

• Check vent hose to be sure it is routed properly and

unobstructed.

2.21
GENERAL INFORMATION
To change gearcase lubricant: 4. Remove fill plug (8 mm hex) and check the O-ring.

Fill Plug

A
B

10 ft. lbs (14 Nm)

1. Remove gearcase drain plug (B) (11 mm) located on the 5. Fill with the recommended fluid amount (5 oz.) or to the
bottom of the gearcase and drain oil. (The drain plug is bottom of the fill plug hole threads.
accessible through the skid plate.) Catch and discard used
Front Gearcase
oil properly.
2. Clean and reinstall drain plug (B) using a new sealing Plug Threads
washer (A). Toque to 10 ft. lbs. (14 Nm).
3. The fill plug can be accessed through the top hood area by
removing the storage box or by removing the left side panel Fill with 5 oz.
in the left wheel well.

Top View of Hood Area

6. Install fill plug and check for leaks.

Middle Gearcase Lubrication (6x6)

Middle Gearcase Specifications

LH Side Panel 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.

• The correct middle gearcase lubricant to use is ATV

Angle Drive Fluid

2.22
 GENERAL INFORMATION
To check the lubricant level: Rear Gearcase Lubrication (4x4)
The gearcase must be drained and re-filled with the proper
amount of lubricant. Refer to the procedure below. REAR GEARCASE SPECIFICATIONS
To change middle gearcase lubricant:
Specified Lubricant:
1. With the RANGER on a level surface, remove the fill plug
and check the lubricant level. Lubricant should be kept at
ATV Angle Drive Fluid (PN 2871653) 2
the specified level, according to the proper gearcase
specifications listed. Capacity: 18 oz. (532 ml)
2. Support the vehicle securely with a jack stand and remove
the front tire on the driver’s side. Fill Plug Torque: 40 ft. lbs. (54 Nm)
3. Remove gearcase drain plug located on the bottom of the Drain Plug Torque: 30-45 in. lbs. (3-5 Nm)
gearcase and drain oil. (The drain plug is accessible through
the skid plate.) Catch and discard used oil properly.
To check the level:
4. Clean and reinstall drain plug using a new sealing washer.
5. Remove fill plug. 1. With machine on level ground and with the parking brake
6. Fill with the recommended fluid amount or fill to the on, remove fill plug from rear gearcase.
bottom of the threads of the fill plug hole. 2. The fluid level should be 0.75 in. (1.9 cm) from the bottom
of the fill plug hole threads. Use a light colored and non-
7. Install fill plug. Check for leaks.
absorbent measuring instrument (white zip tie) to measure
MIDDLE GEARCASE (6X6) the depth of the fluid in the rear gearcase. If level is low,
Make sure vent is unobstructed add ATV Angle Drive Fluid (PN 2871653).

Side View
0.75 in.
(1.9 cm)

Measuring
Instrument

0.75 in.
(1.9 cm)
Fill to bottom of Fluid Level
fill plug hole Fill Plug
threads: 6.75 oz. 14 ft. lbs. (19 Nm)
3. Reinstall fill plug. Tighten to 40 ft. lbs. (54 Nm).
4. Check for leaks.
Bottom View

Drain Plug
14 ft. lbs. (19 Nm)

2.23
GENERAL INFORMATION
To change the lubricant: Rear Gearcase Lubrication (6x6)
1. Remove gearcase drain plug located on the bottom and
drain the oil. Catch and discard used oil properly. Rear Gearcase Specifications
Under Side View
Specified Lubricant:
ATV Angle Drive Fluid (PN 2871653)
Capacity: 10 Oz. (300 ml.)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

Drain Plug The gearcase lubricant level should be checked and changed in
accordance with the maintenance schedule.
30-45 in. lbs.
(3-5 Nm) • Be sure vehicle is level before proceeding with parking
brake on.
2. Clean and reinstall the drain plug with a new sealing washer
and tighten to 30-45 in. lbs. (3-5 Nm). • Check vent hose to be sure it is routed properly and
3. Remove fill plug. unobstructed.

• The correct rear gearcase lubricant to use is Polaris

ATV Angle Drive Fluid

To check the lubricant level:

The gearcase must be drained and re-filled with the proper
amount of lubricant. Refer to the procedure below.
To change rear gearcase lubricant:
Fill Plug
40 ft. lbs. 1. With the vehicle on a level surface, remove the fill plug
(54 Nm) and check the lubricant level. Lubricant should be kept at
the specified level, according to the proper gearcase
4. Add 18 oz. (532 ml.) of ATV Angle Drive Fluid specifications listed.
(PN 2871653). 2. Support the vehicle securely with a jack stand and remove
5. Reinstall fill plug. Tighten to 40 ft. lbs (54 Nm). 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
Make sure vent is unobstructed

40 ft. lbs
(54 Nm)
Fill Plug

6. Check for leaks.

Drain Plug

2.24
 GENERAL INFORMATION
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

2

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
COOLING SYSTEM reservoir. If not:

Liquid Cooling System Overview 1. Remove reservoir cap. Inner splash cap vent hole must be
clear and open.
The engine coolant level is controlled or maintained by the 2. Fill reservoir to upper mark with Polaris Premium 60/40
recovery system. The recovery system components are the Anti Freeze / Coolant or 50/50 or 60/40 mixture of
recovery bottle, radiator filler neck, radiator pressure cap and antifreeze and distilled water as required for freeze
connecting hose. protection in your area.
3. Reinstall cap.
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.

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
period.
Surge Tank
Overheating of engine could occur if air is not fully purged from
system.

Polaris Premium 60/40 is already premixed and ready to use. Do NOTE: If overheating is evident, allow system to
not dilute with water. cool completely and check coolant level in the
radiator and inspect for signs of trapped air in
system.

2.25
GENERAL INFORMATION
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
should be inspected and coolant added if necessary. (PN 2871323)

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

Never remove the pressure cap when the Radiator

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
allow the recovery system to function properly.
2. Check tightness of all hose clamps.
To access the radiator pressure cap raise the front hood.
The radiator cap is located on the drivers side. CAUTION

Coolant Strength / Type Do not over-tighten hose clamps at radiator, or

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.

2.26
 GENERAL INFORMATION
Radiator 4. Remove the outlet radiator hose, inlet radiator hose, surge
tank hose, and overflow hose from the radiator.
1. Check radiator (A) air passages for restrictions or damage.
5. Remove the radiator.

A Inlet Radiator Hose

Outlet Radiator Hose

2

2. Carefully straighten any bent radiator fins.

Surge Tank Hose
3. Remove any obstructions with compressed air or low
pressure water. Plug

Coolant Drain / Radiator Removal

1. Remove the front bumper. Remove three bolts that secure FINAL DRIVE / WHEEL AND TIRE
the bumper to the bottom of the frame. Remove six screws
(both sides) that secure the wheel well panel to the frame. Wheel, Hub, and Spindle Torque Table
Remove two bolts that secure the top bumper to the frame.
Remove the darts that attach the plastic to the bumper. Item Nut Type Specification

Aluminum Wheels
Lug Nut (1) 90 ft. lbs. (122 Nm)
(Cast)
Bolts Steel Wheels
Flange Nut (2) 35 ft. lbs. (47 Nm)
(Black / Camo)
Front Spindle Nut - 70 Ft. Lbs. (95 Nm)
Rear & Center Hub
- 110 Ft. Lbs. (150 Nm)
Wheel Well Retaining Nut

Bolts
2. Remove two mounting screws that secure the top of the
radiator to the frame. Remove the radiator cap. Pull the #1 #2
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 Aluminum Wheel Steel Wheel
hood liner. Prop the front of the hood up 1.5 inches (LE Models) (Standard Models)
90 ft. lbs. (122 Nm) 35 ft. lbs. (47 Nm)
(38.10 mm) to help remove the top bolts that secure
the radiator to the frame.

3. Remove the drain plug and drain the coolant from the
radiator. Drain the coolant into a suitable container and
properly dispose of the coolant.

2.27
GENERAL INFORMATION
CV Shaft Boot Inspection 4. Securely tighten the wheel nuts to the proper torque listed
in the torque table at the beginning of this section.
Inspect the CV shaft boots in the front and rear of the RANGER
for damage, tears, wear, or leaking grease. If the rubber boot CAUTION
exhibits any of these symptoms, replace the boot. Refer to
Chapter 7 for CV boot replacement, or have you Polaris dealer
If wheels are improperly installed it could affect
replace the boot.
vehicle handling and tire wear. On vehicles with
tapered rear wheel nuts, make sure tapered end
of nut goes into taper on wheel.

Tire Inspection
• Improper tire inflation may affect vehicle
maneuverability.

• When replacing a tire always use original equipment

size and type.

• The use of non-standard size or type tires may affect

Inspect Boots
vehicle handling.

Tire Tread Depth

Wheel Removal
Always replace tires when tread depth is worn to 1/8" (3 mm) or
less.
Front & Rear
Wheel Nuts (4) Tread
Depth 1/8" (3 mm)

Front Hub Nut

70 ft. lbs. (95 Nm)

Rear Hub Nut

110 ft. lbs. (150 Nm)

1. Stop the engine, place the transmission in gear and lock the
parking brake. WARNING
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing a suitable stand
Operating a RANGER with worn tires will
under the footrest frame.
increase the possibility of the vehicle skidding
4. Remove the wheel nuts and washers and remove the wheel. easily with possible loss of control.

Wheel Installation Worn tires can cause an accident.

1. With the transmission in gear and the parking brake
Always replace tires when the tread depth
locked, place the wheel in the correct position on the wheel
measures 1/8", (.3 cm) or less.
hub. Be sure the valve stem is toward the outside and
rotation arrows on the tire point toward forward rotation.
2. Attach the washers (if applicable) and wheel nuts and finger
tighten them.
3. Lower the vehicle to the ground.

2.28
 GENERAL INFORMATION
Tire Pressure NOTE: Batteries must be fully charged before use or
battery life will be reduced by 10-30% of full
potential. Charge battery for 3-5 hours at a current
CAUTION equivalent of 1/10 of the battery’s rated amp/hour
capacity. Do not use the alternator to charge a new
Maintain proper tire pressure. battery. (Refer to Battery Activation and
Refer to the warning tire pressure decal
applied to the vehicle.
Maintenance video PN 9917987)
2
Battery Fluid Level (Conventional Battery)
Tire Pressure Inspection (PSI - Cold) A poorly maintained battery will deteriorate rapidly. Check the
Front Rear battery fluid level often. Maintain the fluid level between the
upper and lower level marks.
8-12 8-12
Upper Level

ELECTRICAL AND IGNITION SYSTEM

Battery Maintenance
Keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove the corrosion with a stiff wire
brush. Wash with a solution of one tablespoon baking soda and
one cup water. Rinse well with tap water and dry off with clean
shop towels. Coat the terminals with dielectric grease or
petroleum jelly. Lower Level

Be careful not to allow cleaning solution or tap water into the

battery Add only distilled water. Tap water contains minerals that are
harmful to a battery.

WARNING Battery Removal

Battery electrolyte is poisonous. It contains 1. Open the Hood.

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

prompt medical attention.

Batteries produce explosive gases.

Keep sparks, flame, cigarettes, etc. away. 2. Remove the battery vent tube from the battery.
Ventilate when charging or using in an enclosed 3. Disconnect the black (negative) battery cable.
space. Always shield eyes when
4. Disconnect the red (positive) battery cable.
working near batteries.
KEEP OUT OF REACH OF CHILDREN.

2.29
GENERAL INFORMATION
5. Lift the battery out of the vehicle, being careful not to tip Spark Plug Service
it sideways and spill any electrolyte.
1. Remove both spark plug high tension leads (A). Clean
CAUTION plug area so no dirt and debris can fall into engine when
plug is removed.
To reduce the chance of sparks: Whenever
removing the battery, disconnect the negative A
(black) cable first. When reinstalling the battery,
install the negative cable last.

Battery Installation
Using a new battery that has not been fully charged can damage
the battery and result in a shorter life. It can also hinder vehicle
performance. Follow the battery charging procedure before B
installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.
3. Install the battery vent tube. 2. Remove spark plugs (B).
NOTE: The vent tube must be free of obstructions
3. Inspect electrodes for wear and carbon buildup. Look for
and securely installed. Route the tube away from the
a sharp outer edge with no rounding or erosion of the
frame and vehicle body to prevent contact with
electrodes.
electrolyte.
Inspect electrode for
4. Coat the terminals with dielectric grease or petroleum jelly. wear and buildup
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed.

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
4. Clean with electrical contact cleaner or a glass bead spark
charged, and store it out of the sun in a cool, dry place. Check
plug cleaner only. CAUTION: A wire brush or coated
battery voltage each month during storage and recharge as
abrasive should not be used.
needed to maintain a full charge.
5. Measure gap with a wire gauge. Refer to specifications in
NOTE: Battery charge can be maintained by using a
picture below for proper spark plug type and gap. Adjust
Polaris battery tender charger or by charging about
gap if necessary by bending the side electrode carefully.
once a month to make up for normal self-discharge.
Battery tenders can be left connected during the Spark Plug Gap
storage period, and will automatically charge the
battery if the voltage drops below a pre-determined
point.

Battery Charging
Gap - .035" (0.90 mm)
1. Remove the battery from the vehicle to prevent damage
from leaking or spilled electrolyte during charging.
2. Charge the battery with a charging output no larger than 6. If necessary, replace spark plug with proper type.
1/10 of the battery’s amp/hr rating. Charge as needed to CAUTION: Severe engine damage may occur if the
raise the specific gravity to 1.270 or greater. incorrect spark plug is used.
3. Reinstall the battery.
7. Apply a small amount of anti-seize compound to the spark
plug threads.
2.30
 GENERAL INFORMATION
8. Install spark plug and torque to specification
WARNING
Recommended Spark Plug:
Champion RC7YC3 Due to the critical nature of the procedures
outlined in this chapter, Polaris recommends
steering component repair and adjustment be
Spark Plug Torque:
18 Ft. Lbs. (24 Nm) performed by an authorized Polaris MSD- 2
certified technician when replacing worn or
damaged steering parts.
Use only genuine Polaris replacement parts.
Engine To Frame Ground
One of two methods can be used to measure toe alignment. The
Inspect engine ground cable connection. Be sure it is clean and string method and the chalk method. If adjustment is required,
tight. The ground cable runs from the engine to the terminal refer to following pages for procedure.
block located under the front hood next to the battery.
Tie Rod End / Steering Inspection
Black Ground
• To check for play in the tie rod end, grasp the steering
tie rod, pull in all directions feeling for movement.

• Repeat inspection for inner tie rod end (on steering

post).
Terminal Block
(under hood) • Replace any worn steering components. Steering
should move freely through entire range of travel
without binding.

STEERING AND SUSPENSION

Steering
The steering components should be checked periodically for
loose fasteners, worn tie rod ends, and damage. Also check to
make sure all cotter pins are in place. If cotter pins are removed,
they must not be re-used. Always use new cotter pins. • Elevate front end of machine so front wheels are off the
ground. Check for any looseness in front hub / wheel
Replace any worn or damaged steering components. Steering
assembly by grasping the tire firmly at top and bottom
should move freely through entire range of travel without
first, and then at front and rear. Try to move the wheel
binding. Check routing of all cables, hoses, and wiring to be
and hub by pushing inward and pulling outward.
sure the steering mechanism is not restricted or limited.
• If abnormal movement is detected, inspect the hub and
NOTE: Whenever steering components are wheel assembly to determine the cause (loose wheel
replaced, check front end alignment. Use only nuts or loose front hub nut).
genuine Polaris parts.
• Refer to the Body/Steering or Final Drive chapter for
more information.

Camber and Caster

The camber and caster are non-adjustable.

2.31
GENERAL INFORMATION
Wheel Toe Alignment Inspection Toe Adjustment
1. Place machine on a smooth level surface. If toe alignment is incorrect, measure the distance between
2. Set steering wheel in a straight ahead position and secure vehicle center and each wheel. This will tell you which tie rod
the steering wheel in this position. needs adjusting.
3. Place a chalk mark on the center line of the front tires
approximately 10” (25.4 cm) from the floor or as close to NOTE: Be sure steering wheel is straight ahead
the hub/axle center line as possible. before determining which tie rod(s) need
adjustment.

CAUTION

During tie rod adjustment, it is very important that

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.

Chalk Mark Measurement “B” • Shorten or lengthen the tie rod until alignment is as
Measurement “A” required to achieve the proper toe setting as specified in
“Wheel Toe Alignment”.
NOTE: It is important that the height of both marks
be equally positioned in order to get an accurate • IMPORTANT: When tightening the tie rod end jam
measurement. nuts, the rod ends must be held parallel to prevent rod
end damage and premature wear. Damage may not be
4. Measure the distance between the marks and record the immediately apparent if done incorrectly.
measurement. Call this measurement “A”.
5. Rotate the tires 180° by moving vehicle forward or Hold
backward. Position chalk marks facing rearward, even with Rod End
the hub/axle centerline.
6. 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 Correctly Incorrectly
measurement at the rear (B). Tightened Tightened
Jam Nut Jam Nut

= In. / mm. • After alignment is complete, torque jam nuts to 12-14

ft. lbs. (16-19 Nm).
Wheel Toe-Out:
(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)
=T
Tie Rod Jam Nut Torque:
12-14 ft. lbs. (16-19 Nm)

2.32
 GENERAL INFORMATION
Front Suspension Rear Suspension
• Compress and release front suspension. Damping
should be smooth throughout the range of travel.

• Check all front suspension components and fasteners

for wear or damage.

• Inspect front strut cartridges for leakage.

2

Bolt Torque
15 ft. lbs. (20 Nm)

RANGER 4X4
Independent Rear Suspension

Inspect for leaks

RANGER 6X6
Rear Swingarm Suspension

• Compress and release rear suspension. Damping should

be smooth throughout the range of travel.

• Check all rear suspension components for wear or

damage.

• Inspect shock for leakage.

2.33
GENERAL INFORMATION
Rear Suspension Adjustment (4x4) BRAKE SYSTEM
The rear suspension may be adjusted to provide a stiffer
Brake System Inspection
suspension if necessary.
The following checks are recommended to keep the brake
1. Remove the top shock mounting bolts from the inside system in good operating condition. Service life of brake system
mounting holes. components depends on operating conditions. Inspect brakes in
2. Reposition the shocks to the outside mounting holes. accordance with the maintenance schedule and before each ride.
3. Reinstall the shock mounting bolts. Torque to 30 ft. lbs. (40
Nm).

Outside Mounting Holes

• Keep fluid level in the master cylinder reservoir to the

indicated level inside reservoir.
Inside Mounting Holes
• Use Polaris DOT 3 or DOT 4 Brake Fluid.

• Check brake system for fluid leaks.

• Check brake for excessive travel or spongy feel.

Rear Spring Adjustment
• Check friction pads for wear, damage or looseness.
The rear shock absorber springs are adjusted by rotating the
adjustment cam either clockwise or counterclockwise to • Check surface condition of the disc.
increase or decrease spring tension.

To adjust the suspension, use the adjustment cam located near

Brake Pad Inspection
the bottom of the rear shock. This will allow you to increase or Pads should be changed when the friction material is worn to
decrease the amount of spring preload. .180" (4.6 mm). When the pad are new the thickness is .298 ±
.007" (7.56 ± .178 mm).

Rear Spring
Adjustment Cam

Brake Pad
Measure
Thickness
Service Limit - .180" (4.6 mm)

Shock Spanner Wrench

(PN 2870872)

2.34
 GENERAL INFORMATION
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) 2
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)

Brake Hose and Fitting Inspection

Check brake system hoses and fittings for cracks, deterioration,
abrasion, and leaks. Tighten any loose fittings and replace any
worn or damaged parts.

2.35
 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
CYLINDER HONE SELECTION AND HONING PROCEDURE . . . . . . . . . . . . . . . . . . . 3.20
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
ENGINE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CYLINDER HEAD ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
ROCKER ARMS / PUSH RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER HEAD WARP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
VALVE SEAL / SPRING SERVICE (ON ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
VALVE LIFTER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
OIL PUMP PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59

3.1
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
 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 OW-40

oil to component
Apply White Lithium
Grease

3.3
ENGINE
Stator Cover / Starter / Water Pump Exploded View

Apply Polaris 3 5
Starter Grease Water Pump Cover
2
Bolt Tighten Sequence 7
Apply Polaris 0W-40
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

3.4
 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)

3.5
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 0W- 40 to 2C Head Bolt Tighten
25-55 mm of cylinder bore. Sequence

Apply 0W-40 to piston pin or pin

bore. D3
Apply 0W- 40 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 0W-40 Oil

Apply Moly Lube Grease

3.6
 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.
18 ± 2 ft. lbs. (9.5 ± 0.9 Nm)
R (24.5 ± 2.7 Nm)

3.7
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.

3.8
 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)

3.9
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.

3.10
 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)

3.11
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)

3.12
 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
3.13
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 cap and test cap using a commercially

Radiator available cap tester.

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

does not meet this specification.
Water Radiator Cap
Thermostat
Pump

Cylinder Cylinder
Head

Cooling System Pressure Test

1. Open front hood.

2. Remove surge tank hose from coolant filler neck.

3. Connect a Mity Vac™ (PN 2870975) to the filler neck

nipple and pressurize system to 10 psi. The system must
retain 10 psi for five minutes or longer. If pressure loss is
evident within five minutes, check the radiator, hoses,
clamps and water pump seals for leakage.

Coolant Flow Diagram

Surge Tank

From
Thermostat Housing

Radiator
To Water Pump

3.14
 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 PROCEDURE 1:

1. Park machine on a flat surface. Place the vehicle in Neutral
WARNING and set the parking brake.

CAUTION
Always wear safety glasses and proper shop
clothing when performing the procedures in this
Be sure the engine has cooled and there is no
manual. Failing to do so may lead to possible
pressure built up in the cooling system before
injury or death.
removing the radiator cap. The coolant may be
hot and could cause severe injury or burns.
CAUTION
2. Remove radiator cap (A) and top off coolant.
Use caution when performing these procedures. 3. Remove surge tank fill cap (B) and fill the surge tank to the
Coolant may be hot and may cause full line.
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.

3.15
ENGINE
4. Leave the cap off of the radiator to allow any possible air PROCEDURE 2:
to escape. Start the engine and let it idle for 5-10 minutes
1. Drive the machine onto a slight incline or use properly
or until the thermostat opens and allows coolant to flow
weight rated ramps. Place the machine in Neutral and set
through the system.
the parking brake. Block the rear wheels. The radiator
5. Slightly loosen the bleed screw (C) on the thermostat cover
neck should be above the level of the top of the engine.
to let air 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

CAUTION
6. Squeeze the coolant lines by hand to help purge the system
of air. Be sure the engine has cooled and there is no
7. Add Polaris Premium Antifreeze to the radiator if the level pressure built up in the cooling system before
goes down. removing the radiator cap. The coolant maybe
8. Tighten the bleed screw to 70 ± 10 in.lbs. (8 ± 1.13 Nm) on hot and could cause severe injury or burns.
the thermostat housing and properly install the radiator cap.
2. Remove radiator cap and top off coolant. Fill the surge tank
WARNING to the full line.
3. Leave the cap off of the radiator to allow any possible air
to escape. Start the engine and let it idle for 5-10 minutes
Be sure to install the radiator cap before
or until the thermostat opens and allows coolant to flow
shutting off the engine.
through the system.
Coolant may spit out of the radiator.
NOTE: If there is air in the system you will see air
9. Stop the engine and let cool, top off the radiator filler neck bubbles forming through the radiator fill 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 4. Add coolant as needed. If no bubbles are seen at the filler
coolant has been pulled into the system. Fill the surge tank neck, the system should be purged of air.
only after you have completely filled the cooling system at 5. Install the radiator cap and turn off the machine.
the radiator filler neck.
10. Repeat this procedure, if overheating still occurs. WARNING
If overheating occurs after repeating this procedure,
proceed to Procedure 2. Be sure to install the radiator cap before
shutting off the engine.
Coolant may spit out of the radiator.

3.16
 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.

3.17
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.
3. Disconnect battery (-) negative cable.
D
4. Remove the following parts as required:

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

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

9. Remove the air breather line (A).

10. Remove PVT exhaust duct (B).

11. Remove the exhaust shield (C).

3.18
 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.

NOTE: Properly route all electrical harnesses and

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

3.19
ENGINE
Exhaust Cylinder Hone Selection And Honing
Procedure
1. Replace exhaust gaskets. Seal connections with high temp
silicone sealant. Cylinders may be wet or dry honed depending upon the hone
manufacturer’s recommendations. Wet honing removes more
2. Check to be sure all springs are in good condition. material faster and leaves a more distinct pattern in the bore.
Bleed Cooling System
NOTE: Follow coolant bleeding procedure outlined CAUTION
earlier in this chapter
A hone which will straighten as well as remove
Engine Break-In Period material from the cylinder is very important.
Using a common spring loaded glaze breaker
The break-in period for a Polaris RANGER engine is defined as
for honing is not advised for nicasil cylinders.
the first ten hours of operation, or the time it takes to use two full
Polaris recommends using a rigid hone or arbor
tanks of gasoline. No single action on your part is as important
honing machine. Cylinders may be wet or dry
as a proper break-in period. Careful treatment of a new engine
honed depending upon the hone manufacturer's
will result in more efficient performance and longer life for the
recommendations.
engine. Perform the following procedures carefully.
Wet honing removes more material faster and
leaves a more distinct pattern in the bore.
CAUTION
Honing To Deglaze
Use only Polaris Premium 0-40W All Season
A finished cylinder should have a cross-hatch pattern to ensure
synthetic oil or equivalent.
piston ring seating and to aid in the retention of the fuel/oil
Never substitute or mix oil brands.
mixture during initial break in. Hone cylinder according to hone
Serious engine damage and voiding of
manufacturer's instructions, or these guidelines:
warranty can result.
Do not operate at full throttle or high speeds for • Honing should be done with a diamond hone. Cylinder
extended periods during the first three hours of could be damaged if the hone is not hard enough to
use. Excessive heat can build up and cause scratch the nicasil lining.
damage to close fitted engine parts.
• Use a motor speed of approximately 300-500 RPM, run
1. Fill fuel tank with unleaded or leaded fuel which has a the hone in and out of the cylinder rapidly until cutting
minimum pump octane number of 87= (R+ M)/2. tension decreases. Remember to keep the hone drive
shaft centered (or cylinder centered on arbor) and to
2. Check oil level indicated on dipstick. Add oil if necessary bring the stones approximately 1/2, (1.3 cm) above and
(Refer to Chapter 2, “Engine Oil Level” ). below the bore at the end of each stroke.
3. Drive slowly at first to gradually bring engine up to • Release the hone at regular intervals and inspect the
operating temperature. bore to determine if it has been sufficiently de-glazed,
and to check for correct cross-hatch.
4. Vary throttle positions. Do not operate at sustained idle or NOTE: Do not allow cylinder to heat up during
sustained high speed. honing.
5. Perform regular checks on fluid levels, controls and all • After honing has been completed, inspect cylinder for
important bolt torques. Pull only light loads during initial thinning or peeling.
break in.

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

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

3.20
 ENGINE
If cylinder wear or damage is excessive, it will be necessary to Oil Pressure Test
replace the cylinder. The cylinders are lined with a nicasil
coating and are not repairable. Hone only enough to de-glaze 1. Remove blind plug/sender from left side of crankcase.
the outer layer of the cylinder bore.
2. Insert a 1/8 NPT oil pressure gauge adaptor into the
crankcase and attach the gauge.

3. Start engine and allow it to reach operating temperature,

monitoring gauge indicator.

NOTE: Use only Polaris Premium 0W-40 Synthetic

Engine Lubricant.
3
Oil Pressure at 5500 RPM (Engine Hot):
Standard: 39 PSI
Example of Cross Hatch Pattern Minimum: 35 PSI

IMPORTANT: Clean the cylinder after honing

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
the outer layer of the cylinder bore.

Cleaning the Cylinder After Honing

It is very important that the cylinder be thoroughly cleaned after
honing to remove all grit material. Wash the cylinder in a
solvent, then in hot, soapy water. Pay close attention to areas
where the cylinder sleeve meets the aluminum casting (transfer
port area). Use electrical contact cleaner if necessary to clean
these areas. Rinse thoroughly, dry with compressed air, and oil
the bore immediately with Polaris Lubricant.

Engine Lubrication Specifications

Capacity - Approximately 2 U.S. Quarts (1.9 l)

Oil Type - Polaris Premium 0W-40 Synthetic
Filter Wrench - PV-43527 or equivalent
- Oil Pressure Specification -
35-39 PSI @ 5500 RPM, Polaris 0W-40
Synthetic, Engine at operating temperature.

3.21
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.

3.22
 ENGINE
ENGINE DISASSEMBLY AND INSPECTION
Cylinder Head Assembly Exploded View

Rocker Arms

3
Retainer Locks (keepers)
Push Rods
Spring Retainers

Springs

Valve Seals

Valve Spring Seats

Cylinder Head

Hydraulic Lifters

Valves

3.23
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 3. Remove cylinder head (B) and head gasket (C) from the
wear, cracks, nicks or burrs. 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.

WARNING
A
Always wear safety glasses when working with
compressed air to prevent personal injury.

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

3.24
 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.

