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Polaris 2008 ranger 700 xp, Service Manual

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10.3

ELECTRICAL

10

GENERAL INFORMATION

Special Tools

Electrical Service Notes

Keep the following notes in mind when diagnosing an electrical
problem.

• Refer to wiring diagram for stator and electrical 

component resistance specifications.

• When measuring resistance of a component that has a 

resistance value under 10 Ohms, remember to subtract 
meter lead resistance from the reading. Connect the 
leads together and record the resistance. The resistance 
of the component is equal to tested value minus the lead 
resistance.

• Become familiar with the operation of your meter. Be 

sure leads are in the proper jack for the test being 
performed (i.e. 10A jack for current readings). Refer to 
the Owner’s manual included with your meter for more 
information.

• Voltage, amperage, and resistance values included in 

this manual are obtained with a Fluke™ 77 Digital 
Multimeter (PV-43568). This meter is used for when 
diagnosing electrical problems. Readings obtained with 
other meters may differ.

• Pay attention to the prefix on the multimeter reading (K, 

M, etc.) and the position of the decimal point.

• For resistance readings, isolate the component to be 

tested. Disconnect it from the wiring harness or power 
supply.

Under-Hood Components

Part Number

Tool Description

PV-43568

Fluke™77 Digital Multimeter

2870630

Timing Light

2870836

Battery Hydrometer

2460761

Hall Sensor Probe Harness

2871745

Static Timing Light Harness

PU-47063

Digital Wrench™ Diagnostic Software

PU-47471

Digital Wrench™ SmartLink Module Kit

A

B

C

D

E

F

G

A. Voltage Regulator / Rectifier

B. Starter Solenoid

C. Terminal Block

D. Positive Battery Cable

E. Negative Battery Cable

F. Battery

G. Starter Motor Positive Lead

H. Relays 

H

Summary of Contents for 2008 ranger 700 xp

Page 1: ...POLARIS RANGER XP 700 4X4 RANGER 6X6 SERVICE MANUAL ...

Page 2: ...1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 FUEL INJECTION 5 BODY STEERING SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION BRAKES 9 ELECTRICAL 10 ...

Page 3: ...POLARIS RANGER XP 700 4X4 RANGER 6X6 SERVICE MANUAL ...

Page 4: ...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 ME...

Page 5: ...gine model number and serial number This information can be found on the sticker applied to the cylinder head on the side of engine Machine Model Number Identification Model Year Designation Basic Chassis Designation Engine Designation Emissions Model Option R 0 7 R H 6 8 A G 4 X A R H 6 8 A 7 P 0 0 0 0 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg ID Engine Vehicle Description Vehicle I...

Page 6: ...ehicle identification The machine serial number A is 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 Transmission I D Number Location A A A B The transmission I D number is located on the right side when installed in the machine ...

Page 7: ...1 4 GENERAL INFORMATION VEHICLE DIMENSIONS RANGER 4X4 6X6 75 in 190 50 cm 10 in 25 4 cm 58 in 147 cm RANGER 4x4 ...

Page 8: ...1 5 GENERAL INFORMATION 1 Vehicle Dimensions RANGER 4X4 6X6 120 in 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 ...

Page 9: ...ons 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Vehicle Payload 1500 lbs 681 kg Includes driver and two passengers 500 lbs 227kg Hitch Towing Capacity 1500 lbs 681 kg Hitch Tongue Capacity 150 lbs 68 kg 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 k...

Page 10: ...mp Dash Harness 20 Amp Accessory Terminal 20 Amp Power Relay 15 Amp ECU Battery Supply 6 Amp Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio Front Rear High Low Rev 3 34 1 2 89 1 8 67 1 7 49 1 5 92 1 5 11 1 Drive Ratio Front 3 818 1 Drive Ratio Final 3 70 1 Shift Type In Line Shift H L N R Trans Oil Requirements Polaris AGL Gearcase Lube Belt 3211106 Drive Belt Deflection 1 125 28 57...

Page 11: ... Fan 20 Amp Dash Harness 20 Amp Accessory Terminal 20 Amp Power Relay 15 Amp ECU Battery Supply 6 Amp Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio Front Rear High Low Rev 3 89 1 3 36 1 10 08 1 8 71 1 6 87 1 5 94 1 Drive Ratio Front 3 818 1 Drive Ratio Mid 3 70 1 Drive Ratio Final 3 70 1 Shift Type In Line Shift H L N R Trans Oil Requirements Polaris AGL Gearcase Lube Belt 3211106 ...

Page 12: ...Special Tools when servicing any Polaris product Dealers may order special tools through Polaris official tool supplier SPX Corporation 1 800 328 6657 M 20 20 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 ...

Page 13: ...1 10 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 ...

Page 14: ...The following torque specifications are to be used only as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views or each manual section for torque values of fasteners before using standard torque ...

Page 15: ...1 12 GENERAL INFORMATION SAE Tap Drill Sizes Metric Tap Drill Sizes Decimal Equivalents ...

Page 16: ...he 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 cm 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 in Pounds per...

Page 17: ... 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...

Page 18: ...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 SYST...

Page 19: ...mediately 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 vehicl...

Page 20: ...ly Inspect clean often E Air Box Sediment Tube Daily Drain deposits when visible Coolant Level Daily Check level daily change coolant every 2 years Head Lamp Tail Lamp Daily Check operation apply dielectric grease if replacing E Air Filter Main Element Weekly Inspect replace as needed Brake Pad Wear Inspect Parking Brake Pads 10 H Monthly Inspect periodically Battery 20 H Monthly Check terminals c...

Page 21: ... Linkage 50 H 6 M Inspect lubricate adjust Steering 50 H 6 M Lubricate Front Suspension 50 H 6 M Lubricate Rear Suspension 50 H 6 M Lubricate E Throttle Cable Throttle Pedal 50 H 6 M Inspect adjust lubricate replace if necessary E Throttle Body Air Intake Ducts Flange 50 H 6 M Inspect ducts for proper sealing air leaks Drive Belt 50 H 6 M Inspect adjust replace as needed Cooling System 50 H 6 M In...

Page 22: ... 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 E Spark Plug 100 H 12M Inspect replace as needed Wiring 100 H 12M Inspect for wear routing security apply dielectricgreasetoconnectorssubjectedto water mud etc Clutches Drive and Driven 100 H 12M Inspect clean replace worn parts Front Wheel Bearing...

Page 23: ... Front Gearcase Behind Radiator Engine under seat Rear Gearcase Gas Tank Dash Components Cup Holder Cup Holder Storage Compartment with lid AWD Differential Switch if equipped 12V Accessory Outlet Mode Button Storage Tray Ignition Switch Storage Box Light Switch Instrument Cluster ...

Page 24: ...2 8 GENERAL INFORMATION LH Side and Rear View 4X4 Battery Front Prop Shaft Storage Transmission Rear Prop Shaft Tail Gate Latch Air Cleaner Muffler 2 Hitch Drive Shafts Compartment ...

Page 25: ...2 9 GENERAL INFORMATION 2 LH Side and RH Side Views 6X6 Battery Rear Gearcase Mid Gearcase Transmission Engine under seat Front Gearcase behind radiator Front Prop Shaft Rear Prop Shaft Drive Shafts ...

Page 26: ...ialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 24 Count 2871423 Premium All Season Grease 14 oz cartridge 10 Count 2871460 Starter Drive Grease 12 Count 2871515 Premium U Joint Lube 3 oz 24 Count 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 P...

Page 27: ...rty conditions or short trip cold weather operation 2 Brake Fluid DOT 3 PN 2870990 or Dot 4 Fill reservoir between MAX and Min lines As required Change fluid every 2 years 3 Transmission Polaris AGL Gearcase Lubricant PN 2873602 Add lube to bottom of fill plug threads Change annually Change more often if used in severe conditions 4 Front Gearcase Polaris Demand Drive Hub Fluid PN 2871654 Drain com...

Page 28: ...Locate grease fitting on the underside of the hubstrut assembly and grease with grease gun Semi annually 7 Swing Arm Pivot Polaris All Season Grease PN 2871423 Locate grease fitting on inside of the swing arm pivot Semi annually 8 Rear Prop Shaft Yoke Polaris Premium U Joint Lube PN 2871551 Locate fittings and grease with grease gun Semi annually 9 Front Prop Shaft Yoke Polaris Premium U Joint Lub...

Page 29: ...ly 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 Linkage Inspection Adjustment Linkage rod adjustment is necessary when symptoms include No All Wheel Drive light Noise on deceleration Inability to engage a gear Excessive gear clash noise Shift selectors moving o...

Page 30: ...ive play due to cable stretch or cable misadjustment it will cause a delay in throttle speed Also the throttle may not open fully If the throttle pedal has no play the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart and adjust the play if necessary WARNING Gasoline is extremely flammable ...

Page 31: ...r the cable adjuster to its original position Air Filter Service It is recommended that the air filter be replaced annually When riding in extremely dusty conditions replacement will be required more often The filter should be inspected periodically before each ride using the following procedure 1 Lift the box to access the filter box cover 2 Remove clips 2 from air box cover and remove cover Insp...

Page 32: ...air box cover and secure with clips Air Intake Inspection 1 Lift the hood 2 Inspect the foam inserts in the air baffle boxes If the foam inserts are dirty clean the foam with a high flash point solvent followed by hot soapy water 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 Foam Air Baffing Bo...

Page 33: ...gh pressure leakage testers as crankshaft seals may dislodge and leak 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 NOTE Make sure lines are not kinked or pinched Engine Oil Level The twin cylinder eng...

Page 34: ...iately Engine Oil and Filter Change 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 front engine cover and storage removal 3 Run engine two to three minutes until warm Stop engine 4 Clean area around drain plug at bottom of oil eng...

Page 35: ...n below 2 Place the transmission in Park and start the engine Purge accumulated carbon from the system by momentarily revving the engine several times 3 If some carbon is expelled cover the exhaust outlet and lightly tap on the pipe around the clean out plugs with a rubber mallet while revving the engine several more times Crankcase Drain Plug Torque 192 24 in lbs 21 7 2 7 Nm Oil Filter Torque Tur...

Page 36: ...plugs TRANSMISSION AND GEARCASES Transmission Lubrication NOTE It is very important to follow a regular transmission fluid check change schedule The service manual of the RANGER recommends the level be checked every twenty five 25 hours of operation and changed once 1 a year The transmission lubricant level should be checked and changed in accordance with the maintenance schedule Be sure vehicle i...

