Polaris 2009 Ranger RZR 800 EFI Manual Download Page 109

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ELECTRONIC FUEL INJECTION

4.1

CHAPTER 4

ELECTRONIC FUEL INJECTION

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
EFI SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
EFI SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

FUEL LINES - QUICK CONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

PRINCIPAL COMPONENTS / EFI OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . 4.9
INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

ECU SERVICE / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11

TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP) . . . . . . . . . 4.11

T-BAP TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11

CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12

CPS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
CPS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13

FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17

FUEL INJECTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
FUEL INJECTOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18

FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20

FUEL SENDER TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
FUEL TANK / FUEL PUMP REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22

THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24

TPS TESTER / REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
CHECKING TPS READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
TPS ADJUSTMENT / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26

ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . 4.27

ECT SENSOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27

IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28

IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28
IGNITION COIL / HT LEAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28

GENERAL TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29

DIAGNOSTIC “BLINK CODES” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29
EFI TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30

EFI SYSTEM BREAKOUT DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31

Summary of Contents for 2009 Ranger RZR 800 EFI

Page 1: ...E INFORMATION 1 4 PUBLICATION NUMBERS 1 4 PAINT CODES 1 4 REPLACEMENT KEYS 1 4 SPECIAL TOOLS 1 4 GENERAL SPECIFICATIONS 1 5 GENERAL 2009 RANGER RZR 1 5 GENERAL 2009 RANGER RZR S 1 5 DETAILED 2009 RANGER RZR 1 6 DETAILED 2009 RANGER RZR S 1 7 MISC SPECIFICATIONS AND CHARTS 1 8 CONVERSION TABLE 1 8 STANDARD TORQUE SPECIFICATIONS 1 9 SAE TAP DRILL SIZES 1 10 METRIC TAP DRILL SIZES 1 10 DECIMAL EQUIVA...

Page 2: ...responding about an engine be sure to refer to the engine model number and serial number This information can be found on the sticker applied to the cylinder head on the side of engine Machine Model Number Identification Model Year Designation Basic Chassis Designation Engine Designation Emissions Model Option R 0 9 V H 7 6 A D 4 X A V H 7 6 A 9 P 0 0 0 0 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 3: ...ial number VIN are important for vehicle identification The VIN number A is stamped on a portion of the front left frame rail close to the left front wheel The VIN and model number are also located on a decal B attached to the frame support accessible through the front right wheel well A A B ...

Page 4: ...maybe substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may order special tools through Polaris official tool supplier SPX Corporation by phone at 1 800 328 6657 or on line at http polaris spx com Model Model No Owner s Manual PN Parts Manual PN 2009 RANGER RZR R08VH76AD AG AH AO 9921878 9921879 2009 RANGER R...

Page 5: ...y 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 336 4 kg Includesrider s cargo accessories and trailer tongue weight Hitch Towing Capacity 1500 lbs 680 kg Hitch Tongue Capacity 150 lbs 68 kg Category Dimension Capacity Length 106 in 269 cm Width 60 5 in 154 cm Height 70 5 in 179 cm Wheel Base 77 in 196 cm Ground Clearance 12 in 30 5 cm Dry Weight 1000 lbs 454 kg Gross Vehicle Weight 1782 ...

Page 6: ... 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 Oil R...

Page 7: ... 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 Oil Requirements Polaris Demand Drive LT Premium F...

Page 8: ...1 8 GENERAL INFORMATION MISC SPECIFICATIONS AND CHARTS Conversion Table C to F 9 5 C 32 F F to C 5 9 F 32 C ...

Page 9: ...he 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 10: ...1 10 GENERAL INFORMATION SAE Tap Drill Sizes Metric Tap Drill Sizes Decimal Equivalents ...

Page 11: ...he end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In lb 12 in lbs 1 ft lb kg cm Kilograms per square centimeter kg m Kilogram meters Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a rotational direction l or ltr Liter lbs in Pounds per...

Page 12: ...NOTES GENERAL INFORMATION 1 12 ...