Cylinder Head Warp WARNING

1. Lay a straight edge (A) across the surface of the cylinder
3
head (B) at several different points and measure warp by Wear eye protection or a face shield during
inserting a feeler gauge between the straight edge and the cylinder head disassembly and reassembly.
cylinder head surface. If warp exceeds the service limit,
replace the cylinder head. 1. Having already removed the valve cover, rocker arms and
pushrods, align the cylinder to be worked on at top dead
A center (TDC). Install the Valve Pressure Hose (PU-
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),

B compress the valve spring and remove the valve keepers.

NOTE: A small parts magnet (A) can aid in the

Measure at different removal of the retainers (B).
points on the surface.

= In. / mm.

Cylinder Head Warp Limit:

.004" (.1016 mm) max
A

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.

3.25
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

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)

3.26
 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 3
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.

3.27
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
IMPORTANT: Do not use a wire brush, metal scraper, uneven, compression leakage will result. If the seat
or abrasive cleaners to clean the bottom of the is too wide, seat pressure is reduced, causing
cylinder head. Extensive damage to the cylinder head carbon accumulation and possible compression
may result. Wear safety glasses during cleaning. loss. If the seat is too narrow, heat transfer from
valve to seat is reduced. The valve may overheat
Combustion Area and warp, resulting in burnt valves.

Valve Seat Reconditioning 1. Install pilot into valve guide.

NOTE: Polaris recommends that the work be done 2. Apply cutting oil to valve seat and cutter.
by a local machine shop that specializes in this area.
3. Place 46° cutter on the pilot and make a light cut.
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.

3.28
 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%, 3
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™
indicates seat contact on the valve face. The valve seat Seat
should contact the middle of the valve face or slightly Width
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.

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

3.29
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. 0W-40 Synthetic oil.

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

3.30
 ENGINE
Valve Sealing Test Valve Lifter Removal / Inspection
1. Clean and dry the combustion chamber area (A). 1. Remove the valve lifter's 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

3

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.

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

3.31
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

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.

3.32
 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.

3
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)

3.33
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

3.34
 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.
NOTE: Do not thread the puller bolts into the
See “700 EFI Engine Service flywheel more than 1/4, or stator coils may be
Specifications” on page 3.11 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
the starter. Tap on the starter assembly (B) with a soft faced
Piston Ring Installed Gap
mallet to loosen the starter from the crankcase.
See “700 EFI Engine Service
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.

3.35
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

Remove Stator B
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.

3.36
 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

3.37
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 in the parts book.

9. Use the Cam Gear Tooth Alignment Tool (PU-45497-2)

(O) to align the cam split gear assembly. With the split gear
aligned, remove the bolt and cam gear assembly.
PU-45497-1
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.

3.38
 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:
16. Insert the pointed dowels from the Tapered Pins (PU- (PU-45497-1)
45497-1) into the cam gear. Cam Gear Tooth Align Tool:
(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

3.39
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) (R), use a twisting
motion when pushing down on the tool.

3.40
 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 edges as
24. Install the two puller bolts (R). Tighten the puller bolts up
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 old oil/water pump housing.
crankshaft gear, if needed.
28. Use a feeler gauge to measure the clearance between the
two rotors. Measure the gap between the two rotor tips as
2871043 shown below. The clearance should not exceed 0.006"
(0.15 mm).

Max Tip Clearance

0.006” (0.15 mm)

3.41
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
spring, washer, and bolt. Torque to specification . Wear appropriate safety gear during this
procedure. Protective gloves, clothing and eye
22 ± 2 ft. lbs. wear are required.
(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

Chamfer and bearing
End First assembly.

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

3.42
 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).

3.43
ENGINE
40. Remove balance shaft and crankshaft. Camshaft Inspection
1. Thoroughly clean the cam shaft.
2. Visually inspect each cam lobe for wear, chafing 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)

3.44
 ENGINE
5. Measure ID of camshaft journal bores. 1. Install oil pick up (A), if removed. Torque to specification.

= In. / mm.
B
Camshaft Journal Bore I.D.:
(Mag): 1.656" ± 0.00039" (42.07± 0.010 mm)
(Ctr.) 1.637" ± 0.00039" (41.58 ± 0.010 mm) A
(PTO) 1.617" ± 0.00039" (41.07 ± 0.010 mm)

6. Calculate oil clearance by subtracting journal O.D.'s from

journal bore I.D.'s. Compare to specification. 3
= In. / mm. 2. Install oil baffle weldment (B). Torque bolts to
specification.

Calculated Camshaft Oil Clearance:

Std: 0.0027" (.070mm) =T
Limit: .0039" (.10 mm)
Oil Baffle Weldment &
NOTE: Replace camshaft if damaged or if any part is Oil Pick Up Bolt Torque:
worn past the service limit. 60 ± 6 in. lbs. (6.8 ± 0.68 Nm)

NOTE: Replace engine block if camshaft journal 3. Install the balance shaft. Inspect balance shaft clearance
bores are damaged or worn excessively. (C) in both gearcase halves. Rotate balance shaft to ensure
that there is clearance between it and oil baffle weldment.

ENGINE REASSEMBLY C
Crankcase Reassembly

CAUTION

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 Steps 45-46 of this section to prime
the engine and to help aid proper break-in.

NOTE: Before assembly, clean the bolts and bolt

holes with Primer N (PN 2870585) to remove any NOTE: Always install new balance shaft bearings.
debris. This will ensure proper sealing when
installing bolts.

3.45
ENGINE
4. Apply assembly lube to cam journals and balance shaft 7. Assemble the crankcase halves. Apply LocTite™ 242 (PN
bearing surfaces of the MAG case halve. Install camshaft 2871949) to the threads and pipe sealant to the bolt flanges.
and balance shaft. Torque bolts to specification following torque pattern at
beginning of this chapter.

=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.
NOTE: Always replace the camshaft and lifters as a
D set.

6.Apply Crankcase Sealant (PN 2871557) to the top gearcase

halve.
NOTE: Do not apply sealant to cam relief hole (E).

3.46
 ENGINE
10. Lubricate connecting rods with 0W-40 engine oil. 13. Install piston assemblies into cylinder aligning the piston
pin holes, to ensure proper alignment of the pistons to the
connecting rods upon assembly. Partially install the piston
pins into the pistons.

3
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.

14. Position cylinder and piston assemblies onto the connecting

rods and push the piston pins through the piston and
connecting rods.

12. Orientate the piston rings on the piston before installation

into the cylinders. Set the gaps of the rings every 120°
(See Illustration Below).
1
Piston Ring
Orientation 2
3 Push in Piston Pins

15. Install the piston pin circlips. The circlip ends should be
1. Top Ring 2. Second Ring installed at the 12 O'clock position.

3. Oil Ring

Piston Pin Cirlcip in

12 O’clock position

3.47
ENGINE
NOTE: While installing in piston circlips, cover all 17. Assemble rotors as marked when disassembled. Use a
engine passages. The clip could fall into the engine cleaner to remove the marks previously made on the rotors.
during installation.
Line Up Marks

18. 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.
16. Install camshaft thrust plate (G) with new bolts. Torque
bolts to specification.
Lubricate Rotors
NOTE: New bolts have patch lock on the threads
and do not require Loctite™.

19. Align the bolt holes and install oil pump assembly into
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
=T outward or away from the case.

Thrust Plate Screw Torque:

115 ± 12 in.lbs. (13 ± 1.35 Nm)

NOTE: Before assembly, clean the bolts and bolt

holes with Primer N (PN 2870585) to remove any
debris. This will ensure proper sealing when
installing bolts and new Loctite™.

3.48
 ENGINE
20. Install oil pump housing bolts (H). The new bolts contain 22. Before installing the crankshaft gear (I), heat the crankshaft
patch lock, so Loctite™ is not needed on the new bolts. gear to 250° F (121°C) on a hot plate (J).
Torque bolts to specification and follow the torque
sequence at beginning of the chapter.
I J

NOTE: Occasionally spin the oil pump when CAUTION

installing bolts to check for binding of the rotors.
The crankshaft gear is extremely hot! Severe
=T burns or injury can occur if the gear is not
handled with extreme care and caution. Follow
Oil Pump Bolt Torque: the procedure below to help ensure safety.
84 ± 8 in.lbs. (9.50 ± 0.90 Nm)
23. Use extreme caution when removing the crankshaft gear
* Torque in Sequence
from the hot plate. Use a pair of pliers and leather gloves
when handling the crankshaft gear.
21. Apply Loctite™ 242 (PN 2871949) to the crankshaft.
24. Install the crankshaft gear (I) onto the crankshaft.
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.

3.49
ENGINE
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: NOTE: Be sure all of the timing marks are properly
22 ± 2 ft. lbs. (30 ± 3 Nm) aligned.

26. Use the Cam Gear Alignment Tool (PU-45497-2) to align K Water Pump Gear
the teeth of the cam gear (M). Install the cam gear (M) (with
the Cam Gear Alignment Tool still in place) onto the Timing Marks
camshaft. The timing marks on the camshaft gear should
align with the keyway on the balance shaft gear.

PU-45497-2

M N
M

Timing Marks

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.

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

3.50
 ENGINE
28. Before installing the gear / stator housing, replace the seals NOTE: Install the crankshaft seal (P) with the seal lip
in the cover. Install a new water pump seal (N) into the gear facing out (towards the crankcase).
/ stator housing. Use the Water Pump Mechanical Seal
Installer (PA-44995) to properly install the seal to the
correct depth in the cover. P

PA-44995
O
PA

3
-4 4
99

N
5

Seal lip goes towards the crankcase.

30. Once the crankshaft seal is installed into the gear / stator
housing cover, set the direction of the paper lip by sliding
the Main Crankshaft Seal Saver (PA-45658) into the
crankshaft seal from the rubber lipped side to the paper lip
side. (Back to Front) Remove the tool.
IMPORTANT: Due to seal design and construction,
seals MUST be installed DRY (no lubricant) during
Important: Set the direction
assembly. Use of lubricants (oil, soapy water, etc.)
of the paper lip seal
will not allow the seal to wear-in and seal properly. Do
not touch seal surface or allow seal surface to come
in contact with contaminates during installation.
Thoroughly clean parts, tools and hands before
PU-45658
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
will occur.

NOTE: Install the water pump seal (N) with the seal
lip facing out (towards the crankcase). Use of a 31. Carefully install the tapered end of the Crankshaft Seal
hydraulic press is recommended for this procedure. Protection Tool (PA-45658) through the paper side of the
crankshaft seal. (Back to Front) Leave the seal protector
29. Install a new crankshaft seal (P) into the gear/stator housing
installed in the crankshaft seal. Check the crankshaft seal
cover. Use the Universal Driver Handle (PU-45543) and
lips to verify they have not been rolled or damaged.
the Main Seal Installer (PA-45483) to seat the crankshaft
seal into place.

PU-45543
PU-45658

PA-45483

3.51
ENGINE
32. Before installing the gear/stator housing cover, install the
Water Pump Seal Saver (PA-45401) onto the water pump
shaft.

PA-45401

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

Gear / Stator
Housing Gasket

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

crankcase. With the tools installed, carefully place the
gear/stator housing cover over the protection tools.

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.

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.

PA-45401

PA-45658

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

3.52
 ENGINE
NOTE: Before assembly, clean the bolts and bolt 39. Install water pump cover (R) with new O-ring seal. Torque
holes with Primer N (PN 2870585) to remove any bolts to specification in proper sequence (See front of this
debris. This will ensure proper sealing when chapter).
installing bolts.
Install the O-ring dry, no lubricants
37. Install shaft seal with ceramic surface facing inward.

96 ± 3 in. lbs.
(10.85 ± 1.35 Nm)

38. Install water pump impeller (P). Secure the impeller with =T
the washer and a new nylok nut (Q). Torque the nut to
specification. Water Pump Housing Bolt Torque:
96 ± 3 in. lbs. (10.85 ± 0.35 Nm)
*Torque in proper sequence
P
40. Sparingly apply Starter Drive Grease (PN 2871423) to the
starter drive. Install the starter bendix.
NOTE: There are thrust washers on both sides of
starter drive.

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

3.53
ENGINE
Flywheel / Stator Installation
NOTE: Before assembly, clean the bolts and bolt =T
holes with Primer N (PN 2870585) to remove any
debris. This will ensure proper sealing when Flywheel Nut Torque
installing bolts. 65 ± 7 ft.lbs. (88 ± 9.50 Nm)

1. Install stator assembly (S) and bolts. Torque bolts to 4. Install stator housing with new o-rings. Torque the bolts to
specification. specification and follow proper bolt torque sequence at the
2. Install the wire hold down bracket (T). Install two new wire beginning of this chapter.
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™ 96 ± 3 in.lbs.
Grease (PN 2871329). (10.85 ± 0.35 Nm)
NOTE: Verify stator wires are routed properly under
the wire hold down bracket.

Replace 2 bolts with new bolts

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

Cylinder Head Reassembly

=T NOTE: Before reassembly, clean the bolts and bolt
holes with Primer N (PN 2870585) to remove any
Stator Assembly Bolt Torque:
debris. This will ensure proper sealing when
96 ± 3 in.lbs. (10.85 ± 0.35 Nm)
installing bolts.

3. Install the flywheel, washer, nut, and key. Torque flywheel 1. Install the head gasket (A) on the cylinder (B).
nut to specification.

65 ± 7 ft. lbs.
(88 ± 9.50 Nm) A

3.54
 ENGINE
2. Install cylinder head on cylinder. 5. Lubricate rockers (E) with engine oil.

3. Lubricate threads and top of washers underside of bolt head

with engine oil. Install head bolts (C) and torque to E
specification.

3
6. Verify pushrods are engaged in lifters.
7. Install rockers. Be sure that tab of fulcrum (F) is seated in
head stand-off. Torque bolts to specification.

=T
Cylinder Head Bolt Torque:
Initial setting: 35± 4 ft. lbs. (47.5 ± 5.5 Nm)
Allow to set for 1 minute, then turn
additional 90° (1/4 turn)
*Torque Bolts In Sequence

4. Lubricate push rods (D) and install into lifters.

=T
D Rocker Arm Bolt Torque
22 + 2 ft. lbs. (30 ± 3 Nm)

8. Install breather reed (G) into rocker cover (H). Lightly

apply black RTV sealant to the outer edges of the breather
reed. The reed has a tab and will assemble one-way only.
Torque the breather bolts to specification.
20 ± 5 in.lbs.
(2.5 ± .55 Nm)

G I

3.55
ENGINE
11. Install thermostat (J), new O-ring, and thermostat housing.
Torque to specification.
=T
17 ± 2 ft. lbs.
Breather Bolt Toque: K
(23 ± 3 Nm)
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 J

bolt holes with Primer N (PN 2870585) to remove any
debris. This will ensure proper sealing when
installing bolts. 84 ± 8 in. lbs.
(9.5 ± 0.9 Nm)
10. Install rocker cover. Torque bolts to specification.

=T
Thermostat Housing Bolt Torque:
84 ± 8 in. lbs. (9.5± 0.9 Nm)

12. Install temperature sender (K) and torque to specification.

=T
=T
Rocker Cover Bolt Torque:
84 ± 8 in.lbs. (9.5 ± 0.9 Nm) Temperature Sender Torque:
Torque in Sequence 17 ± 2 ft.lbs. (23 ± 3 Nm)

3.56
 ENGINE
Oil Pump Priming
CAUTION
1. After the engine is completely assembled and ready for
installation, the engine must be properly primed with
After any reassembly or rebuild, the engine
Polaris 0W-40 Synthetic Oil (PN 2871281). Fill the oil
must be primed using the Oil Priming Adapter
filter three-quarters full with Polaris 0W-40 Synthetic Oil
(PU-45778) and a 3/4-full oil filter before initial
(PN 2871281). Let the oil soak into the filter for 8-10
start-up. Follow the steps in this section to
minutes. Install the filter onto the engine.
properly prime the engine and aid proper engine
break in. Failure to perform this procedure may
cause internal engine damage on initial start-up.

Fill 3/4 full

with 0W-40

2. Remove primer plug from the engine. Install Oil System

Priming Adapter (PU-45778) into the oil plug hole. Push
3-5 oz. (approx.) of Polaris 0W-40 into the adapter or until
resistance is felt. Remove the adapter. Apply sealant to the
plug threads. Install the plug and torque to specification.

PU-45778

=T
Primer Plug Torque
18 ± 2 ft.lbs. (24.4 ± 2.71 Nm)

3.57
ENGINE
TROUBLESHOOTING Engine Idles But Will Not Accelerate
• Spark plug fouled/weak spark
Engine
• Broken throttle cable
Spark Plug Fouling
• Obstruction in air intake
• Spark plug cap loose or faulty
• Air box removed (reinstall all intake components)
• Incorrect spark plug heat range or gap
• Incorrect or restricted carburetor jetting
• PVT system calibrated incorrectly/ components worn or
mis-adjusted • ETC switch limiting speed
• Reverse speed limiter limiting speed
• Fuel quality poor (old) or octane too high
• Incorrect ignition timing
• Low compression
• Restricted exhaust system
• Restricted exhaust
• Cam worn excessively
• Weak ignition (loose coil ground, faulty coil, stator, or
ETC switch) Engine Has Low Power
• ETC switch mis-adjusted • Spark plug fouled
• Restricted air filter (main or pre-cleaner) or breather • Cylinder, piston, ring, or valve wear or damage (check
system 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 Excessive Smoke and Carbon Buildup
• Tank vent plugged or pinched • Excessive piston-to-cylinder clearance
• Engine flooded • Wet sumping
• Low compression (high cylinder leakage) • Worn rings, piston, or cylinder
• No spark (Spark plug fouled) ignition component • Worn valve guides or seals
failure
• Restricted breather
Engine Does Not Turn Over • Air filter dirty or contaminated
• Dead battery
Piston Failure - Scoring
• Starter motor does not turn
• Lack of lubrication
• Engine seized, rusted, or mechanical failure
• Dirt entering engine through cracks in air filter or ducts
Engine Runs But Will Not Idle • Engine oil dirty or contaminated
• Restricted carburetor pilot system
• Low compression
• Crankcase breather restricted

3.58
 ENGINE
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
• Ignition timing mis-adjusted
Backfiring • Low oil level
• ETC or speed limiter system malfunction • Spark plug incorrect heat range
• Fouled spark plug or incorrect plug or plug gap • Faulty hot light circuit
• Exhaust system air leaks • Thermostat stuck closed or not opening completely
• Exhaust system air leaks Temperature Too Low
• Ignition system faulty:
• Thermostat stuck open
Spark plug cap cracked / broken
Ignition coil faulty Leak at Water Pump Weep Hole
Ignition or kill switch circuit faulty
Poor connections in ignition system • Faulty water pump mechanical seal (coolant leak)
Ignition timing incorrect • Faulty pump shaft oil seal (oil leak)
Sheared flywheel key

• Valve sticking

3.59
 FUEL INJECTION
CHAPTER 4
FUEL INJECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
EFI SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
EFI SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FUEL LINES - QUICK CONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
PRINCIPAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
EFI OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
4
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
ECU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL PUMP / TANK ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL PRESSURE REGULATOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL PRESSURE REGULATOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL INJECTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
CPS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
CPS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP). . . . . . . . . . . . . 4.16
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
T-BAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
T-BAP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
TPS TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
TPS INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
TPS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
ECT SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
ECT SENSOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
GENERAL TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
DIAGNOSTIC “BLINK CODES” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
EFI TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22

4.1
FUEL INJECTION
GENERAL INFORMATION Fuel Pressure Gauge Kit - PU43506-A
IMPORTANT: The EFI fuel system remains under high
WARNING pressure, even when the engine is not running.
Before attempting to service any part of the fuel
system, the pressure must be relieved. The pressure
* Gasoline is extremely flammable and explosive
adapter has an integrated relief valve. Connect to the
under certain conditions.
test valve and release the pressure.
* EFI components are under high pressure. Verify
system pressure has been relieved before
disassembly.
* Never drain the fuel system when the engine is hot.
Severe burns may result .
* Do not overfill the tank. The tank is at full capacity
when the fuel reaches the bottom of the filler neck.
Leave room for expansion of fuel.
* Never start the engine or let it run in an enclosed
area. Gasoline powered engine exhaust fumes are
poisonous and can cause loss of consciousness and
death in a short time. Fuel Pressure Gauge Kit
* Do not smoke or allow open flames or sparks in or PU-43506-A
near the area where refueling is performed or where
gasoline is stored.
* If you get gasoline in your eyes or if you should
swallowgasoline,seekmedicalattentionimmediately.
* If you spill gasoline on your skin or clothing,
immediately wash with soap and water and change
clothing.
* Always stop the engine and refuel outdoors or in a
well ventilated area.

Special Tools
Test Valve
PART NUMBER TOOL DESCRIPTION
PU-43506-A Fuel Pressure Gauge Kit
PU-47063 Digital Wrench™ Diagnostic Software
Digital Wrench™
PU-47471 SmartLink Module Kit
(PU-47470, PU-47469, PU-47468)
Digital Wrench™
PU-47470
PC Interface Cable
Digital Wrench™
PU-47469
Vehicle Interface Cable
Digital Wrench™
PU-47468
SmartLink Module
2201519 Throttle Position Sensor Tester
Throttle Body Adjustment Screwdriver
PU-47315
(small “D” shape)

4.2
 FUEL INJECTION
Digital Wrench™ Diagnostic Software - PU-47063 Throttle Position Sensor Tester - PU-47082
This dealer-only software installs on laptop computers equipped This tester allows the use of a digital multi-meter to test TPS
with a CD drive and serial port connection, and is designed to function as well perform initialization procedures.
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 4
Polaris EFI systems. This kit is available to Polaris dealers
through our tool supplier, SPX (1-800-328-6657).
Throttle Body Adjustment Screwdriver
PU-47315
PU-47469 This tool has a special ‘D’ shaped end for adjusting the throttle
stop screw during a TPS initialization procedure.

PU-47468
PU-47470

Digital Wrench™ - Diagnostic Connector

(Located under the hood as shown below)

4.3
FUEL INJECTION
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 XP 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
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.

4.4
 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)

4.5
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.

5. Fuel Pump / Regulator / Gauge Sender Assembly

2. Intake Air Temperature and Barometric Air Pressure Located in fuel tank as an assembly.
Sensor (T-BAP)
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

4.6
 FUEL INJECTION
7. Throttle Position Sensor (TPS)
Located on the right-hand side of the throttle body.

TPS

8. Engine Coolant Temperature Sensor (ECT)

Located in the cylinder head. 4

4.7
FUEL INJECTION
FUEL TANK
Exploded View

Fuel Flow

4.8
 FUEL INJECTION
Fuel Lines - Quick Connect EFI Operation Overview
RANGER EFI models use quick connect fuel lines. Refer to the The EFI system is designed to provide peak engine performance
steps below for fuel line removal. with optimum fuel efficiency and lowest possible emissions.
The ignition and injection functions are electronically
1. Place a shop towel around the fuel line to catch any controlled, monitored and continually corrected during
dripping fuel. Squeeze the connector tabs together and operation to maintain peak performance.
push the locking slide back.
The central component of the system is the Bosch Engine
Control Unit (ECU) which manages system operation,
determining the best combination of fuel mixture and ignition
timing for the current operating conditions.

An in-tank electric fuel pump is used to move fuel from the tank
through the fuel line and in-line fuel filter. The in-tank fuel
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
4
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
Squeeze Connector Tabs 1.5-8.0 milliseconds depending on fuel requirements. The
controlled injection of the fuel occurs each crankshaft
2. Pull on the fuel line for removal. revolution, or twice for each 4-stroke cycle. One-half the total
3. To install the line, verify the connector and fuel tank nipple amount of fuel needed for one firing of a cylinder is injected
are clean and free of debris. during each injection. When the intake valve opens, the fuel/air
4. Snap the fuel line back over the nipple and slide the locking mixture is drawn into the combustion chamber, ignited. and
mechanism back into place. Verify the connector tabs snap burned.
back into place.
The ECU controls the amount of fuel being injected and the
ignition timing by monitoring the primary sensor signals for air
temperature, barometric air pressure, engine temperature, speed
ELECTRONIC FUEL INJECTION (RPM), and throttle position (load). These primary signals are
compared to the programming in the ECU computer chip, and
Principal Components the ECU adjusts the fuel delivery and ignition timing to match
The Electronic Fuel Injection (EFI) system is a complete engine the values.
fuel and ignition management design. This system includes the
following principal components: During operation the ECU has the ability to re-adjust
temporarily, providing compensation for changes in overall
• Fuel Pump engine condition and operating environment, so it will be able
• Fuel Rail to maintain the ideal air/fuel ratio.
• Fuel Line(s)
• Fuel Filter(s) During certain operating periods such as cold starts, warm up,
• Fuel Injectors acceleration, etc., a richer air / fuel ratio is automatically
• Pressure Regulator calculated by the ECU.
• Throttle Body / lntake Manifold
• Engine Control Unit (ECU)
• Ignition Coils
• Coolant Temperature Sensor
• Throttle Position Sensor (TPS)
• Crankshaft Position Sensor (CPS)
• Intake Air Temperature and Barometric Air
Pressure Sensor (T-BAP)
• Wire Harness Assembly
• Check Engine Light

4.9
FUEL INJECTION
Initial Priming / Starting Procedure ELECTRONIC CONTROL UNIT (ECU)
NOTE: The Injection system must be purged of all
Operation Overview
air prior to the initial start up, and / or any time the
system has been disassembled. The ECU is the brain or central processing computer of the
entire EFI fuel/ignition management system. During operation,
If the EFI system is completely empty of fuel or has been sensors continuously gather data which is relayed through the
disassembled and repaired: wiring harness to input circuits within the ECU. Signals to the
ECU include: ignition (on/off), crankshaft position and speed
1. Cycle the key switch from “OFF” to “ON” 6 times,
(RPM), throttle position, engine coolant temperature, air
waiting for approximately 3 seconds at each “ON” cycle to
temperature, intake manifold air pressure and battery voltage.
allow the fuel pump to cycle and shut down.
The ECU compares the input signals to the programmed maps
2. Once step 1 is completed, turn the key switch to “START”
in its memory and determines the appropriate fuel and spark
until the engine starts or 5 seconds has passed.
requirements for the immediate operating conditions. The ECU
3. If the engine failed to start, repeat step 1 for 2 more cycles then sends output signals to set the injector duration and ignition
and attempt to start the engine. timing.
If the engine fails to start, a problem may still exist, and should
be diagnosed.

NOTE: Accurate testing of EFI components is

recommended utilizing the Digital Wrench™
Diagnostic Software (dealer only).

During operation, the ECU continually performs a diagnostic

check of itself, each of the sensors, and system performance. If
a fault is detected, the ECU turns on the “Check Engine” light
in the speedometer and stores the fault code in its fault memory.
Depending on the significance or severity of the fault, normal
operation may continue, or "Fail-Safe" operation (slowed speed,
richer running) may be initiated. A technician can determine the
cause of the “Check Engine” light by initiating the “Blink Code”
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.

To prevent engine over-speed and possible failure, a rev-

limiting feature is programmed into the ECU. If the maximum
RPM limit (6200) is exceeded, the ECU suppresses the injection
signals, cutting off the fuel flow. This process repeats it self in
rapid succession, limiting operation to the preset maximum.

4.10
 FUEL INJECTION
RANGER 700 EFI RPM Limit: FUEL PUMP
Hard Limit - Injector suppression occurs
Operation Overview
• High: 6200
NOTE: All EFI units utilize quick connect lines.
• Low: 6200
An electric fuel pump assembly is used to transfer fuel to the EFI
• Neutral: 6200
system from inside the fuel tank. This assembly includes the fuel
• Reverse: 6200 pump, regulator and fuel gauge sender. The pump is rated for a
minimum output of 25 liters per hour at 39 psi and has a non-
Soft Limit - Timing suppression occurs
serviceable internal 60-micron filter.
• High: None
Fuel pump is not
• Low: 5900
replaceable, picture
• Neutral: 5900 is for reference only.
• Reverse: 5900
4
ECU Service Regulator

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.
Fuel Pump
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 Internal 60 Micron
Strainer (Bottom)
faulty, contact the Polaris Service Department for specific
handling instructions. Do not replace the ECU without factory Fuel Gauge Sender
authorization.