Page 37: ...nce 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 front gearcase lubricant to use is Polaris Premium Demand Hub Fluid To check the lubricant level The front gearcase lubricant level cannot be checked with a dipstick The gearcase must be drained and re filled with the prope...

Page 38: ...ith the recommended fluid amount 5 oz or to the bottom of the fill plug hole threads 6 Install fill plug and check for leaks Middle Gearcase Lubrication 6x6 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 corre...

Page 39: ...l to the bottom of the threads of the fill plug hole 7 Install fill plug Check for leaks Rear Gearcase Lubrication 4x4 To check the level 1 With machine on level ground and with the parking brake on remove fill plug from rear gearcase 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 absorbent measuring instrument white zip tie to ...

Page 40: ...e gearcase must be drained and re filled with the proper amount of lubricant Refer to the procedure below To change rear gearcase lubricant 1 With the vehicle on a level surface remove the fill plug and check the lubricant level Lubricant should be kept at the specified level according to the proper gearcase specifications listed 2 Support the vehicle securely with a jack stand and remove the fron...

Page 41: ...em is purging itself of trapped air Observe coolant levels often during the break in period 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 not dilute with water Coolant Level Inspection The recovery bottle located on the left side of the machine must be maintained between the minimum and maximum levels indicate...

Page 42: ...nd 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 Straight water or antifreeze may cause the system to freeze corrode or overheat Cooling System Pressure Test Refer to Chapter 3 for cooling system pressure test procedure Cooling System Hoses 1 Inspect all hoses for cracks deterio...

Page 43: ...op radiator bolts remove four screws from the top front of the hood liner Prop the front of the hood up 1 5 inches 38 10 mm to help remove the top bolts that secure the radiator to the frame 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 4 Remove the outlet radiator hose inlet radiator hose surge tank ...

Page 44: ...s if applicable and wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts to the proper torque listed in the torque table at the beginning of this section 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 v...

Page 45: ... the battery fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery Battery Removal 1 Open the Hood 2 Remove the battery vent tube from the battery 3 Disconnect the black negative battery cable 4 Disconnect the red positive battery cable CAUTION Maintain proper tire pressure Refer to the ...

Page 46: ...ders can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging 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 1 10 of the battery s amp hr rating Charge as needed to raise the speci...

Page 47: ...ure Tie Rod End Steering Inspection 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 Replace any worn steering components Steering should move freely through entire range of travel without binding Elevate front end of machine so front wheels are off the ground Check for any looseness...

Page 48: ...to 1 4 3 to 6 cm wider than the measurement at the rear B Toe Adjustment If toe alignment is incorrect measure the distance between vehicle center and each wheel This will tell you which tie rod needs adjusting NOTE Be sure steering wheel is straight ahead before determining which tie rod s need adjustment To adjust toe alignment Hold tie rod end to keep it from rotating Loosen jam nuts at both en...

Page 49: ...asteners for wear or damage Inspect front strut cartridges for leakage Rear 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 Bolt Torque Inspect for leaks 15 ft lbs 20 Nm RANGER 4X4 RANGER 6X6 Independent Rear Suspension Rear Swingarm Suspension ...

Page 50: ...EM Brake System Inspection The following checks are recommended to keep the brake system in good operating condition Service life of brake system components depends on operating conditions Inspect brakes in accordance with the maintenance schedule and before each ride Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir Use Polaris DOT 3 or DOT 4 Brake Fluid Ch...

Page 51: ...d 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 Inboard Pad Outboard Pad Inboard Pad Thickness New 304 7 72 mm Limit 0 24 6 1 mm 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 ...

Page 52: ...2 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 CYLIND...

Page 53: ...6 in lbs 6 8 68 Nm 192 24 in lbs 21 7 2 7 Nm 115 12 in lbs 13 1 35 Nm 60 6 in lbs 6 8 68 Nm NOTE If needed heat the oil baffle bolts with a heat gun to remove 22 2 ft lbs 30 3 Nm A JournalBearings B Camshaft C ThrustPlate D Balance Shaft E Woodruff Key F Flange Seal G Crankshaft H Oil Pickup I Journal Bearings J Baffle K Oil Plug L Washer M O ring N Crankcase O Crankcase Bolts ...

Page 54: ... Bolts N Engine Cover O Wire Hold down P StatorHousingBolts A B C D E F G H J K L M N P 22 2 ft lbs 30 3 Nm 84 8 in lbs 9 5 90 Nm Apply corrosion resistant grease to stator grommet area 96 3 in lbs 10 85 0 35 Nm 108 12 in lbs 6 8 68 Nm Oil Pump Bolt Tighten Sequence Apply White Lithium Grease Apply Polaris OW 40 oil to component Mag Cover Bolt Tighten Sequence No Grease on this Portion of the Gask...

Page 55: ...sher N Flywheel Apply Polaris Starter Grease Apply Polaris 0W 40 oil to seal Loctite Pipe Sealant PN 2871956 A 1st 2nd Tighten Top Bolt First 84 8 ft lbs 9 5 0 9 Nm No Grease or Oil B C D E F G H I J K L M N O 108 12 ft lbs 12 1 35 Nm 96 12 in lbs 10 85 1 35 Nm 65 7 ft lbs 88 9 5 Nm 96 12 in lbs 10 85 1 35 Nm Water Pump Cover Bolt Tighten Sequence Stator Cover Bolt Tighten Sequence 2 1 3 4 5 6 7 ...

Page 56: ... Clamp B Oil Fill Tube C Dipstick D O ring E Hex Plug F Oil Filter Nipple G Oil Filter H Dowel I GalleyPlugAsm J Screw K Relief Spring A B C D E F G H I J K 50 5 in lbs 5 65 0 56 Nm 22 2 ft lbs 30 3 Nm 18 2 ft lbs 24 4 2 71 Nm 35 4 ft lbs 47 5 5 4 Nm 50 5 in lbs 5 65 0 56 Nm ...

Page 57: ...cker Arms C HeadAssembly D Gasket E Pushrods F Bushing G Expansion Plug H Cylinder I PistonAssembly J Circlip K Gasket L Hydraulic Lifter A C D E F G H I J K L Apply each Bolt Threads 1 2 3 4 4 5 6 3 Circlip UP for Install Do Not install expansion plug more than 1 5 mm inward Apply Polaris 0W 40 Oil Apply Moly Lube Grease Side View Initial 35 4 ft lbs 47 5 5 5 Nm in sequence Finalize sequence by t...

Page 58: ... 9 Nm 18 2 ft lbs 24 5 2 7 Nm A Screws B Rocker Cover C Breather D O ring Seal E Breather Bolts F Spark Plugs G Intake Boot H Bolts I Boot Clamp J Throttle Body K Crank Position Sensor L Thermistor M O ring N Thermostat O Bolts P Gasket Q Exhaust Manifold R Bolts S Thermostat Housing A B E C D F G H I J Apply Corrosion Resistant Grease K L M N O P Q 18 2 ft lbs 24 5 2 7 Nm R Apply Dielectric Greas...

Page 59: ...3 8 ENGINE EFI Harness Fuel Injection Exploded View A Fuel Injector B Fuel Rail C EFI Harness A B C 18 2 ft lbs 24 5 2 7 Nm NOTE See Chapter 4 for more information on the EFI system ...

Page 60: ...olt 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 Cylinder Head Bolt Tighten Sequence ...

Page 61: ...neto 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 21...

Page 62: ...78 88 35 mm Valve Seat Valve Seat Contacting Width Intake 0 0472 0 00787 0 0039 1 20 0 20 0 10mm 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 Valve Guide Inner diameter 0 2367 0 00029 6 012 0 007 mm Valve Guide Protrusion Above Head 0 807 0 0039 20 50 0 01 mm Valve Valve Margin Thickness Intake Standard 0 79 20 06 mm Max 0 98 2...

Page 63: ... 0 005 mm 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 Piston Ring Installed Gap Top Ring Standard 0 0059 0 138 0 15 0 35mm Top Ring Limit 15 Leakdown Second Ring Standard 0 0098 0 197 0 25 0 50mm Second Ring Limit 15 Leakdown Oil Ring Standard 0 0196 0 00984 0 50 0 ...

Page 64: ...w to identify pistons and rings Cooling System Specifications Part Number Tool Description PV 43527 OIL FILTER WRENCH 2200634 VALVE SEAT RECONDITIONING KIT PU 45257 VALVE SPRING COMPRESSOR PU 45652 VALVE PRESSURE HOSE 2871043 FLYWHEEL PULLER 2870390 PISTON SUPPORT BLOCK PU 45497 1 CAM GEAR SPRING INSTALLATION KIT PU 45497 2 CAM GEAR TOOTH ALIGNMENT TOOL PU 45498 CAM SPANNER WRENCH PU 45838 GEAR HO...

Page 65: ... 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 Radiator Cap Pressure Test 1 Remove radiator cap and test cap using a commercially available cap tester 2 The radiator cap relief pressure is 13 psi ...

Page 66: ...nt 3 Remove surge tank fill cap B and fill the surge tank to the full line Surge Tank Engine Inlet Hose Engine Outlet Hose Radiator Inlet Hose Radiator Outlet Hose Shroud Drain Plug Radiator Radiator Cap Fan WARNING Always wear safety glasses and proper shop clothing when performing the procedures in this manual Failing to do so may lead to possible injury or death CAUTION Use caution when perform...

Page 67: ...heating occurs after repeating this procedure proceed to Procedure 2 PROCEDURE 2 1 Drive the machine onto a slight incline or use properly weight rated ramps Place the machine in Neutral and set the parking brake Block the rear wheels The radiator neck should be above the level of the top of the engine 2 Remove radiator cap and top off coolant Fill the surge tank to the full line 3 Leave the cap o...

Page 68: ... removed through the dog house 5 Remove the heat shield shown below and loosen the exhaust mounts 6 Remove the upper engine mount 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 9 Move the ...

Page 69: ...e exhaust shield C 12 Disconnect the air intake hose D from the air box and remove the air intake hose 13 Disconnect the Throttle Position Sensor at the electrical connector E Remove the clamps that secure the throttle body F to the air intake boot and engine intake boot Remove the throttle body F Insert a shop towel into the engine intake to prevent dirt from entering the intake port 14 Relieve t...

Page 70: ... 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 re attach any fasteners or protective tubing Check for any possible rubbing po...