Page 13: ...ROTTLE FREEPLAY ADJUSTMENT 2 12 THROTTLE CABLE REPLACEMENT 2 12 AIR FILTER SERVICE 2 14 ENGINE 2 16 ENGINE OIL LEVEL 2 16 ENGINE OIL AND FILTER SERVICE 2 17 ENGINE BREATHER HOSE INSPECTION 2 18 ENGINE AND TRANSMISSION MOUNT LOCATIONS 2 18 COMPRESSION AND LEAKDOWN TEST 2 18 EXHAUST SPARK ARRESTOR 2 18 TRANSMISSION AND GEARCASES 2 19 TRANSMISSION GEARCASE SPECIFICATION CHART 2 19 TRANSMISSION LUBRIC...

Page 14: ...E GROUND 2 29 STEERING 2 29 STEERING INSPECTION 2 29 STEERING WHEEL FREEPLAY 2 29 STEERING INSPECTION TIE ROD ENDS AND HUBS 2 30 TOE ALIGNMENT INSPECTION 2 30 TOE ADJUSTMENT 2 31 SUSPENSION RZR 2 31 SPRING PRELOAD ADJUSTMENT 2 31 SUSPENSION RZR S 2 32 SPRING PRELOAD ADJUSTMENT 2 32 SHOCK COMPRESSION ADJUSTMENT 2 32 BRAKE SYSTEM 2 33 BRAKE FLUID INSPECTION 2 33 BRAKE PAD DISC INSPECTION 2 33 BRAKE ...

Page 15: ...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 16: ... 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 17: ... 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 18: ...2 6 MAINTENANCE COMPONENT INSPECTION SERVICE LOCATIONS Front and Rear View Standard RZR Shown Standard RZR Shown ...

Page 19: ...2 7 MAINTENANCE 2 RH and LH Side Views Standard RZR Only Standard RZR Shown Standard RZR Shown ...

Page 20: ...ubricants 2871312 Grease Gun 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 De...

Page 21: ... Page 2 7 AGL Synthetic 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 Add fluid to bottom of fill plug threads 6 75 oz 200 ml ...

Page 22: ...ame 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 deceleration...

Page 23: ...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 24: ... 1 5 3 mm of freeplay is achieved at the throttle pedal NOTE While adjusting lightly move the throttle pedal in and out 6 Re tighten the jam nut 7 Apply a small amount of grease to the inside of the boot and slide it over the cable adjuster to its original position Throttle Cable Replacement 1 Place the vehicle in PARK and stop the engine 2 Remove the seats and rear service panel see Chapter 5 3 R...

Page 25: ... the upper A arm and between the front left hand drive shaft and frame and between the front gearcase and frame 18 Install the front upper cable clamp making sure to allow enough cable slack to attach the cable bracket to the frame support 19 Open the front lower cable retainer place over the cable and reinstall retainer into the frame hole 20 Route the cable through the retainer at the bottom of ...

Page 26: ...e body cover and PVT inlet duct 34 Verify the vehicle is still in PARK 35 Start the engine and allow it to warm up 36 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 1 8 1 5 3 mm If freeplay is correct proceed to next step If adjustment is required refer to Throttle Freeplay Adjustment procedure 37 Using a 10 mm open end wrench tighte...

Page 27: ... the air box thoroughly 2 Install a new or clean pre filter over the main air filter element 3 Place filter ring over the end of the filter and install 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 and secure with clips...

Page 28: ...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 29: ...er 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 PS 4 PLUS 2W 50 Synthetic Engine Oil PN 2876244 15 Verify the transmission is still positioned in PARK P 16 Start the engine and let it id...

Page 30: ...eakage testers as crankshaft seals may dislodge and leak Exhaust Spark Arrestor Periodically clean spark arrestor to remove accumulated carbon 1 Remove the retaining screw and remove the arrestor from the end of the silencer 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 Reinsta...

Page 31: ...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 32: ...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 33: ...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 34: ... 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 35: ...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 36: ...rneath the radiator fitting on the front RH side of the vehicle 4 Drain the coolant from the radiator by removing the lower coolant hose from the radiator as shown 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 R...

Page 37: ...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 38: ...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 39: ...ife 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 negative cable last 6 Verify that ...

Page 40: ...arge the battery 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...

Page 41: ...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 Position the...