The relationship between the ECU and the throttle position

sensor (TPS) is very critical to proper system operation. If the
TPS is faulty, or the mounting position of the TPS to the throttle
body is altered, the TPS must be re-initialized.
When the key switch is turned to "ON", the ECU activates the
For the purpose of troubleshooting, a known-good ECU from fuel pump, which pressurizes the system for start-up.
another Polaris RANGER XP EFI of the same model may be
used without system or engine component damage. The ECU switches off the pump preventing the continued
delivery of fuel in these instances:
ECU Replacement
• If the key switch is not promptly turned to the "start"
1. Remove the retaining screws (2) holding the ECU. position.
2. With the Ignition turned off, disconnect the wire harness
from the ECU. • If the engine fails to start, or
3. To install, reverse the procedures and tighten screws to
• If the engine is stopped with the key switch "on" (as in
specification.
the case of an accident)

=T In these situations, the “check engine” light will go on, but will
turn off after 4 cranking revolutions if system function is OK.
ECU Retaining Screws Once the engine is running, the fuel pump remains on.
10 in. lbs. (1.1 Nm)

4.11
FUEL INJECTION
Fuel Pump Test 3. Turn on the key switch to activate the pump and check the
system pressure on the gauge. If system pressure of 39 psi
NOTE: FUEL GAUGE SENDER TEST - To test fuel ± 3 is observed, the ignition switch, ECU, fuel pump, and
gauge sender function, refer to Chapter 10. pressure regulator are working properly. Turn the key
switch off and depress the valve button on the tester to
The fuel pump/tank assembly is non-serviceable and must be
relieve the system pressure.
replaced if determined to be faulty. If a fuel delivery problem is
suspected, make certain the filters are not plugged, that the
pump is being activated through the ECU, all electrical Normal Fuel Pressure: 39 psi. ± 3
connections are properly secured, the fuses are good, and a
minimum of 7.0 volts is being supplied. If during starting the NOTE: If the pressure is too high or too low, replace
battery voltage drops below 7.0 volts, the ECU will fail to the fuel tank assembly.
operate the system.
4. If the pump did not activate (Step 2), disconnect the plug
from the fuel pump. Connect a DC voltmeter across
WARNING terminals “A” and “C” in the plug, turn on the key switch
and observe if a minimum of 7 volts is present. If voltage
Check the fuel test valve for any possible fuel is between 7 and 14, turn key switch off and connect an
seepage after performing any tests or ohmmeter between the terminals “A” and “C”' on the pump
procedures. Fuel is extremely flammable and to check for continuity.
may cause severe burns, injury, or death. NOTE: If there was no continuity between the pump
Do not use any device that produces a flame or terminals, replace the fuel tank assembly.
electrical devices that may spark around
fuel or fuel vapors. NOTE: If the voltage was below 7Vdc, test the
battery, ignition switch, wiring harness and ECU.
1. Remove the cap from the fuel test valve.
5. If voltage at the plug was good, and there was continuity
across the pump terminals, reconnect the plug to the pump,
making sure you have good, clean connections. Turn on the
key switch and listen for the pump to activate.
NOTE: If the pump starts, repeat steps 1 and 2 to
verify correct pressure.

NOTE: If the pump still does not operate, check for

correct ECU operation by plugging in a known-good
ECU of the same model.

NOTE: If the pump still does not operate, replace the

pump/tank assembly.
2. Connect the pressure hose of the Polaris pressure tester
(PN PU-43506) to the test valve on the fuel rail. Route the
Fuel Pump / Tank Assembly Replacement
clear hose into a portable gasoline container or the
equipment fuel tank. NOTE: All EFI units utilize quick connect fuel lines.

WARNING

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.

4.12
 FUEL INJECTION
1. Disconnect the negative battery cable. 6. Remove the RH rear fender and fuel cap.

2. Remove the seat.

3. Disconnect the fuel line from the fuel pump.

7. Remove the two inner bolts that hold the fuel tank to the
frame.
4
4. Disconnect the fuel pump electrical harness.

8. Remove the two outer lower bolts that hold the fuel tank to
the frame.

5. Remove the fuel tank vent hose

NOTE: A small amount of fuel may come out of the

fuel line or tank. Plug the fuel line and tank inlet or
use a shop towel during removal.

NOTE: Properly drain fuel into a suitable container.

4.13
FUEL INJECTION
9. Reinstall the fuel cap and carefully pull the fuel tank out the Fuel Pressure Regulator Test
RH side of the frame.
Refer to the “FUEL PUMP TEST” procedure.
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.

FUEL INJECTORS
Operation Overview
NOTE: All EFI units utilize quick connect fuel lines.
WARNING
The fuel injectors mount into the intake manifold, and the fuel
rail attaches to them at the top end. Replaceable O-rings on both
Wear safety goggles while performing this
ends of the injector prevent external fuel leaks and also insulate
procedure, failure to do so could result
it from heat and vibration.
in serious injuries.

Fuel Tank Installation

1. Reinstall the 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.
When the key switch is on, the fuel rail is pressurized, and
voltage is present at the injector. At the proper instant, the ECU
completes the ground circuit, energizing the injector. The valve
FUEL PRESSURE REGULATOR needle in the injector is opened electromagnetically, and the
pressure in the fuel rail forces fuel down through the inside. The
Operation Overview “director plate” at the tip of the injector (see inset) contains a
The fuel pressure regulator maintains the required operating series of calibrated openings which directs the fuel into the
system pressure of 39 psi + 3psi. A rubber-fiber diaphragm intake port in a cone-shaped spray pattern.
divides the regulator into two separate sections-, the fuel
chamber and the pressure regulating chamber. The pressure The injector is opened and closed once for each crankshaft
regulating spring presses against the valve holder (part of the revolution, however only one-half the total amount of fuel
diaphragm), pressing the valve against the valve seat. The needed for one firing is injected during each opening. The
combination of atmospheric pressure and regulating spring amount of fuel injected is controlled by the ECU and determined
tension equals the desired operating pressure. Any time the fuel by the length of time the valve needle is held open, also referred
pressure against the bottom of the diaphragm exceeds the to as the “injection duration” or “pulse width”. It may vary in
desired (top) pressure, the valve opens, relieving the excess length from 1.5-8 milliseconds depending on the speed and load
pressure, returning the excess fuel back to the tank. requirements of the engine.

4.14
 FUEL INJECTION
Fuel Injector Service 5. Remove the fuel rail mounting screw and carefully loosen
/ pull the rail away from the injectors.
Injector problems typically fall into three general categories-
6. Reverse the procedures to install the new injector(s) and
electrical, dirty / clogged, or leakage. An electrical problem
reassemble. Use new O-rings any time an injector is
usually causes one or both of the injectors to stop functioning.
removed (new replacement injectors include new O-rings).
Several methods may be used to check if the injectors are
Lubricate O-rings lightly with oil to aid installation. Torque
operating.
the fuel rail mounting screw to specification.
• With the engine running at idle, feel for operational
vibration, indicating that they are opening and closing. =T
• When temperatures prohibit touching, listen for a Fuel Rail Mount Screws
buzzing or clicking sound with a screwdriver or 16-20 ft. lbs. (22.6-27 Nm)
mechanic's stethoscope.

• Disconnect the electrical connector from an injector and

listen for a change in idle performance (only running on
one cylinder) or a change in injector noise or vibration.
CRANKSHAFT POSITION SENSOR
(CPS)
4
NOTE: Do not apply voltage directly to the fuel
injector(s). Excessive voltage will burn out the Operation Overview
injector(s). Do not ground the injector(s) with the
ignition on." lnjector(s) will open/turn on if relay is The engine speed sensor is essential to engine operation,
energized. constantly monitoring the rotational speed (RPM) and position
of the crankshaft.
If an injector is not operating, it can indicate either a bad injector,
or a wiring/electrical connection problem. Check as follows:

Injector leakage is very unlikely, but in rare instances it can be

internal (past the tip of the valve needle), or external (weeping
around the injector body). The loss of system pressure from the
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
by a buildup of deposits on the director plate, restricting the flow A ferromagnetic 60-tooth ring gear with two consecutive teeth
of fuel, resulting in a poor spray pattern. Some contributing missing is mounted on the flywheel. The inductive speed sensor
factors to injector clogging include; dirty air filters, higher than is mounted 1.0 ± 0.26 mm (0.059 ± 0.010 in.) away from the
normal operating temperatures, short operating intervals and ring gear. During rotation, an AC pulse is created within the
dirty, incorrect, or poor quality fuel. Cleaning of clogged sensor for each passing tooth. The ECU calculates engine speed
injectors is not recommended; they should be replaced. from the time interval between the consecutive pulses. The two-
Additives and higher grades of fuel can be used as a preventative tooth gap creates an “interrupt” input signal, corresponding to
measure if clogging has been a problem. specific crankshaft position for PTO cylinder. This signal serves
as a reference for the control of ignition timing by the ECU.
Fuel Injector Replacement Synchronization of the CPS and crankshaft position takes place
during the first two revolutions each time the engine is started.
1. Engine must be cool. Depressurize fuel system through This sensor must be properly connected at all times. If the sensor
test valve in fuel rail. fails or becomes disconnected for any reason, the engine will
2. Remove the front fender assembly and fuel tank. quit running.
3. Thoroughly clean the area around and including the throttle
body / manifold and the injectors.
4. Disconnect the fuel injector harness(s) at the ECU.

4.15
FUEL INJECTION
CPS Test TEMPERATURE / BAROMETRIC AIR
The crankshaft position sensor is a sealed, non-serviceable PRESSURE SENSOR (T-BAP)
assembly. If fault code diagnosis indicates a problem within this
area, test and correct as follows: Operation Overview
1. Disconnect main harness connector from ECU. Mounted on the throttle body intake, the temperature and
2. Connect an ohmmeter between the pin terminals. A barometric air pressure sensor (T-BAP) performs two functions
resistance value of 560Ω ± 10% at room temperature (20° in one unit.
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.
NOTE: If the resistance is incorrect, remove the
screw securing the sensor to the mounting bracket Air passing through the intake is measured by the T-BAP and
and replace the sensor. If the resistance in step 2 relayed to the ECU. These signals, comprised of separate air
was incorrect, but the resistance of the sensor alone temperature and barometric air pressure readings, are processed
was correct, test the main harness circuit between by the ECU and compared to it's programming for determining
the sensor connector terminals and the the fuel and ignition requirements during operation.
corresponding pin terminals in the main connector.
Correct any observed problem, reconnect the T-BAP Test
sensor, and perform step 2 again.
The temperature and barometric air pressure sensor (T-BAP) is
CPS Replacement 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
1. Disconnect sensor harness connector. sensor should only be tested using the Digital Wrench™
2. Using a 6 mm hex wrench, remove the retaining bolt and Diagnostic Software (dealer only). Refer to the EFI Diagnostic
replace the sensor, using a light coating of oil on the o-ring Software Manual for more information.
to aid installation.
3. Torque the retaining bolt to specification. T-BAP Replacement

=T 1. Disconnect sensor from engine harness.

2. Using a 10mm wrench, remove the retaining bolt and
replace the sensor, using a light coating of oil on the o-ring
CPS Retaining Bolt Torque:
to aid installation.
25 in. lbs. (2.8 Nm)
3. Torque the retaining bolt to specification.

=T
T-BAP Retaining Bolt Torque:
29 in. lbs. (3.3 Nm)

4.16
 FUEL INJECTION
THROTTLE POSITION SENSOR (TPS) • Harness Test: Insert black voltmeter probe into the
“Bk” test port.
Operation Overview
• Connect the red meter probe into the “R” port and
The throttle position sensor (TPS) is used to indicate throttle verify the voltage is 4.99-5.01 Vdc. If this reading is
plate angle to the ECU. low, verify the 9 volt battery is good or try a new 9 volt
battery.
Mounted on the throttle body and operated directly off the end
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.

NOTE: The correct position of the TPS is

established and set at the factory. Do not loosen the
TPS or alter the mounting position. If the TPS is
repositioned, replaced or loosened it must be re-
4
calibrated.

TPS Test
The throttle position sensor (TPS) is a non-serviceable item. If
it is faulty, it must be replaced. It can be tested using the
following method:

NOTE: Before proceeding with any of the following

measurements or tests, it’s extremely important to
verify the throttle body bore is clean of any carbon
build-up. Remove the intake boot and inspect the
throttle body bore. If required, remove the throttle
body and clean the bore.

• Set up the TPS Test Adapter Harness (PU-47082),

according to the instructions that accompanied the
tester. Make sure that the 9 volt battery is new.
Test Procedure
1. Plug the TPS test adaptor harness in the TPS harness.
PU-47082 TPS Test 2. Connect the red test probe in yellow test port and black test
Adapter Harness probe in the black test port and the meter to VDC. Move
Use NEW
9V battery the throttle open and closed slowly while reading the
display. The voltage should increase smoothly with no
“jumps” or decreases when the throttle is applied.

PU-47082 Harness No “Jumps” in read out

VERIFY TPS TESTER REFERENCE VOLTAGE

A 5 volt reference voltage from the harness is required for the

TPS test to be accurate. Refer to the instructions provided with
the TPS Test Adapter Harness (PU-47082) or follow the bullet
point steps to check reference voltage.

4.17
FUEL INJECTION
3. If voltage varies with throttle movement, continue on to • With engine off, back out air flow screw until it no
step 3 and measure the idle air flow reading. If the sensor longer is in contact with throttle plate cam. The throttle
does not function correctly, replace it. plate should seal off throttle bore completely.
4. With voltmeter still attached to the TPS Test Adapter Back Air Flow Screw Out
Harness (PU-47082) as shown below, the voltmeter should Until No Contact is Made
read .710 ± .01 volts at idle position.
TPS Tester Adapter
Harness- PU-47082 Should Read: .710 V

.710

5. If the voltage does not read within the specification,

“TPS Initialization” will need to be performed.

TPS Initialization • Open and close throttle plate a couple of times to ensure
full throttle closing. Do not snap closed, as this could
NOTE: The correct position of the TPS is cause unnecessary throttle plate to throttle body
established and set at the factory. Use this interference and/or damage.
procedure only if the TPS was repositioned,
replaced or loosened. • Set up the TPS Test Adapter Harness (PU-47082)
according to the instructions. Verify that the 9 volt
STEP 1 battery is new. See illustration below.
Establishing zero offset voltage: This step is crucial as it sets TPS Tester Adapter
the TPS position using a fixed physical stop. This will insure Harness- PU-47082 Should Read: .528 V
that the correct offset voltage is reached once the correct throttle
body flow is set. .528

• Using a voltmeter attached to the TPS Tester Harness

(PU-47082), check the voltage output of the TPS. It
should read .528 ± .01 volts.

Throttle Plate • If it does not read .528 ± .01 volts, loosen the screw
Must Be Closed holding the TPS to the throttle body. Rotate TPS until
voltmeter reads .528 ± .01 volts.

• Remove cover and disconnect throttle cable from • Retighten TPS mounting screw, and verify the voltage
throttle cam. did not change. If changed, repeat the previous steps.

4.18
 FUEL INJECTION
STEP 2 2. Disconnect sensor (A) from the harness.
Establishing correct flow: Now that the zero offset voltage has
been set, you can now set the throttle body to the correct air flow
value.
B

6. With voltmeter still attached to the TPS Test Adapter

Harness (PU-47082), turn the air flow adjustment screw
until the voltmeter reads .710 ± .01 volts. The throttle body
is now adjusted to the correct flow value.
Turn Air Flow Screw In

3. Loosen and rotate the throttle body (B) to gain access to the 4
retaining screw.
4. Remove the retaining screw and replace the sensor.
5. Refer to “TPS Initialization” for setting the TPS voltage.

ENGINE COOLANT TEMPERATURE

SENSOR (ECT)
Operation Overview
TPS Tester Adapter
Harness- PU-47082 Should Read: .710 V Mounted on the cylinder head, the engine temperature sensor
measures coolant temperature. The engine temperature sensor
is a Negative Temperature Coefficient (NTC) type sensor, as the
.710
temperature increases the resistance decreases.

• Reconnect the TPS harness lead

• Reinstall throttle cable on throttle cam and install cover.
Adjust cable freeplay.

TPS Replacement
Coolant passes through the cylinder and by the sensor probe,
The correct position of the TPS is established and set at the varying a resistance reading which is relayed to the ECU. This
factory. If the TPS is repositioned, replaced or loosened it must signal is processed by the ECU and compared to it's
be re-calibrated. programming for determining the fuel and ignition
requirements during operation. The ECU also uses this signal to
1. Remove the seat base to gain access to the throttle body.
determine when to activate the fan during operation. If for any
reason the engine temperature sensor circuit is interrupted, the
fan will default to “ON”.

4.19
FUEL INJECTION
ECT Sensor Test

Engine Temperature Sensor

To quickly rule out other components and wiring related to the

ETS, disconnect the harness from the ETS. The fan should turn
on and ‘HOT’ should indicate on the instrument cluster. This
indicates all other components are working properly.

Refer to Chapter 10 for ECT testing. Polaris dealers can also test
the sensor by using the Digital Wrench™ Diagnostic Software
(dealer only). Refer to the Digital Wrench™ User Guide for
more information.

ECT Sensor Resistance Readings

Temperature °F (°C) Resistance

68 °F (20 °C) 2.5 kΩ ± 6%
212 °F (100 °C) 0.186 kΩ ± 2%

ECT Sensor Replacement

1. Drain coolant to level below sensor

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
 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

4
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

4.21
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
• Fuel lines or fuel injectors restricted • Plugged air filter

• Fuel filter plugged • Leaking injector (rich condition)

• Fuel pump inoperative • Belt dragging

• Air leak in system • Throttle stop screw tampering

• Intake air leak (throttle shaft, intake ducts, airbox or air Symptom: Erratic Idle
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
• Ignition timing incorrect
performance, bog, engine loads up, backfire.
• Belt dragging
• Air intake restricted (inspect intake duct)
• Dirty air cleaner
• Air filter dirty/plugged
• Engine worn
• Poor fuel quality (old fuel)
• Spark Plug fouled
• Fouled spark plug
• Throttle stop screw set incorrectly (out of sync with
• TPS setting incorrect ECU)
• Injector failure

4.22
 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 COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
HOOD / DASH COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
DASH INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
CAB FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
ASSEMBLY / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
CHASSIS / MAIN FRAME (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
CHASSIS / MAIN FRAME (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
SEAT / HEAD REST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
SEAT BASE / SEAT BACK / HEAD REST ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 5.10
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
FRONT A-ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
FRONT STRUT CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
BALL JOINT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
MID AXLE A-ARM (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
REAR A-ARM (4X4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
REAR STABILIZER BAR (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
SWING ARM (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
REAR DRIVE AXLE AND SWINGARM EXPLODED VIEW (6X6) . . . . . . . . . . . . . . . . . 5.21
REAR CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
CARGO BOX - PANELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
CARGO BOX - TAILGATE / BOX SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
STORAGE BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25

5.1
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
Rear Shock Bolt (upper) 30 ft. lbs. (41 Nm)
Strut Spring Compressor Tool (LH) 2871573
Rear Shock Bolt (lower) 30 ft. lbs. (41 Nm)
Strut Spring Compressor Tool (RH) 2871574
Rear Wheel Hub 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 15 ft. lbs. (21 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
 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
BODY / STEERING / SUSPENSION
Lower Body Components

5.4
 BODY / STEERING / SUSPENSION
Hood / Dash Components

T-27 4-5 ft. lbs. Glove Box Assembly

(5-6 Nm)

8-10 in. lbs. T-30

(0.9-1.0 Nm)

Hinges

4-5 ft. lbs. Cup Holder

(5-6 Nm)

T-27
5

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

Grille
Headlights

Hood Latch Strap Hood Liner

5.5
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

G
A

F D
E

5.6
 BODY / STEERING / SUSPENSION
CAB FRAME
Assembly / Removal
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. 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 hex bolts and nuts. Tighten all 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. Tighten
all 3/8" screws to 25-28 ft. lbs. (34-38 Nm).
4. Place the assembled cab frame onto the vehicle and align the rear mount holes. Secure the rear of the frame using the two
2 1/4" bolts on the outer tubes, two 3/4" bolts on the inner mounts 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.
5. Secure the front flanges to the vehicle with 5/16 x 3/4 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. Check all nuts and bolts for proper torque and installation. To remove the cab frame, reverse the installation instructions.

5
25-28 ft. lbs.
(34-38 Nm)
1

3
25-28 ft. lbs.
(34-38 Nm)

4
16-18 ft. lbs. 2
(20-24 Nm) 4 16-18 ft. lbs.
(20-24 Nm)

3
25-28 ft. lbs.
1
(34-38 Nm)

5
16-18 ft. lbs. 4
(20-24 Nm)
16-18 ft. lbs. 4
5 (20-24 Nm)
16-18 ft. lbs.
(20-24 Nm)

5.7
BODY / STEERING / SUSPENSION
CHASSIS / MAIN FRAME (4X4)
Exploded View

Seat Base
Frame Extension

RH Floor Support

45 ft. lbs.
(61 Nm)

Main Frame
Front Cab Support

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)

5.8
 BODY / STEERING / SUSPENSION
CHASSIS / MAIN FRAME (6X6)
Exploded View

Seat Base

Frame Extension

Front Cab Support

RH Floor Support
45 ft. lbs.
(61 Nm) 5
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)

5.9
BODY / STEERING / SUSPENSION
SEAT / HEAD REST
Seat Base / Seat Back / Head Rest Assembly
1. After attaching the frame to the vehicle, install the two headrests onto the frame using T-27 nuts. Install the bolts loosely, then
tighten to 4-6 ft. lbs. (5-8 Nm).
2. Make sure that the chimney nuts are centered in the mounting hole of the seat back base. Place the seat back cover over the
seat back base.
3. Using the illustrations for reference, install the seat back base and seat back cover onto the cab frame. NOTE: Be sure the
indented section of the seat back is positioned upward.
4. Insert T-27 nuts through the mounting strap and into the seat back. Install all of the T-27 nuts loosely, then tighten to 4-6 ft.
lbs. (5-8 Nm).
5. Install the bolts and nuts that secure the seat belt assemblies to the rear of the seat frame. Tighten to 38-42 ft. lbs. (51-57 Nm).
6. Check all nuts and bolts for proper torque and installation.

4-6 ft. lbs. Indented Section of Seat

T-27 (5-8 Nm)

Step 3

T-27 4-6 ft. lbs.

(5-8 Nm)
38-42 ft. lbs. 4
(51-57 Nm) 5

Seat
Step 2 Mounting
Strap
5 Chimney Nut

Seat Back Cushion

Bolt
Seat Back Base
Seat Back Cover

5.10
 BODY / STEERING / SUSPENSION
STEERING ASSEMBLY
Exploded View

Cap
25-30 ft. lbs.
(34-41 Nm) Nut
Rod End & Jam Nut
Steering Wheel
Bushing
Wave Washers
Screw & Lock Washer

15-22 ft. lbs.

(20-30 Nm)

Screw & Nut

Upper Steering Shaft
Tie Rod
Bolt
30 ft. lbs. Lower Steering Shaft
5
(41 Nm)

Boots
Tie Rod
Steering Box End Bolt

40-45 ft. lbs.

(54-61 Nm)

5.11
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. The stee-
upon reassembly
reassembly. ring post arm bolt (B) points up; the rod end
bolts (A) point down. Be sure inner rod ends
are placed between the steering post arms.
Apply LoctiteTM 242
25-30 ft. lbs.
(34-41 Nm)

15-22 ft. lbs.

(20-30 Nm)

30 ft. lbs.
(41 Nm)
12-14 ft. lbs.
(16-19 Nm)

30 ft. lbs. 40-45 ft. lbs.

(41 Nm) (54-61 Nm)
Front

30 ft. lbs.
(41 Nm)

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

5.12
 BODY / STEERING / SUSPENSION
FRONT A-ARM 8. Attach A-arm to hub strut assembly. Tighten ball joint nut
to 25 ft. lbs. (35 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
25 ft. lbs. (35 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 25 ft. lbs. 8 ft. lbs.

20-30 in. lbs. New Cotter Pin (35 Nm) (11 Nm)
(2-3.5 Nm)

5.13
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

18 ft. lbs.
Strut Bumper (24 Nm)
Wheel Speed Sensor
(Hall Effect Sensor)
Washer

Bearing

Retaining Ring

5.14
 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 Illustration on Page 5.14.
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.
4. Remove coil spring and collapse strut cartridge. • Thread bolt (K) with nut (J) onto ball joint stud as
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 15 ft. lbs. (21 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.

5.15
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 25 ft. lbs.
destroyed during removal. DO NOT reuse old
(35 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)

5.16
 BODY / STEERING / SUSPENSION
REAR A-ARM (4X4) 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).

5.17
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)

5.18
 BODY / STEERING / SUSPENSION
REAR STABILIZER BAR (4X4) 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

3. Remove the stabilizer bar nut from the lower A-arm on each 8.
if needed.
Reverse the procedure for installation. Torque the stabilizer
5
side. bolts to 16-18 ft.lbs. (21-25 Nm).

Inspect Bushings

16-18 ft. lbs.

(21-25 Nm)
Stabilizer Assembly

Inspect Bushings

5.19
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 Pivot Bolt and Nut Torque:
swing arm assembly. 150 ft. lbs. (75.9 Nm)
5. Remove the pivot bolt lock brackets (A), swing arm pivot
bolts (B), bolts swing arm bushings, lower swing arm and
Rear Shock Mount Bolt Torque:
rear axle. 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

5.20
 BODY / STEERING / SUSPENSION
REAR DRIVE AXLE AND SWINGARM 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

40 ft. lbs.
5
(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

5.21
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)

5.22
 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)

5.23
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

CAUTION recommended to have two people carefully
remove the box from the frame.
Safely support the box during the remainder of
the removal process. The box is not as stable Box Installation
with the shock removed.
1. If the shock was replaced, install the lower portion of the
4. Remove the screw (A) that secures the hinge pin to the shock to the frame and secure it with the pin and clip.
frame on both sides.

Lower
Shock Pin

2. Place the cargo box onto the frame. Align the hinges of the
5. Remove the hinge pin from both sides. box with the bracket on the frame.
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
6. Lower the box and secure the latch.
with the hinge pins removed.

5.24
 BODY / STEERING / SUSPENSION
STORAGE BOX 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).

Example of Decal Placement

Decal

5.25
 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
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 DEFLECTION (TENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
CLUTCH ALIGNMENT / OFFSET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
CLUTCH ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
CLUTCH OFFSET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
SPRING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
6
SHIFT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
ROLLER, PIN, AND THRUST WASHER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6.15
BUSHING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
MOVEABLE SHEAVE - BUSHING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
MOVEABLE SHEAVE - BUSHING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
CLUTCH COVER - BUSHING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
CLUTCH COVER - BUSHING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
CLUTCH DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22

6.1
CLUTCHING
SPECIAL TOOLS AND SUPPLIES PVT SYSTEM OVERVIEW
TOOL DESCRIPTION PART NUMBER General Operation
Clutch Puller 2870506
Clutch Holding Wrench 9314177 WARNING
Clutch Holding Fixture 2871358
Spider Nut Socket 2870338 All PVT maintenance or repairs should be
performed only by a certified Polaris Master
Drive Clutch Spider Removal and Service Dealer (MSD) technician who has
2870341
Install Tool received the proper training and understands
Driven Clutch Puller 2870913 the procedures outlined in this manual.
Roller Pin Tool 2870910 Because of the critical nature and precision
balance incorporated into the PVT
Clutch Bushing Replacement Tool Kit 2871226 components, it is absolutely essential that
Piston Pin Puller 2870386 no disassembly or repair be made without
Clutch Compression Tool 8700220 factory authorized special tools and
service procedures.
Clutch Bushing Replacement Tool Kit 2871025
Standard Clutch Alignment Tool PA-47346 The Polaris Variable Transmission (PVT) consists of three
major assemblies:
SPECIAL SUPPLIES PART NUMBER 1) The Drive Clutch
Loctite™ 680 2870584
2) The Driven Clutch
RTV Silicone Sealer 2870661
3) The Drive Belt
Loctite Gasket Remover 2870601
The internal components of the drive clutch and driven clutch
control engagement (initial vehicle movement), clutch upshift
and backshift. During the development of a Polaris ATV, the
TORQUE SPECIFICATIONS PVT system is matched first to the engine power curve; then to
average riding conditions and the vehicle’s intended usage.
PVT System Fastener Torques
Therefore, modifications or variations of components at random
are never recommended. Proper clutch setup and careful
TORQUE VALUE
ITEM inspection of existing components must be the primary
ft. lbs. (Nm)
objective when troubleshooting and tuning.
Drive Clutch Retaining Bolt 40 ft. lbs. (54 Nm)
Driven Clutch Retaining Bolt 17 ft. lbs. (23 Nm) Drive Clutch Operation
PVT Inner Cover Bolts 12 ft. lbs. (16 Nm)
Drive clutches primarily sense engine RPM. The two major
PVT Outer Cover Bolts 45-50 in. lbs (5-5.6 Nm) components which control its shifting function are the shift
Drive Clutch Spider 200 ft. lbs. (271 Nm) weights and the coil spring. Whenever engine RPM is
Drive Clutch Spider Lock Nut increased, centrifugal force is created, causing the shift
15 ft. lbs. (20.3 Nm)
(Plastic) weights to push against rollers on the moveable sheave, which
Drive Clutch Cover Plate 90 in. lbs. (10 Nm) 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
 CLUTCHING
Driven Clutch Operation Maintenance / Inspection
Driven clutches primarily sense torque, opening and closing Under normal operation the PVT system will provide years of
according to the forces applied to it from the drive belt and the trouble free operation. Periodic inspection and maintenance is
transmission input shaft. If the torque resistance at the trans- required 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 Tension, Drive to Driven Clutch Offset, Belt
drive belt increases, resulting in the belt rotating up toward the
Width. See these sections later in chapter for each model.
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. See these sections later in chapter.
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 illustration 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.

6.3
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 pulling or plowing 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
 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 6. Install the Drive Clutch Holder (PN 9314177) (A).

Some fasteners and procedures will vary. Refer to the 7. Remove drive clutch retaining bolt and remove drive clutch
appropriate parts manual for proper fasteners and fastener using the Drive Clutch Puller (PN 2870506) (B).
placement.