Page 71: ...ld have a cross hatch pattern to ensure piston ring seating and to aid in the retention of the fuel oil mixture during initial break in Hone cylinder according to hone manufacturer s instructions or these guidelines Honing should be done with a diamond hone Cylinder could be damaged if the hone is not hard enough to scratch the nicasil lining Use a motor speed of approximately 300 500 RPM run the ...

Page 72: ...ntion 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 Oil Pressure Test 1 Remove blind plug sender from left side of crankcase 2 Insert a 1 8 NPT oil pressure gauge adaptor in...

Page 73: ... 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 crank...

Page 74: ... 3 ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Push Rods Hydraulic Lifters Valves Cylinder Head Valve Seals Springs Spring Retainers Rocker Arms Retainer Locks keepers Valve Spring Seats ...

Page 75: ...oves 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 the valve closed Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness 5 If the push rod A is visibly bent it should be replaced Cylinder Head Removal 1 Loosen the six cylinder head bolts eve...

Page 76: ... valve cover rocker arms and pushrods align the cylinder to be worked on at top dead 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 ...

Page 77: ...ut of specification 4 Remove valve guide seals 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 In mm Valve Spring...

Page 78: ...tem with a micrometer in three places then rotate 90 degrees and measure again six measurements total Compare to specifications 6 Measure valve guide C inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer Measure in two directions 7 Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance NOTE The valve guides ca...

Page 79: ...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 NOTE Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the entire circumference o...

Page 80: ...ly into place a few times 7 Remove valve and check where the Prussian Blue indicates seat contact on the valve face The valve seat should contact the middle of the valve face or slightly above and must be the proper width If the indicated seat contact is at the top edge of the valve face and contacts the margin area B it is too high on the valve face Use the 30 cutter to lower the valve seat If to...

Page 81: ...ly NOTE Assemble the valves one at a time to maintain proper order 1 Apply engine oil to valve guides and seats 2 Coat valve stem with molybdenum disulfide grease or 0W 40 Synthetic oil 3 Install valve carefully with a rotating motion to avoid damaging valve seal 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 ...

Page 82: ...PN 2870390 Valve Lifter Removal Inspection 1 Remove the valve lifter s by reaching into the crankcase and pushing the lifter up through the lifter bore by hand 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 reasse...

Page 83: ...emove 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 rin...

Page 84: ...r a dial bore gauge Measure in two different directions front to back and side to side on three different levels 1 2 down from top in the middle and 1 2 up from bottom Record measurements If cylinder is tapered or out of round beyond 002 the cylinder must be replaced In mm Cylinder Warp 004 0 1 mm Max Measure atdifferent points on surface A B A B C In mm Cylinder Taper Limit 002 9 05mm Max Cylinde...

Page 85: ... O D Replace piston and or piston pin if out of tolerance 3 Measure connecting rod small end ID Piston to Cylinder Clearance See 700 EFI Engine Service Specifications on page 3 11 Piston O D See 700 EFI Engine Service Specifications on page 3 11 Piston Pin Bore See 700 EFI Engine Service Specifications on page 3 11 5 mm Piston Piston Pin Piston Pin O D See 700 EFI Engine Service Specifications on ...

Page 86: ...ap after re boring a cylinder or when installing new rings A re bored cylinder should always be scrubbed 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 1 Remove stator housing bolts and remove housing 2 Remove the flywheel nut and washer Install Flywheel Puller PN 2871043...

Page 87: ...871043 and remove flywheel 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 5 Remove the bendix E if necessary Engine Crankcase Disassembly Inspection 1 Remove the stator cover A and water pump cover B CAU...

Page 88: ...nd the woodruff key I from the crankshaft The stator does not have to be removed at this point 6 Remove the gear stator housing bolts and remove the gear stator housing cover J and gasket from the crankcase Be sure to catch the excess oil from the crankcase 7 Note the positions of the gears in the photo CAUTION Do not thread the puller bolts into the flywheel more than 1 4 or stator coils may be d...

Page 89: ... 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 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 ...

Page 90: ...ll 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 1 are below flush with end of the springs This helps to align the three gear tabs during the next step 18 Line up the two gears using the timing marks and the three gear tabs that were referenced earlier Pus...

Page 91: ...ase of installing the Cam Gear Alignment Tool PU 45497 2 R use a twisting motion when pushing down on the tool 21 To remove the balance shaft gear the flat side of the camshaft P must face the balance shaft gear To rotate the camshaft use the Cam Spanner Wrench PU 45498 to rotate the camshaft so the flat side of the camshaft faces the balance shaft gear NOTE This Cam Spanner Wrench PU 45498 is onl...

Page 92: ...l pump gear S so that all four bolts are visible though the gear Remove the four bolts with a hex wrench Pull out the pump 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 previously installed NOTE If replacing the old rotors new replacement rotors will fit into the ...

Page 93: ... the valve is installed incorrectly oil pressure and oil priming problems will occur 31 Carefully press the gear off the assembly while supporting the housing assembly 32 Remove the snap ring from the assembly Place the housing in a support and press out the bearing shaft assembly 33 Place the shaft in a press to remove the bearing T 22 2 ft lbs 30 3 Nm 22 2 ft lbs 30 3 Nm Chamfer End First CAUTIO...

Page 94: ...d engine mount Remove crankcase bolts Tap on the reinforced areas on the cases using soft hammer Carefully separate the two crankcase halves 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 ...

Page 95: ...ion 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 4 Measure camshaft journal outside diameters O D In mm Cam Lobe Height Intake Exhaust Std 1 3334 33 8674 mm 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 Cam...

Page 96: ...fle weldment B Torque bolts to specification 3 Install the balance shaft Inspect balance shaft clearance C in both gearcase halves Rotate balance shaft to ensure that there is clearance between it and oil baffle weldment NOTE Always install new balance shaft bearings In mm Camshaft Journal Bore I D Mag 1 656 0 00039 42 07 0 010mm Ctr 1 637 0 00039 41 58 0 010mm PTO 1 617 0 00039 41 07 0 010 mm In ...

Page 97: ...f hole E 7 Assemble the crankcase halves Apply LocTite 242 PN 2871949 to the threads and pipe sealant to the bolt flanges Torque bolts to specification following torque pattern at beginning of this chapter 8 Lubricate cam lobes and valve lifters with Moly Lube Grease 9 Lubricate lifters with engine oil and install in the original order as removed in disassembly Apply Lubricant or Moly Lube to the ...

Page 98: ...ment of the pistons to the connecting rods upon assembly Partially install the piston pins into the pistons 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 15 Install the pisto...

Page 99: ...ation of lubrication aids in priming the oil pump during initial engine start up 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 o...

Page 100: ...ot plate J 23 Use extreme caution when removing the crankshaft gear from the hot plate Use a pair of pliers and leather gloves when handling the crankshaft gear 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 T Oil Pump...

Page 101: ...ming 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 NOTE Cam Spanner Wrench PU 45498 is only needed to rotate the camshaft when the entire valve train is assembled 27 Reinstall the camshaft gear so the timing marks are properly aligned Install the washer and bolt Torque to specificatio...

Page 102: ...seal lip facing out towards the crankcase Use of a hydraulic press is recommended for this procedure 29 Install a new crankshaft seal P into the gear stator housing cover Use the Universal Driver Handle PU 45543 and the Main Seal Installer PA 45483 to seat the crankshaft seal into place NOTE Install the crankshaft seal P with the seal lip facing out towards the crankcase 30 Once the crankshaft sea...

Page 103: ...557 to the outside edges of the crankcase halves See arrows where the crankcases mate See photos below This helps to prevent coolant leakage 35 Install the gear stator housing gasket onto he crankcase 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 PA 4...

Page 104: ...the nut to specification 39 Install water pump cover R with new O ring seal Torque bolts to specification in proper sequence See front of this chapter 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 P Q T Water Pump Housing Bolt T...

Page 105: ...roperly under the wire hold down bracket 3 Install the flywheel washer nut and key Torque flywheel nut to specification 4 Install stator housing with new o rings Torque the bolts to specification and follow proper bolt torque sequence at the beginning of this chapter Cylinder Head Reassembly NOTE Before reassembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This wi...

Page 106: ...sure that tab of fulcrum F is seated in head stand off Torque bolts to specification 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 T Cylinder Head Bolt Torque Initial setting 35 4 ft lbs 47 5 5 5 Nm Allow to set for 1 minute then turn ...

Page 107: ... proper sealing when installing bolts 10 Install rocker cover Torque bolts to specification 11 Install thermostat J new O ring and thermostat housing Torque to specification 12 Install temperature sender K and torque to specification T Breather Bolt Toque 20 5 in lbs 2 5 0 55 Nm T Rocker Cover Bolt Torque 84 8 in lbs 9 5 0 9 Nm Torque in Sequence T Thermostat Housing Bolt Torque 84 8 in lbs 9 5 0 ...

Page 108: ...U 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 T Primer Plug Torque 18 2 ft lbs 24 4 2 71 Nm Fill 3 4 full with 0W 40 PU 45778 CAUTION After any reassembly or rebuild the engine must be primed using the Oil Priming Adapter PU 45778 and a...

Page 109: ...ailure Engine Runs But Will Not Idle Restricted carburetor pilot system Low compression Crankcase breather restricted Engine Idles But Will Not Accelerate Spark plug fouled weak spark Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Incorrect or restricted carburetor jetting ETC switch limiting speed Reverse speed limiter limiting speed Incorrect igni...

Page 110: ...nition or kill switch circuit faulty Poor connections in ignition system Ignition timing incorrect Sheared flywheel key Valve sticking Cooling System Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiator lines pump or water jacket...

Page 111: ...L 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 ...

Page 112: ... 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 Do not smoke or allow open flames or sparks in or 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 c...

Page 113: ...oftware Polaris dealers can also order the following separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 This module kit is used on all 8 pin connector based Polaris EFI systems This kit is available to Polaris dealers through our tool supplier SPX 1 800 328 6657 Digital Wrench Diagnostic Connector Located under the hood as shown below Throttle Pos...

Page 114: ...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 ...

Page 115: ...ure 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 ...

Page 116: ... BAP Located in the rubber intake boot between the air box and throttle body 3 Crankshaft Position Sensor CPS Located in the magneto cover on the right hand side of the engine 4 Fuel Injectors Fuel Rail Attached to the fuel rail located in the intake track of the cylinder head 5 Fuel Pump Regulator Gauge Sender Assembly Located in fuel tank as an assembly 6 Throttle Body Throttle Body ...

