Polaris 2008 Ranger RZR Service Manual Download

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6.23

CLUTCHING

Clutch Assembly

Install a new bearing onto the output shaft using a press.

Install the shaft/bearing into the outer sheave.

Install the small and large retaining rings into the outer
sheave above the bearing.

Line up the “X” on the moveable sheave with the “X” on
the stationary sheave or use the marks previously used. Put
the sheaves together.

Install the roller (A) onto the roller pin (B) on both sides.

Align X’s

Summary of Contents for 2008 Ranger RZR

Page 1: ... 1 2 UNIT SERIAL NUMBER VIN LOCATION 1 3 GENERAL SPECIFICATIONS 1 4 MODEL 2008 RANGER RAZR 1 5 VEHICLE INFORMATION 1 6 PUBLICATION NUMBERS 1 6 PAINT CODES 1 6 REPLACEMENT KEYS 1 6 SPECIAL TOOLS 1 6 MISC SPECIFICATIONS AND CHARTS 1 7 CONVERSION TABLE 1 7 STANDARD TORQUE SPECIFICATIONS 1 8 SAE TAP DRILL SIZES 1 9 METRIC TAP DRILL SIZES 1 9 DECIMAL EQUIVALENTS 1 9 GLOSSARY OF TERMS 1 10 ...

Page 2: ...efer to the engine model number and serial number This information can be found on the sticker applied to the cylinder head on the side of engine Machine Model Number Identification Model Year Designation Basic Chassis Designation Engine Designation Emissions Model Option R 0 8 V H 7 6 A D 4 X A V H 7 6 A 8 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 Descrip...

Page 3: ...n The machine model number and serial number VIN are important for vehicle identification The VIN number A is stamped on a portion of the LH frame rail close to the front wheel The model and VIN numbers are also located on a sticker under the hood B A A B B ...

Page 4: ...l Base 77 in 196 cm Ground Clearance 10 in 25 4 cm Dry Weight 945 lbs 429 kg Gross Vehicle Weight 1727 lbs 783 kg Front Storage Capacity 25 lbs 11 3 kg Cargo Box Dimension 42 in x 22 in 107 cm x 56 cm Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 336 4 kg Includes rider s cargo and accessories Hitch Towing Capacity 1500 lbs 680 kg Hitch Tongue Capacity 150 lbs 68 kg FRO...

Page 5: ...alog Speedometer with Multifunction LCD DC Outlet Standard 12 V Relays EFI Fan Circuit Breaker Fan Motor 20 Amp Fuses Chassis 20 Amp EFI 15 Amp Lights 15 Amp Accessory 15 Amp Speedo ECU 5 Amp Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio Front Rear High Low Rev 3 14 1 8 71 1 5 94 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 70 1 Shift Type In Line Shift H L N R P Front Gearcase O...

Page 6: ...atory while other tools maybe substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may order special tools through Polaris official tool supplier SPX Corporation 1 800 328 6657 Model Model No Owner s Manual PN Parts Manual PN 2008 RANGER RZR Red R08VH76AD 9921181 9921207 2008 RANGER RZR Green R08VH76AG 9921181 9...

Page 7: ...1 7 GENERAL INFORMATION 1 MISC SPECIFICATIONS AND CHARTS Conversion Table C to F 9 5 C 32 F F to C 5 9 F 32 C ...

Page 8: ...e following torque specifications are to be used only as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views or each manual section for torque values of fasteners before using standard torque ...

Page 9: ...1 9 GENERAL INFORMATION 1 SAE Tap Drill Sizes Metric Tap Drill Sizes Decimal Equivalents ...

Page 10: ...e 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 11: ...LINES 2 11 THROTTLE PEDAL INSPECTION 2 12 THROTTLE FREEPLAY ADJUSTMENT 2 12 AIR FILTER SERVICE 2 12 ENGINE 2 14 ENGINE OIL LEVEL 2 14 ENGINE OIL AND FILTER SERVICE 2 15 ENGINE BREATHER HOSE INSPECTION 2 16 ENGINE AND TRANSMISSION MOUNT LOCATIONS 2 16 COMPRESSION AND LEAKDOWN TEST 2 16 EXHAUST SPARK ARRESTOR 2 16 TRANSMISSION AND GEARCASES 2 17 TRANSMISSION GEARCASE SPECIFICATION CHART 2 17 TRANSMI...

Page 12: ...Y 2 26 SPARK PLUG SERVICE 2 26 ENGINE TO FRAME GROUND 2 27 STEERING AND SUSPENSION 2 27 STEERING 2 27 STEERING WHEEL INSPECTION 2 27 STEERING INSPECTION TIE ROD ENDS AND HUBS 2 28 TOE ALIGNMENT INSPECTION 2 28 TOE ADJUSTMENT 2 29 SUSPENSION SPRING PRELOAD ADJUSTMENT 2 29 BRAKE SYSTEM 2 30 BRAKE FLUID INSPECTION 2 30 BRAKE PAD DISC INSPECTION 2 30 BRAKE HOSE AND FITTING INSPECTION 2 30 ...

Page 13: ...egins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Break In Period The break in period consists of the first 25 hours of operation or the time it takes to use 14 gallons 53 liters of fuel Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Drive ...

Page 14: ... as needed 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 10 H Monthly 100 160 Inspect periodically Battery 25 H Monthly 250 400 Check terminals clean test Front Gearcase Oil Demand Drive Fluid LT 25 H Monthly 250 400 Inspect l...

Page 15: ... 1000 Check for leaks at tank cap fuel line fuel pump and fuel rail Replace lines every two years E Spark Plug 100 H 12 M 600 1000 Inspect replace as needed E Engine Oil Filter Change 100 H 6 M 1000 1600 Perform a break in oil changeat 25 hours or one month always replace oil filter when changing engine oil Drive Belt 100 H 12 M 1000 1600 Inspect replace as needed Radiator 100 H 12 M 1000 1600 Ins...

Page 16: ...2 6 MAINTENANCE COMPONENT INSPECTION SERVICE LOCATIONS Front and Rear View ...

Page 17: ...2 7 MAINTENANCE 2 RH and LH Side Views ...

Page 18: ...n Kit 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 2871329 Dielectric Grease Nyogel Coolant 2871323 60 40 Coolant Gallon 6 Count 2871534 60 40 Coolant Quart 12 Count Part No Description Additives Sealant...

Page 19: ...thetic Gearcase Lubricant PN 2873602 Add lube to bottom of fill plug threads 24 oz 710 ml Change annually Transmission Transfer Case Page 2 7 AGL Synthetic Gearcase Lubricant PN 2873602 Add lube to bottom of level check plug threads 14 oz 414 ml Change annually Front Gearcase Page 2 7 Premium Demand Drive Fluid LT PN 2876251 Drain completely and add specified quantity of lube 6 75 oz 200 ml Change...

Page 20: ...mage Frame Nuts Bolts and Fasteners Periodically inspect the torque of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each chapter Shift Cable Inspection Adjustment Shift cable adjustment may be necessary if symptoms include No AWD or gear position display on instrument cluster Ratcheting noise on decel...

Page 21: ...heck fuel tank front gear case rear gear case and transmission vent lines for signs of wear deterioration damage or leakage Replace every two years 2 Be sure vent lines are routed properly and secured with cable ties IMPORTANT Ensure lines are not kinked or pinched WARNING Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refuel outdoors or in a well...

Page 22: ...ubber boot and slide it far enough to expose the end of the inline cable adjuster 4 Loosen the adjuster lock nut 5 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle pedal NOTE While adjusting lightly flip the throttle pedal up and down 6 Tighten the lock nut 7 Squeeze the end of the rubber boot and slide it over the cable adjuster to its origin...

Page 23: ...t high throttle openings for extended periods Installation 1 Clean the air box thoroughly 2 Install a new or clean pre filter over the main air filter element 3 Reinstall the filter into the air box Be sure the filter fits tightly in the air box NOTE Apply a small amount of general purpose grease to the sealing edges of the filter and the air box cap seal before installing 4 Install air box cap an...

Page 24: ...pth of dipstick consistent 7 Remove the dipstick and check the oil level Maintain the oil level in the SAFE range Add oil as indicated by the level on the dipstick Do not overfill see NOTE below NOTE Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Proper level indication is determined on the upper surface of the dipstick as it is...

Page 25: ...w filter with a film of fresh engine oil Check to make sure the O ring is in good condition 13 Installnew filter and turn by hand until filter gasket contacts the sealing surface then turn an additional 1 2 turn 14 Remove dipstick and fill sump with 2 quarts 1 9 l of Polaris Premium 4 Cycle Synthetic Oil PN 2871281 15 Verify the transmission is still positioned in PARK P 16 Start the engine and le...

Page 26: ...ure leakage testers as crankshaft seals may dislodge and leak Exhaust Spark Arrestor Periodically clean the spark arrestor to remove accumulated carbon 1 Remove the retaining screw and remove the arrestor from the end of the muffler 2 Use a non synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm 3 Inspect the screen for wear and damage Replace if needed 4...

Page 27: ...s to flow out the level check plug hole 5 Reinstall the level check plug and torque to 30 45 in lbs 3 5 Nm 6 Reinstall the fill plug and torque to 40 50 ft lbs 54 68 Nm GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN LEVEL CHECK PLUG TORQUE Transmission Main Gearcase AGL Synthetic ATV Gearcase Lubricant 24 oz 710 ml 40 50 ft lbs 54 68 Nm 30 45 in lbs 3 5 Nm Transmission Transfer Case AGL Synthe...

Page 28: ...in plug 3 Remove the drain plug and allow to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring and torque to 30 45 in lbs 3 5 Nm 6 Add the recommended fluid through the fill plug hole until it begins to flow out the check plug hole Do not overfill 7 Reinstall the level check plug and torque to 30 45 in lbs 3 5 Nm 8 Reinstall the fill plug and torque to 40 50 ft l...

Page 29: ...ue to 8 10 ft lbs 11 14 Nm Lubricant Change The drain plug is located on the bottom of the gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug and allow fluid to drain completely 4 Clean the drain plug Inspect the O ring and replace if damaged 5 Reinstall the drain plug torque to 8 10 ft lbs 11 14 Nm 6 Add the recommended fluid Maintain the lubricant le...

Page 30: ... plug 2 Place a drain pan under the drain plug 3 Remove the drain plug and allow the lubricant to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with new O ring and torque to 30 45 in lbs 3 5 Nm 6 Add the recommended lubricant Maintain the fluid level even with the bottom threads of the fill plug hole 7 Reinstall the fill plug and torque to 40 50 ft lbs 54 68 Nm 8 Check for lea...

Page 31: ...he grommets 3 View the coolant level in the recovery bottle 4 If the coolant level is below the MIN line inspect the coolant level in the radiator NOTE If overheating is evident allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system 5 Remove the pressure cap Using a funnel add coolant to the top of the filler neck 6 Reinstall the pres...

Page 32: ...neath the T fitting on the front RH side of the vehicle 4 Drain the coolant from the radiator by removing the lower engine inlet hose from the T fitting Properly dispose of the coolant 5 Allow coolant to completely drain CAUTION Do not over tighten hose clamps at radiator or radiator fitting may distort causing a restriction to coolant flow Radiator hose clamp torque is 36 in lbs 4 Nm Recovery Fil...

Page 33: ...ve the cotter pin and loosen the hub nut slightly 4 Elevate the appropriate side of the vehicle by placing a suitable stand under the frame 5 Remove the wheel nuts and remove the wheel 6 If hub removal is required remove the hub nut and washers Wheel Installation 1 Verify the transmission is still in PARK P 2 Install the wheel hub washers and hub nut if previously removed 3 Place the wheel in the ...

Page 34: ...amage tears wear or leaking grease If the rubber boots exhibit any of these symptoms replace the boot s Refer to Chapter 7 for drive shaft boot replacement CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear On vehicles with tapered rear wheel nuts make sure tapered end of nut goes into taper on wheel Wheel Nuts 4 Hub Nut Use a new cotter pin Note Tire Rotatio...