1. Remove seat. Drive Clutch Puller (PN 2870506)

2. Remove the LH storage box to gain access to PVT outer
cover. (See Chapter 5 for removal) Drive Clutch Holder (PN 9314177)
3. Remove PVT air outlet duct hose.
4. Remove outer PVT cover screws. 8. Remove the driven clutch retaining bolt and driven clutch.
5. Mark the drive belt direction of rotation and remove drive
belt. See “Drive Belt Removal”. Retaining Bolt

6.5
CLUTCHING
9. Use the Driven Clutch Puller (PN 2870913), (C) if Assembly
necessary.
1. Inspect PVT inner cover-to engine seal. Replace if cracked
C or damaged.
Apply RTV Silicone Here

Driven Clutch Puller (PN 2870913)

10. Remove driven clutch offset spacers from the transmission

input shaft.
Keep Spacer(s) In Order

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

3. Apply RTV silicone sealant to outside edge of inner cover-
to-engine seal, to ensure a water tight fit between the seal
and the cover. Surfaces must be clean to ensure adhesion
of silicone sealant.
4. Reinstall cover and tighten rear cover bolts just enough to
hold it in place.
11. Remove screws and retainer plate.
5. Fit lip of inner cover seal (A) to engine. Install seal retainer
plate and tighten screws securely.

B
C

Seal outer edge to cover

with RTV silicone sealant
12. Remove inner cover retaining bolts at rear of cover.
6. Torque rear inner cover bolts (B) to specification.
13. Remove cover along with foam seal on back of cover or 7. Install clutch offset spacers on transmission input shaft.
shaft.
Offset Spacer(s)

6.6
 CLUTCHING
8. Clean splines inside driven clutch and on the transmission DRIVE BELT
input shaft.
9. Apply a light film of grease to the splines on the shaft. Belt Deflection (Tension)
10. Install the driven clutch, washer, lock washer, and retaining
bolt. Torque to specification. Straight Edge
11. Clean end of taper on crankshaft and the taper bore inside
Deflection Measurement
drive clutch.
See Spec Below
12. Install drive clutch and torque retaining bolt to
specification.
13. Reinstall drive belt noting direction of rotation. If a new belt
is installed, install so numbers can be easily read.

Toward outer cover

PVT Cover Gasket Belt Deflection (Tension):

14. Replace PVT outer cover rubber gasket with the narrow 1 1/8” (2.9 cm) - 1 1/4” (3.2 cm)
side out (C).
15. Reinstall PVT outer cover and secure with screws Torque Pinch the sheaves lightly together with clamp to prevent the belt
to 45-50 in. lbs. (5-5.6 Nm). from being pushed into the driven sheave.
16. Install the PVT cover outlet duct and tighten the clamps.
1. Place a straight edge on top of the belt between drive and
driven clutch.
6
2. Push down on drive belt until it is lightly tensioned.
3. Measure belt deflection as shown in photo.

If belt deflection is out of specification, adjust by removing or

adding shims between the driven clutch sheaves.

• Remove shims to decrease belt deflection

• Add shims to increase belt deflection
See “Driven Clutch Service”.
At least one shim must remain between the inner and outer
sheave of the driven clutch. If proper belt deflection cannot be
obtained, measure drive belt width, length, and center distance
Inner Cover Bolt Torque (Rear): of drive and driven clutch, outlined in this section; all have an
12 ft. lbs. (16.6 Nm) effect on belt deflection.

Outer Cover Bolt Torque: Belt Removal

45-50 in.lbs. (5-5.6 Nm) 1. Remove outer PVT cover as described in PVT
Disassembly.
Driven Clutch Retaining Bolt Torque:
2. Mark the drive belt direction of rotation so that it can be
17 ft. lbs. (23.5 Nm)
installed in the same direction.

Drive Clutch Retaining Bolt Torque:

40 ft. lbs. (55 Nm)

6.7
CLUTCHING
NOTE: Belt is normally positioned so that part 1. Measure belt width and replace if worn severely.
numbers are easily read. Generally, belt should be replaced if clutches can no
longer be adjusted to provide proper belt deflection.

• The top edges have been trimmed on some drive belts.

It will be necessary to project the side profiles and
measure from corner to corner.

• Place a straight edge on each side of the drive belt.

• Place another straight edge on top of belt.

• Measure the distance where the side straight edges

intersect the top.

2. Inspect belt for loose cords, missing cogs, cracks,

abrasions, thin spots, or excessive wear. Replace if
necessary.
3. To remove drive belt, put transmission in gear, apply brake,
pull upward and rearward on belt to open driven clutch 3. Inspect belt for hour glassing (extreme circular wear in at
sheaves, pull out and down on belt to slip over the driven least one spot and on both sides of the belt). Hour glassing
clutch outer sheave. occurs when the drive train does not move and the drive
clutch engages the belt.

Center
Distance

Clutch Center Distance:

Belt Inspection 10” + .1/-.05 (254 + 2.5 / -1.3 mm)

Belt Outer Circumference

Belt Width New: 41.225” (104.71 cm)
Wear Limit: 41.413” (105.19 cm)

4. Measure belt length with a tape measure around the outer

circumference of the belt. Belts which measure longer than
nominal length may require driven shimming or engine
adjustment for a longer center distance to obtain proper belt
deflection. Belts which measure shorter than nominal
length may require driven shimming or a shorter center
distance. Remember, proper belt deflection is the desired
goal - not a specific center distance.
5. Replace belt if worn past the wear limit. Belts with thin
Belt Width spots, burn marks, etc., should be replaced to eliminate
New: 1.188” (3.02 cm) noise, vibration, or erratic PVT operation. See
Wear Limit: 1.157 (2.94 cm) Troubleshooting Chart at the end of this chapter for
possible causes.

6.8
 CLUTCHING
NOTE: If a new belt is installed, check belt CLUTCH ALIGNMENT / OFFSET
deflection.
Clutch Alignment
Clutch Alignment Tool
Belt Installation
1. Loop belt over the drive clutch and over top of the driven
sheave. (PN PA-47346)

1/8” +0/ - 1/16

3.2 mm +0 / -1.6 mm

2. While pushing down on top of belt, turn the back or 1. Remove belt and install the Clutch Alignment Tool as
moveable driven sheave clockwise. shown above.

Clutch Alignment Tool PN: PA-47346 6

2. With tool touching rear of driven clutch inner sheave, the
distance at point “A” should be 1/8".

If the distance is greater than 1/8" or less than 1/16", clutch

alignment must be adjusted as follows:

3. Remove drive and driven clutch. See “PVT System

Service, Disassembly.”
4. Remove PVT inner cover.
5. Loosen all engine mounts. Move front of engine to the right
or left slightly until alignment is correct.
3. The belt then should be able to be pushed down into and
6. Tighten engine mounts and verify alignment is correct.
between the sheaves.
Center line
Be sure to position belt so part number is easily read.

Measure offset above and below centerline

7. Measure belt deflection and measure offset both above and

below sheave centerlines. Adjust if necessary.

6.9
CLUTCHING
NOTE: On some models, minor adjustments can be
made by adding shims between the frame and front
lower left engine mount to increase the distance at
point “A”. If a shim is present, it can be removed to
decrease the distance at point “A”.

Shim Kit PN: 2200126

Clutch Offset
IMPORTANT: Inspect clutch alignment and center
distance before adjusting offset.

1. Install clutch alignment tool as shown.

Offset is correct when rear of tool contacts rear of inner sheave

with driven clutch pushed completely inward on shaft and bolt
torqued. Adjust offset by adding or removing spacer washers
between back of driven clutch and spacer as shown.

Clutch Alignment Tool

should contact rear edge
of driven clutch sheave

Driven Clutch Offset

To adjust, add or remove
washers from behind the
driven clutch

Spacer Washer PN: 7556401

6.10
 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.
2. To control the rate at which the drive belt moves
upward in the drive clutch sheaves. This is referred
to as drive clutch upshift.

There are other components which control upshift, but the

spring is one of the primary components in insuring
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 Secondary Clutch Springs

PART WIRE FREE LENGTH PART
COLOR CODE DESCRIPTION
NUMBER DIAMETER ± .125” NUMBER
7041021 Plain .157" 4.38" 7041198 Red
7041022 Black .140" 4.25" 7041782 Black 5-coil
7041063 Purple .168" 4.37" 7041501 Gold 6-coil
7041132 White .177" 2.92" 7041499 Silver
7041168 Green .177" 3.05" 7041296 Blue
7041157 Blue/Green .177" 2.53" 7041646 Silver/Blue
7042202 Blue/Gray .187" 2.55" 7043167 Black/Almond

6.11
CLUTCHING
Shift Weights
Shown below are the shift weights which have been designed for, or which may be used in 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.

6.12
 CLUTCHING
Exploded View

TeflonTM coated Drive Clutch DRIVE CLUTCH

Spring
brass bushing
Shift Weight

TeflonTM coated
brass bushing

Mark with permanent

marker before disassembly

Clutch Inspection 6
All PVT system maintenance repairs must be performed only by
an authorized Polaris service technician who has attended a WARNING
Polaris sponsored service training seminar and understands the
proper procedures as outlined in this manual. Because of the The clutch assembly is a precisely balanced
critical nature and precision balance incorporated into the PVT unit. Never replace parts with used parts from
system, it is absolutely essential that no attempt at disassembly another clutch assembly.
or repair be made without factory authorized special tools and
service procedures. 1. Remove shift weight bolts and weights. Inspect as shown.
The contact surface of the weight should be smooth and
free of dents or gall marks. Inspect the weight pivot bore
and pivot bolts for wear or galling. If weights or bolts are
worn or broken, replace in sets of three with new bolts.

Broken Worn Good

NOTE: A damaged shift weight is usually caused by

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

6.13
CLUTCHING
Button To Tower Clearance Inspection 3. Inspect cover bushing (A). The outer cover bushing is
manufactured with a Teflon™ coating. Bushing wear is
1. Inspect for any clearance between spider button to tower.
determined by the amount of Teflon™ remaining on the
If clearance exists, replace all buttons and inspect surface
bushing.
of towers. See “Spider Removal”

Cover Bushing Inspection:

Button to Tower Clearance:
Replace the cover bushing if more brass
000-.001”
than Teflon™ is visible on the bushing.
Refer to bushing replacement
2. Inspect sheave surfaces. Replace the entire service clutch
if worn, damaged or cracked.
in this chapter.

4. Inspect area on shaft where bushing rides for wear, galling,

Clutch Disassembly nicks, or scratches. Replace clutch assembly if worn or
1. Using a permanent marker, mark the cover, spider, damaged.
moveable and stationary sheaves, and steel post to the
Inspect Shaft
stationary sheave for reference. The X’s may not have
been in alignment before disassembly.

Mark

“X” Mark
5. Remove and inspect the clutch spring.

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

cover plate.

6.14
 CLUTCHING
Spider Removal Roller, Pin, and Thrust Washer Inspection
1. Install clutch in holding fixture and loosen the spider 1. Inspect all rollers, bushings and roller pins by pulling a flat
(counterclockwise) using spider removal tool. metal rod across the roller. Turn roller with your finger. If
you notice resistance, galling, or flat spots, replace rollers,
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.

Clutch Holding Fixture:

(PN 2871358)

Spider Removal Tool:

(PN 2870341)

It is important that the same number and thickness of washers

2. Rubber backed buttons can be used in all ATV clutches if
the hollow roller pin is changed to the solid roller pin.
6
are reinstalled beneath the spider during assembly. Be sure to
note the number and thickness of these washers. NOTE: The rubber side of the button is positioned
toward the solid roller pin.
Moveable Sheave Bushing Inspection
2. Inspect the Teflon™ coating on the moveable sheave
bushing.

TeflonTM

Moveable Sheave Bushing Inspection:

Replace the cover bushing if more brass

than Teflon is visible on the bushing.
Refer to bushing replacement
in this chapter.

6.15
CLUTCHING
Bushing Service 4. Insert the Number Two Adapter (#10) (PN 5020633) into
the bushing from belt side as shown. With towers pointing
*Clutch Bushing Replacement Tool Kit (PN 2871226) toward vise, slide sheave and bushing onto puller rod.
#10
#2 #3
#5

#9
#10
#8

Stamp Qty. Part Description Part # 5. Install the nut removed in Step 2 onto end of puller rod and
P-90 Drive/Driven Clutch hand tighten. Turn puller barrel to increase tension on
#2 1 5020628
Bushing Install Tool sheave if needed. Nut is left hand thread
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
#9 1 Adapter Reducer 5010279
Number Two Puller
#10 1 5020633
Adapter

Moveable Sheave - Bushing Removal

1. Install handle end of the Piston Pin Puller (PN 2870386) 6. Turn sheave and puller barrel together counterclockwise on
securely into bench vise and lightly grease puller threads. puller rod until bushing is removed.
7. Remove nut from puller rod and set aside.
Piston Pin Puller (PN 2870386) 8. Pull bushing removal tool and adapter from puller rod.
Remove bushing from tool and discard.
2. Remove nut from puller rod and set aside.
3. Install the Main Puller Adapter (#8) (PN 5020632) onto the Moveable Sheave - Bushing Installation
Piston Pin Puller (PN 2870386). 1. Place the Main Puller Adapter (#8) (PN 5020632) onto the
puller.
2. Apply Loctite™ 680 (PN 2870584) to the back side of new
Piston Pin Puller bushing. Push bushing into center of sheave on tower side
(PN 2870386) by hand.

Bushing (PN 3576504)

Loctite™ 680 (PN 2870584)
Main Puller Adaptor (#8)
(PN 5020632) 3. Insert the Clutch Bushing Installation Tool (#2) (PN
5020628) into center of sheave and with towers pointing
away from vise, slide sheave onto puller rod.

6.16
 CLUTCHING
4. Install nut on puller rod and hand tighten. Turn barrel to 4. Install nut onto puller rod and hand tighten. Turn puller
apply additional tension if needed. barrel to increase tension as needed.
5. Turn sheave and barrel together counterclockwise until
bushing is seated. 5. Turn clutch cover counterclockwise on puller rod until
bushing is removed.

6. Remove nut from puller rod and set aside.

7. Remove sheave from puller. 6. Remove nut from puller rod and set aside.
8. Remove installation tool.
7. Remove bushing and bushing removal tool from puller.
Clutch Cover - Bushing Removal Discard bushing.

1. Install the Main Puller Adapter (#8) (PN 5020632) onto

the Piston Pin Puller (PN 2870386). Clutch Cover - Bushing Installation 6
1. Apply Loctite™ 680 (PN 2870584) to the back side of new
bushing. Working from inside of cover, insert bushing and
Piston Pin Puller
(PN 2870386) bushing installation tool into center of clutch cover.

Main Puller Adaptor (#8)

(PN 5020632)

2. From outside of clutch cover, insert the Drive Cover

Bushing Remover (#3) (PN 5020629) into cover bushing.

#3
Bushing (PN 3576510)
Loctite™ 680 (PN 2870584)

2. With the Main Puller Adapter (#8) (PN 5020632) on the

puller, insert cover onto puller rod, placing outside of cover
toward vise.

3. Install nut on rod and hand tighten. Turn puller barrel to

apply more tension if needed.
3. With inside of cover toward vise, slide cover onto puller.

6.17
CLUTCHING
4. Turn clutch cover and barrel together counterclockwise on 3. Compress spider buttons for each tower and install spider,
puller rod until bushing is seated. 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.
4. Torque spider to specification using the holding fixture and
spider tool. Torque with smooth motion to avoid damage
to the stationary sheave. Refer to Page 6.2 for torque
specification.

CAUTION

Be sure the spider spacer washers are fully

seated in the recessed area in the spider.
Any misalignment will alter clutch balance.
Inverting the clutch while initially tightening the
5. Remove nut from puller rod and take installation tool and spider will help position the washers.
clutch cover off the rod.
5. Install shift weights using new lock nuts on the bolts.
Clutch Assembly
It is important that the same number and thickness of washers
are reinstalled beneath the spider during assembly. The
Teflon™ bushings are self-lubricating. Do not apply oil or
grease to the bushings

Reassemble the drive clutch in the following sequence. Be sure

the “X”, or the marks that were made earlier are aligned during
each phase of assembly

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.

1. Install moveable sheave onto fixed sheave.

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

Spider torque:
200 ft. lbs. (276 Nm)

Cover Screw Torque:

90 in. lbs. (10.4 Nm)
Spacer washers

6.18
 CLUTCHING
DRIVEN CLUTCH SERVICE
Exploded View

DRIVEN CLUTCH

Compression Spring

Spring Retainer
Secondary Stationary Sheave

Retaining Ring
Inner Spring Retainer
Moveable Inner Sheave
6

Clutch Disassembly / Inspection 2. With the snap ring (A) removed and spring pressure
relieved, remove the outer retainer (B), spring (C), and
inner retainer (D).
CAUTION
B
Wear eye protection when removing snap ring to
prevent serious personal injury.
Use caution when removing, the snap ring
pressure is loaded by the compression spring.

1. Apply and hold downward pressure on the outer spring

A C
retainer. Carefully remove the snap ring. Remember the
outer spring retainer contains strong spring pressure. D
Remove Snap Ring

B
A
D

Outer Spring Retainer C

6.19
CLUTCHING
3. Separate the two clutch sheaves. 6. Check the rollers in the stationary sheave for wear. If the
rollers are worn, a new driven clutch assembly may be
needed.

Check Rollers for Wear

4. Inspect the helix and inner spring retainer on the moveable
sheave.
7. Inspect the bearings inside the moveable sheave.
Inspect For Abnormal Wear
Inspect Bearings For Wear

5. Remove the inner spring retainer from the inner sheave.

Inspect for wear and replace as needed.
Moveable Sheave Bearing Inspection:
Inspect For Abnormal Wear
Replace the bearing if more brass than
Teflon™ is visible on the bearing.

8. Inspect the Teflon™ coating on the moveable sheave

bearings.

9. Inspect driven clutch sheave faces for wear or damage.

10. Clean and inspect splines on helix and transmission input

shaft.

11. Lube splines with a light film of grease. Do not lubricate

the bearings!

6.20
 CLUTCHING
Clutch Assembly 3. Install spring into inner retainer.

1. Install moveable inner spring retainer if removed. Do not 4. Install outer retainer on top of spring.
apply oil or grease to the bearings.

5. Compress the outer retainer and install the snap ring.

2. Align the “X” marks on each of the sheaves during
reassembly. Snap Ring

Reassemble Sheaves

6.21
CLUTCHING
TROUBLESHOOTING
Situation Probable Cause Remedy
-Wrong or broken drive clutch spring. -Replace with recommended spring.
Engine RPM below
specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine
range, although application.
engine is properly
tuned. -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).

-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 alignment offset.

-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.

6.22
 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.

PVT noise
-Belt worn or separated, thin spots, loose belt -Replace belt.
6
-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.

6.23
 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
DRIVE SHAFT / PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
DRIVESHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
CV JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
FRONT PROPSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
FRONT GEARCASE CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
AWD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
GEARCASE DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
GEARCASE REASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
BACKLASH PAD (THRUST PAD) ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
7
MID DRIVE HUB / BEARING CARRIER (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
HUB DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
MID DRIVE EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
MID DRIVE SHAFT (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
DISASSEMBLY / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
MID PROP SHAFT (6X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
MID DRIVE GEARCASE (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
MID GEARCASE EXPLODED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
REAR DRIVE (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36

7.1
FINAL DRIVE
REAR HUB / BEARING CARRIER (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
HUB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
HUB DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
REAR DRIVE SHAFT (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39
CV JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.42
REAR PROPSHAFT (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.43
REAR GEARCASE (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44
OPERATION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45
DIFFERENTIAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.46
DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.46
DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
DIFFERENTIAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51
DIFFERENTIAL EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.52
REAR AXLE / GEARCASE SERVICE (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.53
REAR AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.53
AXLE TUBE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.54
AXLE TUBE BEARING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55
GEARCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
GEARCASE / AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.57
GEARCASE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.60

7.2
 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

CAUTION
TORQUE SPECIFICATIONS Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
Wheel, Hub, and Spindle Torque Table
service procedure. Wear eye protection when
removing bearings and seals.
ITEM NUT TYPE SPECIFICATION
2. Check bearings for side play by grasping the tire / wheel
Aluminum Wheels
Lug Nut (1) 90 ft. lbs. (122 Nm) firmly and checking for movement. Grasp the top and
(Cast)
bottom of the tire. The tire should rotate smoothly without
Steel Wheels binding or rough spots.
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

#1 #2 7
Aluminum Wheel Steel Wheel 3. Remove wheel nuts, washers, and wheel.
(LE Models) (Standard Models)
90 ft. lbs. (122 Nm) 35 ft. lbs. (47 Nm)
4. Remove the two brake caliper attaching 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.

7.3
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® RC™ 680 to the outer circumference of the
Hubstrut Bearing Replacement new bearing race and carefully install the new bearing into
the strut housing.
Bearing Removal
1. Remove outer snap ring.

Apply Loctite® RC™ 680

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
 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
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
 FINAL DRIVE
DRIVE SHAFT / PROPSHAFT
Exploded View

RANGER Front Driveshaft

30g Grease Packet
CV Joint 30g Grease Packet Plunging Joint
Inner Clamps

Circlip
Boots Clamp
Clamp

RANGER Front Propshaft

Joint Kit
Grease Zerk O-ring

7
Shaft

Front Yoke Yoke

RANGER 4X4 & 6X6 Rear Propshaft

Spring Pin
O-ring O-ring
4X4 Grease Zerk
6X6

Cross & Bearing Kit

Cross & Bearing Kit Cross & Bearing Kit
Spring Pin

7.7
FINAL DRIVE
DRIVESHAFT / CV JOINT 2. Check bearings for side play by grasping tire / wheel firmly
and checking for movement. It should rotate smoothly
HANDLING TIPS without binding or rough spots.

Care should be exercised during driveshaft removal or when

servicing CV joints. Driveshaft components are precision parts.

Cleanliness and following these instructions is very important to

ensure proper shaft function and a normal service life.

• The complete driveshaft and joint should be handled by

getting hold of the interconnecting shaft to avoid
disassembly or potential damage to the driveshaft
joints.

• Over-angling of joints beyond their capacity could

result in boot or joint damage.

• Make sure surface-ground areas and splines of shaft are 3. Remove wheel nuts, washers, and wheel.
protected during handling to avoid damage.
4. Remove the two brake caliper attaching bolts.
• Do not allow boots to come into contact with sharp
CAUTION: Do not hang the caliper by the brake line. Use
edges or hot engine and exhaust components.
wire to hang the caliper to prevent possible damage to the
• The driveshaft is not to be used as a lever arm to brake line.
position other suspension components.

• Never use a hammer or sharp tools to remove or to

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.

FRONT DRIVE SHAFT

Removal 5. Remove the hub spindle nut.

1. Elevate front end and safely support machine under 6. Remove hub.
footrest / frame area.

CAUTION

Serious injury may result if machine tips or falls.

Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.

7.8
 FINAL DRIVE
7. Remove cotter pin and nut from lower A-arm ball joint. CV Joint / Boot Replacement
Remove lower A-arm from ball joint.
1. Remove wheel, brake caliper and wheel hub. Refer to
“Front Hub Removal” for procedure.

2. Remove cotter pin and castle nut from A-arm ball joint.

8. Pull strut assembly out while pivoting front drive shaft

downward until it clears strut assembly.

3. Disconnect A-arm from ball joint using a tie rod fork.

7
9. With short sharp jerks, remove drive shaft from front
gearcase.
4. Slide strut off end of drive shaft and tie it up out of the way
of the shaft.

5. Remove clamps from rubber boot using the proper boot

clamp pliers.

CV Boot Clamp Pliers:

Earless Type - 8700226

7.9
FINAL DRIVE
6. Remove the large end of the boot from the CV joint, slide
the boot back and separate the wheel spindle and CV joint FRONT DRIVE SHAFT
assembly from the axle shaft by pulling the shaft sharply
outward, away from the CV joint. It may be necessary to
tap the CV joint assembly outward with a soft faced
hammer.
Retaining Ring Boot Capacity
30 Grams

Joint Capacity*
30 Grams

Pull shaft to remove

from CV joint

7. Remove small clamp and boot from driveshaft.

If the vehicle has been operated with a damaged boot, the Joint Capacity**
CV joint grease may be contaminated. Inspect the grease 20 Grams
carefully for contamination, and clean the joint thoroughly
Boot Capacity
if necessary. Front drive axle outer boot replacement
requires 30g of grease. Inner boot replacement requires 20g 20 Grams
of grease. If either of the joints are cleaned, double the
amount of grease is required. Refer to information below
and illustration to the right.

Boot Replacement Grease Requirement:

Outer
CV Joint Grease - 30g PN 1350046 *CV joint capacity: 30g if boot is replaced only.
Inner Another 30g (60g total) if joint is cleaned.
Plunging Joint Grease - 20g PN 1350059
**Plunging joint capacity: 20g if boot is replaced
only. Another 20g (40g total) if joint is cleaned.
8. Before installing the new boot, remove all grease from the
boot area and shaft.

NOTE: It is very important to use the correct type

and quantity of grease by using the grease
contained in the boot kit. DO NOT use a substitute
grease and DO NOT overfill or underfill the CV joint.

9. Slide the new clamp and boot (small end first) over the
splined shaft, then slide (tap) the CV joint into the splines
of the axle. Install small boot clamp.

10. Add grease through large end of boot.

11. Position large end of boot on CV joint, purge excess air by

partially compressing axle into CV bell, lift one edge of
boot to let out excess air Secure the CV boot with clamp.

7.10
 FINAL DRIVE
Installation FRONT PROPSHAFT REMOVAL
1. Install new spring ring on drive shaft. Apply an anti-seize
compound to splines. Align splines of drive shaft with 1. Elevate front end and safely support machine under
front gearcase and install by lightly tapping on drive shaft footrest / frame area.
with rubber faced hammer.

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. Remove wheel nuts and wheel.

3. Remove cotter pin and nut from lower A-arm ball joint.
Remove lower A-arm from ball joint. (See below)

2. Install drive shaft in strut.

3. Install the lower A-arm onto the lower ball joint, torque nut
to 25 ft. lbs. (35 Nm) and install new cotter pin.

7
4. Use the Roll Pin Removal Tool (PN 2872608), to remove
the roll pin from prop shaft at the front housing. Slide prop
shaft back and away from front housing. Pull sharply
forward to remove from transmission shaft.

NOTE: The roll pin can also be accessed through

the hole in the skid plate shown in the photo below.
Cotter Pin 25 ft. lbs.
(35 Nm)

4. Install hub and tighten spindle nut to 70 ft. lbs. (95 Nm).

Front Spindle Nut Torque

70 ft. lbs. (95 Nm)

Roll Pin Removal Tool (PN 2872608)

7.11
FINAL DRIVE
NOTE: Remove the drive shaft floor cover to help 2. Support inner yoke as shown and drive outer yoke down
align the roll pin removal tool to the roll pin for (bearing cap out) with a soft face hammer.
removal. The drive shaft can be removed through
the floor covering.

3. Support U-joint in vise as shown and drive inner yoke down

to remove remaining bearing caps.

PROPSHAFT U-JOINT SERVICE

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.

7.12
 FINAL DRIVE
Assembly 4. Install outer yoke, aligning marks made before
disassembly.
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.

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.

2. Using a suitable arbor, fully seat bearing cap in one side.

Continually check for free movement of bearing cross as
bearing caps are assembled.

7. When installation is complete, yokes must pivot freely in

all directions without binding. If the joint is stiff or binding,
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.

7.13
FINAL DRIVE
FRONT GEARCASE
CENTRALIZED HILLIARD CAUTION

AWD Operation If the rear wheels are spinning, release the

throttle before turning the AWD switch on.
Engaging Front Gearcase: The AWD switch may be turned on If AWD is engaged while the wheels are
or off while the vehicle is moving. Initially, the vehicle’s spinning, severe drive shaft and clutch
electronic system will not enable the AWD until the engine RPM damage could result.
is below 3100. Once enabled, the AWD remains while the front
gearcase is moving, it will not disengage until the rear wheels Roller Cage and Roller’s Rotate Inward and Grip the Output hub
regain traction. for AWD Engagement

Engage the AWD switch before getting into conditions where Output Hub Rollers
the front wheel drive may be needed. If the rear wheels are
spinning , release the throttle before switching to AWD.

CAUTION

Switching to AWD while the rear wheels are

spinning may cause severe drive shaft and
gearcase damage. Always switch to AWD while
the rear wheels have traction or are at rest. Roller Cage
& Bearings
Normal Operation: With the AWD switch off the vehicle
drives only the rear wheels (2 wheel drive). When the AWD
Disengagement: As the front and rear wheels gain traction,
switch is activated it engages the Hilliard, locking both front
rotating very close to the same speed, the front wheels
axles into All Wheel Drive.
“overdrive” the output hubs and the rollers are forced outward,
Roller Cage disengaging the AWD. The vehicle is now back to rear wheel
drive until the next loss of traction.

Armature plate design may

differ from what is shown

Output Hub

Armature
Plate Coil Cover

4X4 Engagement: When the AWD switch is activated, a 12

VDC current charges the central coil which creates a magnetic
field. This magnetic field attracts an armature plate keyed to a
roller cage that contains 14 rollers and roller cam. The difference
in rpm by input shaft and front axles the forces the rollers up the
external cam. The rollers engage themselves to the output hubs
that link both front axles, resulting in True All Wheel Drive.