Page 117: ...4 7 FUEL INJECTION 4 7 Throttle Position Sensor TPS Located on the right hand side of the throttle body 8 Engine Coolant Temperature Sensor ECT Located in the cylinder head TPS ...

Page 118: ...4 8 FUEL INJECTION FUEL TANK Exploded View Fuel Flow ...

Page 119: ...ation 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 i...

Page 120: ...osition and speed RPM throttle position engine coolant temperature air temperature intake manifold air pressure and battery voltage The ECU compares the input signals to the programmed maps in its memory and determines the appropriate fuel and spark requirements for the immediate operating conditions The ECU then sends output signals to set the injector duration and ignition timing During operatio...

Page 121: ...eplacement 1 Remove the retaining screws 2 holding the ECU 2 With the Ignition turned off disconnect the wire harness from the ECU 3 To install reverse the procedures and tighten screws to specification FUEL PUMP Operation Overview NOTE All EFI units utilize quick connect lines An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank This assembly include...

Page 122: ... of 7 volts is present If voltage is between 7 and 14 turn key switch off and connect an ohmmeter between the terminals A and C on the pump to check for continuity NOTE If there was no continuity between the pump terminals replace the fuel tank assembly NOTE If the voltage was below 7Vdc test the battery ignition switch wiring harness and ECU 5 If voltage at the plug was good and there was continu...

Page 123: ... 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 6 Remove the RH rear fender and fuel cap 7 Remove the two inner bolts that hold the fuel tank to the frame 8 Remove the two outer lower bolts that hold the fuel tank to the frame ...

Page 124: ...ator 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 The fuel injectors mount into the intake manifold and the fuel rail attaches to them at the top end Replaceable O rings on both ends of the injector prevent exter...

Page 125: ...lude dirty air filters higher than normal operating temperatures short operating intervals and dirty incorrect or poor quality fuel Cleaning of clogged injectors is not recommended they should be replaced Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem Fuel Injector Replacement 1 Engine must be cool Depressurize fuel system through test valv...

Page 126: ...m hex wrench remove the retaining bolt and replace the sensor using a light coating of oil on the o ring to aid installation 3 Torque the retaining bolt to specification TEMPERATURE BAROMETRIC AIR PRESSURE SENSOR T BAP Operation Overview Mounted on the throttle body intake the temperature and barometric air pressure sensor T BAP performs two functions in one unit Air passing through the intake is ...

Page 127: ...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 VERIFY TPS TESTER REFERENCE VOLTAGE A 5 volt reference voltage from the harness is required for the TPS test to b...

Page 128: ...m throttle cam With engine off back out air flow screw until it no longer is in contact with throttle plate cam The throttle plate should seal off throttle bore completely Open and close throttle plate a couple of times to ensure full throttle closing Do not snap closed as this could cause unnecessary throttle plate to throttle body interference and or damage Set up the TPS Test Adapter Harness PU...

Page 129: ...hrottle body B to gain access to the 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 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 t...

Page 130: ...sor by using the Digital Wrench Diagnostic Software dealer only Refer to the Digital Wrench User Guide for more information 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 ECT Sensor Resistance Read...

Page 131: ...s 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...

Page 132: ... engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug TPS setting incorrect Injector failure Poor Idle Symptom Idle Too High If greater than 1300 RPM when engine is warm Throttle stop screw set incorrect Throttle cable sticking improperly adjusted routed incorrectly Sym...

Page 133: ...G ASSEMBLY 5 11 EXPLODED VIEW 5 11 STEERING AND SUSPENSION 5 12 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 ...

Page 134: ...olt 6x6 35 ft lbs 47 Nm Lower Middle Wheel Bearing Carrier Bolt 6x6 35 ft lbs 47 Nm Lower Rear Wheel Bearing Carrier Bolt 30 ft lbs 41 Nm Upper Middle Wheel Bearing Carrier Bolt 6x6 35 ft lbs 47 Nm Upper Rear Wheel Bearing Carrier Bolt 30 ft lbs 41 Nm 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 Nu...

Page 135: ...R 1 Lift the hood 2 Remove the 3 front Torx screws from LH and RH wheel well panels 3 Remove the 2 top bumper mounting bolts 4 Remove the 3 lower bumper mounting bolts CARGO BOX 1 Place box in the dump position 2 Remove the pin and clip from the shock at the cargo box 3 Disconnect light harnesses 4 Remove 2 screws holding hinge pins 5 Tap out hinge pins 6 Lift the box off the frame with assistance...

Page 136: ...5 4 BODY STEERING SUSPENSION Lower Body Components ...

Page 137: ...SPENSION 5 Hood Dash Components Glove Box Assembly Cup Holder Hood Hood Liner Hood Latch Strap Headlights Hinges T 27 4 5 ft lbs 5 6 Nm 8 10 in lbs 0 9 1 0 Nm T 30 T 27 Torx 4 5 ft lbs 5 6 Nm T 27 4 5 ft lbs 5 6 Nm Grille ...

Page 138: ...NG SUSPENSION Dash Instruments and Controls C D E F G A Speedometer B Headlight Switch C 2WD AWD Switch D 12 Volt Accessory Receptacle E Speedometer Mode Button F Key Switch G Speedometer Mount Plate B C D B E F G A A ...

Page 139: ...me 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 N...

Page 140: ... MAIN FRAME 4X4 Exploded View Seat Base Front Cab Support Bumper Grills LH Floor Support 45 ft lbs 61 Nm RH Floor Support 28 32 ft lbs 38 43 Nm 28 32 ft lbs 38 43 Nm 13 15 ft lbs 17 20 Nm Frame Extension Main Frame T 27 4 6 ft lbs 6 8 Nm ...

Page 141: ...S MAIN FRAME 6X6 Exploded View Seat Base Front Cab Support Bumper Grills LH Floor Support 45 ft lbs 61 Nm RH Floor Support 28 32 ft lbs 38 43 Nm 28 32 ft lbs 38 43 Nm 13 15 ft lbs 17 20 Nm Frame Extension Main Frame T 27 4 6 ft lbs 6 8 Nm ...

Page 142: ...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 nut...

Page 143: ...ew Rod End Jam Nut Tie Rod Boots Steering Box Tie Rod End Bolt Lower Steering Shaft Upper Steering Shaft Cap Nut Steering Wheel Wave Washers Bushing Screw Lock Washer 25 30 ft lbs 34 41 Nm 30 ft lbs 41 Nm 15 22 ft lbs 20 30 Nm Bolt 40 45 ft lbs 54 61 Nm Screw Nut ...

Page 144: ...ents be sure to install tie rod end bolts in the proper direction The stee 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 15 22 ft lbs 20 30 Nm 30 ft lbs 41 Nm Front 12 14 ft lbs 16 19 Nm 30 ft lbs 41 Nm 30 ft lbs 41 Nm 25 30 ft lbs 34 41 Nm 40 45 ft lbs 54 61 Nm 25 ft lbs 35 Nm 8 ft lbs 11 Nm 20 30...

Page 145: ...e Torque new bolts to 30 ft lbs 41 4 Nm 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 tighten nut slightly to align Install a new cotter pin with open ends toward rear of machine Bend both ends in opposite directions around nut WARNING The locking features on the existing bolts were destroyed during removal DO NOT reuse old bolts...

Page 146: ... View Nut 15 ft lbs 21 Nm Washer Spacer Rubber Top Spacer Bottom Spring Spring Washer Bolt Bearing Retaining Ring Washer Clamp Front Strut Strut Bumper 18 ft lbs 24 Nm Pivot Ball Retainer Pivot Ball 18 ft lbs 24 Nm Wheel Speed Sensor Hall Effect Sensor ...

Page 147: ...nt castlenut 5 Remove castle nut B and separate A arm C from ball joint stud 6 Remove screws D and ball joint retaining plate E 7 Using ball joint removal installation tool kit PN 2870871 remove ball joint F from strut housing Install puller guide G with extension cap H Apply grease to extension cap and threads of puller bolt to ease removal Thread bolt K with nut J onto ball joint stud as shown A...

Page 148: ...e 6 Insert A arm bushings and A arm shaft into new A arm 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 to 30 ft lbs 41 Nm 9 Attach A arm to wheel bearing carrier Install the shock to the upper mid A arm Torque bolts as shown 10 Locate grease fitting in center of A arm tube and pump A arm full ...

Page 149: ...g from the brake line or damage may occur 5 Remove the hub and brake disc assembly by sliding it off of the axle 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 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 up...

Page 150: ...ighten shock bolt to 30 ft lbs 41 Nm 17 Re install wheel and caliper Refer to Chapter 2 for wheel toque specifications Stabilizer Bar 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 WARNING Upon A arm installation completion test vehicle at low speeds before putting...

Page 151: ...h side 4 Remove the two bolts that secure the stabilizer bar to the main frame each side 5 Remove the stabilizer from the frame 6 Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed 7 Inspect the rubber bushings on the linkage rod and replace if needed 8 Reverse the procedure for installation Torque the stabilizer bolts to 16 18 ft lbs 21 25 Nm Stabilizer Bar Sta...

Page 152: ...ngs lower swing arm and rear axle 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 Ins...

Page 153: ...Tube Screw Washer Washer Axle Tube U Bolt Nut Washer U Bolt Swing Arm Pivot Bolt Grease Fitting Swing Arm Bushing Wheel O Ring Jam Nut 150 ft lbs 203 Nm Bolt Lock Bracket Bearing 60 ft lbs 81 Nm 60 ft lbs 81 Nm Screw Washer 60 ft lbs 81 Nm Axle Wheel Bearing Assembly Skid Plate Pivot Bushing 150 ft lbs 203 Nm 30 ft lbs 40 Nm 40 ft lbs 54 Nm Apply LoctiteTM 242 ...

Page 154: ... Cargo Box Panels Taillight Tailgate Support Seal Foam Side Panel Front Panel T 27 8 10 in lbs 0 9 1 0 Nm T 30 T 30 8 10 in lbs 0 9 1 0 Nm 8 10 in lbs 0 9 1 0 Nm T 20 8 10 in lbs 0 9 1 0 Nm T 20 T 20 8 10 in lbs 0 9 1 0 Nm T 20 4 6 ft lbs 5 8 Nm ...