Page 35: ...y and result in a shorter life It can also hinder vehicle performance Follow the battery charging procedure before installing the battery 1 Ensure the battery is fully charged 2 Place the battery in the battery holder and secure with rubber strap 3 Coat the terminals with dielectric grease or petroleum jelly 4 Connect and tighten the red positive cable first 5 Connect and tighten the black negativ...

Page 36: ... at 1 2 amps or less until battery voltage is 12 8 VDC or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for battery charging directions When using a constant current charger follow the guidelines in the following table Spark Plug Service 1 Remove both driver and passenger seats 2 Remove the rear service panel 3 The PTO side spark plug can be accessed...

Page 37: ...eplace any worn or damaged steering components Steering should move freely through the entire range of travel without binding Check routing of all cables hoses and wiring to be sure the steering mechanism is not restricted or limited NOTE Whenever steering components are replaced check front end alignment Steering Wheel Freeplay Check the steering wheel for specified freeplay and operation 1 Posit...

Page 38: ... this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible NOTE It is important that the height of both marks be equally positioned in order to get an accurate measurement 4 Measure the distance between the marks and record the measurement Call this measurement A 5 Rotate the tires 180 by mov...

Page 39: ... to change spring tension preload Suspension Spring Adjustment 1 Position the vehicle on a level surface 2 Stop the engine 3 Raise and safely support the front or rear of the vehicle off the ground to allow the suspension to fully extend NOTE The tires should not be touching the ground 4 To adjust the suspension use the adjustment cam located near the bottom of the shock 5 Rotate the adjustment ca...

Page 40: ...line add brake fluid until it reaches the MAX level line 5 Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings Brake Pad Disc Inspection 1 Check the brake pads for wear damage or looseness 2 Inspect the brake pad wear surface for excessive wear 3 Pads should be changed when t...

Page 41: ...SEAL SPRING SERVICE ON ENGINE 3 26 CYLINDER HEAD DISASSEMBLY 3 27 VALVE INSPECTION 3 28 COMBUSTION CHAMBER 3 29 VALVE SEAT RECONDITIONING 3 29 CYLINDER HEAD REASSEMBLY 3 31 VALVE SEALING TEST 3 32 CYLINDER REMOVAL 3 32 VALVE LIFTER REMOVAL INSPECTION 3 32 PISTON REMOVAL 3 33 CYLINDER INSPECTION 3 34 CYLINDER HONE SELECTION AND HONING PROCEDURE 3 35 HONING TO DEGLAZE CLEANING THE CYLINDER AFTER HON...

Page 42: ...3 2 ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views ...

Page 43: ...3 3 ENGINE 3 Oil Pump Water Pump Engine Cover Exploded View ...

Page 44: ...3 4 ENGINE Stator Cover Starter Water Pump Oil Filter Pressure Relief Exploded View ...

Page 45: ...3 5 ENGINE 3 Cylinder Cylinder Head Piston Exploded View ...

Page 46: ...3 6 ENGINE Engine EFI Sensors Valve Cover General Component Exploded View NOTE See Chapter 4 for more information on the EFI System ...

Page 47: ...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 48: ...eto Cover 6 mm 96 3 10 85 0 35 Oil Baffle Weldment 5 mm 60 6 6 8 0 68 Oil Drain Bolt Crankcase 12 mm 192 24 21 7 2 7 16 21 7 Oil Fill Tube Bolt 5 mm 50 5 5 64 0 56 Oil Filter Pipe Fitting 20 mm 35 4 47 5 5 4 Oil Pick Up 5 mm 60 6 6 8 0 68 Oil Pressure Relief Plug 10 mm 22 2 30 3 Oil Pump Housing Screw 6 mm 84 8 9 50 0 90 Rocker Arm 8 mm 22 2 30 3 Rocker Cover 6 mm 84 8 9 5 0 9 Spark Plug 14 mm 216...

Page 49: ...478 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 ...

Page 50: ... 012 0 006 mm Piston Pin Degree of Fit Piston pin must be push fit by hand at 68 F 20 C Piston Connecting Rod Crankshaft Engine Specifications Main Components Piston Connecting Rod EH076OLE021 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 ...

Page 51: ...R 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 HOLDER PA 44995 WATER PUMP MECHANICAL SEAL INSTALLER PU 45543 UNIVERSAL DRIVER HANDLE PA 45483 MAIN SEAL INSTALLER PU 45658 CRANKSHAFT MAIN SEAL SAVER PA 45401 WATER PUMP SEAL SAVER 2870975 MITY VAC PRESSURE TEST TOOL PU 45778 OIL SYSTEM PRIM...

Page 52: ...y available pressure tester 3 The system must maintain 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 Pressure Cap Test 1 Remove pressure cap and test cap using a commercially available pressure cap tester 2 The pressure cap relief pressure is 13 psi Replace cap if it does not meet this specificatio...

Page 53: ...let Hose Radiator Radiator Shroud Radiator Pressure Cap Fan Motor Water Pump Cover Thermostat Housing If Built After 4 16 2007 Outlet Hose Inlet Hose Filler Neck To Filler Neck To Bottle Coolant Flow Diagram Radiator Recovery Bottle Engine Water Pump Engine Thermostat Housing Filler Neck ...

Page 54: ...adiator if the level goes down 9 Tighten the bleed screw to 70 10 in lbs 8 1 13 Nm on the thermostat housing and properly install the pressure cap 10 Stop the engine and let cool top off the radiator filler neck with coolant If you hear or see a glug at the filler neck or there is a dropping of the coolant level indicating that coolant has been pulled into the system Fill the recovery bottle only ...

Page 55: ...r Arms Water Pump The following components require engine removal for service Flywheel Alternator Stator Counterbalance Shaft or Bearings Gear Train Components Camshaft Oil Pump Oil Pump Drive Gear Connecting Rod Crankshaft Crankshaft Main Bearings Crankcase Oil Pressure Test 1 Remove blind plug sender from left side of crankcase 2 Insert a 1 8 NPT oil pressure gauge adaptor into the crankcase and...

Page 56: ...is supplied to the main oil galley through a crankcase passage Oil is then diverted three ways from the main oil galley with the first path entering the camshaft bores onto the rear balance shaft journal and then draining back into the crankcase sump The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump The third oil path flows through a cra...

Page 57: ...cool down before attempting to perform any work 2 Clean work area 3 Thoroughly clean the engine and chassis 4 Drain appropriate lubricant s If servicing the engine drain engine oil If servicing the transmission drain the lubricant from the main gearcase and transfer case If servicing the rear gearcase drain the gearcase lubricant 5 Remove the driver and passenger seats see Chapter 5 6 Disconnect n...

Page 58: ...onnect the ignition coil harness 17 Remove the vent lines from the upper bolt in frame brace andplugventlinestopreventfluidleakageduringremoval 18 Remove the 6 fasteners retaining the upper bolt in frame brace and remove it from the vehicle with the ignition coil and PVT duct attached 19 Remove the upper nut and grommet from the stabilizer bar linkage on both sides of the vehicle 20 Remove the 4 f...

Page 59: ...y bent or kinked while removed from the vehicle 26 Mark the fuel injector harnesses to identify MAG and PTO harness connections to aid during reassembly Disconnect the fuel injector harnesses NOTE The Bosch harness connector and locking spring is bonded to the fuel injectors with an epoxy mix DO NOT attempt to disconnect the Bosch connector from the fuel injectors Damage will occur to the injector...

Page 60: ... see Chapter 2 Shift Cable Inspection Adjustment 30 Disconnect the transmission gear indicator switch harness 31 Disconnect the CPS harness 32 Disconnect the stator alternator harness 33 Disconnect the transmission speed sensor harness 34 Remove the castle nuts from both rear wheel hubs Lower Jam Nut Mark Upper Jam Nut Gear Switch Connector CPS Connector Stator Connector Speed Sensor Connector Cas...

Page 61: ...ngine coolant temperature ECT sensor harness 39 Loosen the hose clamp and remove the lower coolant hose from the water pump cover inlet and drain coolant into a suitable container 40 Remove the filler neck pressure cap to relieve the cooling system vacuum NOTE Use a portable wet vac or syphon to prevent any coolant from spilling 41 Remove the upper coolant hose from the thermostat housing outlet t...

Page 62: ... rear gearcase assembly 47 Using an engine hoist hook a chain between the engine transmission mounting plate and the transmission rear gearcase mounting plate NOTE Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components 48 Lift the front portion of the assembly out first to allow the engine valve cover...

Page 63: ... removed from the vehicle the engine and transmission will need to be separated to allow engine servicing Use the following procedure to separate the engine from the assembly 1 Remove the drive belt drive clutch and driven clutch see Chapter 6 2 Remove the 6 fasteners retaining the inner clutch cover to the engine and transmission 3 Remove only the 4 outer fasteners retaining the engine to the tra...

Page 64: ...E 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 65: ...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 NOTE The cargo box assembly and the upper frame bolt in brace must be removed to allow enough clearance to remove all t...

Page 66: ...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 4...

Page 67: ...out 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 Sprin...

Page 68: ...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 69: ... 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 ...

Page 70: ...y 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 too...

Page 71: ...bly 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 72: ...N 2870390 Valve Lifter Removal Inspection 1 Remove the valve lifters 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 reassemb...

Page 73: ...Remove top compression ring Using a piston ring pliers Carefully expand ring and lift it off the piston CAUTION Do not expand the ring more than the amount necessary to remove it from the piston or the ring may break By hand Placing both thumbs as shown spread the ring open and push up on the opposite side Do not scratch the ring lands 4 Repeat procedure for second ring 5 Remove the oil control ri...

Page 74: ...th a telescoping gauge or 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 Limi...

Page 75: ...amage is excessive it will be necessary to replace the cylinder The cylinders are lined with a nicasil coating and are not repairable Hone only enough to de glaze the outer layer of the cylinder bore IMPORTANT Clean the cylinder after honing If cylinder wear or damage is excessive it will be necessary to replace the cylinder The cylinders are lined with a nicasil coating and are not repairable Hon...

Page 76: ...pin O D Replace piston and or piston pin if out of tolerance 3 Measure connecting rod small end ID Piston to Cylinder Clearance See 800 EFI Engine Service Specifications on page 3 9 Piston O D See 800 EFI Engine Service Specifications on page 3 9 Piston Pin Bore See 800 EFI Engine Service Specifications on page 3 9 5 mm Piston Piston Pin Piston Pin O D See 800 EFI Engine Service Specifications on ...

Page 77: ...gap 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 287104...

Page 78: ...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 79: ...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 80: ...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 two gears...

Page 81: ...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 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 Push th...

Page 82: ...ease of installing the Cam Gear Alignment Tool PU 45497 2 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 only...

Page 83: ...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 or...

Page 84: ... 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 85: ... thrust plate U 38 Remove PTO end 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 ...

Page 86: ...isassembled Camshaft Inspection 1 Thoroughly clean the cam shaft 2 Visually inspect each cam lobe for wear chafing or damage 3 Measure height of each cam lobe using a micrometer Compare to specification 4 Measure camshaft journal outside diameters O D W V 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...

Page 87: ...up A if removed Torque to specification 2 Install oil baffle 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 there is clearance between it and the oil baffle weldment 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 0...

Page 88: ...ply sealant to cam relief 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 Lubric...

Page 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...to the outside edges of the crankcase halves see arrows where the crankcases mate see the following photos 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 ...

Page 95: ...Torque the nut to specification 39 Install water pump cover R with new O ring seal Torque bolts to specification in proper sequence see Page 3 4 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 Torque ...

Page 96: ...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 will ensure proper s...

Page 97: ... 5 Lubricate rockers E with engine oil 6 Verify pushrods are engaged in lifters 7 Install rockers Be sure that tab of fulcrum F is seated in head stand off Torque bolts to specification T Cylinder Head Bolt Torque Initial setting 35 4 ft lbs 47 5 5 5 Nm Allow to set for 1 minute then turn additional 90 1 4 turn Torque Bolts In Sequence C D T Rocker Arm Bolt Torque 22 2 ft lbs 30 3 Nm E F ...