7.14
 FINAL DRIVE
Centralized Hilliard Exploded View

1
2
3
17 ft. lbs.
4 (23 Nm)

9 15
5
6 11 14
7 8
10 20
12
15 6
13
17 ft. lbs.
(23 Nm)
7
14

26 24
16
25
18 17
23 19
22
10 ft. lbs. 14
(14 Nm)
21
8-30 ft. lbs.
(11-41 Nm)

7
REF# DESCRIPTION QTY REF# DESCRIPTION QTY

1 Set Screw 1 14 Seal Kit (Includes O-Rings and Seals) 1

2 Cover Plate Asm. 1 15 Screw 11
3 Thrust Button 1 16 Input Cover 1
4 Thrust Plate 1 17 Roller Ball Bearing 1
5 Armature Plate Shim 1 18 Pinion Shaft, 11T 1
6 Roller Ball Bearing 2 19 Bushing 1
7 Race / Output Hub Asm. 1 20 Gearcase LH 1
8 Dowel Pin 1 21 Oil Fill Plug 1
9 Clutch Housing / Ring Gear 1 22 Drain Plug Asm. (Includes Plug and Washer) 1
10 Roll Cage Asm (Includes H-Springs) 1 23 Roller Thrust Needle Bearing 1
11 Rollers 14 24 Clutch Asm. 1
12 Bushing 1 25 Internal Retaining Ring 1
13 Vent Fitting 1 26 Armature Plate 1

7.15
FINAL DRIVE
AWD Diagnosis
Symptom: AWD Will Not Engage. Possible
Wear Ring on
1. Check the gearcase coil resistance. To test the gearcase Armature Plate
coil resistance. Test between the Grey & Brown / White
wires. The gearcase coils should measure between 22.8
ohms and 25.2 ohms. OK Condition

Front Gearcase Coil Resistance:

22.8--25.2 Ohms

2. Check the minimum battery voltage at the Gray & Brown

/ White wires that feed the hub coil voltage. There should
be a minimum of 11.0-12.0 Volts present for proper
operation.
Bad Condition
(Wear from coil
on armature plate)

4. 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
should be seated below the U-shaped insert. The U-shaped
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
the coil will not be strong enough to engage the AWD
system. If this is the cause order a new Plate Cover
Assembly.

Gearcase Cover
3. Inspect the armature plate for a consistent wear pattern.
There should one or two distinct wear bands (one band
inside the other). If only one band of wear is present (or if
Coil
there is wear between the two bands, inspect the coil area
as indicated in Step 4. A band with an interrupted wear mark
may indicate a warped plate, which may cause intermittent
operation. See the following illustrations.

U-shaped insert
Armature Plate Side cutaway view of
Centralized Hilliard cover
Armature plate design may
differ from what is shown

Check for wear bands

7.16
 FINAL DRIVE
5. Inspect the rollers for nics and scratches. The rollers must 8. The front gearcase and drive shafts can be accessed from
slide up and down and in and out freely within the roll cage both sides of the vehicle and limited access from the top.
sliding surfaces.

Rollers

Top View - From under hood

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.
7
4. Remove right wheel nuts and wheel. 10. Remove the roll pin from the front drive shaft.Remove the
5. Remove cotter pin, lower ball joint nut, and A-arm from front drive shaft from the front gearcase splines.
ball joint. 11. Remove bolts securing bottom of gearcase to frame.
Remove vent line. Remove gearcase from right side of
frame.

6. Repeat Step 1 through Step 5 on the opposite side. Remove 4 Bolts

7. Pull each axle out from the front gearcase, refer to the
"FRONT DRIVE SHAFT REMOVAL" procedure earlier
in this chapter.

7.17
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
between 22.8 ohms and 25.2 ohms. B

4. Remove output shaft assembly

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.

7.18
 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.

J
7
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

7.19
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
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement side to side.
O
M
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)

7.20
 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

C
7
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.

7.21
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 is loctited into place. 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.
Re-apply red loctite onto the bottom screw threads.
Armature plate tabs
fit into roll cage slots

Armature plate design may

differ from what is shown

NOTE: This photo is for reference only, the armature

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 4. Turn the screw in until it is lightly seated, then turn the
the cover surface. If the O-ring is twisted fluid screw out 1/4 turn.
leakage may occur. 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)

7.22
 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)

Front Housing Mount Bolt Toque: 4. Remove the hub nut, domed washer, and flat washer.
30 ft. lbs. (41 Nm)

3. Add the proper lubricant to the front gearcase. Check drain 7

plug for proper torque. Refer to Chapter 2 for fluid fill and
change information.

Premium Front Drive Hub Fluid

(PN 2871654)
Hub Nut & Washers
Front Housing Capacity
5 fl. oz. (148 ml)

5. Remove the hub from the axle shaft.

7.23
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.
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.

7.24
 FINAL DRIVE
2. Start bearing (B) in housing (A). Hub Installation
B 1. Install hub carrier to lower A-arm. Hand tighten lower A-
arm bolt.

A 2. Slide mid drive shaft through the hub carrier.

3. Press bearing into place until outer race bottoms on

housing.

CAUTION
3. Install upper A-arm bolt and torque both upper and lower
Use an arbor and press only on the outer race, bolts.
as bearing damage may occur.

Lower Control Arm Bolt Torque:

35 ft. lbs. (47 Nm)

Upper Control Arm Bolt Torque:

35 ft. lbs. (47 Nm)

4. Pull drive shaft outward and install hub onto driveshaft

7
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)

4. Install snap ring into groove.

Out
Cone
Washer

7.25
FINAL DRIVE
6. Install the castle nut (C), wheel, and wheel nuts. 7. Remove jackstand and torque mid hub nut to 110 ft. lbs.
(149 Nm) and wheel nuts to 35 ft. lbs. (47 Nm).

Mid Hub Nut Torque:

110 ft. lbs. (149 Nm)

Mid Wheel Nut Torque

35 ft. lbs. (47 Nm)

A B C
8. Install a new cotter pin. Tighten nut slightly to align holes
if required.

9. Install hub cap.

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

7.26
 FINAL DRIVE
MID DRIVE SHAFT (6X6) Installation
1. Apply Anti-Seize compound onto the mid gearcase output
Removal
shaft splines. Slide mid drive shaft (A) onto the mid
1. Repeat Steps 1-7 in the “Mid Drive Hub / Bearing Carrier gearcase output shaft (B).
Removal” section.
B
2. Slide the middle axle out of the bearing carrier by pulling A
the bearing carrier assembly outward and down.

2. Install the outer end of the mid drive shaft into the hub
carrier (C).

3. Pull the middle axle straight out from the frame. The axle
will slide off the mid gearcase splined output shaft.

7
3. Lift hub carrier into place and install bolt to upper control
arm. Torque bolt to 35 ft. lbs. (47 Nm).
Upper Bolt

Disassembly / Assembly
NOTE: For mid drive shaft service information, see
“REAR DRIVE SHAFT (4X4) - CV Joint / Boot
Replacement”

4. Pull drive shaft outward and install hub onto driveshaft

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)

7.27
FINAL DRIVE
6. Install the castle nut (C), wheel, and wheel nuts. 8. Install a new cotter pin. Tighten nut slightly to align holes
if required.

9. Install hub cap.

MID PROP SHAFT (6X6)

Removal
1. Use the Roll Pin Removal Tool (PN 2872608), to remove
the roll pin from prop shaft at rear of transmission.
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).

Mid Hub Nut Torque:

110 ft. lbs. (149 Nm)

Mid Wheel Nut Torque

35 ft. lbs. (47 Nm)

2. The transmission or middle differential mounting will have

to be loosened to allow the propshaft to slide off of the
transmission output shaft.

MID DRIVE GEARCASE (6X6)

Gearcase Removal

PIN

MID DRIVE GEARCASE

REAR DRIVE SHAFT

PIN

MID DRIVE SHAFT

TRANSMISSION
COUPLER

MOUNTING BOLTS
& WASHERS

7.28
 FINAL DRIVE
NOTE: To ease the removal of the middle axle Gearcase Disassembly
gearcase, remove the box from the frame. Refer to
the Box Removal Procedure in Chapter 5. 1. Drain the oil from the mid drive gearcase. Properly dispose
of the oil.
1. Remove the vent line clamp and vent line (A) from the top
of the mid drive gearcase (B). 2. Remove the output cover bolts (A) and the output cover (B).

A B B

D C
D

2. Remove the mid drive shafts (D). Repeat steps 1-3 in the 3. Remove the O-ring (C) and two shims (D) from the output
“Mid Drive Shaft Removal” section. cover.

3. Remove the parking brake caliper (C), refer to Chapter 9, NOTE: The two shims are different of thickness. Be
“Parking Brake Caliper Service - Caliper Removal”. sure to note the placement of the shims as they are
removed from the output cover for later installation.
4. Use the Roll Pin Removal Tool (PN 2872608) to remove
the roll pins that secure the rear prop shaft and middle prop
C
shaft to the mid drive gearcase.

Roll Pin Removal Tool

2872608 7

NOTE: If the rear drive shaft does not slide off the
mid gearcase output shaft, compress the rear
suspension and the rear driveshaft will move back.

5. Remove the four bolts and washers that secure the gearcase
to the frame. The bolts are accessible through the skid plate
on the bottom of the frame.

6. With the drive shafts removed from the mid gearcase, lift
the gearcase out of the frame.

7.29
FINAL DRIVE
4. Remove the output shaft and ring gear assembly (E) from 7. Remove the input cover bolts (I). Remove the input cover
the gearcase. Inspect the ring gear for abnormal wear, (H) and pinion gear assembly from the gearcase.
broken, or chipped teeth. Inspect and spin the bearings (F),
the bearings should rotate smoothly.

I
H

F F
8. Remove the pinion gear assembly (J) from the front cover
(H). If the pinion gear does not come loose from the front
5. Remove the wave spring (G) from the gearcase assembly. 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

4 3
6. Remove the bolts from the input cover (H).

7.30
 FINAL DRIVE
9. Inspect the pinion gear (K) and 26T output gear (L) for nics 12. Carefully pull the output thru shaft (Q) through the
or uneven wear. Inspect the bearing (M), the bearing should gearcase.
spin smoothly. Replace the parts as needed.
K L M

Q
10. Remove the rear output seal (N).
N 13. Remove the retaining ring (O), shim (P), and input gear (R)
from the output shaft (Q). Inspect the input gear for
abnormal wear, broken, or chipped teeth.

P
O
7
11. Remove the retaining ring (O) and shim (P) from the rear 14. Inspect the two flange bearings (S) inside the gearcase.
output thru shaft. Inspect the pinion shaft bushing (T) for wear that is inside
the gearcase.
O

P S

7.31
FINAL DRIVE
2. Install the 26T input gear (D), shim (E), and a new retaining
ring (F) onto the output shaft.

E
S

D
F
15. Replace all O-ring, seals, and worn components. Replace
the seals as shown in the photo. 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).
Pinion Shaft Assembly
Step Of Gear

I
G
Gearcase Assembly H
1. Install the shim (A) and a new retaining ring (B) onto the
output end of the output shaft (C). Install the output thru Pinion Shaft Assembly Assembled
shaft into the gearcase.

A&B 4. Install the pinion shaft assembly into the input cover.

NOTE: Alignment of the pinion shaft bearing into the

input cover maybe be difficult. If needed, use the
following steps to aid in installation (refer to photo
on right):
7.32
 FINAL DRIVE
• Hold the pinion gear assembly 7. Install the wave spring (L) into the gearcase assembly. Be
sure the wave spring is fully seated into the bearing cup of
• Use a rubber mallet to lightly tap on the front of the
the gearcase.
input cover, around the bearing cup

• Tap the front cover in an X pattern (follow the pattern in L

the photo on the right), until the pinion gear assembly
comes loose

3
1

4 2

8. Install the output shaft and ring gear into the gearcase. Be
sure the 10T input pinion gear and the output pinion gear
mesh smoothly.

5. Apply Polaris Crankcase Sealant (PN 2871557) to the

inside surface of the input cover (J).

9. Install the shims (M) into the output cover (N). Install the
Sealant
shims in the order that they were removed during the
disassembly process.

6. Install the pinion shaft assembly and input cover onto the M
gearcase. Install the input cover bolts (K). Torque the bolts
to 18 - 23 ft. lbs. (24 - 31 Nm).

7.33
FINAL DRIVE
10. Install a new O-ring (O) onto the output cover.
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)

O

Gearcase Installation
11. Carefully install the output cover onto the gearcase. 1. Place the middle gearcase in the frame assembly.
Install the output cover bolts. Torque the bolts to 18 - 23 A B
ft. lbs. (24 - 31 Nm).

D C
D

2. Attach the mid and rear prop shafts to the mid gearcase, but
do not install the new roll pins yet.

3. Install the four middle drive gearcase bolts. Torque the

Input Cover Bolt Torque: bolts to 30 ft. lbs. (41 Nm) in a cross pattern.
18 - 23 ft. lbs. (24 - 31 Nm) 4. Install a new roll pins into the mid and rear prop shafts and
middle gearcase input and rear output shafts.
12. Remove the fill plug (P) and fill the mid gearcase with 6.75 5. Install the mid drive shafts (D) onto the mid gearcase (B).
oz. (200 ml) of Polaris ATV Angle Drive Fluid
(PN 2871653). Torque the fill plug to 14 ft. lbs. (19 Nm). 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,

P “Parking Brake Caliper Service - Caliper Installation”

7.34
 FINAL DRIVE
Mid Gearcase Exploded

18-23 ft. lbs.

(24-31 Nm) 30 ft. lbs.
18-23 ft. lbs. (41 Nm)
(24-31 Nm)

7
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

7.35
FINAL DRIVE
REAR DRIVE (4X4)
Exploded View

Rear Gearcase 30 ft. lbs.

(41 Nm)

Coil
A-arm bolts

Shaft
Bushings
Shock
Upper A-arm

Bushings
Rear Drive Axle 30 ft. lbs.
(41 Nm)
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

REAR HUB / BEARING CARRIER (4X4)

Hub Inspection Hub Removal
1. Support machine securely with rear wheels elevated. 1. Elevate rear end and safely support machine under main
frame area.
2. Grasp wheel / hub and check for movement.
2. Check bearings for side play by grasping the tire / wheel
3. If movement is detected, inspect hub, hub nut torque and
firmly and checking for movement. Grasp the top and
bearing condition and correct as necessary.
bottom of the tire. The tire should rotate smoothly without
binding or rough spots.
CAUTION
3. Remove wheel nuts and wheel.
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.

7.36
 FINAL DRIVE
4. Remove the two brake caliper attaching bolts. 7. Remove the upper and lower control arm bolts from the rear
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.

5. Remove hub cap, cotter pin, front spindle nut, and washer.
Hub Disassembly
1. Remove outer snap ring (A).

7
6. Slide the rear hub from the rear drive axle.

2. From the back side, tap on the outer bearing race with a drift
punch in the reliefs as shown.
NOTE: 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.

7.37
FINAL DRIVE
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.

Hub Assembly
4. Install snap ring into groove.
1. Support bottom of bearing carrier housing. (A) Bearing
Carrier Housing; (B) Bearing; (C) Snap Ring
Hub Installation
A 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
B with the lower control arm bolt.

3. With the driveshaft placed in the wheel bearing carrier,

align the carrier with the top control arm. Secure with the
C upper control arm bolt.

NOTE: The lower shock bolt may need to be

removed to allow the upper A-arm to move more
freely.
2. Start bearing (B) in housing (A).

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.

7.38
 FINAL DRIVE
4. Torque the top and bottom A-arm bolts as shown in the REAR DRIVE SHAFT (4X4)
photo.
Removal
1. Repeat all of the steps in 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.

30 ft. lbs.
(41 Nm)

5. Install the hub assembly onto the rear drive axle.

6. Install the washer with domed side out. Install the spindle
retainer nut.

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.

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. Inspect the axle splines and CV boots for any damage.

110 ft. lbs

(149 Nm)

7.39
FINAL DRIVE
CV Joint / Boot Replacement NOTE: When replacing a damaged boot, check the
grease for contamination by rubbing it between two
1. Remove clamps from rubber boot(s) using the CV Boot fingers. A gritty feeling indicates contamination. If
Clamp Pliers (PN 8700226) (A). the grease is not contaminated, the boot can be
replaced without cleaning the CV joint. Use the
A recommended amount of grease for boot
replacement only.

4. Remove boot from the shaft.

5. Thoroughly clean and dry the CV joint and inspect ball
tracks and cages for wear, cracks or other damage.
NOTE: Shiny areas in ball tracks and on the cage
spheres are normal. Do not replace CV joints
because parts have polished surfaces. Replace CV
joint only if components are cracked, broken, worn
or otherwise unserviceable.
CV Boot Clamp Pliers:
6. Place a new snap ring in the groove of the CV joint inner
Earless Type - 8700226
hub, with tabs facing the shaft as shown.

2. Remove the large end of the boot from the CV joint and
slide the boot back. Tabs face the shaft
Snap ring located in recessed area

Snap ring

NOTE: Photo above is shown without shaft for

clarity. Wipe grease away from recess in CV joint
inner hub to locate snap ring

3. Open the snap ring using a snap ring pliers or small needle
nose pliers. Tap CV housing off shaft with a soft faced
hammer while holding snap ring open.
Spread ends of snap ring
to remove joint from shaft

7. Before you assemble the CV joint, slide the new boot (small
end first) and clamp over the splined shaft.

7.40
 FINAL DRIVE
8. Refit CV joint on the shaft by tapping with a plastic hammer 11. While pulling out on the CV shaft, fully extend the CV joint
on the joint housing. Take care not to damage threads on and slide a straight O-ring pick or a small slotted screw
the outboard CV joint. The joint is fully assembled when driver between the small end of the boot and the shaft. This
the snap ring is located in the groove on 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
Tap joint onto shaft
remove your instrument, be sure the small end of the boot
is in its correct location on the axle.

NOTE: It is very important to use the correct type

and quantity of grease by using the grease
contained in the boot kit. DO NOT use a substitute
grease and DO NOT overfill or underfill the CV joint. 12. Install the small clamp on the boot.

9. Fill the CV joint and/or boot with the recommended type REAR SHAFT
and amount of grease. Rear drive shaft inner or outer boot
replacement requires 50g of grease if the CV joints were not CV Joint
disassembled. Joint Capacity*
NOTE: If the joints were disassembled and cleaned, 25 Grams
refer to the call-out below or Figure 7-31 for the Retaining
correct amount of grease required. Ring

Large Clamp 7
Boot Replacement Grease Requirement: Grease
PN 1350047
Inner Plunging Joint Grease - PN 1350047 Boot Capacity
50 Grams Boot
Only boot replacement - 50g
Boot replacement w/joint cleaning - 100g
Small Clamp
Outer CV Joint Grease - PN 1350047
Boot Capacity
Only boot replacement - 50g 50 Grams Boot
Boot replacement w/joint cleaning - 75g
Grease
PN 1350047
10. Remove excess grease from the CV joint's external surfaces
and position the boot over the housing, making sure the Large Clamp
boot is seated in the groove. Position clamp over the large
boot end and make sure clamp tabs are located in slots. Retaining
Ring
NOTE: Before tightening boot clamp on inboard
joint, make sure any air pressure which may have
built up in joint boot has been released. The air
should be released after the plunging joint has been Joint Capacity* Plunging Joint
centered properly. Tighten boot clamp using boot 50 Grams
clamp pliers. Spring Ring

Figure 7-31

7.41
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 driveshaft splines (both cotter pin and hub cap.
ends).

Apply Anti-Seize

New Circlip

Rear Hub Nut Torque:

3. Reinstall the rear driveshaft 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 driveshaft 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

7.42
 FINAL DRIVE
REAR PROPSHAFT (4X4) 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 7
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.

7.43
FINAL DRIVE
REAR GEARCASE (4X4) When the clutch gear is unlocked the rear axle becomes a
differential. When it’s locked it becomes a solid rear axle
General Operation increasing traction. (See images below)

The RANGER rear gearcase has three traction operational Shift Yoke Clutch Gear
modes: AWD, Differential Lock, and Differential Unlock.
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
Shift yoke slides clutch gear to
lock and unlock the rear differential
Differential - Locked

Clutch Gear
Differential - Unlocked

When the “Unlocked” option is chosen on the selector, the rear

differential becomes unlocked for tighter turns. An electrical
solenoid mounted on the rear axle housing actuates the shift
yoke and slides the clutch gear to lock and unlock the rear axle
housing.
When switch position is set
to “Unlock”, the solenoid is Locked Mode
powered and the Clutch Gear
plunger extends IRS Axle
to disengage the Locked
clutch gear and Locked
unlock the
axle housing.

Unlocked Mode
Clutch Gear
IRS Axle
Unlocked

7.44
 FINAL DRIVE
Operation Modes

Differential Locked Differential Unlocked

Both rear wheels rotate at same speed. Rear wheels can rotate at different
speeds. (Allow for sharper turning)

AWD Mode
7

Rear Wheels rotate as same speed.

Front Wheels rotate as same speed when AWD activated.

7.45
FINAL DRIVE
Differential Removal Differential Disassembly
1. Follow “Rear Drive Shaft Removal” procedure to remove IMPORTANT: The pinion gear assembly is NOT
the drive axles 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. Remove the four bolts that secure the rear differential Pinion and ring gear shimming information is NOT
brackets to the frame. provided due to OEM manufacturing requirements.

1. Drain and properly dispose of used gearcase fluid.

2. If necessary, remove the rear differential mount brackets
from the rear differential.

Remove 2 bolts from each side

4. Carefully pull the rear differential case assembly from the

frame. Let the rear propshaft slide off of the rear
differential.
3. Remove the bolts that secure the carrier cover (A) bolts to
the carrier housing (B).

Remove Cover Bolts

7.46
 FINAL DRIVE
4. Remove the differential assembly (C) from the housing. 6. Remove the differential lock solenoid (F) from the carrier
Inspect the bevel gear teeth for chipped, worn, or broken housing by turning the solenoid counterclockwise.
teeth.
F
C

7. Inspect the tip of the solenoid (F) for wear. If the tip of the
solenoid is flat the solenoid may need to be replaced.

5. Remove the bearings from each side of the carrier assembly

(C). Inspect the bearings (D) for smoothness and wear. Be F
sure to keep the shims (E) together for reassembly.
C

D 7
E
8. Remove the clutch gear (G) from the carrier cover (B) and
shift yoke (H).

C G

J
H
K

D E

7.47
FINAL DRIVE
9. Inspect the shift yoke (H), shift lever (J), and shift lever 12. Thread the bolt into the shift yoke pivot shaft (L).
return spring (K).

K J

13. Carefully pull the shift yoke pivot shaft (L) out of the carrier
cover.

10. Remove the set screw.

L

14. Remove the shift lever (M) and springs (N) from the shift
yoke (H). Inspect the components for wear and replace as
11. Remove the shift yoke pivot shaft (L) Use a 1/4 in.- 20 needed.
coarse thread bolt approximately 3 in. long to thread into
the pivot shaft.
H
M

7.48
 FINAL DRIVE
15. Remove the pinion shaft seal (P) using a seal puller. 2. Install the original shims (A) onto the differential assembly
(B) on both sides. Install the bearings (C), replace with new
bearings if needed.

C
A

16. SPECIAL NOTE: The Pinion assembly is NOT intended

to be disassembled, as it requires special OEM tooling in
order to properly assemble the pinion assembly. If there is
any damage to the pinion gear, bearings or case, the
B
assembly must be replaced.

C A

7
3. Install the differential assembly into the carrier housing.

Differential Assembly
1. Replace all O-rings, seals, and worn components. Replace
the O-ring and oil seal on the carrier housing.

NOTE: Grease all seals and O-rings with Polaris All

Season Grease (PN 2871322) upon assembly.

4. Install the spring lever and shift yoke into the carrier cover,
if previously removed.

7.49
FINAL DRIVE
5. Assemble the shift yoke (D), shift lever (G), spring lever 8. Install the new lightly greased O-ring (K) onto the carrier
(F), and return spring (E). cover.
H
Carrier Cover

F
E G D
K

6. Use the bolt that was used to remove the shift yoke pivot
shaft (H) to reinsert the shaft into the carrier cover. Place 9. Install the carrier cover bolts. Tighten and torque the bolts
the shift yoke assembly into the carrier cover and secure in a criss cross pattern to 25-35 ft.lbs. (34-48 Nm).
with the shift yoke pivot shaft (H).
25-35 ft. lbs.
Install Shift Yoke Assembly (34-48 Nm)

10. Install the rear differential mount brackets from the rear
7. Install the differential lock solenoid into the carrier cover. differential onto the rear differential. Torque the bracket to
Torque solenoid to 30-40 ft. lbs. (41-54 Nm). differential bolts to 26-33 ft.lbs. (35-45 Nm)

30-40 ft. lbs.

(41-54 Nm)

26-33 ft. lbs. (35-45 Nm)

Bracket to Differential

7.50
 FINAL DRIVE
Differential Installation
1. Place the differential assembly into the frame. Torque the
bracket to frame bolts to 38-42 ft.lbs. (35-45 Nm).

Bracket to Frame
38-42 ft. lbs. (35-45 Nm)

2. Slide the rear propshaft onto the rear differential input shaft.

3. Reverse the removal procedure for the rest of the

installation.

4. 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 ft.lbs. (54 Nm).

Fill Plug
40 ft. lbs. Drain Plug
(54 Nm) 30-45 in. lbs.
(3-5 Nm)

Rear Gearcase capacity:

18 fl. oz. (532 ml)

or
0.75” (1.9 cm) below bottom of fill plug
hole threads - See Chapter 2

7.51
FINAL DRIVE
Differential Exploded View
30-45 in. lbs. 8 9 10
(3-5 Nm) 11 40 ft. lbs.
(54 Nm)
7

20
5 12
4 6
3 13 12
25-35 ft. lbs.
(34-48 Nm)
1 2 14 19
21
18
15 16
37 22
17
38
23
36 24
31 25-35 ft. lbs.
35 (34-48 Nm)
3
4
25
34
29 26
27
33 32
30 30-40 ft. lbs.
(41-52 Nm) 28

REF# DESCRIPTION QTY REF# DESCRIPTION QTY

1 Pinion Oil Seal 1 20 Flanged Hex Nut 3
2 Pinion Nut 1 21 Flanged Hex Bolt 3
3 Pinion Bearing Cone 2 22 Vent Tube 1
4 Pinion Bearing Cup 2 23 Differential Case Half Cover 1
5 Pinion Spacer AR 24 Flanged Hex Bolt 6
6 Pinion Bearing Spacer 1 25 Clutch Gear 1
7 Drain Plug 1 26 Shift Yoke 1
8 Oil Seal Shaft 1 27 Shift Spring Lever 1
9 O-Ring 1 28 Shift Lever 1
10 Carrier Half Cover 1 29 Shift Return Spring 2
11 Fill / Check Plug 1 30 Diff. Lock Solenoid 1
12 Gear-Side, Differential 2 31 Hex Bolt 8
13 Gear-Pinion, Mate, Differential 2 32 Differential Case Half 1
14 Differential Case Half Cover 1 33 Differential Cross-Pin 1
15 Differential Bearing Spacer AR 34 Differential Roll-Pin 1
16 Tapered Roller Bearing 1 35 Pinion Spacer AR
17 O-Ring, Housing Halves 1 36 Differential Bearing Spacer AR
18 Shift Yoke Pivot Shaft 1 37 Differential Bearing Cup 1
19 Set Screw 1 38 Differential Bearing Cone 1

7.52
 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

7
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.

7.53
FINAL DRIVE
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.

7.54
 FINAL DRIVE
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. 7

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.

7.55
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. Remove the pinion shaft from the differential. Inspect for

abnormal wear, broken, or chipped teeth.

2. Install the pinion shaft into the differential housing.

7.56
 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
6. Install a new O-ring onto the lip of the gearcase housing. side of the gearcase. Do not torque the bolts.

7.57
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
driveshaft 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).

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)

7.58
 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.

7
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.

7.59
FINAL DRIVE
Gearcase Exploded View

26 ft. lbs.
(35 Nm)

30 ft. lbs.
(41 Nm)

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

7.60
 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 VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
EXPLODED VIEW (4X4, 6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16

8.1
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 15.2 oz. Installation
Lubricant / Amount (450 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
 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.

NOTE: On the 4x4 & 6x6 transmission the front

Neutral Position output shaft yolk slides off during the transmission
removal.
4x4 Shown

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)

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
Outside Jam Nut
top of the transmission.

3. After turning the outside jam nut 1 1/2 turns. Hold the Vent Tube & Air Intake Hose
outside jam nut with a wrench and tighten the inside jam
8
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
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
 TRANSMISSION
Transmission Disassembly 5. Mark the detent gear with a white pen. Remove the detent
gear from the case.
NOTE: The following disassembly procedure shows
the 4x4 transmission disassembly. Follow the same NOTE: It may be helpful to place a mark just above
procedure for the 6x6 transmission disassembly. the keyed spline.
The transmissions are very similar. Refer to the
exploded view at the end of this chapter. Detent Gear

1. Place the bellcrank in neutral position.

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

the keyed spline. Note the raised edge on the detent.
3. Remove the five bolts that secure the cover and remove the
cover from the transmission.

Cover
Lockout Disc

7. Remove the shift shaft and detent lever.

4. Remove the detent spring.

Spring

8.5
TRANSMISSION
8. Note the transmission gear position and mark the two shift NOTE: You may have to tap the shift drum from the
gears before removing them to aid with reassembly. backside of the case to aid in removal.
Remove the shift gears from the case.