Page 155: ...lgate Box Support Tailgate Cap Latch Tailgate Cable Tailgate Tube Inner Panel Rod Outer Panel T 20 20 25 in lbs 2 3 Nm 8 10 in lbs 0 9 1 0 Nm Box Box Support T 20 Box Latch Assembly Shock Pins Shock 8 10 ft lbs 10 13 Nm Heat Bolt Hinge Pin Shield ...

Page 156: ...with the pin and clip 2 Place the cargo box onto the frame Align the hinges of the box with the bracket on the frame 3 Install the box hinges on both sides 4 Secure the box hinges with the hinge screws on both sides 5 With the hinges installed attach the shock to the cargo box by inserting the pin and clip 6 Lower the box and secure the latch CAUTION Safely support the box during the remainder of ...

Page 157: ...ten be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged 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 a few seconds of flame treating Do not hold the torch too clo...

Page 158: ...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 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 I...

Page 159: ...e 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 TOOL DESCRIPTION PART NUMBER Clutch Puller 2870506 Clutch Holding Wrench 9314177 Clutch Holding Fixture 2871358 Spider Nut Socket 2870338 Drive Clutch Spider Removal and Install Tool...

Page 160: ... as a conventional governor does the PVT system changes engine load requirements by either upshifting or backshifting Maintenance Inspection Under normal operation the PVT system will provide years of trouble free operation Periodic inspection and maintenance is required to keep the system operating at peak performance The following list of items should be inspected and maintained to ensure maximu...

Page 161: ...ttle in short bursts 5 to 7 times The belt will 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 speed Use Low only Plowing snow dirt etc utility use Use Low only Stuck in mud or snow Shift the transmission to Low carefully use fast aggressive throttle application to engage...

Page 162: ...Remove outer PVT cover screws 5 Mark the drive belt direction of rotation and remove drive belt See Drive Belt Removal 6 Install the Drive Clutch Holder PN 9314177 A 7 Remove drive clutch retaining bolt and remove drive clutch using the Drive Clutch Puller PN 2870506 B 8 Remove the driven clutch retaining bolt and driven clutch Inner Cover Clutch Outlet Duct Clamps Inner Cover Seal Retainer Outer ...

Page 163: ...pply 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 5 Fit lip of inner cover seal A to engine Install seal retainer plate and tighten screws securely 6 Torque rear inner cover bolt...

Page 164: ...e and driven clutch 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 sheav...

Page 165: ...ry 3 Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt 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 cen...

Page 166: ...ol 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 6 Tighten engine m...

Page 167: ...stance 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 Shim Kit PN 2200126 Spacer Washer PN 7556401 Clutch Alignment Tool should contact rear edge...

Page 168: ...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 ...

Page 169: ... system These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance clutch balance and shifting pattern ...

Page 170: ...ve 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 NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See Roller Pin and Thru...

Page 171: ...y not have been in alignment before disassembly 2 Remove cover bolts evenly in a cross pattern and remove cover plate 3 Inspect cover bushing A The outer cover bushing is manufactured with a Teflon coating Bushing wear is determined by the amount of Teflon remaining on the bushing 4 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or dam...

Page 172: ...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 2 Rubber backed buttons can be used in all ATV clutches...

Page 173: ...Remove nut from puller rod and set aside 8 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard Moveable Sheave Bushing Installation 1 Place the Main Puller Adapter 8 PN 5020632 onto the puller 2 Apply Loctite 680 PN 2870584 to the back side of new bushing Push bushing into center of sheave on tower side by hand 3 Insert the Clutch Bushing Installation Tool 2 ...

Page 174: ...uller rod and hand tighten Turn puller barrel to increase tension as needed 5 Turn clutch cover counterclockwise on puller rod until bushing is removed 6 Remove nut from puller rod and set aside 7 Remove bushing and bushing removal tool from puller Discard bushing Clutch Cover Bushing Installation 1 Apply Loctite 680 PN 2870584 to the back side of new bushing Working from inside of cover insert bu...

Page 175: ...ider buttons for each tower and install spider 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 5 Install shift weights using new ...

Page 176: ...ing A removed and spring pressure relieved remove the outer retainer B spring C and inner retainer D Secondary Stationary Sheave Moveable Inner Sheave Inner Spring Retainer DRIVEN CLUTCH Compression Spring Spring Retainer Retaining Ring CAUTION Wear eye protection when removing snap ring to prevent serious personal injury Use caution when removing the snap ring pressure is loaded by the compressio...

Page 177: ... be needed 7 Inspect the bearings inside the moveable sheave 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 Inspect For Abnormal Wear Inspect For Abnormal Wear Moveable Sheave Bearing Inspe...

Page 178: ...f removed Do not apply oil or grease to the bearings 2 Align the X marks on each of the sheaves during reassembly 3 Install spring into inner retainer 4 Install outer retainer on top of spring 5 Compress the outer retainer and install the snap ring Reassemble Sheaves Snap Ring ...

Page 179: ...pplication too light Drive clutch binding Driven clutch binding Converter sheaves greasy belt slipage Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassemble clean and inspect driven clutch noting ...

Page 180: ...and Maintenance Manual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt slippage Belt worn out Water ingestion Belt contaminated with oil or grease Replace belt Inspect and seal PVT system Inspect and clean PVT noise Belt worn or separa...

Page 181: ...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 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 VI...

Page 182: ... 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 AS...

Page 183: ... not hang the caliper by the brake line Use wire to hang the caliper to prevent possible damage to the brake line PART NUMBER TOOL DESCRIPTION 2872608 Roller Pin Removal Tool 8700226 CV Boot Clamp Pliers ITEM NUT TYPE SPECIFICATION Aluminum Wheels Cast Lug Nut 1 90 ft lbs 122 Nm Steel Wheels Black Camo Flange Nut 2 35 ft lbs 47 Nm Front Spindle Nut 70 ft lbs 95 Nm Rear Middle Hub Retaining Nut 110...

Page 184: ...st 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 damage Replace hubstrut housing if damaged Bearing Installation 5 Thoroughly c...

Page 185: ...oth 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 10 Install brake caliper using new bolts Tighten bolts to specified torque 11 Install wheel washers wheel nuts and tighten evenly in a cross pattern to specified torque Refer to Torque Specifications on Page 7 3 Spindle Nut Torque...

Page 186: ... DRIVE Front Hub Exploded View 18 ft lbs 24 Nm Use new bolts with pre applied locking agent Disc Brake Stud Front Hub Rim Tire Wheel Nut Dust Cover Cotter Pin Washer Slotted Nut 70 ft lbs 95 Nm Spec on page 7 3 ...

Page 187: ...ase Packet Inner Clamps Plunging Joint Circlip Clamp Clamp Boots 30g Grease Packet RANGER Front Propshaft Joint Kit Front Yoke Shaft Yoke Grease Zerk O ring RANGER 4X4 6X6 Rear Propshaft Cross Bearing Kit 6X6 4X4 Spring Pin O ring Cross Bearing Kit Grease Zerk O ring Cross Bearing Kit Spring Pin ...

Page 188: ...ther 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 1 Elevate front end and safely support machine under ...

Page 189: ...rive shaft from front gearcase CV Joint Boot Replacement 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 3 Disconnect A arm from ball joint using a tie rod fork 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...

Page 190: ...t 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 ...

Page 191: ... area 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 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...

Page 192: ...aring caps 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 2 Support inner yoke as shown and drive outer yoke down bearing cap out with a soft face hammer 3 Support U joint in vise as shown and drive inner yoke down to remove remaining bearing caps 4 Force U joint cross...

Page 193: ... movement of bearing cross as bearing caps are assembled 3 Install snap ring to contain bearing cap just installed Repeat procedure for other side 4 Install outer yoke aligning marks made before disassembly 5 Repeat Steps 1 3 to install bearing caps on outer yoke 6 Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown 7 When installation is complete...

Page 194: ... 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 Roller Cage and Roller s Rotate Inward and Grip the Output hub for AWD Engagement Disengagement As the front and rear wheels gain tracti...

Page 195: ...er 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ...

Page 196: ...r mark may indicate a warped plate which may cause intermittent operation See the following illustrations 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 armat...

Page 197: ...ONT DRIVE SHAFT REMOVAL procedure earlier in this chapter 8 The front gearcase and drive shafts can be accessed from both sides of the vehicle and limited access from the top 9 Remove the access panel on the side of the vehicle T 25 screws secure the panel to the frame 10 Remove the roll pin from the front drive shaft Remove the front drive shaft from the front gearcase splines 11 Remove bolts sec...

Page 198: ...E Be careful not to misplace the thrust bearing located between the two output shafts 5 Clean all parts and inspect spacers for wear Inspect ring gear for chipped broken or missing teeth 6 Remove the roll cage assembly rollers and H springs 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 Inspec...

Page 199: ... the cover remove the thrust bearing F from the output hub G Inspect the thrust bearing F and the dowel H 14 Inspect the magnetic coil I in the output housing NOTE See FRONT GEARCASE DIAGNOSIS earlier in this chapter for more details on the coil 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 th...

Page 200: ... Inspection 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 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 Whi...

Page 201: ...aring 7 Install the armature plate D and spacer washer E into the output cover NOTE Be sure backlash plate is in place 8 Install the retaining ring F into the output cover Be sure the retaining ring is properly seated into the cover 9 Install the ring gear G onto the output hub on the output cover 10 Install the rollers and roll cage into the ring gear Insert the rollers as the roll cage is instal...

Page 202: ...h 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 3 Using a hex wrench turn the back lash screw out 3 4 turns Re apply red loctite onto the bottom screw threads 4 Turn the screw in until it is lightly seated then turn the screw out 1 4 turn 5 Set the gea...

Page 203: ...nt gearcase Check drain plug for proper torque Refer to Chapter 2 for fluid fill and change information MID DRIVE HUB BEARING CARRIER 6X6 Removal 1 Lock the emergency parking brake Safely raise the center of the machine with a floor jack Raise the machine just enough to remove the middle wheel 2 Remove the four wheel nuts and wheel 3 Remove the hub cap and cotter pin 4 Remove the hub nut domed was...

Page 204: ...ing can be removed 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 housi...

Page 205: ...rier 3 Install upper A arm bolt and torque both upper and lower bolts 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 CAUTION Use an arbor and press only on the outer race as bearing damage may occur B A Lower Control Arm Bolt Torque 35 f...