Page 98: ...uence to specification 11 Install thermostat J new O ring and thermostat housing Torque to specification 12 Install temperature sender K and torque to specification Oil Pump Priming 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 20 5 in lbs 2 5 55 Nm G H I T Thermostat Housing Bolt Torque 84 8 in lbs 9 5 0 9 Nm T Temperature Sender Torque 17 2 ft lb...

Page 99: ...emble the engine to the transmission on a work bench prior to installation 1 Support the transmission rear gearcase assembly while setting the engine in place NOTE A small number of vehicles were manufactured with shims placed between the rear transmission casting ear and the engine crankcase Be sure to use the same amount of shims upon reassembly If shims were present upon disassembly but have si...

Page 100: ...gine transmission rear gearcase mounting hardware and torque to specification NOTE If isolator mounts were removed or replaced use the following illustration to ensure proper orientation during installation Replace exhaust gaskets Seal connections with high temp silicone sealant Check to be sure all exhaust springs are in good condition Inspect transmission operation and adjust linkage if necessar...

Page 101: ...operating temperature 4 Vary throttle positions Do not operate at sustained idle or sustained high speed 5 Perform regular checks on fluid levels controls and all important bolt torques 6 Pull only light loads during initial break in 7 Change oil and oil filter after break in period at 25 hours CAUTION Use only Polaris Premium 0 40W All Season synthetic oil or equivalent Never substitute or mix oi...

Page 102: ...turn Engine seized rusted or mechanical failure Engine Runs But Will Not Idle Restricted fuel supply 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 ignition timing Restricted exhaust system Cam worn excessively Engine Has Low Pow...

Page 103: ...ion coil faulty Ignition or kill switch circuit faulty Poor connections in ignition system Ignition timing incorrect Sheared flywheel key 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 jac...

Page 104: ...NOTES ENGINE 3 64 ...

Page 105: ...DER TEST 4 21 FUEL PUMP TEST 4 21 FUEL TANK FUEL PUMP REPLACEMENT 4 23 FUEL PRESSURE REGULATOR 4 25 FUEL PRESSURE REGULATOR TEST REPLACEMENT 4 25 THROTTLE POSITION SENSOR TPS 4 26 TPS TEST PROCEDURE 4 26 TPS INITIALIZATION 4 28 TPS REPLACEMENT 4 29 ENGINE COOLANT TEMPERATURE SENSOR ECT 4 30 ECT SENSOR TEST REPLACEMENT 4 30 IGNITION COIL 4 31 IGNITION COIL TESTS REPLACEMENT 4 31 GENERAL TROUBLESHOO...

Page 106: ...fuel reaches the bottom of the filler neck Leave room for expansion of fuel Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time 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...

Page 107: ...rom SPX at 1 800 328 6657 Throttle Body Adjustment Screwdriver PU 47315 This tool has a special D shaped end for adjusting the throttle stop screw during a TPS initialization procedure Fuel Pressure Gauge Kit PU 43506 A IMPORTANT The EFI fuel system remains under high pressure even when the engine is not running Before attempting to service any part of the fuel system the pressure must be relieved...

Page 108: ... www diagsys com Digital Wrench SmartLink Module Kit PU 47471 This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench diagnostic software Polaris dealers can also order the following kit components separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 This module kit is used on all 8 pi...

Page 109: ...r 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 o...

Page 110: ...nifold 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 Ignition Coil 12 Spark Plugs 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 111: ...Crankshaft Position Sensor CPS Located in the magneto cover between the engine and transmission 4 Fuel Injectors Fuel Rail Attached to the fuel rail located in the intake track of the cylinder head 5 Fuel Pump Regulator Fuel Gauge Sender Assembly Located under the passenger seat and in the fuel tank as a complete assembly ECU T BAP CPS Fuel Injectors Fuel Rail Fuel Pump Assembly Located in Fuel Ta...

Page 112: ...the right hand side of the throttle body 8 Engine Coolant Temperature Sensor ECT Located in the cylinder head next to the thermostat housing The sensor can be accessed with the driver and passenger seats and rear service panel removed 9 Ignition Coil Located behind the driver s seat and rear service panel just above the PVT cover Throttle Body TPS ECT Ignition Coil ...

Page 113: ... Rear Tank Bracket Screw Pad Fuel Tank Front Tank Bracket Gasket Cap Hi Temp Flex Conduit Fuel Pump Asm Screw Pad Quick Connect Fuel Line Fuel Flow Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line Fuel Rail Fuel Injectors Pressure Regulator Fuel Tank ...

Page 114: ...iew The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions The ignition and injection functions are electronically controlled monitored and continually corrected during operation to maintain peak performance The central component of the system is the Bosch Engine Control Unit ECU which manages system operation determining the best c...

Page 115: ...nch Diagnostic Software dealer only ELECTRONIC CONTROL UNIT ECU Operation Overview The ECU is the brain or central processing computer of the entire EFI fuel ignition management system During operation sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECU Signals to the ECU include ignition on off crankshaft position and speed RPM throttle po...

Page 116: ...r Polaris RANGER RZR EFI of the same model may be used without system or engine component damage ECU Replacement 1 Remove the 2 retaining screws 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 TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR T BAP Operation Overview Mounted in the throttle...

Page 117: ...ing to specific crankshaft position for PTO cylinder This signal serves as a reference for the control of ignition timing by the ECU Synchronization of the CPS and crankshaft position takes place during the first two revolutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will quit running...

Page 118: ...he rear portion of the exhaust system and the mounting bracket between the transmission and rear gearcase will need to be removed 3 Remove the exhaust pipe between the elbow pipe and the exhaust silencer Remove the exhaust silencer 4 Remove the 3 bolts retaining the front portion of the mounting bracket to the transmission Retain the bolts washers and spacers for installation 5 Remove the bottom b...

Page 119: ...ssion and rear gearcase are installed in the vehicle 1 Clean bolt threads with solvent and allow them to dry Coat the cicumference of the first 4 threads of the bolts with Loctite before installing the bolts 2 Reinstall mounting bracket and hand tighten the 7 bolts 3 Torque ALL mounting bracket bolts to specification T CPS Retaining Bolt Torque 25 in lbs 2 8 Nm Remove Bracket This tool is specific...

Page 120: ...n extension to the torque wrench Torque the bottom bolt that attaches the bracket to the rear gearcase through the hole in the frame support Bottom Rear Gearcase Bolt NOTE Special Tool is not required for this torque 6 Using special tool PA 48873 torque the upper 2 bolts retaining the mounting bracket to the rear gearcase Place the torque wrench through the rear exhaust silencer opening to gain ac...

Page 121: ... the bracket to the front side of the rear gearcase Front Rear Gearcase Bolt NOTE A multi directional torque wrench is required in this application because of the limited access to this bolt Check with the manufacturer of your torque wrench to see if it can be used to tighten left hand threaded bolts ...

Page 122: ...ration indicating that they are opening and closing When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration NOTE Do not apply voltage directly to the fuel injector s E...

Page 123: ...fuel injector s by measuring between the two harness pin terminals Fuel Injector Replacement 1 Be sure the engine has cooled enough to work on 2 Depressurize the fuel system by connecting the Fuel Pressure Gauge Kit PU 43506 A to the test valve at the end of the fuel rail and properly drain the fuel into a suitable container 3 Remove the exhaust pipe between the exhaust silencer and the elbow pipe...

Page 124: ... this procedure 7 Thoroughly clean the area around the fuel injectors including the throttle body manifold 8 Using a 6mm hex wrench loosen the fuel rail mounting screw from the cylinder head Carefully pull the rail away from the injectors and remove the injector s from the cylinder head along with the harness 9 Reverse the previous procedures to install the new injector s and reassemble IMPORTANT ...

Page 125: ...el pump sending unit connection and measure the resistance between the Purple and Brown wires see chapter 10 for further details If out of specification replace the fuel pump assembly NOTE See the Electronic Parts Catalog for fuel pump availability It may be possible that the fuel tank assembly must be replaced Fuel Pump Test The fuel pump assembly may be a serviceable item on some vehicles NOTE S...

Page 126: ...e voltage was below 7 VDC test the battery ignition switch relay s wiring harness and ECU 5 If the reading is between 7 and 14 volts turn key switch off and connect an ohmmeter between the terminals A and C in the plug on the pump harness side to check for continuity within the fuel pump NOTE If there was no continuity between the pump terminals replace the fuel pump assembly See the Electronic Pa...

Page 127: ...seats along with the rear service panel 2 Disconnect the negative battery cable from the battery located under the driver s seat 3 Bleed off fuel pressure at the test valve using the Fuel Pressure Gauge Kit PU 43506 A 4 While holding a shop towel over the fuel line connector disconnect the quick connect fuel line from the fuel pump NOTE A small amount of fuel may come out of the fuel line or tank ...

Page 128: ...oved place the mechanism in the rear cargo box to keep it out of the way 11 Remove the 3 Torx fasteners from the rear RH fender well and remove the fender well from the vehicle NOTE Lift fender well up over the fuel tank filler neck and out from the vehicle IMPORTANT Take care not to place any excessive force on the filler neck 12 Remove the 2 tank bracket fasteners that retain the fuel tank in th...

Page 129: ...he key and listening for the pump to activate 11 Finally install the rear service panel along with the driver and passenger seats FUEL PRESSURE REGULATOR Operation Overview The fuel pressure regulator maintains the required operating system pressure of 39 psi 3psi A rubber fiber diaphragm divides the regulator into two separate sections the fuel chamber and the pressure regulating chamber The pres...

Page 130: ...e tested using the following method NOTE Before proceeding with any of the following measurements or tests it s extremely important to verify the throttle body bore is clean of any carbon build up Remove the intake boot and inspect the throttle body bore If required remove the throttle body and clean the bore using carburetor cleaner Set up the TPS Tester PU 47082 according to the instructions tha...

Page 131: ...silencer 2 Plug the TPS tester harness in the TPS harness 3 Connect the red volt meter test probe in yellow test port and black volt meter test probe in the black test port and set the meter to read VDC 4 Move the throttle open and closed slowly while reading the display The voltage should increase and decrease smoothly with no jumps when the throttle is applied 5 If voltage varies with throttle m...

Page 132: ...e body in the intake boot and intake adaptor This will allow you to rotate the throttle body to access the TPS or allow you to remove the throttle body to perform this procedure 5 Remove the throttle body side cover and disconnect throttle cable from throttle cam 6 Back out air flow screw until it no longer is in contact with throttle plate cam The throttle plate should seal off throttle bore comp...

Page 133: ... to the correct flow value 2 Reconnect the TPS harness lead 3 Reinstall throttle cable on throttle cam and install cover Adjust cable freeplay TPS Replacement NOTE The correct position of the TPS is established and set at the factory Do not loosen the TPS or alter the mounting position If the TPS is repositioned replaced or loosened it must be re calibrated by performing TPS Initialization 1 If th...

Page 134: ...s interrupted the fan will default to ON ECT Sensor Test To quickly rule out other components and wiring related to the ETS disconnect the harness from the ETS The fan should turn on and HOT should indicate on the instrument cluster This indicates all other components are working properly Refer to Chapter 10 for ECT testing Polaris dealers can also test the sensor by using the Digital Wrench Diagn...

Page 135: ...e the spark plugs Ignition Coil Tests The ignition coil can be tested by using an ohm meter Use the following illustration and specification table to test the ignition coil Primary Test Secondary Test Ignition Coil HT Lead Replacement 1 Remove the driver and passenger seats 2 Remove the rear service panel to access the ignition coil 3 Disconnect the ignition coil harness and remove the high tensio...

Page 136: ...t Circuit to Battery Yes P0601 23 RAM Error Defective ECU Yes P0914 25 Transmission Input Invalid Gear 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 Barometri...