Page 42: ... 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 43: ...e by rotating the adjustment cam to change spring tension preload Suspension Spring Adjustment 1 Position the vehicle on a level surface and stop the engine 2 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 3 To adjust the suspension rotate the adjustment cam clockwise to increase spri...

Page 44: ...flat blade screwdriver to make damping adjustments NOTE When the adjuster screw is turned clockwise until it stops the damping is in the fully closed position Turn the clicker clockwise to increase compression damping Turn the clicker counter clockwise to decrease compression damping NOTE The factory setting is 8 clicks from closed see Compression Adjustment Table WARNING Uneven adjustment may cau...

Page 45: ... 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 ...

Page 46: ...2 34 MAINTENANCE MAINTENANCE LOG Service Date Hours Miles km Service Performed Comments Dealer Technician ...

Page 47: ...SEAL SPRING SERVICE ON ENGINE 3 26 CYLINDER HEAD DISASSEMBLY 3 27 VALVE INSPECTION 3 28 COMBUSTION CHAMBER 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 3 35 CLEANING THE CYLINDER AFTER HON...

Page 48: ...3 2 ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views ...

Page 49: ...3 3 ENGINE 3 Oil Pump Water Pump Engine Cover Exploded View ...

Page 50: ...3 4 ENGINE Stator Cover Starter Water Pump Oil Filter Pressure Relief Exploded View ...

Page 51: ...3 5 ENGINE 3 Cylinder Cylinder Head Piston Exploded View ...

Page 52: ...3 6 ENGINE Engine EFI Sensors Valve Cover General Component Exploded View NOTE See Chapter 4 for more information on the EFI System ...

Page 53: ...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 54: ...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 55: ...unter Balance Counter Balance End Play 0 005 0 127 mm Cylinder Head Cylinder Head Surface warp limit 0 00394 0 1 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 Abo...

Page 56: ... 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 EH076OLE022 EH076OLE072 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 0 019...

Page 57: ...PPORT 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 PRIMING TOOL ...

Page 58: ...ailable 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 specification Co...

Page 59: ...se Engine Outlet Hose Radiator Radiator Shroud Radiator Pressure Cap Fan Motor Water Pump Cover Thermostat Housing 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 60: ...ightly loosen the bleed screw C on the thermostat cover to let air escape If no air is present a steady stream of coolant will stream out If air is present the screw will bubble and sputter as the air escapes 8 Tighten the bleed screw to 70 10 in lbs 8 1 13 Nm on the thermostat housing and properly install the pressure cap 9 Squeeze the coolant lines by hand to help purge the system of air NOTE If...

Page 61: ...r Piston Rings Rocker 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 in...

Page 62: ...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 63: ...operated allow it to cool down before attempting to perform any work 2 Clean work area 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 negative battery cable...

Page 64: ...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 65: ...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 66: ... 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 67: ...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 68: ...smission 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 val...

Page 69: ... 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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ... 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 76: ...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 77: ... 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 2W 50 Synthetic engine 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 guid...

Page 78: ...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 79: ...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 80: ...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 81: ...l 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 Hone only enough to de glaze...

Page 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ... 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 91: ... 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 92: ...ace the bearings anytime the engine is disassembled 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 W V In mm Cam Lobe Height Intake Std 800 EFI 1 334 33 867 mm 800 H O EFI 1 357 34 477 mm Exhaust std 800 EFI 1 334 33 867 mm 800 H O EFI 1 342 34 096 mm Cam ...

Page 93: ...tion 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 O D A Mag 1 654 00039 42 010 mm B Ctr 1 634 00039 41 50 010 mm C PTO 1 614 00039 41 010 mm In mm Camshaft Journal Bore I D Mag 1 656 0 ...

Page 94: ...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 95: ...alignment 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 ...

Page 96: ...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 97: ...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 98: ...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 99: ... 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 se...

Page 100: ...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 101: ...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 102: ...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 2874275 to remove any debris This will ensure proper s...

Page 103: ... 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 104: ...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 105: ...ort the transmission rear gearcase assembly while setting the engine in place 2 Lightly tighten all fasteners evenly to eliminate any gaps that may be present in the mounting areas 3 Torque fasteners to specification using a 2 part sequence Torque fasteners to half of the specified torque value Then torque fasteners to the full specified torque value Install the inner clutch cover drive clutch and...