Page 206: ... a new cotter pin Tighten nut slightly to align holes if required 9 Install hub cap Mid Drive Exploded View A B C Mid Hub Nut Torque 110 ft lbs 149 Nm Mid Wheel Nut Torque 35 ft lbs 47 Nm BUSHING MID UPPER A ARM BEARING CARRIER BEARING SNAP RING HUB MID LOWER A ARM SHAFT MID DRIVE AXLE BUSHING BUSHING 35 ft lbs 47 Nm 35 ft lbs 47 Nm 35 ft lbs 47 Nm 35 ft lbs 47 Nm SHAFT ...

Page 207: ...rmation see REAR DRIVE SHAFT 4X4 CV Joint Boot Replacement Installation 1 Apply Anti Seize compound onto the mid gearcase output shaft splines Slide mid drive shaft A onto the mid gearcase output shaft B 2 Install the outer end of the mid drive shaft into the hub carrier C 3 Lift hub carrier into place and install bolt to upper control arm Torque bolt to 35 ft lbs 47 Nm 4 Pull drive shaft outward ...

Page 208: ...oval 1 Use the Roll Pin Removal Tool PN 2872608 to remove the roll pin from prop shaft at rear of transmission 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 Mid Hub Nut Torque 110 ft lbs 149 Nm Mid Wheel Nut Torque 35 ft lbs 47 Nm A B C MID DRIVE GEARCASE MID D...

Page 209: ...e 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 Gearcase Disassembly 1 Dra...

Page 210: ... Remove the input cover bolts I Remove the input cover H and pinion gear assembly from the gearcase 8 Remove the pinion gear assembly J from the front cover H If the pinion gear does not come loose from the front cover use the following steps to aid in removal Hold the pinion gear assembly Use a rubber mallet to lightly tap around the bearing cup of the front cover Tap the front cover in an X patt...

Page 211: ...he retaining ring O and shim P from the rear output thru shaft 12 Carefully pull the output thru shaft Q through the gearcase 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 14 Inspect the two flange bearings S inside the gearcase Inspect the pinion shaft bushing T for wear that is inside the gearcase K...

Page 212: ... shaft 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 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 follow...

Page 213: ...ll the pinion shaft assembly and input cover onto the gearcase Install the input cover bolts K Torque the bolts to 18 23 ft lbs 24 31 Nm 7 Install the wave spring L into the gearcase assembly Be sure the wave spring is fully seated into the bearing cup of the gearcase 8 Install the output shaft and ring gear into the gearcase Be sure the 10T input pinion gear and the output pinion gear mesh smooth...

Page 214: ...into the mid and rear prop shafts and middle gearcase input and rear output shafts 5 Install the mid drive shafts D onto the mid gearcase B 6 Install the vent tube A and clamp 7 Lift bearing carrier into place and install bolt to upper control arm Torque bolt to 35 ft lbs 47 Nm Refer to the MID DRIVE SHAFT INSTALLATION section for more details 8 Install hub flat washer domed washer domed side out ...

Page 215: ... 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 18 23 ft lbs 24...

Page 216: ... the tire wheel firmly and checking for movement Grasp the top and bottom of the tire The tire should rotate smoothly without binding or rough spots 3 Remove wheel nuts and wheel Rear Gearcase A arm bolts Rear Drive Axle A arm bolts Nuts Bushings Lower A arm Carrier Bolt Shaft Bushings Snap Ring Coil 30 ft lbs 41 Nm Shock Shaft Bearing Bushings 30 ft lbs 41 Nm Bushings Shaft Upper A arm Caliper 18...

Page 217: ...xle 7 Remove the upper and lower control arm bolts from the rear hub bearing carrier 8 Remove the bearing carrier Inspect the bearing again for smoothness and side to side movement replace as needed Hub Disassembly 1 Remove outer snap ring A 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...

Page 218: ... Bearing Carrier Housing B Bearing C Snap Ring 2 Start bearing B in housing A 3 Press bearing into place until outer race bottoms on housing 4 Install snap ring into groove Hub Installation 1 Start the wheel bearing carrier onto the drive shaft 2 Align the bottom of carrier housing and lower control arm Slide the lower control arm bushings into place Secure with the lower control arm bolt 3 With t...

Page 219: ...10 ft lbs 149 Nm Install a new cotter key and the hub cap REAR DRIVE SHAFT 4X4 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 3 Pull the rear drive shaft straight out of the frame Use short s...

Page 220: ...ontaminated the boot can be replaced without cleaning the CV joint Use the 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 Replac...

Page 221: ...e 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 centered properly Tighten boot clamp using boot clamp pliers 11 While pulling out on the CV shaft fully extend the CV joint and slide a straight O ring pick or a small slotted screw driver between the small end of t...

Page 222: ...ard end of the driveshaft if necessary 4 Lift bearing carrier into place and install the bolt into the upper control arm Torque bolt to 30 ft lbs 41 Nm 5 Install hub domed washer domed side out and nut Torque rear spindle nut to 110 ft lbs 149 Nm Install new cotter pin and hub cap 6 Install rear wheel and torque washers and wheel nuts to specification See Torque Specifications on page 7 3 Apply An...

Page 223: ...that it s parallel with the frame supports as shown below 5 Remove the shaft by placing the brake disc over the top of the rear frame support and under the front frame support Installation 1 When installing the propshaft ensure that the shaft is touching the rear frame support and reinstall the shaft the same way it was removed with the brake disc over the top of the rear frame support and under t...

Page 224: ...ical 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 the clutch gear is unlocked the rear axle becomes a differential When it s locked it becomes a solid rear axle increasing traction See images below AWD Differential Unlocked Differential Locked When switch position is set to Unlock the solenoid is powered ...

Page 225: ...ferential Locked Differential Unlocked AWD Mode Both rear wheels rotate at same speed Rear wheels can rotate at different speeds Allow for sharper turning Rear Wheels rotate as same speed Front Wheels rotate as same speed when AWD activated ...

Page 226: ... Disassembly IMPORTANT The pinion gear assembly is NOT intended to be disassembled from the case as it requires special OEM tooling in order to properly reassemble If there is any damage to the pinion gear bearings or case the assembly must be replaced Pinion and ring gear shimming information is NOT provided due to OEM manufacturing requirements 1 Drain and properly dispose of used gearcase fluid...

Page 227: ...e bearings D for smoothness and wear Be sure to keep the shims E together for reassembly 6 Remove the differential lock solenoid F from the carrier housing by turning the solenoid counterclockwise 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 8 Remove the clutch gear G from the carrier cover B and shift yoke H C C E D C D E F F...

Page 228: ... L Use a 1 4 in 20 coarse thread bolt approximately 3 in long to thread into the pivot shaft 12 Thread the bolt into the shift yoke pivot shaft L 13 Carefully pull the shift yoke pivot shaft L out of the carrier cover 14 Remove the shift lever M and springs N from the shift yoke H Inspect the components for wear and replace as needed H J K L L M N H ...

Page 229: ...ed 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 2 Install the original shims A onto the differential assembly B on both sides Install the bearings C replace with new bearings if needed 3 Install the differential assembly into the ...

Page 230: ...o the carrier cover Torque solenoid to 30 40 ft lbs 41 54 Nm 8 Install the new lightly greased O ring K onto the carrier cover 9 Install the carrier cover bolts Tighten and torque the bolts in a criss cross pattern to 25 35 ft lbs 34 48 Nm 10 Install the rear differential mount brackets from the rear differential onto the rear differential Torque the bracket to differential bolts to 26 33 ft lbs 3...

Page 231: ...cedure 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 Rear Gearcase capacity 18 fl oz 532 ml or 0 75 1 9 cm below bottom of fill plug hole threads See Chapter 2 Bracket to Frame 38 42 ft lbs 35 45 Nm Fill Plug D...

Page 232: ... 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 ...

Page 233: ...oth sides 5 Pull the hub off of the axle 6 Remove the hose clamp from the rear gearcase breather hose Remove the breather hose 7 Remove the bottom shock bolts and shocks both sides 8 Remove the two bolts that secure the rear axle housing to the frame 9 Mark the positions of the four U bolts that secure the axle to the frame This will aid with proper U bolt and axle placement during reassembly CAUT...

Page 234: ...embly Extra jacks maybe needed to lower the rear axle assembly safely Axle Tube 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 3 Remove the axle and axle tube s from the rear gearcase Note the placement of the axle spacer seals for placement during reassembly 4 Slide the axles out ...

Page 235: ...llation 4 Reinstall the retaining ring Gearcase Disassembly Inspection 1 Drain and properly dispose of used oil 2 Remove the differential housing cover bolts and the gearcase housing cover 3 Remove the shim and O ring from the differential cover 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 wea...

Page 236: ...l Remove the pinion gear cover and O ring 7 Remove the pinion shaft from the differential Inspect for abnormal wear broken or chipped teeth 8 Inspect the pinion shaft bushing for wear Gearcase Assembly 1 Replace all O rings seals and worn components 2 Install the pinion shaft into the differential housing Wave Spring 4 Bolts O Ring Pinion Gear Cover ...

Page 237: ...d installed 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 after assembly 9 Torque the output cover bolts to 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...

Page 238: ...with the rear axle assembly installation NOTE Use caution when removing the rear axle assembly Extra jacks maybe needed to raise the rear axle assembly safely 6 Install the four U bolts Align the U bolts with the white marks previously made on the axle tube for proper rear axle alignment NOTE Use a floor jack to help align the rear axle assembly for the U bolt installation 7 Install the U bolt nut...

Page 239: ...le nut onto the axle 13 Install the brake caliper Torque the bolts to 18 ft lbs 24 8 Nm 14 Install the tire and four wheel nuts Torque the castle nut and the wheel nuts to specifications 15 Install a new cotter pin Tighten nut slightly to align holes if required Install the hub cap U Bolt Nut Torque 40 ft lbs 54 Nm Rear Coil Over Shock Bolt Torque 25 ft lbs 35 Nm 25 ft lbs 35 Nm Brake Caliper Torq...

Page 240: ...g 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 26 ft lbs 35 Nm 30 ft lbs 41 Nm ...

Page 241: ...ATION 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 ...

Page 242: ... Excessive gear clash noise 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 2 Be sure idle speed is adjusted properly ITEM TORQUE VALUE Transmission Fill Plug 10 14 ft lbs 14 19 Nm Transmission D...

Page 243: ...mission cable 5 Use this procedure to loosen or tighten the shift linkage cable as needed TRANSMISSION SERVICE Transmission Removal 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 output shaft yolk slides off during the transmission removal 3 Remove the air intake hose from the air box that is loca...