Page 137: ...conomy 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 incorrect...

Page 138: ...4 34 ELECTRONIC FUEL INJECTION EFI SYSTEM BREAKOUT DIAGRAMS Diagnostic Connector Circuit Malfunction Indicator Lamp MIL Circuit ...

Page 139: ...4 35 ELECTRONIC FUEL INJECTION 4 Fuel Injector PTO Circuit Fuel Injector MAG Circuit ...

Page 140: ...4 36 ELECTRONIC FUEL INJECTION Engine Coolant Temperature Sensor ECT Circuit Engine Overheat Lamp Driver Circuit ...

Page 141: ...4 37 ELECTRONIC FUEL INJECTION 4 Crankshaft Position Sensor CPS Circuit Air Temperature Manifold Air Pressure Sensor T BAP Circuit ...

Page 142: ...4 38 ELECTRONIC FUEL INJECTION Throttle Position Sensor TPS Circuit Fuel Pump Circuit ...

Page 143: ...BUMPER 5 11 HOOD AND FRONT BODY WORK 5 12 ROCKER PANELS CONSOLE AND FLOOR 5 13 REAR FENDERS AND CARGO BOX 5 13 STEERING ASSEMBLY 5 14 EXPLODED VIEW 5 14 WHEEL HUBS 5 15 FRONT HUB EXPLODED VIEW 5 15 REAR HUB EXPLODED VIEW 5 15 FRONT A ARMS 5 16 REMOVAL REPLACEMENT 5 16 EXPLODED VIEW 5 17 BALL JOINT SERVICE 5 17 REMOVAL 5 17 INSTALLATION 5 18 FRONT STABILIZER BAR 5 19 SWAY BAR LINKAGE REMOVAL 5 19 S...

Page 144: ...0 Nm Upper LH RH Rear Bearing Carrier 37 ft lbs 50 Nm Outer Tie Rod to Bearing Housing 42 5 ft lbs 58 Nm Front Ball Joint Pinch Bolts 17 ft lbs 23 Nm Front Upper Lower Shock Bolt 27 33 ft lbs 37 45 Nm Rear Upper Lower Shock Bolt 27 33 ft lbs 37 45 Nm Front Wheel Hub Castle Nut 80 ft lbs 108 Nm Rear Wheel Hub Castle Nut 80 ft lbs 108 Nm Wheel Nuts Cast Rims Wheel Nuts Steel Rims 90 ft lbs 122 Nm 27...

Page 145: ...ehicle and align the rear mount holes Fasten the rear cab frame brackets to vehicle with four 5 16 18 bolts and 5 16 18 nuts Tighten bolts to 16 18 ft lbs 22 24 Nm Fasten the two tap screws to the rear inner portion of the bracket on each side Tighten tap screws to 15 ft lbs 20 Nm 3 Fasten the front of the cab frame to the base brackets and secure with four 3 8 16 x 1 1 4 screws and 3 8 16 Nyloc n...

Page 146: ...SPENSION BODY EXPLODED VIEWS Dash Instruments Controls A Instrument Cluster Speedo B Headlight Switch C 2WD AWD Switch D 12 Volt Accessory Receptacle E Speedometer Mode Button F Key Switch G Work Light Switch C D E F G B A ...

Page 147: ...mper Headlight Radiator Screen O Ring Front Bumper Support Front Bumper Winch Pocket Cover T25 Screws T25 Screw T27 Screw T27 Screw T30 Screws Torx Screw Washer RH Tail Work Light Rear Bumper Speed T25 Screws T27 Screws T27 Screw LH Tail Work Light Nuts ...

Page 148: ...SPENSION Hood Front Body Work Grommet Pin Center Hood Panel Hood Dash Front Bumper Front RH Fender Flair Front LH Fender Flair Winch Pocket Cover Push Rivets Grommet Push Rivets Push Rivets Push Rivets T27 Screws Reflector ...

Page 149: ...Body Grommets Seat Seat Back Seat Bottom Hoop Tube Nuts 41 57 in lbs 4 6 6 4 Nm 48 in lbs 5 4 Nm 41 57 in lbs 4 6 6 4 Nm Driver 3 Point Seat Belt Rear Seat Base Latch Seat Passenger Seat 3 Point Seat Belt 3 Point Seat Belt Plunger 35 ft lbs 47 Nm 35 ft lbs 47 Nm 35 ft lbs 47 Nm 35 ft lbs 47 Nm 35 ft lbs 47 Nm ...

Page 150: ...p Holder Rear Front Push Rivets U Type Plastic Dart Support Bracket Rear Support Bracket Push Rivets Support Bracket Front Support Bracket Self Tapping Screws Self Tapping Screws Self Tapping Screw Self Tapping Screw Torx Screws T27 Screw Nuts T27 Screw Self Tapping Screw Plastic Dart Plastic Dart ...

Page 151: ...oam Pin Fender Flair Rear LH Fender Flair Fender Rear LH Fender Cargo Box Tie Down Bracket Panel Divider Rear RH Panel Divider Rear Main Service Panel Supports Heat Shield Grommet Push Rivets Rivets T27 Tie Down Bracket Torx Screw Bolts T25 Screws T25 Screws Torx Nut Torx Screw Nut Screws Screws T27 Screws ...

Page 152: ...5 10 BODY STEERING SUSPENSION Chassis Main Frame Main Frame Bolt In Brace Skid Plate Rear Bumper Support Hitch 15 ft lbs 20 Nm 15 ft lbs 20 Nm 17 ft lbs 23 Nm 30 ft lbs 41 Nm 6 8 ft lbs 8 11 Nm ...

Page 153: ...the upper latch pins from the grommets Front Bumper 1 Remove the 4 push rivets from the sides of the front bumper 2 Remove the 6 Torx screws retaining the upper middle and lower portion of the bumper 3 Disconnect the front head lamp connectors and remove the front bumper from the vehicle Rear Bumper 1 Remove the 4 Torx screws retaining the upper portion of the rear bumper to the cargo box 2 Remove...

Page 154: ...rame assembly to allow dash removal Refer to CAB FRAME Assembly Removal for assembly torque specifications 4 Remove the 8 push rivets that attach the dash assembly to the rocker panels on each side 5 Remove the 2 Torx screws and 2 push rivets that retain the front and rear portions of the dash assembly and remove the dash assembly from the vehicle Front Fender Flair Removal 1 If dash is installed ...

Page 155: ...nd remove floor panel from the vehicle Rear Fender Flair and Tie Down Removal 1 Remove the rear bumper see BODY COMPONENT REMOVAL Rear Bumper 2 Remove the 8 push rivets that retain the rear portion of the rocker panels to the rear fenders 3 Remove the 3 push rivets and remove the fender flair from the rear fender 4 Remove the 3 Torx screws from the bottom side of the fender and the upper push rive...

Page 156: ...e Upper Steering Shaft Lower Steering Shaft Cotter Pin Gear Box Bushing Bushing Bushing Oil Locking Shock Asm Asm 17 ft lbs 23 Nm 17 ft lbs 23 Nm 12 14 ft lbs 16 19 Nm Nut 42 5 ft lbs 58 Nm 42 5 ft lbs 58 Nm 12 14 ft lbs 16 19 Nm 27 33 ft lbs 37 45 Nm 15 19 ft lbs 20 26 Nm 25 31 ft lbs 34 42 Nm 23 ft lbs 31 Nm 23 ft lbs 31 Nm 7 ft lbs 10 Nm 12 ft lbs 16 Nm ...

Page 157: ...r Pin Cone Wheel Hub Stud Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Carrier Front Tire Washers 27 ft lbs 37 Nm 80 ft lbs 108 Nm Ring Flanged Nuts Front Rim Valve Castle Nut Cotter Pin Cone Wheel Hub Stud Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Carrier Front Tire Washers 27 ft lbs 37 Nm 80 ft lbs 108 Nm Ring ...

Page 158: ...7 ft lbs 23 Nm 13 Attach shock to A arm with spacer D and fastener A see FRONT STABILIZER BAR Exploded View Torque lower shock bolt to 27 33 ft lbs 37 45 Nm 14 Remove the lower ball joint pinch bolt E from the front bearing carrier 15 Using a soft face hammer tap on bearing carrier to loosen the lower A arm ball joint end while pushing downward on the lower A arm Completely remove the ball joint e...

Page 159: ...the removal of the ball joint Use the dimensions below to fabricate or locate the correct size driver to use in the following process Upper A arm Lower A arm Grease Screws Ball Joint Pinch Bearing CV Shield Bushings 37 ft lbs 50 Nm Pivot Tube Bushing Grease Zerk Ball Joint Carrier Pivot Tube Bolts Zerk 17 ft lbs 23 Nm 37 ft lbs 50 Nm Ball Joint Upper A arm Retaining Ring 1 75 in 1 375 in 3 49 cm 3...

Page 160: ...l joint into place until the ball joint is properly seated 2 After the new ball joint is installed into the A arm install a NEW retaining ring 3 Reinstall the A arm see FRONT A ARMS Removal Replacement 4 Repeat the ball joint service procedure for any additional A arm ball joint replacements Correct Driver Placement The driver must fit the inside diameter of the Upper A arm Shown A arm end Press o...

Page 161: ...bs 37 45 Nm Stabilizer Bar Removal 1 If stabilizer bar linkages are installed remove the bolts that attach the upper portion of the linkages to the sway bar clamps see Exploded View on page 5 20 2 Remove the front bumper see BODY COMPONENT REMOVAL Front Bumper 3 Remove the 4 T30 Torx fasteners retaining the front bumper support to the frame 4 Remove the 2 upper radiator retaining bolts 5 Remove th...

Page 162: ... and remove it from the vehicle 10 Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed 11 Reverse the procedure for installation Torque the linkage fasteners to 27 33 ft lbs 37 45 Nm Exploded View Main Frame Mount Bracket Clamp Stabilizer Bushings Grease Zerk Linkage Nuts Spacer Clamp Bar 27 33 ft lbs 37 45 Nm Linkage T30 Screws ...

Page 163: ...A arm from the vehicle 5 Examine A arm and bearing carrier bushings and pivot tubes see Exploded View on page 5 22 Replace if worn Discard hardware 6 If not replacing the A arm thoroughly clean the a arm and pivot tubes 7 Insert new A arm bushings and pivot tubes into new A arm Lower A arm Removal 8 While holding the stabilizer bar linkage remove the lower nut retaining the linkage to the lower A ...

Page 164: ...ue new fastener to 37 ft lbs 50 Nm 3 Route brake line on top of the lower A arm and between lower shock mounting tabs 4 Reinstall the lower portion of the shock to the lower A arm Torque shock fastener to 27 33 ft lbs 37 45 Nm 5 Install upper A arm assembly onto vehicle frame Torque new fastener to 37 ft lbs 50 Nm 6 Attach upper A arm to bearing carrier Torque new fastener to 37 ft lbs 50 Nm 7 Ins...

Page 165: ... of the vehicle 3 Remove the 4 fasteners retaining the stabilizer bar bracket to the frame 4 Remove the stabilizer bar and bracket from the frame as an assembly 5 Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed 6 Inspect the rubber bushings on the linkage rod and replace if needed 7 Reverse the procedure for installation Torque the stabilizer bolts to 18 ft l...

Page 166: ...e 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 close to the surface 2 ...

Page 167: ...BELT 6 7 BELT REMOVAL 6 7 BELT INSPECTION 6 8 BELT INSTALLATION 6 8 PVT BREAK IN DRIVE BELT CLUTCHES 6 8 DRIVE CLUTCH SERVICE 6 9 SPRING SPECIFICATIONS 6 9 SHIFT WEIGHTS 6 10 EXPLODED VIEW 6 11 CLUTCH DISASSEMBLY 6 11 SPIDER REMOVAL 6 12 ROLLER PIN AND THRUST WASHER INSPECTION 6 13 BUTTON TO TOWER CLEARANCE INSPECTION 6 13 SHIFT WEIGHT INSPECTION 6 13 BEARING INSPECTION 6 14 CLUTCH INSPECTION 6 14...