NOTE: Depending on what gear the transmission is

12. Remove the upper gear cluster and shift forks. You may
in upon disassembly, the stamped timing marks may
need to move the assembly back and forth to aid in removal
not be lined up. To avoid confusion, mark the two
gears as described in Step 8.

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.

11. Remove the shift drum.

8.6
 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 dog” on the end of the shaft instead of a
regular “shift dog”. The transmission will have a
regular shift 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 park lock engagement dog. Remove the wave
spring and reverse engagement dog.

Engagement 20. Remove the reverse gear shaft.

Dogs

8.7
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
 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

8.9
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
 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
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
 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.

Transmission

Lockout Disc

Drain Plug
10-14 ft. lbs.
(14-19 Nm)

Drain Plug Torque: 29. Install the detent gear with the raised edge facing outward.
Note the keyed spline on the end of the shaft.
10-14 ft. lbs. (14-19 Nm)
30. Install the detent lever spring. Install a new o-ring onto the
shift shaft after the detent lever is assembled to the shaft.
26. Place a small amount of grease (PN 2871551) into the Place a small amount of grease on the small O-ring on the
pocket before installing the sector gear. Install the shift gear shift shaft and on the detent gear. Grease the o-ring on the
(16T) on the shift drum shaft. Install the sector gear in the end of the shift drum.
bushing pocket on the left side. Align the timing marks you
made on the gears during disassembly. Detent Gear

Detent Lever 8
Spring

31. Install the cover and hand tighten all of the bolts. Tighten
IMPORTANT: Note the location of the skip tooth on the bolt indicated in the picture below first and torque the
the splines. Apply a light coating of grease on the bolt to 7-9 ft. lbs. (10-12 Nm). This helps to align the cover
gear teeth. and shaft to ensure smoother shifting.
7-9 ft. lbs.
27. Install the shift shaft along with the detent lever. (10-12 Nm)

Tighten This Bolt First

8.13
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. Position transmission in frame.
7-9 ft. lbs. (10-12 Nm)
3. Loosely install the front transmission to frame bolts.

33. Install a new bellcrank onto the shift shaft. Note the keyed 4. Loosely install the rear transmission to frame bolt.
spline on the bellcrank and shaft. Install the washer and nut.
Torque the bellcrank nut to 12-18 ft. lbs. (16-24 Nm). 5. Loosely install the three bottom transmission to frame
bolts.

6. Tighten mounting fasteners in order A-D as shown.

Keyed Spline

Bellcrank Nut Torque:

12-18 ft. lbs. (16-24 Nm)
Transmission Mounting Bolts Torque
34. Install transmission and add Polaris AGL Gearcase 25 ft. lbs. (34.5 Nm)
Lubricant (PN 2872602).

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.

NOTE: Align clutches as outlined in Chapter 6.

7. Align the front input shaft to the front propshaft yoke on

the vehicle.

8. Align rear output shaft to rear propshaft yoke and roll pin
hole.

9. Slide rear output shaft and into propshaft yoke. Drive the
roll pin into the driveshaft yolk.
= 10. Reinstall the shift linkage rod, the air intake hose, and the
vent hose on top of the transmission.
AGL Gearcase Lube
15.2 oz. (450 ml)

8.14
 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.

8.15
TRANSMISSION
TRANSMISSION EXPLODED VIEW
Exploded View (4x4, 6x6)
27-34 ft. lbs.
(37-46 Nm)

GREASE

6-12 ft. lbs.

(8-16 Nm)

7-9 ft. lbs. 27-34 ft. lbs.

(10-12 Nm) (37-46 Nm)

12-18 ft. lbs.

(16-24 Nm)
15-19 ft. lbs.
(20-26 Nm)
10-14 ft. lbs.
(14-19 Nm)

FOR REASSEMBLY
Apply White Lithium
Based Grease.

Apply Polaris
Crankcase Sealant.

Apply LoctiteTM 262 to

the bolt threads.

8.16
 TRANSMISSION
Exploded View (4x4, 6x6), Cont.
Ref. Qty. Description Ref. Qty. Description
1 Asm., 4x4 Transmission 35. 1 22T Sprocket
1. 1 Nut 36. 1 19T Sprocket
2. 1 Shift Drum Bellcrank 37. 1 Silent Chain
3. 5 Cover Screws 38. 1 Front Main Output Shaft
4. 1 Sector Cover 39. 1 Gear Set - 10T / 31T
6. 1 O-ring 40. 1 Ball Bearing
7. 1 Detent Pawl 41. 1 Spacer
8. 1 Compression Spring 42. 1 Retaining Ring
9. 1 Shift Shaft 43. 1 Bearing Center Drive Cover
10. 1 31T Sector Gear 44. 4 Torx Screws
11. 2 Hollow Hex Plug 45. 1 56T Mid Output Helical Gear (6x6: 60T Gear)
12. 2 Triple Lip Seal 46. 4 Ball Bearing
13. 1 Gearcase, Main 47. 1 Reverse Shaft
14. 1 Vent Tube 48. 1 Needle Cage Bearing
15. 1 O-Ring 49. 1 24T 6 Face Sprocket
16. 1 Shift Drum 50. 1 Washer
17. 1 External Retaining Ring 51. 2 External Retaining Ring
18. 1 6-Pin Switch 52. 4 6 Face Engagement Dog
19. 1 O-ring 53. 2 Wave Spring
20. 1 Detent Star 54. 1 Washer
21. 1 Lockout Disc 55. 2 Needle Cage Bearing
22. 1 16T Sector Gear 56. 1 28T 6 Face Gear (6x6: 23T Gear)
23. 2 Lock Nut 57. 1 51T Mid Output Helical Gear (6x6: 47T Gear)
24. 4 Dowel Pin 58. 1 Shift Shaft Rail 8
25. 4 Ball Bearing 59. 2 Shift Fork w/Pin
26. 1 Thrust Washer 61. 1 Silent Chain
27. 1 Vent Plug Cap 62. 1 Input Shaft Assy.
28. 1 Output Shaft 63. 1 LH Main Cover
29. 1 Shim 64. 1 Dual Lip Seal
30. 1 Thrust Button 65. 1 Transmission Mount Bracket
31. 1 Shim 66. 2 Hex Screw
32. 1 Output Cover 67. 1 33T 6 Face Gear
33. 15 Screw 68. 1 Washer
34. 1 Plain Bearing 69. 1 Label

8.17
 BRAKES
CHAPTER 9
BRAKES
GENERAL SPECIFICATIONS / TORQUE SPECIFICATIONS / 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
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
FOOT BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
PEDAL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
PARKING BRAKE CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
NEW BRAKE PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
PARKING BRAKE DISC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
DISC REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
PAD REMOVAL / DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
PAD ASSEMBLY / INSTALLATION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
FRONT CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
FRONT CALIPER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
CALIPER REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
DISC INSPECTION / REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
REAR BRAKE PAD (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
PAD INSPECTION / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
REAR BRAKE PAD (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
PAD INSPECTION / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9
REAR CALIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
REAR CALIPER EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
CALIPER REMOVAL (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
CALIPER REMOVAL (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
CALIPER INSTALLATION (4X4, 6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
BRAKES SQUEAL / POOR BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
PEDAL VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
BRAKES LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26

9.1
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 .150 -.165" ( 3.810 - 4.19mm) .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 .150-.165" (3.81-4.19 mm) .140" (3.56 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 12-15 16-20

Brake Line Banjo Bolts

15 2
(Caliper Attachment)

Brake Line Banjo Bolt

15 20
(Master Cylinder Attachment)

Front Brake Disc to Hub Bolts 18 24

Brake Switch 12-15 16-21

Master Cylinder Clevis Nut 9-13 12-18

9.2
 BRAKES
BRAKE SYSTEM SERVICE NOTES
Disc brake systems are light weight, low maintenance, and perform well in the conditions ATVs routinely encounter. There are a
few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and
maximum pad service life.

• Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment.
• Do not over-fill the master cylinder fluid reservoir.
• Make sure the brake lever and 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)
Improper adjustment
Insufficient lever or pedal clearance
Master cylinder reservoir overfilled
Adjust pad stop (front calipers)
Check position of controls & switches. 9
Set to proper level
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 / park brake
Educate operator
applied)
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
BRAKES
HYDRAULIC BRAKE SYSTEM OPERATION
Typical Hydraulic Brake System Compensating port compensates
E for temperature changes by allowing
fluid back to master cylinder.
Must be clear to allow
proper diaphragm C
movement
F

B
A

Movable D
G
Brake Pad

The Polaris brake system consists of the following components or assemblies: brake pedal; master cylinder; hydraulic hose; brake
calipers (slave cylinder); brake pads; and brake discs, which are secured to the drive line.

When the foot activated brake lever (A) is applied it contacts a piston (B) within the master cylinder. As the master cylinder piston
moves inward it closes a small opening (compensating port) (C) within the cylinder and starts to build pressure within the brake
system. As the pressure within the system is increased, the piston (D) located in the brake caliper moves outward and applies pressure
to the moveable brake pad. This pad contacts the brake disc and moves the caliper in its floating bracket, pulling the stationary side
pad into the brake disc. The resulting friction reduces brake disc and vehicle speed. As the lever pressure is increased, the braking
affect is also increased.

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 (C) which is opened and closed by the master cylinder piston assembly.
The port is open when the lever is released and the master cylinder piston is outward. As the temperature within the hydraulic system
changes, this port compensates for fluid expansion (heated fluid) or contraction (cooled fluid). During system service, be sure this
port is open. 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 past the MAX
LEVEL line!

This system also incorporates a diaphragm (E) as part of the cover gasket; and a vent port (F) located between the gasket and the
cover. The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts.
Make sure the vent is open and allowed to function. If the reservoir is over filled or the diaphragm vent is plugged the expanding
fluid may build pressure in the brake system leading to brake failure.

When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (P/N 2872189). Polaris brake fluid is sold in 12 oz. bottles.
WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use
a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture. 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
 BRAKES
BRAKE SYSTEM EXPLODED VIEW

Caliper Banjo Style Fittings:

1 15 ft. lbs. (20 Nm).
All Caliper Bleed Screws:
2 30-60 in. lbs. (3.4-6.8 Nm)
All Flare Style Fittings:
3 12-15 ft. lbs. (16-20 Nm)

1 2
LH Front
Brake Line

LH Rear Line Master Cylinder

LH Front Caliper
3

1 2 3 3

Brake Switch
2 1
1 3
3 MC Rear MC Front
Brake Line Brake Line
LH Rear Caliper

Cross Fitting
1
RH Rear Line RH Front RH Front Caliper
Brake Line
2

RH Rear Caliper 15 ft. lbs.

(20 Nm)
Master Cylinder Side View

9.5
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 nut and bolt (A) from the brake pedal. 2. Remove the nut, bushing, tube, and bolt from the brake
pedal.
C A Master Cylinder
Bolt

Tube Bushing

Clevis Pin

Cotter
A 9-13 ft. lbs. Nut Bushing Key Brake Pedal
(12-18 Nm)
9-13 ft. lbs.
(12-18 Nm)

3. Remove the clevis pin and cotter key from the master
20-22 ft. lbs. cylinder to remove the brake pedal.
(27-30 Nm) B
Pedal Installation
3. Place a container to catch brake fluid under the master
cylinder brake line banjo bolts (B). 1. Reverse Steps 1-3 for foot brake installation. Torque the
NOTE: Dispose of brake fluid properly and do not clevis nut to 9-13 ft. lbs. (12-18 Nm). After installing the
re-use. foot brake check pedal freeplay. Pedal freeplay should not
exceed .090” (2.28 mm).

CAUTION Brake Pedal Freeplay:

Brake fluid will damage finished surfaces. .090” (2.28 mm)

Do not allow brake fluid to come in contact
with finished surfaces.

4. Loosen the banjo bolts (B) 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 (C) 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” (2.286 mm).
9.6
 BRAKES
BRAKE BLEEDING / FLUID CHANGE 7. Hold brake pedal on to maintain pedal pressure, and open
bleeder screw. Close bleeder screw and release foot pedal.
NOTE: When bleeding the brakes or replacing the NOTE: Do not release foot pedal before bleeder
fluid always start with the furthest caliper from the screw is tight or air may be drawn into master
master cylinder. cylinder.

8. Repeat procedure until clean fluid appears in bleeder hose

CAUTION and all air has been purged. Add fluid as necessary to
maintain level in reservoir.
Always wear safety glasses.
CAUTION
CAUTION Maintain at least 1/2"(1.27 cm) of brake fluid in
the reservoir to prevent air from
Brake fluid will damage finished surfaces. Do not entering the master cylinder.
allow brake fluid to come in contact with finished
surfaces. This procedure should be used to 9. Tighten bleeder screw securely and remove bleeder hose.
change fluid or bleed brakes during 10. Repeat procedure Step 5 through Step 9 for the remaining
regular maintenance. calipers.
11. Add brake fluid to MAX level inside reservoir.
1. Clean reservoir cover thoroughly.
2. Remove cover from reservoir.

Master Cylinder Fluid Level

3. If changing fluid, remove old fluid from reservoir with a
Mity Vac™ pump or similar tool.
Between the MIN and MAX line shown
on the reservoir.
Mity Vac™ (PN 2870975) 9
4. Add brake fluid to the indicated MAX level of 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
Polaris DOT 4 Brake Fluid pedal firmly applied, pedal reserve should be no less than
(P/N 2872189) 1/2"(1.3 cm).
14. Check brake system for fluid leaks.
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.
6. Slowly pump foot pedal until pressure builds and holds.

9.7
BRAKES
PARKING BRAKE
Exploded View
Park Brake Handle / Lever

Mount

Cotter Pin
Washer
Spring
Washer
Spring Handle

Nut
Bushings
Pin Clip

Park Brake Pin

Sensor Switch

Park Brake Lever Latch Grommet

Washer
Brake Release

Park Brake Assembly

Bolt

Parking Brake Assembly

Pin
Washer

Clip Pin
Clip Pin
Park Brake
Caliper Assembly

Mount Bolt
Cable

Rear Prop Shaft / Park Brake Disc

9.8
 BRAKES
Inspection 2. After 2 to 3 clicks the wheels should not rotate when turning
by hand. After 10 full clicks of lever travel, the vehicle
1. Inspect the springs and bushings on the parking brake lever should not roll while parked.
assembly.
3. If the vehicle moves, adjustment is necessary.
4. Adjust the parking brake where the cable attaches to the
Bushings lever assembly on the rear brake caliper.

Adjustment Procedure
1. Place the vehicle in neutral on a flat level surface.
2. Carefully lift the rear of the vehicle off the ground and
stabilize on jack stands.
Springs
3. Locate the parking brake cable located under the front hood
and under the dash on the driver side.
Parking Brake
Switch

2. Inspect the parking brake cable and brake pads on the

caliper assembly located on the rear propshaft.
See “Parking Brake Caliper Service” for brake pad
replacement information.
4x4 Model Shown

Inboard Pad
Parking Brake
Cable Adjustment
NOTE: See Chapter 10 for more information on the
parking brake switch.

4. Use two wrenches to loosen the bottom jam nut (C). Hold
Front the top jam nut (D) with one wrench. Turn the bottom jam
Outboard Pad nut (C) 1 1/2 turns counterclockwise to loosen.
5. Now hold the bottom jam nut (C) and turn the top jam nut
(D) clockwise, until the jam nut is tight against the bracket.
6. Repeat Step 4 and Step 5 until the proper adjustment is
Adjustment made for the park brake cable.
1. Push the parking brake (A) down with your foot.
To Parking
9
Brake Pedal

D
Top of Bracket

C
To Parking
A Brake Caliper

9.9
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 2. If replacing the brake pads, slightly loosen the caliper
assembly bolts before removing the complete caliper
NOTE: Do no get oil, grease, or fluid on the park assembly. This will ease the caliper disassembly procedure
brake pads. Damage to or contamination of the pads later.
may cause the pads to function improperly.
4x4 Model Shown
1. Remove the clip pin and pin (A) from the park brake cable.
4x4 Model Shown

NOTE: Be sure the park brake is not engaged.

9.10
 BRAKES
3. Loosen the two brake caliper mount bolts (B) in equal 6. Slide the brake pads and springs from the assembly.
increments.
NOTE: Retain the lever and ball bearings for
4x4 Model Shown reassembly.

B 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.

10. Measure the thickness of the rear caliper parking brake

pads. Replace assembly or pads as needed. See illustration
below for proper readings.
4. Remove the bolts from the frame and lift park brake
assembly out. Inboard pad thickness
New .304” (7.72 mm)
4x4 Model Shown 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)

Caliper Disassembly / Inspection

New Rotor Disc Thickness
NOTE: The rear park brake caliper assembly is 0.150” - 0.164
(3.81 - 4.16 mm)
replaced as an assembly. Refer to your parts book
for information.

5. Remove the two caliper assembly nuts (C) that were

previously loosened during Step 2 of “Caliper Removal”. 9

9.11
BRAKES
New Brake Pad Installation Caliper Installation
NOTE: Parking Brake Pads can be replaced by 1. Install the park brake assembly into place. Tighten the two
ordering one of the following kits: 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 10. 4x4 Model Shown
Add shims until gap 2. Torque the two mounting bolts to 18 ft. lbs. (24 Nm).
measures 0.203”- 0.193”
(5.156 - 4.902 mm)
=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

PARKING BRAKE DISC SERVICE
use, install the assembly bolts through the sleeves. Install
Disc Removal / Inspection
the nuts and the correct amount of shims, the inner brake
pad, springs, and outer brake pad. Torque the assembly 1. Measure the park brake disc with a micrometer. The
nuts to 25 ft. lbs. (34 Nm). minimum allowable thickness of the disc should be .161”
(4.09 mm). If the thickness of the disc is less than
=T specified, replace the rear propshaft / disc assembly.
2. Follow the “Rear Prop Shaft Removal (4x4 & 6x6)”
Parking Brake Caliper - Assembly Bolts: procedure in Chapter 7 to remove the rear prop shaft / disc
25 ft. lbs. (34 Nm) assembly.
4x4 Shaft Shown
3. Ensure the park brake assembly functions properly by Remove Bolts
actuating the lever before reinstallation.

Minimum Disc Thickness: 0.140” (3.56 mm)

New Disc: 0.150” - 0.164” (3.81 - 4.16 mm)

9.12
 BRAKES
FRONT BRAKE PADS 4. Push caliper piston into caliper bore slowly using a C-
clamp or locking pliers with pads installed.
Pad Removal / Disassembly
1. Elevate and support front of machine.

CAUTION

Use care when supporting vehicle so that it does

not tip or fall. Severe injury may occur
if machine tips or falls.

2. Remove the front wheel. Loosen pad adjuster screw 2-3

turns.
Pad Adjuster Screw 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.

5. Push upper pad retainer pin inward and slip outer brake pad
past edge. Remove the pad.

3. Remove the two caliper bolts and caliper from mounting

bracket.

Pad Inspection
1. Measure the thickness of the pad material. Replace pads if
worn beyond the service limit.
9

Measure
Thickness

9.13
BRAKES
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
Front Brake Pad Thickness: reservoir to prevent air from entering the brake system.
New: 298” (7.56 mm) + .007” (.178 mm)
Pad Adjustment
Service Limit: .180”/4.6 mm
1. Install the adjuster screw and turn clockwise until
stationary pad contacts disc, then back off 1/2 turn
Pad Assembly / Installation (counterclockwise).

1. Lubricate mounting bracket pins with a light film of Pad Adjuster Screw
Polaris Premium All Season Grease, and install rubber
dust boots.

2. Be sure fluid level in reservoir is up to MAX line inside

reservoir and install reservoir cap.

Master Cylinder Fluid

Polaris Premium All Season Grease Up to MAX line inside reservoir
(PN 2871423)
3. Install wheels and torque wheel nuts.
4. It is recommended that a burnishing procedure be
2. Compress mounting bracket and make sure dust boots are performed after installation of new brake pads to extend
fully seated. Install pads with friction material facing each service life and reduce noise. Start machine and slowly
other. Be sure pads and disc are free of dirt or grease. increase speed to 30 mph. Gradually apply brakes to stop
3. Install caliper on hub strut, and torque mounting bolts. machine. Repeat procedure 10 times.

Front Wheel Nut Torque:

37 ft. lbs. (50 Nm)

18 ft. lbs.
(24 Nm)

Front Caliper Mounting Bolts

Torque 18 ft. lbs. (24 Nm)

9.14
 BRAKES
FRONT CALIPER
Front Caliper Exploded View

DURING ASSEMBLY
FRONT CALIPER EXPLODED VIEW
4 4

4 Square O-rings
Bleeder Screw
30-60 in. lbs. Dust Boots
(3.4-6.8 Nm)
Pads

Adjuster Screw
(Finger Tight)
Caliper Body
4 Piston

Caliper Mount

Caliper Removal Caliper Disassembly

1. Elevate and support front of machine. 1. Remove brake pad adjuster screw (A).

CAUTION 2. Push upper pad retainer pin inward and slip brake pads past
edge, if pads are still installed.
Use care when supporting vehicle so that it does
3. Remove mounting bracket (B) and dust boot (C)
not tip or fall. Severe injury may occur
if machine tips or falls. F
2. Remove the front wheel.
3. Remove brake line from the caliper. Place a container under B
D
caliper to catch fluid draining from brake line. 9
A
E

Figure 9.15

4. Remove brake caliper mounting bolts and caliper.

9.15
BRAKES
4. Remove piston (D) and square O-rings (E) from the caliper 2. Inspect piston for nicks, scratches, wear or damage.
body (F). See Figure 9.15. 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 Front Caliper Piston O.D.
body.
Std. 1.4985-1.5000” (38.062 - 38.10 mm)
Caliper Inspection Service Limit 1.4980” (38.049 mm)
1. Inspect caliper body for nicks, scratches or wear. Measure
bore size and compare to specifications. Replace if damage 3. Inspect the brake disc and pads as outlined for brake pad
is evident or if worn beyond service limit. replacement in this chapter.

Caliper Assembly
1. Install new square O-rings (A) in the caliper body. Be sure
that the grooves are clean and free of residue or brakes may
drag.

4
B

Front Caliper Piston Bore I.D.

Std. 1.5050-1.5040” (32.27-30.202 mm)

Service Limit 1.5060” (38.252 mm) A
2. Coat the piston with clean Polaris DOT 4 Brake Fluid
(P/N 2872189). Install piston (B) with a twisting motion
while pushing inward. Piston should slide in and out of bore
smoothly, with light resistance.

9.16
 BRAKES
3. Lubricate the mounting bracket pins with Polaris Premium 3. Install the adjuster screw and turn until stationary pad
All Season Grease (PN 2871423), and install the rubber contacts disc, then back off 1/2 turn.
dust seal boots.
Pad Adjuster Screw
CAUTION

Do not allow grease to come into contact with the

piston and seals.
Damage may occur to the components.

4. Follow brake bleeding procedure outlined earlier in this

chapter.
5. Install wheels and torque wheel nuts to specification.

Front Wheel Nut Torque:

37 ft. lbs. (50 Nm)

NOTE: If new brake pads are installed, it is

4. Compress the mounting bracket and make sure the dust recommended that a burnishing procedure be
seals are fully seated. Install the brake pads. Clean the disc performed to extend pad service life and reduce
and pads with brake parts cleaner or denatured alcohol to noise. Start machine and slowly increase speed to
remove any dirt, oil or grease. 15 mph. Gradually apply brakes to stop machine.
Repeat procedure 10 times.
Caliper Installation
1. Install caliper on hub strut, and torque mounting bolts.

9
18 ft. lbs.
(24 Nm)

Front Caliper Mounting Bolt Torque:

18 ft. lbs. (24 Nm)

2. Install brake line and tighten securely with a flare nut

wrench.

9.17
BRAKES
FRONT BRAKE DISC Disc Removal / Replacement
1. Remove bolts and disc.
Disc Inspection
Bolts
1. Visually inspect the brake disc for nicks, scratches, or 18 ft. lbs.
damage. (24 Nm)
2. Measure the disc thickness at 8 different points around the
pad contact surface using a 0-1"micrometer. Replace disc
if worn beyond service limit.

Disc
Hub

2. Clean mating surface of disc and hub.

3. Install disc on hub.
4. Install new bolts and tighten to 18 ft.lbs. (24 Nm).

CAUTION

Brake Disc Thickness Always use new brake disc mounting bolts. The
New .150-.165” (3.81 - 4.19 mm) bolts have a pre-applied locking agent which is
Service Limit .140”/3.56 mm destroyed upon removal.

REAR BRAKE PAD (4X4)

Brake Disc Thickness Variance
Pad Removal
Service Limit .002” (.051 mm) 1. Elevate and support rear of machine.
difference between measurements
CAUTION
3. Mount dial indicator as shown to measure disc runout.
Slowly rotate the disc and read total runout on the dial Use care when supporting vehicle so that it does
indicator. Replace the disc if runout exceeds specifications. not tip or fall. Severe injury may occur
if machine tips or falls.

2. Remove the rear wheel. Loosen pad adjuster screw 2-3

turns.

Brake Disc Runout

Service Limit .010” (.254 mm)

9.18
 BRAKES
3. Clean caliper area before removal. Pad Inspection
4. Remove caliper mounting bolts and lift caliper off of disc. 1. Clean the caliper with brake cleaner or alcohol.
2. Measure the thickness of the pad material. Replace pads if
NOTE: When removing caliper, be careful not to worn beyond the service limit.
damage brake line. Support caliper so as not to kink
or bend brake line.

Measure
Thickness

Remove Caliper Bolts

Rear Brake Pad Thickness
5. Push caliper piston into caliper bore slowly with pads New .298 + .007” (7.56 + .178 mm)
installed. Service Limit .180” (4.6 mm)
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid Pad Installation
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required. 1. Install new pads in caliper body.

6. Remove the brake pads.

9
2. Install caliper and torque mounting bolts.

18 ft. lbs.
(24 Nm)

9.19
BRAKES
3. Clean caliper area before removal.
Rear Brake Caliper Mounting Bolt: 4. Remove caliper mounting bolts and lift caliper off of disc.
Torque 18 ft. lbs. (24 Nm) NOTE: When removing caliper, be careful not to
damage brake line. Support caliper so as not to kink
or bend brake line.
3. Turn adjuster screw back in finger tight using a hex wrench.
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
Remove Caliper Bolts
reservoir to prevent air from entering the master cylinder.

Do not bend or kink

5. Push caliper piston into caliper bore slowly with pads

installed.
Pump the Brake Pedal
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
REAR BRAKE PAD (6X6) Remove excess fluid from reservoir as required.

6. Remove the brake pads.

Pad Removal
1. Elevate and support rear of machine.

CAUTION

Use care when supporting vehicle so that it does

not tip or fall. Severe injury may occur
if machine tips or falls.

2. Remove the rear wheel. Loosen pad adjuster screw 2-3

turns.
Adjuster Screw

9.20
 BRAKES
Pad Inspection Pad Installation
1. Clean the caliper with brake cleaner or alcohol. 1. Install new pads in caliper body.

2. Measure the thickness of the pad material. Replace pads if

worn beyond the service limit.

Measure
Thickness 2. Install caliper and torque mounting bolts.

Rear Brake Pad Thickness 18ft. lbs. (24 Nm)

New .298 + .007” (7.56 + .178 mm)
Service Limit .180” (4.6 mm)

Rear Brake Caliper Mounting Bolt:

Torque 18 ft. lbs. (24 Nm)

3. Turn adjuster screw back in finger tight using a hex wrench.

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 9
reservoir to prevent air from entering the master cylinder.

Pump the Brake Pedal

9.21
BRAKES
REAR CALIPER
Rear Caliper Exploded View

DURING ASSEMBLY

4 4

Bleeder Screw 4 Piston

30-60 IN. LBS. Caliper Body
(4-6.5 NM)

4 Square Pads
O-rings
Caliper Mount

Adjuster Screw Dust Boots

(Finger Tight)

Caliper Removal (4x4) 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

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

to catch brake fluid draining from brake lines.

4. Clean disc, caliper body, and pistons with brake cleaner or

alcohol.

9.22
 BRAKES
Caliper Removal (6x6) Caliper Disassembly
1. Safely support the rear of the machine. 1. Remove brake pad adjuster screw (A).

2. Push upper pad retainer pin inward and slip brake pads past
CAUTION edge, if pads are still installed.

Use care when supporting vehicle so that it does 3. Remove mounting bracket (B) and dust boot (C)
not tip or fall. Severe injury may occur B Pads
if machine tips or falls.
C
F D
2. Use a wrench to remove the brake line. Place a container
to catch brake fluid draining from brake lines.

Remove Banjo Bolt

4. Remove piston (D) and square O-rings (E) from the caliper
body (F).

3. After the fluid has drained into the container, remove the
two caliper mounting bolts and remove caliper.

Remove Caliper Bolts

5. Clean the caliper body, piston, and retaining bracket with

brake cleaner or alcohol.
9
NOTE: Be sure to clean seal grooves in caliper
body.

4. Clean disc, caliper body, and pistons with brake cleaner or

alcohol.

9.23
BRAKES
Caliper Inspection Caliper Assembly
1. Inspect caliper body for nicks, scratches or wear. Measure 1. Install new square O-rings (A) in the caliper body. Be sure
bore size and compare to specifications. Replace if damage that the grooves are clean and free of residue or brakes may
is evident or if worn beyond service limit. drag.