Page 106: ... number of 87 R M 2 2 Check oil level indicated on dipstick Add oil if necessary Refer to Chapter 2 Engine Oil Level 3 Drive slowly at first to gradually bring engine up to operating temperature 4 Vary throttle positions Do not operate at sustained idle or sustained high speed 5 Perform regular checks on fluid levels controls and all important bolt torques 6 Pull only light loads during initial br...

Page 107: ... 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 Po...

Page 108: ...ty 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 jacket accident damage Lean mixture vents fuel pump or ...

Page 109: ...L SENDER TEST 4 20 FUEL PUMP TEST 4 20 FUEL TANK FUEL PUMP REPLACEMENT 4 22 THROTTLE POSITION SENSOR TPS 4 24 TPS TESTER REGULATOR 4 24 CHECKING TPS READING 4 25 TPS ADJUSTMENT REPLACEMENT 4 26 ENGINE COOLANT TEMPERATURE SENSOR ECT 4 27 ECT SENSOR TEST REPLACEMENT 4 27 IGNITION COIL 4 28 IGNITION COIL TESTS 4 28 IGNITION COIL HT LEAD REPLACEMENT 4 28 GENERAL TROUBLESHOOTING 4 29 DIAGNOSTIC BLINK C...

Page 110: ...capacity when the fuel reaches the bottom of the filler neck Leave room for expansion of fuel Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time 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 gas...

Page 111: ...quipped with a CD drive and serial port connection and is designed to replace multiple shop tools often used to test EFI components It also includes step by step diagnostic procedures to aid technician repair and troubleshooting IMPORTANT If the PC you are using is not equipped with a 9 pin serial port a USB to serial port adaptor will be necessary A USB to serial port adaptor can be purchased thr...

Page 112: ...ny parts removed and wrap any open joints with plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Clean any connector before opening to prevent dirt from entering the system Although every precaution has been taken to prevent water intrusion failure avoid direct water or spray contact with system components...

Page 113: ...rometric 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 114: ... 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 Fuel Rail Injectors Fuel Pump Assembly Located in Fuel Tank Fuel Pump Regula...

Page 115: ... 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 116: ...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 117: ...view 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 ...

Page 118: ...nostic 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 position e...

Page 119: ...e if required For the purpose of troubleshooting a known good ECU from another 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 BA...

Page 120: ...ng 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 121: ...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 bolt that...

Page 122: ...ion and rear gearcase are installed in the vehicle 1 Clean bolt threads with solvent and allow them to dry Coat the circumference 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 specifica...

Page 123: ...an 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 a...

Page 124: ...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 125: ...bration 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 ...

Page 126: ...ctor s by measuring between the two harness pin terminals Fuel Injector Replacement 1 Be sure the engine has cooled enough to work on 2 Place a suitable container below the quick connect plug at the end of the fuel rail Hold a shop rag over the plug and remove it to depressurize the fuel system 3 Remove the exhaust pipe between the exhaust silencer and the elbow pipe to allow better access to the ...

Page 127: ...n 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 128: ...asure 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 If a fuel delivery problem is suspected make certain the fuel pump filters are not plugged that the pump is be...

Page 129: ...voltage to ensure a minimum of 7 volts is present NOTE If the voltage was below 7 VDC test the battery ignition switch relay s wiring harness and ECU 7 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 te...

Page 130: ...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 Properly drain fuel into a suitable container 4 Disconnect the fuel pump electrical harness 5 Remove the fuel tank vent hose 6 Remove the 2 push rivets from the rear of the center console 7 Remove the 2 fasteners from the rear seat base and remove the assembly from ...

Page 131: ...ft the rear of the fuel tank up first and carefully pull it out from the vehicle Fuel Tank Fuel Pump Installation 1 Carefully reinstall the fuel tank assembly 2 Reinstall the 2 tank brackets and fasteners 3 Reinstall the rear RH fender well and secure with fasteners 4 Reinstall the seat belt mechanism and secure the lower bolt 5 Reinstall the RH rocker panel and all 15 fasteners 6 Reinstall the re...