Page 168: ... the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive belt rotates low in the drive clutch sheaves As engine RPM increases centrifugal force causes the drive belt to be forced upward on drive clutch sheaves TOOL DESCRIPTION PART NUMBER Drive Clutch Puller Short PA 48595 Clutch Holding Wrench 9314177 Clutch Holding Fixture 2871358 Spider Nut So...

Page 169: ...e Belt Clutches A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and drive belt by operating at slower speeds during the 10 hours as recommended see Chapter 3 Engine Break In Period for break in example Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period Maintenance Inspection...

Page 170: ...m engine at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle 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 or low ground speed Use Low only Plowing snow dirt etc utility use Use Low only Stuck in mud or...

Page 171: ...ets and 2 fasteners retaining the rear seat base and remove the seat base from vehicle to allow clutch cover removal 4 Loosen the hose clamp on the clutch outlet duct 5 Remove outer clutch cover screws and remove the clutch cover 6 Mark the drive belt direction of rotation and remove drive belt see DRIVE BELT Belt Removal 7 Remove the driven clutch retaining bolt and driven clutch Inner Clutch Cla...

Page 172: ...put shaft 3 Apply RTV silicone sealant to outside edge of inner clutch cover to engine seal to ensure a water tight fit between the seal and the cover 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 r...

Page 173: ... Reinstall outer clutch cover and secure with screws Torque to 45 50 in lbs 5 5 6 Nm 16 Install the clutch cover outlet duct and tighten the clamps DRIVE BELT Belt Removal 1 Remove outer clutch cover as described in PVT Disassembly 2 Mark the drive belt direction of rotation so that it can be installed in the same direction NOTE Belt is normally positioned so that the part number can be easily rea...

Page 174: ... should be replaced to eliminate noise vibration or erratic PVT operation See the Troubleshooting Chart at the end of this chapter for possible causes Belt Installation NOTE Be sure to position belt in the same position as when removed or so part number is easily read 1 Loop belt over the drive clutch and over top of the driven sheave 2 While pushing down on top of belt turn the back or moveable d...

Page 175: ...e spring is subject to during operation it should always be inspected for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from the outer coil surfaces as shown Refer to the spring specification chart for specific free length measurements and tolerances Also check to see that spring coils are parallel to one another ...

Page 176: ...e shift weights have many factors designed into them for controlling engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance clutch balance and shifting pattern ...

Page 177: ...3 Inspect cover bushing A The outer cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing Washers Bearing Spring Cover Bearing Bushing Lock Washer Bolt Flat Washer Cover Screws Button Pin Washers Roller Nut Shift Weight Bolt Non Braking Bearing Spacer Limiter Spider Button Cover Bushing Inspection Replace the cover bushing if more b...

Page 178: ...2870341 NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly Be sure to note the number and thickness of these washers Moveable Sheave Bushing Inspection 3 Inspect the Teflon coating on the moveable sheave bushing Clutch Holding Fixture PN 2871358 Spider Removal Tool PN 2870341 Inspect Shaft Moveable Sheave Bushing Inspection Replace...

Page 179: ...ches if the hollow roller pin is changed to the solid roller pin NOTE The rubber side of the button is positioned toward the solid roller pin Button To Tower Clearance Inspection 1 Inspect for any clearance between spider button to tower If clearance exists replace all buttons and inspect surface of towers See Spider Removal procedure 2 Inspect sheave surfaces Replace the entire clutch if worn dam...

Page 180: ...aking bearing should rotate both directions on the shaft with only a slight amount of drag 2 Verify there is no binding or rough spots If problems are noted in either direction continue with disassembly Clutch Inspection NOTE Remove cover spring and spider following instructions for drive clutch removal then proceed as follows 1 Remove the moveable sheave spacer sleeve 1 and the thrust washer 2 Vi...

Page 181: ...maged Moveable Sheave Bushing Inspection Inspect the Teflon coating arrow on the moveable sheave bushing Inspect both sheaves for signs of wear grooving or cracking De glaze sheave surfaces with a 3M Scotch Brite Pad if needed In mm Shaft Diameter Standard 1 3745 1 375 Service Limit 1 3730 In mm PTFE Washer Thickness Standard 030 76mm Service Limit 025 64mm Moveable Sheave Bushing Inspection Repla...

Page 182: ... sheave with A side toward sheave EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBSBushingRemovalTool 5132028 1 Instructions 9915111 Additional Special Tools Qty Part Description Part 1 Clutch Bushing Replacement Tool Kit 2871226 1 Piston Pin Puller 2870386 Item Qty Part Description Part ...

Page 183: ... puller rod and set aside 9 Remove sheave from puller 10 Remove installation tool Cover Bushing Removal 1 Install main adapter Item 8 on puller 2 Install adapter reducer Item 9 3 From outside of clutch cover insert removal tool Item 3 into cover bushing 4 With inside of cover toward vise slide cover onto puller 5 Install nut onto puller rod and hand tighten Turn puller barrel to increase tension a...

Page 184: ...ue spider to specification using the holding fixture and spider tool Torque with smooth motion to avoid damage to the stationary sheave 5 Install limiter nut on top of spider using the Clutch Spider Nut Socket PN 2870338 Torque to specification 6 Install shift weights using new lock nuts on the bolts 7 Reinstall clutch spring 8 Reinstall cover aligning X mark with other marks 9 Torque cover bolts ...

Page 185: ...nce This will aid in reassembly and helps to maintain clutch balance after reassembly 3 Remove the four torx screws that secure the cam helix assembly using a T25 torx driver 4 Place the clutch into the Clutch Compression Tool PN 8700220 Using Compression Extensions PN PS 45909 press down on top of the spider assembly compressing the spider onto the shaft Remove snap ring A and slowly release the ...

Page 186: ...ect the rollers for wear replace if worn 8 Remove the clutch assembly from the holding tool Remove the large outer retaining ring I and the inner retaining ring J 9 Press out the spring pins K in the inner sheave 10 Pull out the clutch roller pins L and rollers M 11 Press the shaft and bearing out of the outer sheave using a press E D H G F I J K K M L PressShaftand Bearing Out Inspect Bearing ...

Page 187: ...ean all residual Loctite from bushing bore prior to installing new bushing Inspect Sheave Surface Inspect Bushing EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBSBushingRemovalTool 5132028 1 Instructions 9915111 Additional Special Tools Qty Part Description Part 1 Clutch Bushing Replacem...

Page 188: ...ft hand thread from puller rod and set aside 9 Remove adapters from puller 10 Remove bushing and removal tool from adapters Discard bushing Clutch Bushing Installation 1 Install puller adapter Item 10 onto puller 2 Install adapter Item 9 onto puller 3 Apply Loctite 609 evenly to bushing bore inside moveable sheave 4 Install sheave face down on puller 5 Install new bushing on installation tool Item...

Page 189: ...ring into the outer sheave 3 Install the small and large retaining rings into the outer sheave above the bearing 4 Line up the X on the moveable sheave with the X on the stationary sheave or use the marks previously used Put the sheaves together 5 Install the roller A onto the roller pin B on both sides Align X s A B ...

Page 190: ...clutch rollers D onto each side of the outside spider Install the washers E and E clips F to secure the rollers The rollers should spin freely 11 Install the spider dampener G inside the outer spider and install the inside spider plate H 12 Install the spider assembly onto the shaft with the retaining ring on top of the spider NOTE Use the marks previously made to align the skip tooth spider or us...

Page 191: ...etaining ring A 15 Install the cam helix assembly over the shaft Line up the X on the cam X on spider and X on the stationary sheave or use the marks previously made before disassembly NOTE If the cam assembly helix is difficult to install be sure the sheaves are aligned To align the sheaves place the clutch assembly on a flat surface with the cam assembly helix side down Press down on the moveabl...

Page 192: ...sion Thrust Washer Cam Helix T25 Retaining Ring Roller Pin Slotted Ball E Ring Spring Thrust Washer Spider Dampener Outer Spider Spider Insert Stationary Sheave Bearing Spring Pin Moveable Sheave Clutch Shaft Roller Retaining Ring Screws ...

Page 193: ...clutch spring too high spring rate Driveclutchshiftweights incorrectfor application 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 det...

Page 194: ...d 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 separate...

Page 195: ...HILLIARD 7 12 CENTRALIZED HILLIARD EXPLODED VIEW 7 12 ALL WHEEL DRIVE OPERATION 7 13 AWD DIAGNOSIS 7 14 GEARCASE REMOVAL 7 15 GEARCASE DISASSEMBLY INSPECTION 7 15 GEARCASE ASSEMBLY INSPECTION 7 17 BACKLASH THRUST PLATE ADJUSTMENT 7 19 GEARCASE INSTALLATION 7 20 REAR BEARING CARRIER 7 21 BEARING CARRIER INSPECTION REMOVAL 7 21 BEARING REPLACEMENT 7 22 BEARING CARRIER BUSHING REPLACEMENT 7 22 BEARIN...

Page 196: ... washers from the front wheel hub assembly 5 Remove the steering tie rod end fastener from the front bearing carrier 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 27 ft lbs 37 Nm Front Hub Castle Nut 80 ft lbs 108 Nm Rear Hub Castle Nut 80 ft ...

Page 197: ...earings 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 12 Replace bearing if moisture dirt corrosion or roughness is evident Bearing Replacement Bearing Removal 1 Remove outer snap...

Page 198: ...und and install the snap ring Bearing Carrier Installation 1 Install drive shaft axle through the backside of the bearing carrier 2 Install the upper and lower ball joint ends into the front bearing carrier 3 Install pinch bolts and torque to 17 ft lbs 23 Nm 4 Apply grease to drive shaft axle splines 5 Install front wheel hub assembly cone washers and hand tighten the castle nut Install washers wi...

Page 199: ... wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions T Front Caliper Mounting Bolt Torque 30 ft lbs 40 Nm CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly T Tie Rod End Fastener Torque 42 5 ft lbs 58 Nm 42 5 ft lbs 58 Nm T Wheel Hub Castle Nut Torq...

Page 200: ...ke line Use wire to hang caliper to prevent damage to the brake line 5 Remove the front wheel hub assembly 6 Remove the upper ball joint pinch bolt 7 Using a soft faced hammer lightly tap on the bearing carrier while removing the upper ball joint end 8 Remove the drive shaft from the front bearing carrier 9 With a short sharp jerk remove drive shaft from the front gearcase CAUTION Serious injury m...

Page 201: ...liers 2 Remove the large end of the boot from the CV joint and slide the boot back 3 Separate the outer wheel end of the CV joint assembly from the axle shaft by pulling the shaft sharply outward away from the CV joint 4 It may be necessary to tap the CV joint assembly outward with a soft faced hammer 5 Remove the small clamp and boot from the drive shaft NOTE If the vehicle has been operated with...

Page 202: ...rive shaft with front gearcase and reinstall the drive shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 3 Install drive shaft into the front bearing carrier 4 Install the upper ball joint end into the front bearing carrier FRONT DRIVE SHAFT Joint Capacity 45 Grams Boot Capacity 45 Grams CV joint capacity 45g if boot is replaced only Boot Capacity 45 Grams Joint ...

Page 203: ...8 Install wheel and 4 wheel nuts Torque wheel nuts to specification 9 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions T Pinch Bolt Torque 17 ft lbs 23 Nm 17 ft lbs 23 Nm Out Cone Washers Wheel Hub 80 ft lbs NEW Cotter Pin 108 Nm T Wheel Hub Castle Nut Torque 80 ft lbs 108 Nm T Front Caliper Mounting Bolt Torque 30 ft lbs 40 Nm ...

Page 204: ...shaft NOTE You may have to loosen the front gearcase mounting bolts to allow for propshaft removal 6 Remove the fasteners retaining the plastic skid plate and remove the skid plate from the vehicle 7 Remove the propshaft from the vehicle 8 Reverse removal steps to reinstall propshaft Use a NEW Roll Pin Spring Pin upon reassembly PROPSHAFT U JOINT SERVICE Disassembly 1 Remove internal or external s...