B
4

2. Coat the piston with clean Polaris DOT 4 Brake Fluid

(P/N 2872189). Install piston (B) with a twisting motion
Rear Caliper Piston Bore I.D. while pushing inward. Piston should slide in and out of bore
smoothly, with light resistance.
Std. 1.2550” (3.227 mm)
Service Limit 1.256” (31.902 mm) 3. Lubricate the mounting bracket pins with Polaris Premium
All Season Grease, and install the rubber dust seal boots.

2. Inspect piston for nicks, scratches, wear or damage.

Measure diameter and replace if damaged or worn beyond
service limit.

Polaris Premium All Season Grease

(PN 2871423)
Rear Caliper piston O.D.
4. Compress the mounting bracket and make sure the dust
seals are fully seated. Install the brake pads. Clean the disc
Std. 1.250” (31.75 mm) and pads with brake parts cleaner or denatured alcohol to
Service Limit 1.2495” (31.737 mm) remove any dirt, oil or grease.

3. Inspect the brake disc and pads as outlined for brake pad
replacement in this chapter.

9.24
 BRAKES
Caliper Installation (4x4, 6x6) REAR BRAKE DISC
1. Install the rear caliper with the mounting bolts. Torque
Disc Inspection
mounting bolts to 18 ft.lbs. (24 Nm).
1. Visually inspect disc for scoring, scratches, or gouges.
2. Install brake line banjo bolt. Torque banjo bolt to 15 ft. lbs. Replace the disc if any deep scratches are evident.
(21 Nm). 2. Use a 0-1"micrometer and measure disc thickness at 8
different points around perimeter of disc. Replace disc if
18 ft. lbs. 4X4
(24 Nm) worn beyond service limit.
Rear Brake Disc

15 ft. lbs.
(21 Nm)

6X6
18 ft. lbs. Rear Brake
(24 Nm) Disc

Measure
Thickness
15 ft. lbs. Front View of Brake Disc
(21 Nm)

Brake Disc Thickness

3. Install the rear wheel and wheel nuts. Carefully lower the New .150-.165” (3.81-4.19 mm)
vehicle. Service Limit .140” (3.56 mm)

Brake Disc Thickness Variance

Service Limit .002” (.051 mm)

difference between measurements
9
3. Mount dial indicator and measure disc runout. Replace the
disc if runout exceeds specifications.

Brake Disc Runout

Service Limit .010” (.254 mm)

4. Install brake line and tighten with a flare nut wrench.

5. Follow bleeding procedure outlined earlier in this chapter.
6. 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.

9.25
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
• Improper assembly of brake system components

9.26
 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
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
AWD / REAR DIFFERENTIAL SWITCH (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
DIFFERENTIAL SOLENOID (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
INSTRUMENT CLUSTER 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
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
DIAGNOSING SYSTEM FAILURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
GEAR POSITION INDICATOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
TEST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
HEAD LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
HIGH BEAM HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
HEADLAMP BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
HEADLAMP HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
HEADLAMP HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
TAIL LIGHT / BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
FAN CONTROL CIRCUIT OPERATION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
FAN CONTROL CIRCUIT BYPASS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
EFI DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
10
EFI COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
FUSES / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22

10.1
ELECTRICAL
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
CHARGING SYSTEM ALTERNATOR TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
BATTERY TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
BATTERY TERMINALS / BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
BATTERY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
CONVENTIONAL BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
BATTERY ACTIVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
OCV - OPEN CIRCUIT VOLTAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
LOW MAINTENANCE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
BATTERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
BATTERY TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
OCV - OPEN CIRCUIT VOLTAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
OFF-SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
STARTER MOTOR REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
BRUSH INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
ARMATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
STARTER REASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
STARTER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
STARTER SYSTEM TESTING FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
ELECTRIC BOX LIFT ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
DIAGNOSIS (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39

10.2
 ELECTRICAL
GENERAL INFORMATION • When measuring resistance of a component that has a
resistance value under 10 Ohms, remember to subtract
Special Tools 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
Part Number Tool Description
resistance.
PV-43568 Fluke™77 Digital Multimeter
• Become familiar with the operation of your meter. Be
2870630 Timing Light sure leads are in the proper jack for the test being
2870836 Battery Hydrometer performed (i.e. 10A jack for current readings). Refer to
the Owner’s manual included with your meter for more
2460761 Hall Sensor Probe Harness information.
2871745 Static Timing Light Harness
• Voltage, amperage, and resistance values included in
PU-47063 Digital Wrench™ Diagnostic Software this manual are obtained with a Fluke™ 77 Digital
Multimeter (PV-43568). This meter is used for when
PU-47471 Digital Wrench™ SmartLink Module Kit
diagnosing electrical problems. Readings obtained with
other meters may differ.
Electrical Service Notes
• Pay attention to the prefix on the multimeter reading (K,
Keep the following notes in mind when diagnosing an electrical
M, etc.) and the position of the decimal point.
problem.
• For resistance readings, isolate the component to be
• Refer to wiring diagram for stator and electrical
tested. Disconnect it from the wiring harness or power
component resistance specifications.
supply.

Under-Hood Components
H

B
G

10
A. Voltage Regulator / Rectifier
B. Starter Solenoid
C. Terminal Block E
D
D. Positive Battery Cable
E. Negative Battery Cable
F
F. Battery
G. Starter Motor Positive Lead
H. Relays

10.3
ELECTRICAL
SWITCHES / CONTROLS 4. Test the switch connections and check for continuity at the
following pins shown in the illustration.
Headlamp Switch
AWD / REAR DIFFERENTIAL SWITCH
1. Lift the front hood.

2. The wires are located on the back side of the instrument

panel.

3. Disconnect the headlamp switch harness (Brown, Green,

and Yellow), by depressing the connector lock and pulling
on the connector. Do not pull on the wiring.

4. Test the switch connections and check for continuity at the

following pins as shown in the illustration.
HEADLAMP SWITCH

BACK VIEW OF SWITCH

(INTERNAL CONNECTIONS)

Differential Solenoid (4x4)

The differential solenoid is located on the rear gear case. The
solenoid actuates the carrier, which locks and unlocks the rear
carrier. (Refer to Chapter 7 for more information on rear carrier
BACK VIEW OF SWITCH operation.)
(INTERNAL CONNECTIONS)

Solenoid
AWD / Rear Differential Switch (4x4)
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.

10.4
 ELECTRICAL
Differential Solenoid Circuit Operation If the rear carrier fails to switch from operational modes:
When the switch is pushed to activate “Turf” mode, the White/ • Check the connector located under the left rear fender.
Green wire is connected to ground via the Brown wire at the Look for loose wires or bad connections.
AWD / Diff-Lock Switch and signals the ECU to energize the
Rear Diff Solenoid Relay. • Check for power from the connector, to ensure the
solenoid has power to be activated.
Depending on vehicle speed and gear position criteria, the
ground path is then sent from the ECU to the Rear Diff • Check the operator’s switch wires for loose
Solenoid Relay. This activates the solenoid and sends 12 volt connections.
“Key On” power from the RD/WH wire to the OR/WH wire of
• Remove solenoid from carrier and ensure the solenoid
the Differential Solenoid.
plunger is actuating.

Rear Differential Solenoid Circuit

CAUTION
AWD / Diff-Lock
Switch
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.
Key-On
Power

Brake Switch

2. Disconnect wire harness from switch.

3. Connect an ohmmeter across switch contacts. Reading

should be infinite (•).
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.

10.5
ELECTRICAL
Parking Brake Switch TESTING PARK BRAKE SWITCH

The parking brake switch is located under the dash or under the 1. Disconnect the Orange/Red wire and Red/White wire from
hood. Follow the parking brake lever under the dash to locate the the switch.
switch.
2. Place the ohmmeter leads onto terminal leads A and C. The
Parking Brake Switch reading should be infinite (•).

RD/WH

OG/RD

The switch remains in the “open” position when the park brake
lever is not applied.
3. Apply the parking brake. There should be continuity
between the switch terminals. If no continuity exists when
the park brake is applied, try to clean the switch terminals
and re-test. Replace switch if necessary.

Park Brake
Indicator

Parking Brake
Not Applied

The switch makes contact when the park brake is applied and
sends voltage to the ECU and Speedometer to illuminate the
“Park Brake Indicator” near the top-center of the instrument
cluster.

Key-On
Power

Parking Brake
Applied

10.6
 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
right front wheel. The instrument cluster measures distance in NOTE: If the instrument cluster fails to illuminate, a
miles as well as time, hours of operation and engine RPM. battery over-voltage may have occurred and the
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.

10.7
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 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 total
changes to 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
 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 at 50
hours at the factory.

10.9
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: See Page 4.21 for a complete list of
advance the hours quickly. 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
 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
ELECTRICAL
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS
Test 1 - No All Wheel Drive

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10.12
 ELECTRICAL
TEST 2 - No Display
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6
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TEST 3 - Wheel Speed Sensor

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10.13
ELECTRICAL
TEST 4 - No AWD Hub Safety Limiter

127( ,) 7+( $:' ,&21 '2(6 127 &20( 21 25 ,) 

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10.14
 ELECTRICAL
TEST 5 - Fuel Gauge Display Not Working

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TEST 6 - Shift Indicator Not Working (Transmission Switch)

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10.15
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. When this occurs the AWD
High / Low / Neutral / Reverse Switch
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
• Verify the AWD hub coil is functional. Test the AWD Low Range
hub coil using an ohm meter. See specifications below. Neutral
Reverse

Green/White Brown/Red
Violet White/Blue
7HVW5HVLVWDQFH
5HDGLQJVVKRXOGEH
Blue/Red
*<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
connect properly.

• Verify continuity of wire connections with a known

good 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
 ELECTRICAL
HEAD LIGHTS 6. Adjust the beam to desired position. Repeat the procedure
to adjust the other headlight.
High Beam 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)
Headlamp Bulb Replacement
1. Open the hood.

2. Unplug the headlamp 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 park 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.

Headlamp Housing Removal

1. Open the hood.
10
2. Unplug the headlamp from the wiring harness. Be sure to
pull on the connector, not on the wiring.

10.17
ELECTRICAL
3. Remove the O-ring (A) from the headlamp 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 headlamp, Remove

the adjustment screw (B) and pull the headlamp 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).

Headlamp Housing Installation

1. To install the headlamp housing, press the headlamp tabs
back into the brackets.
2. Secure the headlamp 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
 ELECTRICAL
COOLING SYSTEM
Cooling System Break-Out Diagram

+EY /N
 6OLT 0OWER

10

10.19
ELECTRICAL
Fan Control Circuit Operation / Testing EFI DIAGNOSTICS
Power is supplied to the fan via the Orange/Black wire when the
EFI Component Testing
relay is ON. The ground path for the fan motor is through the
Brown harness wire. Refer to “RELAYS” later in this chapter All EFI component information and diagnostic testing
for more information on fan functions. 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 3. Hook up an ohm meter to the fuel sender harness Violet/
for cooling system information. White wire (B) and Brown wire (C).
4. With the sender float in the empty position and compare
Fan Control Circuit Bypass Test to specification.

1. Disconnect harness from coolant temperature sensor on

engine.
Fuel Sender - Empty: 5 Ω ± 5%
2. With the parking brake on, 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
Half: 57Ω ± 5%
temperature (68°F = 20°C), disconnect the harness
connector. Full: 90Ω ± 5%
2. With the meter in the ohms mode, place the meter leads
onto the sensor contacts.
3. Use the table Temperature / Resistance table to determine Fuel Sender - Full: 90 Ω ± 5%
if the sensor needs to be replaced.
6. If the readings are not to specification, or if the reading is
TEMPERATURE °F (°C) RESISTANCE erratic or LCD display “sticks”, check the following before
replacing the fuel pump assembly.
68 °F (20 °C) 2.5 k Ω ± 6%
• Loose float
212 °F (100 °C) 0.186 Ω ± 2%
• Float contact with tank

NOTE: If the coolant temperature sensor or circuit • Bent Float Rod

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.

10.20
 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 20-Amp power, switched by relay,
Orange / Black
%#5 )NPUT provides power to Fan Motor.
ECU input to connect relay Fused 20-Amp
Yellow / Black
power to Fan Motor output.
+EY /N 6 0OWER Fused 20-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.

10.21
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 20-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

CHARGING SYSTEM
Current Draw - Key Off
Current Draw Inspection
Key Off
CAUTION

Do not connect or disconnect the battery cable

or ammeter with the engine running. Damage will
occur to electrical components.

Connect an ammeter in series with the negative battery cable.

Check for current draw with the key off. If the draw is excessive,
30 Amp
loads should be disconnected from the system one by one until
the draw is eliminated. Check component wiring as well as the
component for partial shorts to ground to eliminate the draw.

Current Draw - Key Off:

Maximum of .01 DCA (10 mA)

10.22
 ELECTRICAL
Charging System “Break Even” Test Charging System Alternator Tests
Three tests can be performed using a multimeter to determine
CAUTION the condition of the stator (alternator).

Do not allow the battery cables to become

disconnected with the engine running. Follow the
steps below as outlined to reduce the chance of Y1 Y2 Y3
damage to electrical components.

The “break even” point of the charging system is the point at

which the alternator overcomes all system loads (lights, etc.)
and begins to charge the battery. Depending on battery condition
and system load, the break even point may vary slightly. The
battery should be fully charged before performing this test.

WARNING

Never start the engine with an ammeter TEST 1: Resistance Value of Each Stator Leg
connected in series. Damage to the meter or
meter fuse will result. 1. Measure the resistance value of each of the three stator
Do not run test for extended period of time. legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3.
Do not run test with high amperage accessories. Each test should measure: 0.19Ω ± 15%

1. Connect a tachometer to the engine. Connect Meter

Test Ohms Reading
Leads To:
2. Using an inductive amperage metering device, (set to DC
amps) connect to the negative battery cable Battery Charge Coil Y1 to Y2 0.19Ω ± 15%

3. With engine off and the key, kill switch, and lights in the Battery Charge Coil Y1 to Y3 0.19Ω ± 15%
ON position, the ammeter should read negative amps Battery Charge Coil Y2 to Y3 0.19Ω ± 15%
(battery discharge). Reverse meter lead if a positive reading
is indicated.
NOTE: If there are any significant variations in
4. Shift transmission into neutral with the park brake on and ohm’s readings between the three legs; it is an
start the engine. With the engine running at idle, observe indication that one of the three stator legs maybe
meter readings. weak or failed.

5. Increase engine RPM while observing ammeter and TEST 2: Resistance Value of Each Stator Leg to Ground
tachometer. 1. Measure the resistance value of each of the stator legs to
ground: Y1 to Ground, Y2 to Ground, Y3 to Ground.
6. Note RPM at which the battery starts to charge (ammeter Each test should measure: Open Line (OL)
indication is positive).

7. With lights and other electrical loads off, the “break even”
Test
Connect Meter
Ohms Reading
10
point should occur at approximately 1500 RPM or lower. Leads To:

8. With the engine running, turn the lights on and engage Y1, Y2, or Y3 Open Line
Battery Charge Coil
parking brake lock to keep brake light on. to Ground (Infinity)

9. Repeat test, observing ammeter and tachometer. With NOTE: Any measurement other than Infinity (open)
lights on, charging should occur at or below 2000 RPM. will indicate a failed or shorted stator leg.

10.23
ELECTRICAL
TEST 3: Measure AC Voltage Output of Each Stator Leg at
Charging RPM

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
measure the voltage across each ’leg’ of the stator by
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
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

voltage varies significantly from the specified value,
the stator may need to be replaced.

RPM Reading AC Voltage (VAC) Reading

1300 18 VAC ± 25 %
3000 42 VAC ± 25 %
5000 64 VAC ± 25 %

10.24
 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.Are 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
ELECTRICAL
BATTERY TERMINAL BLOCK Battery Identification
The terminal block is located under the front hood next to the IMPORTANT: Identify what type of battery you have
battery. The terminal block provides easy access to the main installed in your RANGER. Different types of batteries
battery and starting cables. The terminal block also provides require different service procedures. Proper servicing
easy hookup for accessories. and upkeep of your battery is very important for
maintaining long battery life.
TERMINAL BLOCK
Your RANGER may have a Conventional Battery or a Sealed
Orange/White
Low Maintenance Battery. To identify which type of battery
your RANGER has, refer to the illustration below and follow the
Orange/White
Black correct service and charging procedures that follow in the
(Accessories)
manual.
Red Black CONVENTIONAL BATTERY
(Ground)

Removable
Caps
Red
(Battery+)
Top View

=T Electrolyte Level
Indicator
Terminal Block Nuts: 20-25 in. lbs. (2.3-2.8 Nm)

Side View
BATTERY SERVICE
Battery Terminals / Bolts
Use Polaris corrosion resistant Nyogel™ grease (PN 2871329)
on battery terminal bolts. See “Battery Installation” on Page SEALED LOW
10.28. MAINTENANCE BATTERY

No Caps
(Non-removable
sealed Top)

Top View

Polaris Sticker
Apply
Nyogel™

Side View

10.26
 ELECTRICAL
CONVENTIONAL BATTERY 4. Add electrolyte to bring level back to upper level mark on
case.
Battery Activation NOTE: This is the last time that electrolyte should
be added. If the level becomes low after this point,
add only distilled water.
WARNING
5. Charge battery at 1/10 of its amp/hour rating. Examples: 1/
Battery electrolyte is poisonous. It contains 10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4
sulfuric acid. Serious burns can result from amp; 1/10 of 18 amp battery = 1.8 amp (recommended
contact with skin, eyes or clothing. Antidote: charging rates).
6. Check specific gravity of each cell with a hydrometer to
External: Flush with water. assure each has a reading of 1.270 or higher.

Internal: Drink large quantities of water or milk. Battery Inspection

Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately. The battery is located under the hood.

Eyes: Flush with water for 15 minutes and get

prompt medical attention.

Batteries produce explosive gases. Keep

sparks, flame, cigarettes etc. away. Ventilate
when charging or using in an enclosed space.
Always shield eyes when working
near batteries.
KEEP OUT OF REACH OF CHILDREN.

WARNING
Inspect the battery fluid level. When the battery fluid nears the
The gases given off by a battery are explosive. lower level, remove the battery and fill with distilled water only
Any spark or open flame near a battery can to the upper level line. To remove the battery:
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. Maintain
between upper
To ensure maximum service life and performance from a new and lower level
battery, perform the following steps. NOTE: Do not service the marks
battery unless it will be put into regular service within 30 days.
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

10
before use or battery life will be significantly
reduced 10-30% of the battery’s full potential.

To activate a new battery:

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.

10.27
ELECTRICAL
Battery Removal OCV - Open Circuit Voltage Test
1. Disconnect holder strap and remove covers. Battery voltage should be checked with a digital multitester.
2. Disconnect battery negative (-) (black) cable first, followed Readings of 12.6 volts or less require further battery testing and
by the positive (+) (red) cable. charging. See charts and Load Test on below.

CAUTION NOTE: Lead-acid batteries should be kept at or near

a full charge as possible. Electrolyte level should be
kept between the low and full marks. If the battery is
Whenever removing or reinstalling the battery,
stored or used in a partially charged condition, or
disconnect the negative (black) cable first and
with low electrolyte levels, hard crystal sulfation will
reinstall the negative cable last!
form on the plates, reducing the efficiency and
3. Remove the battery. service life of the battery.
4. Remove the filler caps and add distilled water only as
needed to bring each cell to the proper level. Do not overfill OPEN CIRCUIT VOLTAGE
the battery. Conventional
State of Charge YuMicron™ Type
Lead-Acid

Refill using only distilled water. Tap water contains 100% Charged 12.60 V 12.70 V
minerals which are harmful to a battery. 75% Charged 12.40 V 12.50 V
50% Charged 12.10 V 12.20 V
Do not allow cleaning solution or tap water inside the 25% Charged 11.90 V 12.0 V
battery. Battery life may be reduced.
less than less than
0% Charged
5. Reinstall the battery caps. 11.80 V 11.9 V

Battery Installation Specific Gravity Test

1. Clean battery cables and terminals with a stiff wire brush. A tool such as a Battery Hydrometer (PN 2870836) can be used
Corrosion can be removed using a solution of one cup to measure electrolyte strength or specific gravity. As the battery
water and one tablespoon baking soda. Rinse well with goes through the charge/discharge cycle, the electrolyte goes
clean water and dry thoroughly. from a heavy (more acidic) state at full charge to a light (more
2. Route the cables correctly. water) state when discharged. The hydrometer can measure
state of charge and differences between cells in a multi-cell
3. Reinstall battery, attaching positive (+) (red) cable first and
battery. Readings of 1.270 or greater should be observed in a
then the negative (-) (black) cable. Coat terminals and bolt fully charged battery. Differences of more than .025 between the
threads with Nyogel™ Grease (PN 2871329). lowest and highest cell readings indicate a need to replace the
4. Install clear battery vent tube from vehicle to battery vent. battery.
WARNING: Vent tube must be free from obstructions and
kinks and securely installed. If not, battery gases could
accumulate and cause an explosion. The vent tube should
be routed away from frame and body to prevent contact
with electrolyte. Avoid skin contact with electrolyte, as
severe burns could result. If electrolyte contacts the vehicle Battery Hydrometer (PN 2870836)
frame, corrosion will occur. 1.10
5. Reinstall the holder strap. 1.15

Detail A 1.20
Conventional Battery Testing
1.25
Whenever a service complaint is related to either the starting or
1.30
charging systems, the battery should be checked first.

Following are three tests which can easily be made on a battery

to determine its condition: OCV Test, Specific Gravity Test and
Load Test.

10.28
 ELECTRICAL
• Using a wire brush or knife, remove any corrosion from
SPECIFIC GRAVITY
the cables and terminals.
Conventional
State of Charge* YuMicron™ Type • Make sure that the electrolyte is at the proper level. Add
Lead-Acid
distilled water if necessary.
100% Charged 1.265 1.275
• Charge at a rate no greater than 1/10 of the battery’s
75% Charged 1.210 1.225
amp/hr capacity until the electrolyte’s specific gravity
50% Charged 1.160 1.175 reaches 1.270 or greater.
25% Charged 1.120 1.135 • Store the battery either in the machine with the cables
0% Charged less than 1.100 less than 1.115 disconnected, or store in a cool place.

* At 80° F NOTE: Recharge to full capacity every 30 to 60 days

NOTE: Subtract .01 from the specific gravity reading at 40° F. during a non-use period. If the battery is stored
during the winter months, electrolyte will freeze at
Load Test higher temperatures as the battery discharges. The
chart below indicates freezing points by specific
gravity.
CAUTION
Electrolyte Freezing Points
To prevent shock or component damage,
remove spark plug high tension leads and Specific Gravity
Freezing Point
connect securely to engine ground of Electrolyte
before proceeding.
1.265 -75° F
NOTE: This test can only be performed on machines
1.225 -35° F
with electric starters. This test cannot be performed
with an engine or starting system that is not working 1.200 -17° F
properly.
1.150 +5° F
A battery may indicate a full charge condition in the OCV test
and the specific gravity test, but still may not have the storage 1.100 +18° F
capacity necessary to properly function in the electrical system. 1.050 +27° F
For this reason, a battery capacity or load test should be
conducted whenever poor battery performance is encountered.
To perform this test, hook a multitester to the battery in the same Charging Procedure
manner as was done in the OCV test. The reading should be 12.6 1. Remove the battery to prevent damage from leaking or
volts or greater. Engage the starter and observe the battery spilled acid during charging.
voltage while cranking the engine. Continue the test for 15 2. Charge the battery with a charging output no larger than 1/
seconds. During cranking the observed voltage should not drop 10 of the battery’s amp/hr rating. Charge as needed to raise
below 9.5 volts. If the beginning voltage is 12.6 volts or higher the specific gravity to 1.270 or greater.
and the cranking voltage drops below 9.5 volts during the test,
3. Install battery in vehicle with positive terminal toward the
replace the battery.
front. Coat threads of battery bolt with a corrosion resistant
dielectric grease.
Off Season Storage 10
To prevent battery damage during extended periods of non-use, Dielectric Grease
the following basic battery maintenance items must be
(PN 2871329)
performed:

• Remove the battery from the machine and wash the 4. Connect battery cables.
case and battery tray with a mild solution of baking
soda and water. Rinse with lots of fresh water after WARNING
cleaning. NOTE: Do not get any of the baking soda
into the battery or the acid will be neutralized. To avoid the possibility of explosion, connect
positive (+) cable first and negative (-) cable last.

10.29
ELECTRICAL
5. After connecting the battery cables, install the cover on the NOTE: New Batteries: Batteries must be fully
battery and attach the hold down strap. charged before use or battery life will be reduced by
6. Install clear battery vent tube from vehicle to battery vent. 10-30% of full potential. Charge battery for 3-5 hours
WARNING: Vent tube must be free from obstructions and at a current equivalent of 1/10 of the battery's rated
kinks and securely installed. If not, battery gases could amp/hour capacity. Do not use the alternator to
accumulate and cause an explosion. Vent should be routed charge a new battery. (Refer to Battery Activation
away from frame and body to prevent contact with and Maintenance video PN 9917987)
electrolyte. Avoid skin contact with electrolyte, as severe
burns could result. If electrolyte contacts the vehicle frame, NEVER attempt to add electrolyte or water to a Low
corrosion will occur. Maintenance battery. Doing so will damage the case and shorten
the life of the battery. Refer to the Battery Maintenance Video
7. Route cables so they are tucked away in front and behind
(PN 9917987) for proper instruction on servicing Low
battery.
Maintenance batteries.

To service a Low Maintenance battery:

LOW MAINTENANCE BATTERY 1. Remove battery from the vehicle.
2. Test battery with a voltage meter or load tester to determine
Battery Check
battery condition. This will determine the length of time
NOTE: All Low Maintenance batteries are fully required to charge the battery to full capacity. Refer to
charged and tested at the factory before installation. capacity table.
Expected shelf life varies upon storage conditions. 3. Charge battery using a variable rate charger.
As a general rule before placing the battery into
service, check the battery condition and charge
accordingly. Battery Inspection
1. Check the date label on the side of the battery to calculate The battery is located under the front hood.
when to check voltage. The battery should be checked
every 3 months.
2. Check the voltage with a voltmeter or multimeter. A fully
charged battery should be 12.8 V or higher.
3. If the voltage is below 12.8 V, the battery will need to be
recharged.

Low Maintenance Battery

shown, but not used on
current RANGER Models

Battery Removal
1. Remove the seat and remove battery holder strap.
2. Disconnect battery negative (-) (black) cable first, followed
by the positive (+) (red) cable.

CAUTION
Low Maintenance batteries are permanently sealed at the time of
manufacture. The use of lead-calcium and AGM technology Whenever removing or reinstalling the battery,
instead of lead-antimony allows the battery acid to be fully disconnect the negative (black) cable first and
absorbed. For this reason, a Low Maintenance battery case is reinstall the negative cable last!
dark and the cell caps are not removable, since there is no need
to check electrolyte level. 3. Remove the battery.

10.30
 ELECTRICAL
Battery Installation Load Test
1. Clean battery cables and terminals with a stiff wire brush.
Corrosion can be removed using a solution of one cup CAUTION
water and one tablespoon baking soda. Rinse well with
clean water and dry thoroughly. To prevent shock or component damage,
2. Route the cables correctly. remove spark plug high tension leads and
3. Reinstall battery, attaching positive (+) (red) cable first and connect securely to engine ground
then the negative (-) (black) cable. Coat terminals and bolt before proceeding.
threads with Nyogel™ Grease (PN 2871329).
4. Reinstall the holder strap. NOTE: This test can only be performed on machines
with electric starters. This test cannot be performed
with an engine or starting system that is not working
Battery Testing properly.

Whenever a service complaint is related to either the starting or A battery may indicate a full charge condition in the OCV test
charging systems, the battery should be checked first. and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system.
Following are two tests which can easily be made on a Sealed For this reason, a battery capacity or load test should be
Low Maintenance battery to determine its condition: OCV Test conducted whenever poor battery performance is encountered.
and a Load Test. To perform this test, hook a multitester to the battery in the same
manner as was done in the OCV test. The reading should be 12.6
volts or greater. Engage the starter and observe the battery
OCV - Open Circuit Voltage Test voltage while cranking the engine. Continue the test for 15
Battery voltage should be checked with a digital multitester. seconds. During cranking the observed voltage should not drop
Readings of 12.8 volts or less require further battery testing and below 9.5 volts. If the beginning voltage is 12.6 volts or higher
charging. See charts and Load Test. and the cranking voltage drops below 9.5 volts during the test,
replace the battery.
NOTE: Lead-acid batteries should be kept at or near
a full charge as possible. If the battery is 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.

NOTE: Use a voltmeter or multimeter to test batter

voltage.

OPEN CIRCUIT VOLTAGE

Maintenance
State of Charge YuMicron™ Type
Free
100% 13.0 V 12.70 V
75% Charged 12.80 V 12.50 V 10
50% Charged 12.50 V 12.20 V
25% Charged 12.20 V 12.0 V
0% Charged less than 12.0 V less than 11.9 V
* At 80° F
NOTE: Subtract .01 from the specific gravity reading at 40° F.

10.31
ELECTRICAL
Off-Season Storage Battery Charging
To prevent battery damage during extended periods of non-use, If battery voltage is 12.8 V or less, the battery may need
the following basic battery maintenance items must be recharging. When using an automatic charger, refer to the
performed: charger manufacturer’s instructions for recharging. When using
a constant current charger, use the following guidelines for
• Remove the battery from the machine and wash the recharging.
case and battery tray with a mild solution of baking
soda and water. Rinse with lots of fresh water after NOTE: Always verify battery condition before and 1-
cleaning. 2 hours after the end of charging.