Page 132: ...ure the 9 Volt battery is new As mentioned in the instructions included with the tester be sure the TPS Tester Adapter Harness is set up along with the TPS Tester Regulator 4010264 NOTE If your dealership sells Polaris snowmobiles you may already have this regulator from TPS Tester Kit 2201519 If you do not have this regulator you must order one from SPX at 1 800 328 6657 The correct position of t...

Page 133: ... 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 4 Assemble the TPS Tester according to the instructions Refer to TPS Tester Regulator for proper set up and testing Verify the 9 volt tester battery is new 5 Disconnect the vehicle chassis harness from the TPS NOTE To allow better access to the TP...

Page 134: ...ew and verify the voltage did not change If the voltage changed repeat steps 2 4 5 Reconnect the TPS harness to the vehicle chassis harness TPS Replacement NOTE The correct position of the TPS angle on the throttle body is established and set at the factory If the TPS is replaced repositioned or loosened it must be recalibrated Refer to the TPS Adjustment procedure 1 If the vehicle is completely a...

Page 135: ...circuit is interrupted the fan will default to ON ECT Sensor Test To quickly rule out other components and wiring related to the ECT disconnect the harness from the ECT 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 Wre...

Page 136: ... 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 tension...

Page 137: ... Yes P0601 23 RAM Error Defective ECU Yes P0914 25 Gear Switch Signal Fault Yes P0113 41 Intake Air Temp Sensor Open or Short Circuit to Sensor Voltage ECU Yes P0112 41 Intake Air Temp Sensor Short Circuit to Ground Yes P0117 42 Engine Temperature Sensor Circuit Short To Ground Yes P0118 42 Engine Temperature Sensor Circuit Open or Short to Battery Yes P0107 45 Barometric Pressure Sensor Circuit L...

Page 138: ...onomy 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 incorrectl...

Page 139: ...4 31 ELECTRONIC FUEL INJECTION 4 EFI SYSTEM BREAKOUT DIAGRAMS Diagnostic Connector Circuit Malfunction Indicator Lamp MIL Circuit ...

Page 140: ...4 32 ELECTRONIC FUEL INJECTION Fuel Injector PTO Circuit Fuel Injector MAG Circuit ...

Page 141: ...4 33 ELECTRONIC FUEL INJECTION 4 Engine Coolant Temperature Sensor ECT Circuit Engine Overheat Lamp Driver Circuit ...

Page 142: ...4 34 ELECTRONIC FUEL INJECTION Crankshaft Position Sensor CPS Circuit Air Temperature and Barometric Air Pressure Sensor T BAP Circuit ...

Page 143: ...4 35 ELECTRONIC FUEL INJECTION 4 Throttle Position Sensor TPS Circuit Fuel Pump Circuit ...

Page 144: ...NOTES ELECTRONIC FUEL INJECTION 4 36 ...

Page 145: ...FT REMOVAL BEARING REPLACEMENT 5 16 WHEEL HUBS 5 17 FRONT A ARMS 5 18 REMOVAL REPLACEMENT 5 18 EXPLODED VIEWS 5 19 BALL JOINT SERVICE 5 20 REMOVAL 5 20 INSTALLATION 5 21 FRONT STABILIZER BAR RZR 5 21 SWAY BAR LINKAGE REMOVAL 5 21 STABILIZER BAR REMOVAL 5 21 EXPLODED VIEW 5 22 REAR A ARMS 5 23 REMOVAL 5 23 INSTALLATION 5 24 EXPLODED VIEWS 5 25 REAR STABILIZER BAR RZR 5 26 REAR STABILIZER BAR RZR S ...

Page 146: ...2 Nm Upper LH RH Rear Bearing Carrier 33 ft lbs 45 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 147: ...olts and 5 16 18 nuts Tighten bolts to 16 18 ft lbs 22 24 Nm Fasten the two self tapping screws to the rear inner portion of the bracket on each side Tighten screws to 15 ft lbs 20 Nm 3 Place the straps from the safety net over the front coupler posts 4 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 nuts Tighten screws to 25 28 ft...