Page 205: ...ss joint 2 Tighten vise to force bearing caps in 3 Using a suitable arbor fully seat the bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled 4 Install snap ring to contain bearing cap just installed Repeat procedure for other side 5 Install outer yoke aligning marks made at disassembly and repeat Steps 1 3 to install bearing caps on outer yoke...

Page 206: ...ION QTY REF DESCRIPTION QTY 1 Cover Screws 6 6 Roll Cage Assembly with H Springs 1 2 Cover Plate Assembly 1 7 Rollers 20 3 Thrust Plate 1 8 Clutch Housing Ring Gear 1 4 Armature Plate 1 9 Gearcase Housing 1 5 Output Hub Assembly 2 10 Wire Harness Retainer 1 1 2 3 4 5 6 7 8 9 10 7 11 ft lbs 10 15 Nm 5 ...

Page 207: ...re plate keyed to a roller cage that contains 20 rollers The difference in rpm between the input shaft propshaft and the front axles forces the rollers into the external cam of the Hilliard clutch assembly The rollers are forced inward to engage themselves to the output hubs that link directly to both front axles resulting in True All Wheel Drive Roller cage and roller s rotate inward and grip the...

Page 208: ...r mark may indicate a warped plate which may cause intermittent operation See the following illustrations 5 Check to make sure the coil is seated in the U shaped insert that is pressed into the gearcase cover The top of the coil 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 209: ...ont gearcase to frame 7 Remove the gearcase from the front LH wheel well area and slide it between the upper and lower A arm Gearcase Disassembly Inspection 1 Drain and properly dispose of gearcase fluid Remove any metal particles from the drain plug magnet 2 Remove the 6 cover screws and remove the cover plate 3 Check the gearcase coil resistance see AWD Diagnosis The resistance value should meet...

Page 210: ...hub assembly from the gearcase housing 8 Remove the 4 screws retaining the pinion shaft assembly and remove the assembly from the gearcase housing Inspect and clean the gearcase housing and replace the seal 9 Clean and inspect all parts Check for excessive wear or damage 10 Inspect the coil located in the cover plate assembly Refer to AWD Diagnosis for detailed inspection process Replace the cover...

Page 211: ...ches If damaged replace the roll cage assembly 15 Inspect clutch housing ring gear C for a consistent wear pattern Inspect the ring gear for chipped broken or missing teeth 16 Inspect both output hub assemblies Inspect the bearings and replace if needed Gearcase Assembly Inspection 1 As mentioned during gearcase disassembly section replace all O rings seals and worn components 2 Press the pinion s...

Page 212: ...ng the output hub 8 Place the thrust plate onto the adjuster button located in the cover plate assembly using a light film of grease to hold it in place 9 Install the RH output hub into the clutch housing assembly 10 While holding the hub in the clutch housing flip the clutch housing over and install the armature plate Engage the tabs into the slots in the roll cage assembly NOTE Be sure armature ...

Page 213: ... set from the factory No adjustment is required unless the cover plate ring gear clutch housing or pinion gear assembly is replaced Adjustment is also required if the thrust plate adjustment screw is removed 1 Lay the gearcase on its side with the cover plate facing up NOTE The backlash adjustment screw is held in place with Loctite Use a heat gun to loosen the Loctite on the screw 2 Using a hex w...

Page 214: ...ehicle through the LH wheel well area between the upper and lower A arms 2 Install the propshaft assembly onto the front gearcase input shaft Use a NEW spring pin in the front propshaft 3 Install the 4 bolts that secure the front gearcase to the frame and torque to 30 ft lbs 41 Nm 4 Install the vent line 5 Connect the AWD wire harness 6 Refer to FRONT DRIVE SHAFT Drive Shaft Installation and insta...

Page 215: ...wheel hub assembly 5 Remove the two brake caliper attaching bolts CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 6 Remove the rear wheel hub assembly 7 Remove the bolts that attach the rear bearing carrier to the upper and lower A arms 8 Remove the bearing carrier from the rear drive shaft 9 Rotate bearing by hand and check for smooth...

Page 216: ...rear bearing carrier if damaged Bearing Installation 5 Thoroughly clean the rear bearing carrier housing and the outer race on the new bearing Be sure that all oil residue has been removed from each surface 6 Support the bottom of the bearing carrier housing 7 Apply Loctite RC 680 to the outer circumference of the new bearing race and carefully press the new bearing into the bearing carrier housin...

Page 217: ...tall washers with domed side out 5 Install brake caliper mounting bolts and torque to 18 ft lbs 24 Nm 6 Torque wheel hub nut to 80 ft lbs 108 Nm and install a NEW cotter pin Tighten nut slightly if necessary to align cotter pin holes T Rear Bearing Carrier Bolt Torque 37 ft lbs 50 Nm 37 ft lbs 50 Nm Out Cone Washers Wheel Hub T Rear Caliper Mounting Bolt Torque 18 ft lbs 24 Nm CAUTION New bolts ha...

Page 218: ...the nut and 2 cone washers from the rear wheel hub assembly 4 Remove the two brake caliper attaching bolts CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 5 Remove the rear wheel hub assembly 6 Remove the bolt that attaches the rear bearing carrier to the upper A arm T Wheel Nut Torque Steel Wheels 27 ft lbs 37 Nm Aluminum Wheels 90 ft...

Page 219: ...t Boot Replacement 1 Remove clamps from rubber boot s using the CV Boot Clamp Pliers PN 8700226 A 2 Remove the large end of the boot from the CV joint and slide the boot back NOTE Photo above is shown without shaft for clarity Wipe grease away from recess in CV joint inner hub to locate snap ring 3 Open the snap ring using a snap ring pliers or small needle nose pliers Tap CV housing off shaft wit...

Page 220: ...ads on the outboard CV joint The joint is fully assembled when the snap ring is located in the groove on the 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 under fill the CV joint 9 Refer to information below or Figure 7 28 for grease capacity requirements 10 Remove e...

Page 221: ...e small clamp on the boot Installation 1 Install new spring ring on drive shaft Apply anti seize compound to splines 2 Align splines of drive shaft with rear gearcase and reinstall the drive shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary NOTE Take care when installing the drive shaft to prevent damaging the seal 3 Slide the rear drive shaft into the rear beari...

Page 222: ... Nm and install a NEW cotter pin Tighten nut slightly if necessary to align cotter pin holes 9 Install wheel and 4 wheel nuts Torque wheel nuts to specification T Rear Bearing Carrier Bolt Torque 37 ft lbs 50 Nm 37 ft lbs 50 Nm Out Cone Washers Wheel Hub 18 ft lbs 24 Nm T Rear Caliper Mounting Bolt Torque 18 ft lbs 24 Nm CAUTION New bolts have a pre applied locking agent which is destroyed upon re...

Page 223: ...to gain enough clearance to remove the rear gearcase 5 Remove the fasteners and bracket that secure the rear gearcase to the transmission 6 Remove the 4 fasteners and remove the rear mount from the rear gearcase 7 Pull the rear gearcase towards the rear of the vehicle to disengage it from the transmission NOTE If the splined coupler doesn t slide off the input shaft on the rear gearcase use a scre...

Page 224: ...e event damage to the gears or housing requires replacement the entire assembly must be replaced 1 Drain and properly dispose of used gearcase fluid 2 Remove the remaining cover screws from the rear gearcase 3 Remove the ring gear axle spool assembly The bearings are a slip fit and will slide off the axel spool NOTE Record the thickness of the shim pack located under each bearing Keep the shims to...

Page 225: ... housing Replace the o ring in the gearcase cover 7 Remove the input shaft seal using a seal puller or other suitable method 8 Inspect the input shaft by rotating the assembly in the gearcase housing while checking for any looseness or roughness Inspect the pinion gear teeth for chipped worn or broken teeth If damaged replace the ring gear and pinion gear as a set NOTE In the event damage to the g...

Page 226: ... each side of the gearcase housing using a standard seal installer or other suitable method Install a new o ring in the gearcase cover 3 If removed install each axle spool bearing race using standard bearing installation tools and a shop press WARNING Wear the appropriate safety equipment while installing bearing races to reduce the risk of injury ...

Page 227: ...smission to rear gearcase mount bracket it is extremely important to torque all 7 fasteners to specification Refer to the Installation procedure listed on page 4 15 NOTE Special tool PA 48873 will be required to torque the mounting bracket fasteners when the transmission and rear gearcase are installed in the vehicle Refer to the Installation procedure listed on page 4 15 2 Add Polaris ATV Angle D...

Page 228: ...Seal Oil 2 6 Nut Flanged 4 17 Screw Flange Head 4 7 Assembly Rear Housing RH 1 18 Screw 8 8 Bearing Retainer Ring 1 19 Dowel 2 9 Assembly Tapered Roller Bearing 2 20 Plug Drain w O Ring 1 10 Shim 2 21 Plug Fill w O Ring 1 11 Assembly Gear and Pinion 1 1 2 3 4 5 6 7 8 9 10 7 13 14 15 16 17 18 19 20 12 21 30 45 in lbs 3 5 Nm 40 ft lbs 54 Nm 23 27 ft lbs 31 37 Nm 10 9 6 16 7 7 70 80 ft lbs 95 108 Nm ...

Page 229: ... Stud Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Carrier Front Tire Washers See Page 7 2 for Torque Value 80 ft lbs 108 Nm Ring Flanged Nuts Front Rim Valve Castle Nut Cotter Pin Cone Wheel Hub Stud Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Carrier Front Tire Washers See Page 7 2 for Torque Value 80 ft lbs 108 Nm Ring ...

Page 230: ...NOTES FINAL DRIVE 7 36 ...

Page 231: ...DJUSTMENT 8 3 TRANSMISSION SERVICE 8 4 TRANSMISSION REMOVAL 8 4 TRANSFER CASE DISASSEMBLY 8 4 TRANSFER CASE REASSEMBLY 8 7 TRANSMISSION SHIFT HOUSING DISASSEMBLY 8 8 TRANSMISSION SHIFT HOUSING REASSEMBLY 8 13 TROUBLESHOOTING 8 18 TROUBLESHOOTING CHECKLIST 8 18 TRANSMISSION EXPLODED VIEWS 8 19 SHIFT HOUSING TRANSFER CASE EXPLODED VIEW 8 19 ...

Page 232: ... Tighten the shift cable nut to specification ITEM TORQUE VALUE Transmission Fill Plugs 40 50 ft lbs 54 67 Nm Transmission Drain Level Plugs 30 45 in lbs 0 2 0 3 Nm Transmission Case Screws 23 27 ft lbs 31 36 Nm Shift Lever Screw 15 20 ft lbs 20 27 Nm Detent Sleeve Screw 40 45 ft lbs 54 61 Nm Detent Adjustment Screw 23 27 ft lbs 31 36 Nm Drain Plugs Check Plug 30 45 in lbs 0 2 0 3 Nm Speed Sensor ...

Page 233: ... the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH H gear and PARK P 5 Thread the upper or lower jam nut as required to obtain proper cable adjustment NOTE This procedure may require a few attempts to obtain the proper adjustment 6 Once the proper adjustment is obtained place the shift cable and upper jam nut into the mount Tighten the lowe...

Page 234: ... instructions before beginning disassembly NOTE Exploded views are located at the end of this chapter for additional information 1 Place the transmission in neutral position 2 Drain both the transfer case and transmission case halves 3 Remove the 7 bolts retaining the transmission support bracket 4 Remove the connector tube bolts securing the rear gear case and transmission transfer case 5 Inspect...

Page 235: ...iscard removed bearings as they become damaged by the removal process 10 Remove the intermediate pinion shaft assembly from the housing Check bearings and gear teeth for wear or damage and replace as needed The shaft can be disassembled as shown using a press and standard bearing removal tools 11 Disassemble the output pinion shaft assembly by removing the retaining screws on the bearing cup brack...