Page 244: ...ission cable Remove the cable from the mounting bracket 7 Remove the mounting bolts from the transmission mounting on both sides of the transmission 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 Transmission Switch Jam Nuts General Transmission Mount...

Page 245: ...Remove the bellcrank 3 Remove the five bolts that secure the cover and remove the cover from the transmission 4 Remove the detent spring 5 Mark the detent gear with a white pen Remove the detent gear from the case NOTE It may be helpful to place a mark just above the keyed spline 6 Mark the lockout disc this will indicate which side of the disc faces outward during assembly Remove the disc NOTE It...

Page 246: ...9 Remove the bolts on the LH transmission case cover Tap the cover off with a soft face hammer if necessary 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 NOTE You may have to tap the shift drum from the backside of the case to aid in removal 12 Remove the upper gear cluster and shift forks ...

Page 247: ...ave 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 16 Remove the park lock engagement dog Remove the wave spring and reverse engagement dog 17 Remove the bearing from the input shaft with a puller 18 Remove the snap ring and washer from the reverse shaft 19 Remove low gear 33T and the needle bearing 20 Remove the r...

Page 248: ... Use a press to remove the gear from the shaft 23 Make note of the direction of the gear and hub location 24 Remove the gear split bearing and washer from the reverse shaft 25 Slide off the shift dogs and wave springs 26 Remove the snap ring washer gear and split bearing ...

Page 249: ...him thrust button and thrust button shim 31 Remove the shafts as an assembly 32 Remove the silent chain from the assembly for shaft inspection 33 Clean all components in a parts washer and inspect for 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 ...

Page 250: ...y seated in the transmission case Apply Polaris Crankcase Sealant to the mating surfaces 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 NOTE Make sure that the case locating pins knock pipes are in place 5 Apply grease to the seal lips Apply electricians tape or somehow co...

Page 251: ...ternal damage to the transmission 11 Slide the reverse shaft assembly through the silent chain 12 Install a new needle bearing the low gear the thrust washer and the snap ring Use of a new snap ring is recommended 13 Install the engagement dogs wave springs and bearing 14 Install the ball bearing onto the end of the input shaft 15 As the engagement dogs are installed onto the shaft place the wave ...

Page 252: ... it meshes with the tracks on the shift drum Be sure the wave springs are properly in place and that the shift rail is seated into the pocket on the backside of the case 21 Install the helical gear and bearing onto the pinion shaft 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 Reinstal...

Page 253: ... white mars that was previously applied for reference 29 Install the detent gear with the raised edge facing outward Note the keyed spline on the end of the shaft 30 Install the detent lever spring Install a new o ring onto the shift shaft after the detent lever is assembled to the shaft Place a small amount of grease on the small O ring on the shift shaft and on the detent gear Grease the o ring ...

Page 254: ...rame bolts 6 Tighten mounting fasteners in order A D as shown 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...

Page 255: ...kage 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 fun...

Page 256: ...REASSEMBLY Apply White Lithium Based Grease Apply Polaris Crankcase Sealant Apply LoctiteTM 262 to the bolt threads 12 18 ft lbs 16 24 Nm 7 9 ft lbs 10 12 Nm 15 19 ft lbs 20 26 Nm 27 34 ft lbs 37 46 Nm 6 12 ft lbs 8 16 Nm GREASE 27 34 ft lbs 37 46 Nm 10 14 ft lbs 14 19 Nm ...

Page 257: ...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 He...

Page 258: ...VAL 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 ...

Page 259: ...e Pad Thickness Inboard 304 7 72 mm Outboard 360 9 14 mm 240 6 1 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 Item Torque ft lbs Torque Nm 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 Cal...

Page 260: ... 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 Dirt dust or i...

Page 261: ... 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 ...

Page 262: ...Master Cylinder Side View Cross Fitting MC Rear Brake Line RH Rear Line RH Rear Caliper RH Front Brake Line RH Front Caliper Brake Switch MC Front Brake Line Master Cylinder LH Front LH Rear Caliper LH Front Caliper Brake Line LH Rear Line 1 2 1 1 2 2 1 3 All Flare Style Fittings 12 15 ft lbs 16 20 Nm 3 3 3 3 3 1 1 2 2 15 ft lbs 20 Nm ...

Page 263: ...nstalling the foot brake check pedal freeplay Pedal freeplay should not exceed 090 2 286 mm FOOT BRAKE PEDAL Pedal Removal 1 Open the hood Locate the master cylinder 2 Remove the nut bushing tube and bolt from the brake pedal 3 Remove the clevis pin and cotter key from the master cylinder to remove the brake pedal Pedal Installation 1 Reverse Steps 1 3 for foot brake installation Torque the clevis...

Page 264: ...r cylinder 8 Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir 9 Tighten bleeder screw securely and remove bleeder hose 10 Repeat procedure Step 5 through Step 9 for the remaining calipers 11 Add brake fluid to MAX level inside reservoir 12 Install master cylinder reservoir cover 13 Field test machine at low...

Page 265: ... Pin Park Brake Sensor Switch Park Brake Lever Spring Latch Washer Brake Release Grommet Handle Nut Pin Clip Bolt Parking Brake Assembly Clip Pin Cable Park Brake Caliper Assembly Mount Bolt Rear Prop Shaft Park Brake Disc Clip Pin Washer Pin Park Brake Handle Lever Park Brake Assembly ...

Page 266: ...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 3 Locate the parking brake cable located under the front hood and under the dash on the driver side NOTE See Chapter 10 for more information on the parking brake switch 4 Use two wrenches to loosen the bottom jam nut C Hold the top jam nut D with one wrench Turn...

Page 267: ... Be sure the park brake is not engaged 2 If replacing the brake pads slightly loosen the caliper assembly bolts before removing the complete caliper assembly This will ease the caliper disassembly procedure later Pad Holder Nut Hex Head Mount Bolt Sleeve Thrust Washer Shim Pack 4 Shims Pad Holder Lever Asm Bolt Steel Balls 3 Plain Washer Hex Nut Stationary Actuator Compression Spring Spring Pin Fi...

Page 268: ...bearings for reassembly 7 Inspect the brake pads linings for excessive wear Replace as needed 8 Check the three steel balls for any signs of cracking Replace as needed 9 Check ball seats in lever and stationary actuator If excessively worn replace parts as needed 10 Measure the thickness of the rear caliper parking brake pads Replace assembly or pads as needed See illustration below for proper rea...

Page 269: ...assembly nuts to 25 ft lbs 34 Nm 3 Ensure the park brake assembly functions properly by actuating the lever before reinstallation Caliper Installation 1 Install the park brake assembly into place Tighten the two mounting bolts in increments for proper installation 2 Torque the two mounting bolts to 18 ft lbs 24 Nm 3 Install the cable pin and clip pin Test the park brake for proper function PARKING...

Page 270: ...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 Pad Inspection 1 Measure the thickness of the pad material Replace pads if worn beyond the service limit CAUTION Use care when supportin...

Page 271: ...ter screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise 2 Be sure fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap 3 Install wheels and torque wheel nuts 4 It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowl...

Page 272: ...sembly 1 Remove brake pad adjuster screw A 2 Push upper pad retainer pin inward and slip brake pads past edge if pads are still installed 3 Remove mounting bracket B and dust boot C Bleeder Screw 30 60 in lbs 3 4 6 8 Nm Adjuster Screw Finger Tight Caliper Body Piston Caliper Mount Pads Dust Boots Square O rings FRONT CALIPER EXPLODED VIEW DURING ASSEMBLY 4 4 4 4 CAUTION Use care when supporting ve...

Page 273: ...er and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads as outlined for brake pad 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 2 Coat the piston with clean Polaris DOT 4 Brake Fluid P N 2872189 Install piston B with a twisting motion while pu...

Page 274: ... the adjuster screw and turn until stationary pad contacts disc then back off 1 2 turn 4 Follow brake bleeding procedure outlined earlier in this chapter 5 Install wheels and torque wheel nuts to specification NOTE If new brake pads are installed it is recommended that a burnishing procedure be performed to extend pad service life and reduce noise Start machine and slowly increase speed to 15 mph ...

Page 275: ...ce of disc and hub 3 Install disc on hub 4 Install new bolts and tighten to 18 ft lbs 24 Nm REAR BRAKE PAD 4X4 Pad Removal 1 Elevate and support rear of machine 2 Remove the rear wheel Loosen pad adjuster screw 2 3 turns Brake Disc Thickness New 150 165 3 81 4 19 mm Service Limit 140 3 56 mm Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements Brake Disc Runout Se...

Page 276: ...nsating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 6 Remove the brake pads Pad Inspection 1 Clean the caliper with brake cleaner or alcohol 2 Measure the thickness of the pad material Replace pads if worn beyond the service limit Pad Installation 1 Install new pads in caliper body 2 Install caliper and torque mou...

Page 277: ...per off of disc NOTE When removing caliper be careful not to damage brake line Support caliper so as not to kink or bend brake line 5 Push caliper piston into caliper bore slowly with pads installed 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 6 Remove the brake ...

Page 278: ...d torque mounting bolts 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 reservoir to prevent air from entering the master cylinder Rear Brake Pad Thickness New 298 007 7 56 178 mm Service Limit 180 4 6 mm Measure Thickness Rear Brake Caliper Mounting Bolt Torque 18 ft lb...

Page 279: ...uid has drained into the container remove the two caliper mounting bolts and remove caliper 4 Clean disc caliper body and pistons with brake cleaner or alcohol Bleeder Screw 30 60 IN LBS 4 6 5 NM Adjuster Screw Finger Tight Caliper Body Piston Caliper Mount Pads Dust Boots Square O rings DURING ASSEMBLY 4 4 4 4 CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury ...

Page 280: ... Disassembly 1 Remove brake pad adjuster screw A 2 Push upper pad retainer pin inward and slip brake pads past edge if pads are still installed 3 Remove mounting bracket B and dust boot C 4 Remove piston D and square O rings E from the caliper body F 5 Clean the caliper body piston and retaining bracket with brake cleaner or alcohol NOTE Be sure to clean seal grooves in caliper body CAUTION Use ca...

Page 281: ...s may drag 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 3 Lubricate the mounting bracket pins with Polaris Premium All Season Grease and install the rubber dust seal boots 4 Compress the mounting bracket and make sure the dust seals are fully seat...