Page 148: ...er portion of the bracket on each side Tighten screws to 15 ft lbs 20 Nm 3 Place the straps from the safety net over the front coupler posts 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 nuts Tighten screws to 25 28 ft lbs 34 38 Nm 4 Attach the upper side bars to the cab frame Do not fully tighten at this time Fasten the upper si...

Page 149: ...TEERING SUSPENSION 5 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 C D E F B A ...

Page 150: ...ht Radiator Screen O Ring Front Bumper Support Front Bumper Winch Pocket Cover T25 Screws T25 Screw T27 Screw T27 Screw T30 Screws Torx Screws Washers Bumper Retaining Bracket Bulb RH Tail Light Rear Bumper Speed T25 Screws T27 Screws T27 Screw LH Tail Light Nuts ...

Page 151: ... Work Center Hood Panel Hood Dash Front Bumper Front RH Fender Flair Front LH Fender Flair Winch Pocket Cover Push Rivets Push Rivets T27 Screws Reflector 1 4 Turn Latch Grommet Washer Hood Pad Push Rivet Push Rivet T27 Screws T27 Screws T25 Screws ...

Page 152: ...ody 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 153: ...oor Rear Front Push Rivets U Type Support Bracket Rear Support Bracket Push Rivets Support Bracket Front Support Bracket Self Tapping Screws Self Tapping Screws Self Tapping Screw T27 Screws T27 Screws Nuts T27 Screws Self Tapping Screw Plastic Dart T27 Screws Torx Screws Upper Floor T27 Screw ...

Page 154: ...r 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 1 4 Turn Latch Storage Cover Seal T27 Screws Push Rivet Foil Tie Down Ring ...

Page 155: ...5 11 BODY STEERING SUSPENSION 5 Chassis Main Frame Main Frame Bolt In Brace Skid Plate Rear Bumper Support 15 ft lbs 20 Nm 15 ft lbs 20 Nm 17 ft lbs 23 Nm 6 8 ft lbs 8 11 Nm ...

Page 156: ...ard and towards the front of the vehicle to remove it 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 car...

Page 157: ...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 remove the 2 push rivet...

Page 158: ... to the rear fenders 3 Remove the 3 push rivets or 8 T27 screws RZR S 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 rivet from the top side Remove the fender from the vehicle 5 Remove the 4 fasteners that retain the tie down brackets to the cargo box and remove from vehicle Cargo Box Assembly Removal 1 Remove the s...

Page 159: ...Cotter Pin Gear Box Bearing 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 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 Bushing Thick Washer Thin Washer Thick Washers Thin Washer Thin Washer Spacer ...

Page 160: ...ot tube using a drift punch 6 Inspect the pivot tube bearing surfaces for signs of excessive wear or damage 7 Slide a new lower bearing onto the steering shaft and install the steering shaft through the pivot tube NOTE Be sure the lower washers and spacers are still on the steering shaft 8 Slide a new upper bearing onto the steering shaft and press it into the pivot tube by hand NOTE Bearings will...

Page 161: ...ed Ball Bearing Bearing Front Tire Washers 27 ft lbs 37 Nm 80 ft lbs 108 Nm Ring Carrier Steel Front Rim Aluminum Wheel Nuts 90 ft lbs 122 Nm Studs Wheel Nuts Rear Rim Castle Nut Cotter Pin Cone Wheel Hub Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Rear Tire Washers 27 ft lbs 37 Nm 80 ft lbs 108 Nm Ring Carrier Steel Rear Rim Aluminum Wheel Nuts 90 ft lbs 122 Nm Studs ...

Page 162: ...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 end from t...

Page 163: ...Shield Bushings 33 ft lbs 45 Nm Pivot Tube Bushing Grease Zerk Ball Joint Carrier Bolts Zerk 17 ft lbs 23 Nm 33 ft lbs 45 Nm Pivot Tube Upper A arm Lower A arm Grease Screws Ball Joint Pinch Bearing CV Shield Bushings 33 ft lbs 45 Nm Grease Ball Joint Carrier Bolts Zerk 17 ft lbs 23 Nm 33 ft lbs 45 Nm Pivot Zerk Tube Pivot Tube Bushings ...