Page 236: ...mbled as shown using a press and standard bearing removal tools 14 Remove the upper snap ring from the top side of the 21T main pinion gear and remove the gear 15 Remove the lower snap ring from under the gear 16 Remove the intermediate shaft seal using a seal puller or other suitable method ...

Page 237: ... shaft assembly NOTE Bearing is pressed onto the shaft 3 Install the shims bearing cup and alignment dowels into the retaining bracket 4 Install a new output shaft seal flush with the case Install the output pinion shaft assembly and bearing cup bracket assembly as shown Verify the alignment dowels are seated Torque the bracket screws evenly to specification T Output Pinion Shaft Bracket Screws 23...

Page 238: ... Install a new shaft seal flush with the surface the shims and bearing cup Apply a thin coat of sealant to the mating surfaces Apply lubricant to the seal lip 7 Install the transfer case cover Align the dowels 1 7 and insert the cover screws note position of the longest screw 4 Torque the screws evenly to specification in sequence as shown Apply Sealant PN 2871557 To Case Mating Surfaces 2871557 T...

Page 239: ...racket removal is required 2 Place the transmission shift housing onto a flat surface as shown Lift the transmission case half straight up and remove NOTE Shaft components may catch during transmission case half disassembly Work slowly and deliberately to avoid component loss or damage 3 Using a suitable tool pry the reverse retaining plate up from the 2 roll pins and remove the reverse clutch gea...

Page 240: ...rocess damages the bearing 6 Remove the reverse idler snap ring upper washer gear needle bearing and lower washer from the idler shaft NOTE The reverse idler shaft is a non serviceable item and should not be pressed out of the housing 7 Remove the input shaft seal and clutch intermediate shaft seal using a seal puller or punch 8 Remove the 2 screws that attach the shift switch to the shift housing...

Page 241: ... the longer silver detent screw NOTE Never remove the outer shift detent screw first Removal of the outer screw will allow the detent ball and spring to fall into the shift housing 11 Remove the park flange sleeve from the clutch shaft 12 Pull back fully on gear selector arm to bring shift collar up and disengage the shift collar from the clutch yoke Lifting on the clutch shaft may aid in shift co...

Page 242: ...the gear assembly 17 From the back side of the high gear assembly separate the high and low gear assemblies by tapping the gear retaining plate from the roll pins using a brass punch Note the order of disassembly on the entire gear assembly plate thrust washer bearing thrust washer Inspect all parts for wear or damage and replace as required 18 Remove the clutch yoke pivot pin set screw 19 Remove ...

Page 243: ...or wear Replace the shaft if required 22 Remove the screw from the end of the gear selector shaft assembly and remove the assembly from the housing Note the clips spring and plate orientation 23 Inspect the gear selector shaft and housing for excessive wear or damage Replace components as required 24 Inspect and replace the case bearings if required NOTE Do not pull bearings from case for inspecti...

Page 244: ...shaft as shown Lubricate the shaft and install the assembly into the housing Install the shift lever X facing out and screw onto the gear selector shaft Torque to specification 3 Install the input shaft assembly 4 Install clutch yoke into the gear selector shaft and spring Align the pivot pin holes and install clutch yoke pivot pin 5 Apply sealant to the clutch yoke set screw threads and install f...

Page 245: ... shaft into the housing Note that the forward gear assembly is loose in the housing and that alignment of the shaft gear assembly thrust washer and bearing is necessary for shaft installation 9 Install the sliding shoes onto the clutch yoke 10 Install the shift collar onto the shaft Pull back fully on gear selector arm to bring the shift yoke arms up and engage the shift shoes onto the center groo...

Page 246: ...nt uses the longer silver detent screw With the transmission in neutral lubricate and install the thrust washer drum gear plate springs pins and the shift position sensor o ring assembly into the shift housing Verify the shift drum pins are aligned as shown with the transmission in neutral Torque the retaining screws to specification 12 Complete shift detent screw installation Torque the inner scr...

Page 247: ... gear assembly onto the park flange Note the orientation of the 2 thrust washers top bottom of gear assembly and needle bearing Complete the assembly by aligning the roll pin holes and tapping the rollpins through the retaining plate and into the reverse gear using a brass punch 17 Install the input shaft seal and verify it is fully seated Install the intermediate shaft seal circled flush or sligh...

Page 248: ...es 19 Install the shift cable bracket 7 shift housing case screws to the front of the transmission Torque to specification 20 Install the 2 shift housing case screws to the backside as shown Torque to specification NOTE Shift cable bracket installation is required 21 Proceed with transfer case reassembly See Transfer Case Reassembly on page 8 7 Apply Sealant PN 2871557 To Case Mating Surfaces T Sh...

Page 249: ...nt and rod end positioning Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty is caused by an internal transmission problem isolate the transmission by disconnecting the shifter from transmission bellcrank Verify the engine RPM is set to specification Manually select each gear range at the transmission bellcrank and test ride...

Page 250: ...8 20 TRANSMISSION TRANSMISSION EXPLODED VIEWS Shift Housing Transfer Case Exploded View Transfer Case Shift Housing ...

Page 251: ...ERVICE 9 9 CALIPER EXPLODED VIEW 9 9 CALIPER REMOVAL 9 9 CALIPER DISASSEMBLY 9 10 CALIPER INSPECTION 9 11 CALIPER ASSEMBLY 9 11 CALIPER INSTALLATION 9 12 FRONT BRAKE DISC 9 13 DISC INSPECTION 9 13 DISC REPLACEMENT 9 13 REAR BRAKE PAD 9 14 PAD REMOVAL 9 14 PAD INSPECTION 9 15 PAD ASSEMBLY INSTALLATION 9 15 BRAKE BURNISHING PROCEDURE 9 15 REAR CALIPER SERVICE 9 16 CALIPER EXPLODED VIEW 9 16 CALIPER ...

Page 252: ...4 6 mm Rear Brake Disc Thickness 188 4 76 mm 170 4 32 mm Rear Brake Disc Runout 010 254 mm Item Torque ft lbs Torque Nm Front Caliper Mounting Bolts 30 40 Rear Caliper Mounting Bolts 18 24 Brake Line Flare 12 15 16 20 Brake Line Banjo Bolts Caliper Attachment 15 20 Brake Line Banjo Bolt Master Cylinder Attachment 15 20 Front Brake Disc to Hub Bolts 28 38 Rear Brake Disc to Hub Bolts 28 38 Brake Sw...

Page 253: ...t buildup on the brake pads and disc is the most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise Permatex Disc Brake Quiet PN 2872113 can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust Brake Noise Troublesh...

Page 254: ...rakes to feel spongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating port which is opened and closed by the master cylinder piston assembly As the temperature within the hydraulic system changes this port compensates for fluid expansion or contraction Due to the high temperatures created within the system during heavy braking ...

Page 255: ...stallation 1 Reverse Steps 1 5 for master cylinder installation Refer to the torque specifications in the illustration 2 After installing the foot brake check pedal freeplay Pedal freeplay should not exceed 090 2 286 mm BRAKE PEDAL LEVER Pedal Removal 1 Locate the brake pedal lever L and remove the master cylinder clevis pin B and clip A 2 Remove the E ring E from the pedal mount and remove the br...

Page 256: ...at procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir 8 Tighten bleeder screw securely and remove bleeder hose Torque bleeder screw to 47 in lbs 5 3 Nm 9 Repeat procedure Steps 5 8 for the remaining calipers 10 Add brake fluid to MAX level inside reservoir 11 Install master cylinder reservoir cover 12 Field test mac...

Page 257: ...cking pliers 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 5 Push mounting bracket inward and slip outer brake pad past edge Then remove inner pad Pad Inspection 1 Measure the thickness of the pad material Replace pads if worn beyond the servic...

Page 258: ...unterclockwise 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap 7 Install wheel and torque wheel nuts Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine All...

Page 259: ... brake line from caliper 5 Loosen brake pad adjustment set screw 2 3 turns to allow brake pad removal after the caliper is removed A Socket Set Screw B Bleeder Screw C Caliper Assy D Boot E Square O ring thick F Square O ring thin G Piston H Caliper Mount I Brake Pads A B C D E F G H Apply Polaris All Purpose Grease Apply Polaris DOT 4 Brake Fluid to Component I 47 in lbs 5 3 Nm D CAUTION Use care...

Page 260: ... Use low pressure compressed air to remove the pistons from the caliper 6 While holding the caliper and covering the pistons with a shop towel carefully apply compressed air to the brake line inlet to force the pistons out from the caliper IMPORTANT Do not remove the caliper pistons with a pliers The piston sealing surfaces will become damaged if a pliers is used 7 Once the pistons are removed use...

Page 261: ... damaged or worn beyond service limit 3 Inspect the brake disc and pads as outlined in this chapter Caliper Assembly 1 Install new O rings in the caliper body Be sure the grooves are clean and free of residue or brakes may drag upon assembly 2 Coat pistons with clean Polaris DOT 4 Brake Fluid Install pistons with a twisting motion while pushing inward Piston should slide in and out of bore smoothl...

Page 262: ...to specification 6 Install brake line and tighten securely with a line wrench Torque the banjo bolt brake line s to the proper torque specification 7 Install the pad adjustment screw and turn until stationary pad contacts disc then back off 1 2 turn 8 Perform brake bleeding procedure as outlined earlier in this chapter 9 Install wheel and torque wheel nuts to specification NOTE If new brake pads a...

Page 263: ...all new disc on wheel hub 5 Install new bolts and torque to 28 ft lbs 38 Nm 6 Install wheel hub assembly washers and castle nut Torque castle nut to 80 ft lbs 108 Nm and install a new cotter pin 7 Install front brake caliper see FRONT CALIPER SERVICE Follow the bleeding procedure outlined earlier in this chapter 8 Field test unit for proper braking action before putting into service Inspect for fl...

Page 264: ...ine 5 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers 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 Push caliper mounting bracket inward and slip outer brake pad past the edge to remove 7 Remove the inner br...

Page 265: ...tacts the disc then back off 1 2 turn counterclockwise 6 Verify fluid level in reservoir is up to the MAX line inside reservoir and install reservoir cap 7 Install wheel and torque wheel nuts Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mp...

Page 266: ...e pad adjustment set screw to allow brake pad removal after the caliper is removed 6 Remove the two caliper mounting bolts and remove the caliper A Brake Pad B Mount Bracket C Piston D Caliper Assy E Square Ring thick F Square Ring thin G Boot Pin Bushing H Boot Pin Seal I Bleeder Screw K Set Screw A B C D E F G H I K Apply Polaris DOT 4 Brake Fluid to Component Apply Polaris All Purpose Grease 47...

Page 267: ...aner or alcohol NOTE Be sure to clean seal grooves in caliper body Caliper Inspection 1 Inspect caliper body for nicks scratches or wear Measure bore size and compare to specifications Replace if damage is evident or if worn beyond service limit 2 Inspect piston for nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads...

Page 268: ... the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease Caliper Installation 5 Install the rear caliper with the mounting bolts Torque mounting bolts to 18 ft lbs 24 Nm 6 Install brake line banjo bolt and torque to specification 7 Install the pad adjustment screw and turn until stationary pad contacts disc then back off 1 2 turn 8 Perform brake bleeding pr...

Page 269: ...ll new disc on wheel hub 5 Install new bolts and torque to 28 ft lbs 38 Nm 6 Install wheel hub assembly washers and castle nut Torque castle nut to 80 ft lbs 108 Nm and install a new cotter pin 7 Install rear brake caliper see REAR CALIPER SERVICE Follow the bleeding procedure outlined earlier in this chapter 8 Field test unit for proper braking action before putting into service Inspect for fluid...

Page 270: ...ster cylinder or components Damaged break pad noise insulator Brake pads dragging Brake caliper dragging Pedal Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port plugged Pad clearance set incorrectly Brake pedal binding or unable to return fully Residue build up under caliper seals Operator riding brakes Brakes Lock A...