Page 282: ...ator and measure disc runout Replace the disc if runout exceeds specifications 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 asse...

Page 283: ...r 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 Brake...

Page 284: ...EEL 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 H...

Page 285: ...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 MO...

Page 286: ...information Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is used for when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc and the position of the decimal point For resistance readings isolate the component to be tested Dis...

Page 287: ...ocated 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 4 Test the switch connections and check for continuity at the following pins shown in the illustration Differential Solenoid 4x4 The differential solenoid is located on the rear gear case The sole...

Page 288: ...the connector to ensure the solenoid has power to be activated Check the operator s switch wires for loose connections Remove solenoid from carrier and ensure the solenoid plunger is actuating 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 2 Disconnect wire harness from switch 3 Connect an ohmm...

Page 289: ...Park Brake Indicator near the top center of the instrument cluster TESTING PARK BRAKE SWITCH 1 Disconnect the Orange Red wire and Red White wire from the switch 2 Place the ohmmeter leads onto terminal leads A and C The reading should be infinite 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...

Page 290: ...witch is in the AWD position 3 Engine Hour Display Indicator 4 Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the batter...

Page 291: ...he 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 2 Lock the parking brake 3 Place the transmission in neutral 4 Hold the mode button and turn the key switch to the O...

Page 292: ...put of the gauge NOTE A 10 20 variance from these readings is within normal parameters Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance NOTE The service interval is progra...

Page 293: ...etting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers Toggle 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 t...

Page 294: ...e dash panel Only remove the rubber mount if necessary The bezel is a snap on assembly and is a serviceable part Instrument Cluster Installation 1 Spray a soap and water mixture onto the outer surface area of the instrument cluster This will help the instrument cluster slide into the rubber mount more easily 2 Be sure the rubber mount inside the pod is fully installed and that the indexing key on ...

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Page 299: ...fy 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 groun...

Page 300: ...ment screw A and moving the lamp to the appropriate height 6 Adjust the beam to desired position Repeat the procedure to adjust the other headlight 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 4 Insert new bulb Reinstall the harness assembly into the he...

Page 301: ...the previous page TAIL LIGHT BRAKE LIGHT Lamp Replacement Before replacing the tail light use a digital multi meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present 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...

Page 302: ...10 19 ELECTRICAL 10 COOLING SYSTEM Cooling System Break Out Diagram EY N 6OLT 0OWER ...

Page 303: ...th the meter in the ohms mode place the meter leads onto the sensor contacts 3 Use the table Temperature Resistance table to determine if the sensor needs to be replaced NOTE If the coolant temperature sensor or circuit malfunctions the radiator fan will default to ON EFI DIAGNOSTICS EFI Component Testing All EFI component information and diagnostic testing procedures are located in Chapter 4 Refe...

Page 304: ...provides power to Rear Diff Solenoid Brown White ECU ground input to connect relay Key On power to Rear Diff Solenoid output FAN RELAY COLOR FUNCTION Red White Key On battery power supply switched on by key switch enables power to relay Orange Black Fused 20 Amp power switched by relay provides power to Fan Motor Yellow Black ECU input to connect relay Fused 20 Amp power to Fan Motor output Red Fu...

Page 305: ...e draw is excessive 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 6 0OWER TO 3PEEDOMETER CCESSORY 0OWER 4ERMINAL LOCK 6 0OWER TO EY 3WITCH 6 0OWER TO 0OWER 2ELAY MP 0ROTECTION FOR 5 MP 0ROTECTION FOR EY N 0OWER 6 0OWER FROM USIBLE INK 6 0OWER TO AN 2ELAY CAUTION...

Page 306: ...ould occur at or below 2000 RPM Charging System Alternator Tests Three tests can be performed using a multimeter to determine the condition of the stator alternator TEST 1 Resistance Value of Each Stator Leg 1 Measure the resistance value of each of the three stator legs Y1 to Y2 Y1 to Y3 and Y2 to Y3 Each test should measure 0 19Ω 15 NOTE If there are any significant variations in ohm s readings ...

Page 307: ...res 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 t...

Page 308: ...its The battery will continually discharge if operated below the Break Even RPM Con tinued problems would call for battery inspection Yes Inspect the wiring harness between the panel and the stator for remove the recoil and flywheel Inspect the flywheel magnets stator coils and stator wires for damage No Check stator regulator ground battery and battery connections Also check wire connections and ...

Page 309: ...types of batteries require different service procedures Proper servicing and upkeep of your battery is very important for maintaining long battery life Your RANGER may have a Conventional Battery or a Sealed Low Maintenance Battery To identify which type of battery your RANGER has refer to the illustration below and follow the correct service and charging procedures that follow in the manual T Ter...

Page 310: ...ed charging rates 6 Check specific gravity of each cell with a hydrometer to assure each has a reading of 1 270 or higher Battery Inspection The battery is located under the hood Inspect the battery fluid level When the battery fluid nears the lower level remove the battery and fill with distilled water only to the upper level line To remove the battery WARNING Battery electrolyte is poisonous It ...

Page 311: ...uld 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 OCV Open Circuit Voltage Test Battery voltage should be checked with a digital multitester Readings of 12 6 volts or less require further battery testing and charging See charts and Load Test on below NOTE Lead acid batteries should be kept at...

Page 312: ...olyte is at the proper level Add distilled water if necessary Charge at a rate no greater than 1 10 of the battery s amp hr capacity until the electrolyte s specific gravity reaches 1 270 or greater Store the battery either in the machine with the cables disconnected or store in a cool place NOTE Recharge to full capacity every 30 to 60 days during a non use period If the battery is stored during ...

Page 313: ...of lead antimony allows the battery acid to be fully absorbed For this reason a Low Maintenance battery case is dark and the cell caps are not removable since there is no need to check electrolyte level NOTE New Batteries 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 equivalent of 1 10 of the battery ...

Page 314: ...oltmeter or multimeter to test batter voltage Load Test 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 properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the elec...

Page 315: ...s the battery may need recharging When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging NOTE Always verify battery condition before and 1 2 hours after the end of charging Battery Charging Reference Table Electrolyte Freezing Points Specific Gravity of Electrolyte Freezing Po...

Page 316: ... Starter Motor Turns Engine Does Not Rotate Faulty starter drive Faulty starter drive gears or starter motor gear Faulty flywheel gear or loose flywheel Voltage Drop Test 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 show...

Page 317: ...rush wires for damage and repair or replace as necessary 3 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Slide brush end frame off end of starter NOTE The 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 Brush Inspection 1 Measure length of eac...

Page 318: ...wn to armature on any pole the armature is shorted and must be replaced Starter Reassembly Installation 1 Install brush plate to field magnet housing aligning index tab 2 Install O ring two small phenolic spacers large phenolic washer flat washer lock washer and terminal nut 3 While holding brush springs away from brushes push brushes back and hold in place 4 Slide armature into field magnet housi...

Page 319: ...ter Drive Pinion Gear Anti kick Out Shoe Garter Spring Replacement 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 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 cha...

Page 320: ... 3 Thrust Washer 4 Gear Assembly 5 O Ring 6 Brush Complete 7 O Ring 8 Thrust Washer 9 Shaft Complete 10 Gear Assembly 11 Through Bolt 12 Cover 13 Stopper 14 Snap Ring 15 Washer 16 Flange Bolt 17 Thrust Washer 18 Flange Bushing Indicates Do not reuse Replace with new parts ...

Page 321: ...ailed Test starter solenoid coil by connecting an ohmmeter between the solenoid wire and the solenoid mounting plate Resistance should be 3 4Ω Check solenoid ground path by measuring resistance between mounting plate and battery negative terminal Reconnect the solenoid Connect the tester black lead to the battery positive and the red lead to the solenoid end of the battery to solenoid wire Depress...

Page 322: ...r 12 Volts between the RED BLACK wire terminal on the back of the switch and the BROWN wire terminal On the main connector behind the dashboard measure for 12 Volts between RED BLACK wire terminal and ground Not 12 Volts between wires Test wiring between the main connector and the circuit breaker 12 Volts between wires Test the accessory and wiring circuit breaker located under the seat Refer to W...

Page 323: ...st 2 26 Cooling System Specifications 3 13 Cooling System Pressure Test 3 14 Crankshaft Gear Removal 3 40 Crankshaft Position Sensor CPS 4 15 CV Shaft Boot Inspection 2 28 Cylinder Head Assembly 3 30 Cylinder Head Assembly Exploded View 3 23 Cylinder Head Disassembly 3 26 Cylinder Honing To De glaze 3 20 Cylinder Inspection 3 33 D Decal Replacement 5 25 Decimal Equivalent Chart 1 12 Diagnostic Cod...

Page 324: ...4 20 Engine Temperature Sensor Test 4 20 Engine Torque Table 3 10 Engine Troubleshooting 3 58 Engine Valve Inspection 3 27 Engine Valve Lifter Removal Inspection 3 31 Engine Valve Seal Spring Service 3 25 Engine Valve Sealing Test 3 31 Engine Valve Seat Reconditioning 3 28 Engine Accessible Components 3 13 Exhaust Pipe 2 19 F Fan Control Circuit Bypass Test 10 20 Fan Control Circuit Operation 10 2...

Page 325: ...9 Rear Gearcase 4x4 7 44 Rear Gearcase Lubrication 4x4 2 23 Rear Gearcase Lubrication 6x6 2 24 Rear Propshaft Service 7 43 Rear Spring Adjustment 2 34 Rear Stabilizer Bar 5 19 Rear Suspension 2 33 Rear Suspension Adjustment 4x4 2 34 Relays 10 21 S Service Interval Indicator 10 9 Shift Lever Removal 8 2 Shift Lever Installation 8 2 Shift Linkage Inspection and Adjustment 2 13 Shift Linkage Adjustme...

Page 326: ... 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 Transmissi...

Page 327: ...11 1 WIRE DIAGRAM RANGER 700 EFI 4X4 6X6 CHASSIS PAGE 1 OF 2 ...

Page 328: ...11 2 WIRE DIAGRAM RANGER 700 EFI 4X4 6X6 CHASSIS PAGE 2 OF 2 ...

Page 329: ...11 3 WIRE DIAGRAM RANGER 700 EFI 4X4 6X6 DASH ...

Page 330: ...11 4 WIRE DIAGRAM RANGER 700 EFI 4X4 6X6 BREAKOUTS ...

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