• Using a wire brush or knife, remove any corrosion from

the cables and terminals. WARNING
An overheated battery could explode, causing
• Charge at a rate no greater than 1/10 of the battery’s
severe injury or death. Always watch charging
amp/hr capacity.
times carefully. Stop charging if the battery
• Store the battery either in the machine with the cables becomes very warm to the touch.
disconnected, or store in a cool place. Allow it to cool before resuming charging.

NOTE: Stored batteries lose their charge at the rate Battery Charging Reference Table
of 1% per day. Recharge to full capacity every 30 to
60 days during a non-use period. If the battery is State of
Voltage Action Charge Time
stored during the winter months, electrolyte will Charge
freeze at higher temperatures as the battery None, check
discharges. The chart below indicates freezing voltage at 3 mos.
100% 12.8-13 V None Required
points by specific gravity. after manufacture
date
Electrolyte Freezing Points May need slight
75-100% 12.5-12.8 V 3-6 hours
charge
Specific Gravity 50-75% 12.0-12.5 V Needs Charge 5-11 hours
Freezing Point
of Electrolyte
At least 13
1.265 -75° F 25-50% 11.5-12.0 V Needs Charge hours, verify
state of charge
1.225 -35° F 0-25% 11.5 V or less Needs Charge At least 20 hours
1.200 -17° F
WARNING
1.150 +5° F

1.100 +18° F To avoid the possibility of sparks and explosion,

connect positive (red) cable first and negative
1.050 +27° F (black) cable last.

10.32
 ELECTRICAL
STARTER SYSTEM To perform the test, place the meter on DC volts and place the
meter leads across the connection to be tested. Refer to the
Troubleshooting voltage drop tests on the starter system in this chapter.

Starter Motor Does Not Run

Voltage should not exceed
• Battery discharged - Low specific gravity .1 DC volts per connection
• Loose or faulty battery cables or corroded connections
(see Voltage Drop Tests)

• Related wiring loose, disconnected, or corroded Starter Motor Removal / Disassembly

• Poor ground connections at battery cable, starter motor NOTE: Use electrical contact cleaner to clean starter
or starter solenoid (see Voltage Drop Tests) motor parts. Some solvents may leave a residue or
damage internal parts and insulation.
• Faulty key switch
• Faulty kill switch
• 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
direction only.

• Faulty starter solenoid or starter motor

• Engine problem - seized or binding (Can engine be
rotated easily?) 1. Remove the starter from the engine.

Starter Motor Turns Over Slowly 2. Remove the two bolts, washers, and sealing O-Rings.
Inspect O-Rings and replace if damaged.
• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections (see
Voltage Drop Test)

• Engine problem - seized or binding (Can engine be

rotated easily?)

• Faulty or worn brushes in starter motor

Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive
• Faulty starter drive gears or starter motor gear 10
• Faulty flywheel gear or loose flywheel
NOTE: Note the alignment marks on both ends of
Voltage Drop Test the starter motor casing. These marks must align
during reassembly.
The Voltage Drop Test is used to test for bad connections. When
performing the test, you are testing the amount of voltage drop
through the connection. A poor or corroded connection will
appear as a high voltage reading. Voltage shown on the meter
when testing connections should not exceed .1 VDC per
connection or component.

10.33
ELECTRICAL
3. Remove the front bracket assembly and the rear bracket 3. Slide positive brush springs to the side, pull brushes out of
assembly. Remove the shims from the armature shaft and their guides and remove brush plate. Slide brush end frame
inspect the O-rings located on the armature housing. off end of starter.
O-Rings NOTE: The electrical input post must stay with the
field coil housing.

4. Measure resistance between ground brush and brush plate.

Resistance should be .3 ohms or less.

Shims

NOTE: The shims will be replaced during

reassembly.

BRUSH INSPECTION / REPLACEMENT

1. Measure resistance between starter input terminal and
insulated brushes. The reading should be .3 ohms or less. Brush Inspection
Remember to subtract meter lead resistance. 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)

Brush Replacement
1. Remove terminal nut with lock washer, flat washer, large
2. Measure resistance between insulated brush and starter phenolic washer, the small phenolic spacers, and sealing
housing. Reading should be infinite. (OL). Inspect O-ring. Inspect O-ring and replace if damaged.
insulation on brush wires for damage and repair or replace
as necessary.

10.34
 ELECTRICAL
2. Slide positive brush springs to the side, pull brushes out of 6. Place armature in a growler. Turn growler on and position
their guides and remove brush plate. a hacksaw blade or feeler gauge lengthwise 1/8” (.3 cm)
above armature coil laminates. Rotate armature 360°. If
CAUTION hacksaw blade is drawn to armature on any pole, the
armature is shorted and must be replaced.
Some cleaning solvents may damage the
insulation in the starter. Care should be CAUTION
exercised when selecting an appropriate
solvent. If the commutator needs cleaning use Use care when handling starter housing. Do not
only electrical contact cleaner. drop or strike the housing as magnet damage is
possible. If magnets are damaged, starter must be
replaced.
Armature Testing
1. Remove armature from starter casing. Note order of shims Starter Reassembly / Installation
on drive end for reassembly.
1. Install brush plate to field magnet housing aligning index
tab.

2. Inspect surface of commutator. Replace if excessively

worn or damaged.
3. Using a digital multitester, measure the resistance between 2. Install O-ring, two small phenolic spacers, large phenolic
each of the commutator segments. The reading should be washer, flat washer, lock washer, and terminal nut.
.3 ohms or less. 3. While holding brush springs away from brushes, push
4. Measure the resistance between each commutator segment brushes back and hold in place.
and the armature shaft. The reading should be infinite (no 4. Slide armature into field magnet housing. Release brushes.
continuity). 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
10

5. Check commutator bars for discoloration. Bars discolored

in pairs indicate shorted coils, requiring replacement of the
starter motor. 6. Be sure wire insulation is in place around positive brush
wire and pushed completely into slot on phenolic plate.
10.35
ELECTRICAL
7. Using Dielectric Grease (PN 2871329), lubricate brush end Starter Drive
bushing and install shims.
8. Align brush plate and install cover and screws. Pinion Gear - Anti-kick Out Shoe, Garter
9. Lightly grease pinion shaft and install pinion, spring Spring Replacement
stopper, and snap ring.
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:

H
G
A F
D
Set Bolt Torque: 35-52 in. lbs. (3.9-5.9 Nm)
B
10. Completely assembly starter motor and torque set bolts to
35 - 52 in. lbs. (3.9 - 5.9 Nm).
A. Gear Assembly E
11. Install the starter onto the engine case. Hand tighten each B. Thrust Washer C
of the starter bolts. Torque the bottom bolt first to 9 ft.lbs. C. Busing
(12 Nm). Then torque the top bolt to the same specification. D. Retaining Ring
NOTE: It is important to tighten the bottom starter E. Thrust Washer
bolt first (circle), as the bottom hole acts as a pilot F. Stopper
hole to properly align the starter drive (bendix) with G. Cover
the flywheel. This helps to prevent binding and H. Spring
starter damage.

1. Screw the overrun clutch out to the engaged position on the

pinion shaft assembly. Use a small piece of wire with the
end bent in a hook and pick the old spring out of its
channel. Slide it off the end of the shaft. Slide the new
spring over the overrun clutch and into the spring groove.
Make sure that the spring is positioned between the shoe
alignment pins and the back flange of the anti kick-out
shoes.

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
Starter Solenoid Bench Test properly so that it will hold the lock ring in its groove.
To measure the resistance of the pull-in coil, connect one meter
lead to the solenoid lead wire and the other to ground. The
resistance should be 2.8 - 3.6 ohms. Refer to “Electric Starter
System Testing” in this section to further test the solenoid.

10.36
 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 10
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

10.37
ELECTRICAL
STARTER SYSTEM TESTING FLOW CHART
Condition: Starter fails to turn over the engine.
NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing
of starter system. A digital multitester must be used for this test
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 coil engagement wire from the starter Check voltage on both sides of circuit
solenoid. Connect tester black wire to battery breaker, ignition switch/engine stop switch
ground. Connect red tester lead to harness wire at No and starter button. The voltage on both sides
solenoid. Turn on ignition switch and depress the should be the same. NOTE: The ignition
starter button. Tester should read battery voltage. switch and engine stop switch must be on and
the starter button depressed. Replace
component if failed .
Test starter solenoid coil by connecting an ohmmeter between the solenoid
Yes wire and the solenoid mounting plate. Resistance should be 3.4Ω. Check
solenoid ground path by measuring resistance between mounting plate and
Voltage Drop battery negative terminal (-).
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. Depress starter
button. 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. Replace the starter solenoid.
Depress starter button. 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.
Depress the starter button. 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.

10.38
 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

10
(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.

10.39
 A Cooling System Bleeding Procedure . . . . . . . . . . . . . . . . 3.15
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
Air Intake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Cooling System Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Cooling System Pressure Test . . . . . . . . . . . . . . . . . . . . . 2.26 IX
Cooling System Specifications . . . . . . . . . . . . . . . . . . . . 3.13
All Wheel Drive (AWD) Coil . . . . . . . . . . . . . . . . . . . 10.16
Cooling System, Pressure Test . . . . . . . . . . . . . . . . . . . . 3.14
AWD Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Crankshaft Gear, Removal . . . . . . . . . . . . . . . . . . . . . . . 3.40
AWD, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Crankshaft Position Sensor (CPS) . . . . . . . . . . . . . . . . . . 4.15
AWD, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
CV Shaft Boot Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.28
B Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3.30
Balance Shaft Gear, Removal . . . . . . . . . . . . . . . . . . . . . 3.40 Cylinder Head Assembly Exploded View . . . . . . . . . . . 3.23
Ball Joint, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . 3.26
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 Cylinder Honing To De-glaze . . . . . . . . . . . . . . . . . . . . . 3.20
Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 D
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
Diagnostic Codes, Instrument Cluster . . . . . . . . . . . . . . 10.10
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Diagnostics, AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Battery Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . 10.26
Battery, Conventional . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27 Diagnostics, Gear Circuit . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Drive Belt, Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Battery, Sealed Low Maintenance . . . . . . . . . . . . . . . . 10.30
Drive Belt, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
Body Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Drive Belt, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Brake Disc, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
Drive Belt, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Brake Disc, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
Drive Clutch, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
Brake Hose and Fitting Inspection . . . . . . . . . . . . . . . . . 2.35
Drive Clutch, Bushing Service . . . . . . . . . . . . . . . . . . . . 6.16
Brake Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
Drive Clutch, Disassembly . . . . . . . . . . . . . . . . . . . . . . . 6.14
Brake Pad, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
Drive Clutch, Exploded View . . . . . . . . . . . . . . . . . . . . . 6.13
Brake Pad, Rear (6x6) . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
Drive Clutch, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
Brake Pads, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Drive Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Brake Pedal, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
Drive Clutch, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
Brake Pedal, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
Drive Clutch, Shift Weights . . . . . . . . . . . . . . . . . . . . . . 6.12
Brake System Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.34
Drive Clutch, Spider Removal . . . . . . . . . . . . . . . . . . . . 6.15
Brake System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Drive Clutch, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
Brake System, Exploded View . . . . . . . . . . . . . . . . . . . . . 9.5
Driven Clutch, Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6.21
Brake System, Operation . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Driven Clutch, Disassembly / Inspection . . . . . . . . . . . . 6.19
Breather Hose Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Driven Clutch, Exploded View . . . . . . . . . . . . . . . . . . . . 6.19
C Driven Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Cab Frame, Assembly / Removal . . . . . . . . . . . . . . . . . . . 5.7 Driven Clutch, Service . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
Caliper, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15 Driveshaft / CV Joint, Handling Tips . . . . . . . . . . . . . . . . 7.8
Caliper, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22 Driveshaft / Propshaft, Exploded View . . . . . . . . . . . . . . . 7.7
Cam Gear, Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39 Driveshaft, Mid Drive (6x6) . . . . . . . . . . . . . . . . . . . . . . 7.27
Cam Gear, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38 E
Cargo Box, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
EFI Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Cargo Box, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
EFI Priming / Starting Procedure . . . . . . . . . . . . . . . . . . 4.10
Centralized Hilliard, Exploded View . . . . . . . . . . . . . . . 7.15
EFI Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Electric Box Lift Actuator . . . . . . . . . . . . . . . . . . . . . . . 10.39
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Electrical, Cooling System Breakout Diagram . . . . . . . 10.19
Clock, Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . 4.10
Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Engine Balance Shaft Removal . . . . . . . . . . . . . . . . . . . . 3.44
Clutch Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Engine Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . 3.44
Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
Engine Camshaft Installation . . . . . . . . . . . . . . . . . . . . . 3.46
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . 3.13, 3.14
Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Engine Cooling System Troubleshooting . . . . . . . . . . . . 3.59
Coolant Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.25
Engine Crankcase Assembly . . . . . . . . . . . . . . . . . . . . . . 3.45
Coolant Strength and Type . . . . . . . . . . . . . . . . . . . . . . . 2.26
Engine Crankshaft Gear Removal . . . . . . . . . . . . . . . . . . 3.41
IX.1
Engine Crankshaft Installation . . . . . . . . . . . . . . . . . . . .3.46 Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
Engine Cylinder Head Assembly . . . . . . . . . . . . . . . . . .3.30 F
Engine Cylinder Head Inspection . . . . . . . . . . . . . . . . . .3.25
Fan Control Circuit Bypass Test . . . . . . . . . . . . . . . . . 10.20
Engine Cylinder Head Removal . . . . . . . . . . . . . . . . . . .3.24
Fan Control Circuit Operation . . . . . . . . . . . . . . . . . . . 10.20
Engine Cylinder Head Warp . . . . . . . . . . . . . . . . . . . . . .3.25
Flywheel / Stator Removal . . . . . . . . . . . . . . . . . . . . . . . 3.36
Engine Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . .3.20
Flywheel, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
Engine Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . .3.33
Front A-arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . 5.13
Engine Cylinder Installation . . . . . . . . . . . . . . . . . . . . . .3.47
Front Driveshaft, CV Joint / Boot Replacement . . . . . . . 7.9
Engine Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . .3.31
Front Driveshaft, Installation . . . . . . . . . . . . . . . . . . . . . 7.11
Engine Designation Number . . . . . . . . . . . . . . . . . . . . . . .1.2
Front Driveshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.8
Engine Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . .4.21
Front Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . 2.21
Engine Exploded Views . . . . . . . 3.2, 3.3, 3.4, 3.5, 3.7, 3.8
Front Gearcase, Assembly . . . . . . . . . . . . . . . . . . . . . . . 7.20
Engine Fastener Torques . . . . . . . . . . . . . . . . . . . . . . . . . .3.9
Front Gearcase, Backlash Pad Adjustment . . . . . . . . . . 7.22
Engine Flywheel / Stator Installation . . . . . . . . . . . . . . .3.54
Front Gearcase, Centralized Hilliard . . . . . . . . . . . . . . . 7.14
Engine Flywheel / Stator Removal . . . . . . . . . . . . . . . . .3.36
Front Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.18
Engine Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . .3.37
Front Gearcase, Installation . . . . . . . . . . . . . . . . . . . . . . 7.23
Engine Gear(s) Removal . . . . . . . . . . . . . . . . . . . . . . . . .3.37
Front Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.17
Engine Gears, Installation . . . . . . . . . . . . . . . . . . . . . . . .3.49
Front Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Engine Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .3.54
Front Propshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . 7.11
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . . . .3.19
Front Propshaft, U-Joint Service . . . . . . . . . . . . . . . . . . 7.12
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
Front Strut, Cartridge Replacement . . . . . . . . . . . . . . . . 5.15
Engine Oil and Filter Change . . . . . . . . . . . . . . . . . . . . .2.18
Front Strut, Exploded View . . . . . . . . . . . . . . . . . . . . . . 5.14
Engine Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Engine Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . .3.21
Fuel Injection, Component Locations . . . . . . . . . . . . . . . 4.6
Engine Oil Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.57
Fuel Injection, Exploded View . . . . . . . . . . . . . . . . . . . . 4.5
Engine Oil Pump Installation . . . . . . . . . . . . . . . . . . . . .3.48
Fuel Injection, Service Notes . . . . . . . . . . . . . . . . . . . . . . 4.4
Engine Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . .3.41
Fuel Injection, Special Tools . . . . . . . . . . . . . . . . . . . . . . 4.2
Engine Piston Identification . . . . . . . . . . . . . . . . . . . . . .3.13
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Engine Piston Installation . . . . . . . . . . . . . . . . . . . . . . . .3.47
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Engine Piston Removal, Inspection . . . . . . . . . . . . . . . .3.32
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Engine Piston Ring Installed Gap . . . . . . . . . . . . . . . . . .3.35
Fuel Pump / Tank Assembly . . . . . . . . . . . . . . . . . . . . . 4.11
Engine Piston to Cylinder Clearance . . . . . . . . . . . . . . .3.34
Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
Engine Piston to Rod Clearance . . . . . . . . . . . . . . . . . . .3.34
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Engine Pushrod Inspection . . . . . . . . . . . . . . . . . . . . . . .3.24 Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Engine Removal / Install Procedure . . . . . . . . . . . . . . . .3.18 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Engine Rocker Arm Inspection . . . . . . . . . . . . . . . . . . . .3.24
Engine Serial Number Location . . . . . . . . . . . . . . . . . . . .1.2 G
Engine Service Specifications . . . . . . . . . . . . . . . . . . . . .3.11 Gear / Stator Housing Seal Replacement . . . . . . . . . . . . 3.51
Engine Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8 Gear Circuit Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Engine Starter Drive Removal . . . . . . . . . . . . . . . . . . . .3.35 Gear Position Indicator Switch Test . . . . . . . . . . . . . . 10.16
Engine Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . .3.37 General Specifications, Brakes . . . . . . . . . . . . . . . . . . . . 9.2
Engine Stator Gear Cover Seal(s) Installation . . . . . . . .3.51 H
Engine Stator Installation . . . . . . . . . . . . . . . . . . . . . . . .3.54 Head Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Engine Temperature Sensor . . . . . . . . . . . . . . . . . . . . . .4.19 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Engine Temperature Sensor Replacement . . . . . . . . . . .4.20 Hub / Bearing Carrier, Mid Drive (6x6) . . . . . . . . . . . . 7.23
Engine Temperature Sensor Test . . . . . . . . . . . . . . . . . .4.20 Hub / Bearing Carrier, Rear (4x4) . . . . . . . . . . . . . . . . . 7.36
Engine Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .3.58
I
Engine Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . .3.27 Indicator, Service Interval . . . . . . . . . . . . . . . . . . . . . . . 10.9
Engine Valve Lifter Removal, Inspection . . . . . . . . . . . .3.31 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Engine Valve Seal/Spring Service . . . . . . . . . . . . . . . . .3.25 K
Engine Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . .3.31 Keys, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Engine Valve Seat Reconditioning . . . . . . . . . . . . . . . . .3.28 Kilometers to Miles Toggle . . . . . . . . . . . . . . . . . . . . . 10.10
Engine, Accessible Components . . . . . . . . . . . . . . . . . . .3.13

IX.2
 M Rear Driveshaft (4x4), Installation . . . . . . . . . . . . . . . . . 7.42
Maintenance, Brake System . . . . . . . . . . . . . . . . . . . . . . 2.34
Maintenance, Cooling System . . . . . . . . . . . . . . . . . . . . 2.25
Rear Driveshaft (4x4), Removal . . . . . . . . . . . . . . . . . . . 7.39
Rear Gearcase (4x4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44 IX
Rear Gearcase Lubrication (4x4) . . . . . . . . . . . . . . . . . . 2.23
Maintenance, Electrical and Ignition . . . . . . . . . . . . . . . 2.29
Rear Gearcase Lubrication (6x6) . . . . . . . . . . . . . . . . . . 2.24
Maintenance, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Rear Propshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . . 7.43
Maintenance, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Rear Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
Maintenance, Fuel System . . . . . . . . . . . . . . . . . . . . . . . 2.14
Rear Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
Maintenance, General Vehicle Inspection . . . . . . . . . . . 2.13
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
Maintenance, References . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Rear Suspension Adjustment (4x4) . . . . . . . . . . . . . . . . . 2.34
Maintenance, Service Products and Lubricants . . . . . . . 2.10
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
Maintenance, Steering and Suspension . . . . . . . . . . . . . 2.31
Maintenance, Transmission and Gearcases . . . . . . . . . . 2.20 S
Master Cylinder, Installation . . . . . . . . . . . . . . . . . . . . . . 9.6 Service Interval Indicator . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Master Cylinder, Removal . . . . . . . . . . . . . . . . . . . . . . . . 9.6 Shift Lever, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Mid Axle A-arm, Replacement . . . . . . . . . . . . . . . . . . . 5.16 Shift Lever,Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Mid Drive Gearcase (6x6) . . . . . . . . . . . . . . . . . . . . . . . 7.28 Shift Linkage Inspection and Adjustment . . . . . . . . . . . . 2.13
Middle Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . 2.22 Shift Linkage, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Miles to Kilometers Toggle . . . . . . . . . . . . . . . . . . . . . 10.10 Shift Linkage, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Solenoid, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
O Spark Plug Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 Special Tool, Cam Gear Installation Kit . . . . . . . . . . . . . 3.39
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Oil Pump, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
Special Tools, Body/Steering/Suspension . . . . . . . . . . . . . 5.2
Oil Pump, Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
Special Tools, Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Oil Pump, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
Special Tools, Clutching . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
P Special Tools, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 Special Tools, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
Parking Brake Caliper Service . . . . . . . . . . . . . . . . . . . . 9.10 Special Tools, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Parking Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12 Specification, Balance Shaft Gear Bolt Torque . . . . . . . 3.50
Parking Brake Pad Inspection . . . . . . . . . . . . . . . . . . . . . 2.35 Specification, Cam Lobe Height . . . . . . . . . . . . . . . . . . . 3.44
Parking Brake, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 9.9 Specification, Cam Thrust Plate Fastener Torque . . . . . . 3.48
Parking Brake, Exploded View . . . . . . . . . . . . . . . . . . . . 9.8 Specification, Camshaft Gear Bolt Torque . . . . . . . . . . . 3.50
Parking Brake, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 9.9 Specification, Coolant Sensor Resistance . . . . . . . . . . . 10.20
Periodic Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . 2.3 Specification, Cylinder Head Warp . . . . . . . . . . . . . . . . 3.25
Piston Ring Installed Gap . . . . . . . . . . . . . . . . . . . . . . . . 3.35 Specification, Cylinder Taper Limit . . . . . . . . . . . . . . . . 3.33
Piston to Cylinder Clearance . . . . . . . . . . . . . . . . . . . . . 3.34 Specification, Cylinder Warp Limit . . . . . . . . . . . . . . . . 3.33
Piston to Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3.34 Specification, Oil Pump Bolt Torque . . . . . . . . . . . . . . . 3.49
Pre-Ride / Daily Inspection . . . . . . . . . . . . . . . . . . . . . . 2.13 Specification, Oil Pump Rotor Clearance . . . . . . . . . . . . 3.41
Programmable Service Interval . . . . . . . . . . . . . . . . . . . 10.9 Specification, Timing Gear Alignment . . . . . . . . . . . . . . 3.37
Propshaft, Mid Drive (6x6) . . . . . . . . . . . . . . . . . . . . . . 7.28 Specification, Valve Seat Contact Width . . . . . . . . . . . . 3.29
Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 Specification, Valve Spring Free Length . . . . . . . . . . . . 3.26
PVT System, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 Specification, Valve Stem Diameter . . . . . . . . . . . . . . . . 3.27
PVT System, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Specification, Valve Stem Guide I.D. . . . . . . . . . . . . . . . 3.27
PVT System, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Specification, Wheel Toe-Out . . . . . . . . . . . . . . . . . . . . . 2.32
PVT System, Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Specifications, Cam Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3.44
PVT System, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Specifications, Cooling System . . . . . . . . . . . . . . . . . . . . 3.13
PVT Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23 Specifications, Crankcase Fastener Torque . . . . . . . . . .3.46
R Specifications, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 Specifications, Engine Lubrication . . . . . . . . . . . . . . . . . 3.21
Radiator Coolant Level Inspection . . . . . . . . . . . . . . . . . 2.26 Specifications, Engine Oil Pressure . . . . . . . . . . . . . . . . 3.21
Rear A-arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . 5.17 Specifications, General . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Rear Axle Service (6x6) . . . . . . . . . . . . . . . . . . . . . . . . . 7.53 Specifications, Oil Baffle Bolt Torque . . . . . . . . . . . . . . 3.45
Rear Axle, Exploded View . . . . . . . . . . . . . . . . . . . . . . . 5.21 Specifications, Oil Pick-up Bolt Torque . . . . . . . . . . . . . 3.45
Rear Cargo Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Rear Driveshaft (4x4), CV Joint / Boot Replacement . . 7.40 Speedometer Installation . . . . . . . . . . . . . . . . . . . . . . . . 10.11

IX.3
Speedometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . .10.11 Troubleshooting, Brake System . . . . . . . . . . . . . . . . . . . 9.26
Speedometer Troubleshooting Tests . . . . . . . . . . . . . . .10.12 Troubleshooting, Clutching . . . . . . . . . . . . . . . . . . . . . . 6.22
Starter Armature Testing . . . . . . . . . . . . . . . . . . . . . . . .10.35 Troubleshooting, No AWD . . . . . . . . . . . . . . . . . . . . . 10.12
Starter Assembly Exploded View . . . . . . . . . . . . . . . . .10.37 Troubleshooting, No AWD Hub Safety Limiter . . . . . 10.14
Starter Brush Inspection / Replacement . . . . . . . . . . . .10.34 Troubleshooting, No Fuel Gauge Display . . . . . . . . . . 10.15
Starter Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.36 Troubleshooting, No Gear Indicator Display . . . . . . . . 10.15
Starter Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35 Troubleshooting, No Instrument Display . . . . . . . . . . . 10.13
Starter Motor, Removal . . . . . . . . . . . . . . . . . . . . . . . . .10.33 Troubleshooting, Transmission . . . . . . . . . . . . . . . . . . . 8.15
Starter Reassembly / Installation . . . . . . . . . . . . . . . . . .10.35 Troubleshooting, Wheel Speed Sensor . . . . . . . . . . . . 10.13
Starter System Flow Chart . . . . . . . . . . . . . . . . . . . . . .10.38 V
Starter System, Troubleshooting . . . . . . . . . . . . . . . . . .10.33
Valve Seal/Spring Service . . . . . . . . . . . . . . . . . . . . . . . 3.25
Stator, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36
Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . . . . 3.28
Steering, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . .5.11
Vehicle Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Storage Box, Installation . . . . . . . . . . . . . . . . . . . . . . . . .5.25
Vent Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Storage Box, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .5.25
VIN Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Swing Arm, Exploded View . . . . . . . . . . . . . . . . . . . . . .5.21
VIN Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Swing Arm, Installation . . . . . . . . . . . . . . . . . . . . . . . . .5.20
Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
Swing Arm, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
Switch, AWD / Rear Differential (4x4) . . . . . . . . . . . . .10.4 W
Switch, Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5 Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Switch, Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4 Wheel, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
Switch, Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6 Wheel, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
T
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
Tail Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.18
Tap/Drill Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
Temperature / Barometric Air Pressure Sensor (T-Bap) .4.16
Throttle Freeplay Adjustment . . . . . . . . . . . . . . . . . . . . .2.15
Throttle Pedal Inspection . . . . . . . . . . . . . . . . . . . . . . . .2.14
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . .4.17
Throttle Position Sensor Initialization . . . . . . . . . . . . . . .4.18
Throttle Position Sensor Replacement . . . . . . . . . . . . . .4.19
Tie Rod End Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
Timing Gear Mark Alignment . . . . . . . . . . . . . . . . . . . . .3.37
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11
Torque Specifications, Body/Steering/Suspension . . . . . .5.2
Torque Specifications, Brakes . . . . . . . . . . . . . . . . . . . . . .9.2
Torque Specifications, Clutching . . . . . . . . . . . . . . . . . . .6.2
Torque Specifications, Final Drive . . . . . . . . . . . . . . . . . .7.3
Torque Specifications, Transmission . . . . . . . . . . . . . . . .8.2
Torque Specifications, Wheel, Hub, and Spindle . . . . . .2.27
Torque Specs - Engine . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
Transmission I.D. Number Location . . . . . . . . . . . . . . . . .1.3
Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . . . .2.20
Transmission, Assembly . . . . . . . . . . . . . . . . . . . . . . . . .8.10
Transmission, Disassembly . . . . . . . . . . . . . . . . . . . . . . . .8.5
Transmission, Exploded View . . . . . . . . . . . . . . . . . . . .8.16
Transmission, Installation . . . . . . . . . . . . . . . . . . . . . . . .8.14
Transmission, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3
Trip Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
Troubleshooting, Brake Noise . . . . . . . . . . . . . . . . . . . . . .9.3

IX.4
 WIRE DIAGRAM

RANGER 700 EFI 4X4 / 6X6 (CHASSIS) PAGE 1 OF 2

11.1
WIRE DIAGRAM

RANGER 700 EFI 4X4 / 6X6 (CHASSIS) PAGE 2 OF 2

11.2
 WIRE DIAGRAM

RANGER 700 EFI 4X4 / 6X6 (DASH)

11.3
WIRE DIAGRAM

RANGER 700 EFI 4X4 / 6X6 (BREAKOUTS)

11.4