Page 271: ...AFETY LIMITER 10 12 TEST 5 FUEL GAUGE DISPLAY NOT WORKING 10 13 TEST 6 GEAR INDICATOR NOT WORKING TRANSMISSION SWITCH 10 13 ALL WHEEL DRIVE COIL 10 14 OPERATION OVERVIEW 10 14 DIAGNOSING SYSTEM FAILURES 10 14 GEAR POSITION INDICATOR SWITCH 10 14 TEST DIAGRAM 10 14 SPEED SENSOR 10 14 LOCATION TESTING 10 14 HEAD LIGHTS 10 15 HEADLIGHT ADJUSTMENT 10 15 HEADLAMP BULB REPLACEMENT 10 15 HEADLAMP HOUSING...

Page 272: ...G 10 29 OCV OPEN CIRCUIT VOLTAGE TEST 10 29 LOAD TEST 10 29 OFF SEASON STORAGE 10 29 CHARGING PROCEDURE LOW MAINTENANCE 10 30 STARTING SYSTEM 10 30 TROUBLESHOOTING 10 30 VOLTAGE DROP TEST 10 31 STARTER MOTOR REMOVAL DISASSEMBLY 10 31 BRUSH INSPECTION REPLACEMENT 10 31 ARMATURE TESTING 10 32 STARTER REASSEMBLY INSTALLATION 10 33 STARTER DRIVE 10 34 STARTER SOLENOID BENCH TEST OPERATION 10 34 STARTE...

Page 273: ...ance values included in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is used when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc and the position of the decimal point For resistance readings isolate the component to be tested Disconnect it from the wiring harness or power...

Page 274: ...he pins shown in the illustration Brake Light Switch 1 The brake light switch is located under the driver s seat along the lower frame The brake pressure switch is installed into this cross fitting block 2 Disconnect wire harness from switch 3 Connect an ohmmeter across switch contacts Reading should be infinite 4 Apply foot brake and check for continuity between switch contacts If there is no con...

Page 275: ...dicator illuminates when the AWD switch 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...

Page 276: ...tic Display Mode The wrench icon will display when the gauge is in the diagnostic mode To exit the diagnostic mode turn the key switch off and on Any movement of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Lock the parking brake 3 Place the transmission in neutral 4 Hold the mode button and turn the k...

Page 277: ...tes whether or not current is flowing through the AWD coil Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge NOTE A 10 20 variance from these readings is within normal parameters ...

Page 278: ...ench icon flashes Release the button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly NOTE If you scroll past the intended number press and hold the button until the hours cycle back to zero 5 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programm...

Page 279: ...ide of the dash while securely holding the dash and rubber mount NOTE Do not remove the rubber mount from the dash panel Only remove the rubber mount if necessary The bezel is a snap on assembly and is a serviceable part Instrument Cluster Installation 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 ...

Page 280: ... 30 2 54 34 24 2 5 4 2 6 4 4 352 2 6 2 2 7 7 4 4 4 9 2 5 4 3425 4 534 2 02 7 37 4 7 2 6 7 3 4 0 4 2 2 534 2 2 6 2 2 7 4 4 2 5 9 9 37 4 2 4 534 2 3 4 4 7 2 6 7 9 9 2 0 3425 4 534 2 02 4 7 02 0 23 343 7 0 43 7 2 02 452 9 37 4 452 9 37 4 452 9 37 4 OTE 2EVERSING POLARITY WHEN CONNECTING THE BATTERY OR OTHER POWER SOURCE BACKWARDS WILL FAIL THE 7 CONTROL AND THE INSTRUMENT CLUSTER IF THE KEY SWITCH AN...

Page 281: ...HWHU DQG ZDLW VHFRQGV WKHQ WXUQ RQ DJDLQ WR VHH LI SUREOHP FOHDUV 6 30 3 3 2 4OOLS 2EQUIRED 3TATIC 4IMING IGHT ARNESS 0 ALL 3ENSOR 0ROBE ARNESS 0 OR EQUIVALENT JUMPER WIRES 4O TEST WHEEL SPEED SENSOR ISCONNECT 0IN CONNECTOR FROM SPEEDOMETER ONNECT WIRES FROM TEST LIGHT TO SENSOR 0IN CONNECTOR AS SHOWN AT RIGHT USING THE ALL 3ENSOR 0ROBE ARNESS 0 OR JUMPER LEADS 2EMOVE THE SPEED SENSOR FROM THE TRA...

Page 282: ...5 1 1 7851 2 67 57 7 1 1 5 9 1 2 7 530 6 29 7851 21 2 6 5217 5 9 1 6 7 21 21 0 1 352 0 1 163 7 8 2 5 1 25 6 257 5 8 76 72 5281 6 211 7 211 725 0 685 7 1 8 2 52 1 7 5281 5 3 5 8 2 5 1 5 3 63 20 7 5 12 352 0 1 1 127 7 21 2 6 127 20 21 25 9 6 127 5 67 5 1 1 6 1 1 29 530 7 0 0 1 352 0 1 67 57 5 7851 6 7 2 5 67 57 5HG 9 RQVWDQW 5HG KLWH 9 6ZLWFKHG UH 2UDQJH 0RGH EXWWRQ 1 UHHQ OXH HOORZ 530 QSXW URZQ UR...

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Page 284: ...y Verify continuity of wire connections with a known good volt ohm meter IMPORTANT Verify all wires and wiring connections have been tested properly with a known good volt ohm meter before suspecting a component failure 80 of all electrical issues are caused by bad failed connections and grounds GEAR POSITION INDICATOR SWITCH Test Diagram NOTE See Instrument Cluster Troubleshooting for additional ...

Page 285: ...ure 5 Adjust the beam to the desired position by loosening the adjustment 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 Disconnect the headlamp bulb from the wiring harness Be sure to pull on the connector not on the wiring 2 Turn the lamp counterclockwise to remove it 3 Ins...

Page 286: ...re harness or re insert bulb if previously removed 4 Adjust headlights using the Headlight Adjustment procedure in this section TAIL BRAKE WORK LIGHTS Bulb Replacement Before replacing the bulb 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 a tail light brake light or work light does not work the bulb may need to be repla...

Page 287: ...10 17 ELECTRICAL 10 COOLING SYSTEM SCHEMATIC Cooling System Break Out Diagram ...

Page 288: ...er 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 Refer to Chapt...

Page 289: ...relay provides power to Fan Motor Yellow Black ECU input to connect relay Fused 20 Amp power to Fan Motor output Red Fused 20 Amp constant battery power IN supply for EFI component operation EFI RELAY COLOR FUNCTION Orange Fused 15 amp constant battery power IN supply for EFI component operation Red White Key On battery power supply switched on by key switch enables power to relay Red Black EFI po...

Page 290: ...in the fuse box under the dash the fuse panel provides current protection for components such as the Instrument Cluster ECU EFI system Chassis Power and Accessories A separate 20 amp circuit breaker protects the fan motor circuit see wire diagram for details ...

Page 291: ...ransmission into neutral with the park brake on and start the engine With the engine running at idle observe meter readings 5 Increase engine RPM while observing ammeter and tachometer 6 Note RPM at which the battery starts to charge ammeter indication is positive 7 With lights and other electrical loads off the break even point should occur at approximately 1500 RPM or lower 8 With the engine run...

Page 292: ... at Charging RPM 1 Set the selector dial to measure AC Voltage 2 Start the engine and let it idle 3 While holding the engine at a specified RPM separately measure the voltage across each leg of the stator by connecting the meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to Y3 4 Refer to the following table for approximate AC Voltage readings according to RPM Test each leg...

Page 293: ...s 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 wi...

Page 294: ...emove vent plug from vent fitting Remove cell caps 2 Fill battery with electrolyte to upper level marks on case 3 Set battery aside to allow for acid absorption and stabilization for 30 minutes CONVENTIONAL BATTERY Top View Electrolyte Level Side View SEALED LOW MAINTENANCE BATTERY No Caps Non removable sealed Top Top View Side View Polaris Sticker Removable Caps Indicator WARNING Battery electrol...

Page 295: ... reduced 5 Reinstall the battery caps Battery Installation 1 Clean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly 2 Route the cables correctly and reinstall battery attaching positive red cable first and then the negative black cable Coat terminals and bolt...

Page 296: ...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 electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered To perform this test hook a multitester to the battery in the...

Page 297: ...re Conventional 1 Remove the battery to prevent damage from leaking or spilled acid 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 specific gravity to 1 270 or greater 3 Install battery in vehicle with positive terminal toward the front Coat threads of battery bolt with a corrosion resistant dielectric gr...

Page 298: ...t equivalent of 1 10 of the battery s rated amp hour capacity Do not use the alternator to charge a new battery NEVER attempt to add electrolyte or water to a Low Maintenance battery Doing so will damage the case and shorten the life of the battery To service a Low Maintenance battery 1 Remove battery from the vehicle 2 Test battery with a voltage meter or load tester to determine battery conditio...

Page 299: ... in the OCV test The reading should be 12 6 volts or greater Engage the starter and observe the battery voltage while cranking the engine Continue the test for 15 seconds During cranking the observed voltage should not drop below 9 5 volts If the beginning voltage is 12 6 volts or higher and the cranking voltage drops below 9 5 volts during the test replace the battery Off Season Storage To preven...

Page 300: ... direction only Faulty starter solenoid or starter motor Engine problem seized or binding can engine be rotated easily Starter Motor Turns Over Slowly Battery discharged low specific gravity Excessive circuit resistance poor connections see Voltage Drop Test Engine problem seized or binding can engine be rotated easily Faulty or worn brushes in starter motor Starter Motor Turns Engine Does Not Rot...

Page 301: ...er to clean starter motor parts Some solvents may leave a residue or damage internal parts and insulation 1 Remove the starter from the engine 2 Remove the two bolts washers and sealing O Rings Inspect O Rings and replace if damaged NOTE Note the alignment marks on both ends of the starter motor casing These marks must align during reassembly 3 Remove the front bracket assembly and the rear bracke...

Page 302: ...ely in their holders Brush Replacement 1 Remove terminal nut with lock washer flat washer large phenolic washer the small phenolic spacers and sealing O ring Inspect O ring and replace if damaged 2 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Armature Testing 1 Remove armature from starter casing Note order of shims on drive end for reassembly 2 ...

Page 303: ...ce 4 Slide armature into field magnet housing Release brushes 5 Lightly grease the drive roller bearing and reinstall drive end frame on armature Inspect seal for wear or damage Replace drive end cap if necessary 6 Be sure wire insulation is in place around positive brush wire and pushed completely into slot on phenolic plate 7 Using Dielectric Grease PN 2871329 lubricate brush end bushing and ins...

Page 304: ...crew the overrun clutch off the end of the pinion shaft Remove the old spring and install a new one Lightly grease the pinion shaft and reinstall the clutch spring retainers end washer and lock ring in the reverse order Make sure the end washer is positioned properly so that it will hold the lock ring in its groove Starter Solenoid Bench Test Test the start solenoid by powering the solenoid via th...

Page 305: ... 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 306: ... energized resistance should read about 0 5Ω 10 between the two terminals If resistance measurement is out of specification replace the starter solenoid see Starter Solenoid Bench Test 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 Turn the ignition key to the start position Reading should be less th...

Page 307: ...10 37 ELECTRICAL 10 ELECTRICAL BREAKOUT DIAGRAMS 12V Key On Power Circuit Starting System Circuit ...

Page 308: ...10 38 ELECTRICAL Instrument Cluster Circuit Transmission Switch Circuit ...

Page 309: ...10 39 ELECTRICAL 10 Wheel Speed Sensor Circuit AWD Circuit ...

Page 310: ...10 40 ELECTRICAL Fuel Gauge Display Circuit Cooling Fan Circuit ...

Page 311: ...10 41 ELECTRICAL 10 Charging System Circuit ...

Page 312: ...NOTES ELECTRICAL 10 42 ...

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Polaris 2008 Ranger RZR, Service Manual

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