Page 164: ... press and correct size driver to remove the ball joint from the A arm NOTE The driver must fit the ball joint housing in the A arm This will allow the ball joint to be properly pressed out of the A arm without damaging the A arm Ball Joint Upper A arm Retaining Ring Standard RZR Shown 1 75 in 1 375 in 3 49 cm 3 in 7 62 cm Driver Dimensions Outside diameter of driver cannot be any larger than 1 75...

Page 165: ...loded View on page 5 22 3 Remove the bolts that attach the upper portion of the linkages to the sway bar clamps and remove the linkages from the vehicle see Exploded View on page 5 22 4 Inspect the linkage assemblies for signs of excessive wear or damage Replace linkage assembly if damaged 5 Reverse the procedure for installation Torque the linkage fasteners to 27 33 ft lbs 37 45 Nm Stabilizer Bar...

Page 166: ...to access the 4 bolts retaining the upper radiator mount bracket 8 Remove the 4 bolts retaining the upper radiator mount bracket and remove the bracket from the frame 9 Lift up on the stabilizer bar 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 ...

Page 167: ...the vehicle 3 Examine A arm and bearing carrier bushings and pivot tubes see Exploded View on page 5 25 Replace if worn Discard hardware 4 If not replacing the A arm thoroughly clean the a arm and pivot tubes 5 Insert new A arm bushings and pivot tubes into new A arm Lower A arm Removal RZR 1 While holding the stabilizer bar linkage remove the lower nut retaining the linkage to the lower A arm 2 R...

Page 168: ... arm from the vehicle see previous illustration 5 Examine A arm and bearing carrier bushings and pivot tubes see Exploded View 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 the new A arm Installation 1 Install lower A arm assembly onto vehicle frame Torque new fasteners to 33 ft lbs 45 Nm 2 ...

Page 169: ...ivot Tube Carrier Pivot 33 ft lbs 45 Nm Grease Zerk Shield 38 ft lbs 52 Nm Tube 33 ft lbs 45 Nm Bushings Pivot Tube Pivot Tube Bushings Upper A arm Lower A arm Screws Bearing CV Bushings 33 ft lbs 45 Nm Pivot Tube Carrier Pivot 33 ft lbs 45 Nm Grease Zerk Shield 38 ft lbs 52 Nm Tube 33 ft lbs 45 Nm Bushings Pivot Tube Bushings Pivot Tube ...

Page 170: ... side 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...

Page 171: ...ilizer bar to the linkage on each side of the vehicle 3 Remove the 4 fasteners retaining the stabilizer bar to the bracket 4 Remove the stabilizer bar from the bracket bracket can remain attached to the frame 5 Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed 6 Reverse the procedure for installation Torque the stabilizer bolts to 18 ft lbs 24 Nm Remove Remove ...

Page 172: ... View Shock Removal Installation 1 Elevate the vehicle off the ground to relieve the suspension load 2 Remove the upper and lower fasteners retaining the shock and remove the shock from the vehicle 3 Reverse the procedure to reinstall the shock Torque new fasteners to 27 33 ft lbs 37 45 Nm Shock Replacement 1 Using a spring compressor compress the shock spring far enough to remove the spring retai...

Page 173: ... 1 Bearing External 5 Shock Oil 2870995 19 1 Bearing External 6 1 Decal 20 2 Retaining Ring Wire 7 2 Bearing 21 1 Spring Guide 8 4 Retaining Ring 22 1 Piston Damping 9 1 Eyelet 23 1 Reservoir End Cap Asm 10 1 Spacer 24 1 Retaining Ring Wire 11 1 Piston Asm Floating IFP 25 1 Damping Adjust Asm Piston 12 1 Valving Asm 26 1 Damping Adjust Asm Concentric Adjuster 13 1 Bearing Asm 27 1 Screw Asm 14 1 B...

Page 174: ...08 1 250 x 0 006 1 300 x 0 008 1 250 x 0 006 0 800 x 0 004 1 250 x 0 008 1 250 x 0 008 1 100 x 0 006 1 100 x 0 006 1 000 x 0 006 1 000 x 0 006 0 900 x 0 008 0 900 x 0 010 0 800 x 0 010 0 800 x 0 010 0 700 x 0 010 0 700 x 0 010 0 620 x 093 Back Up 1 125 x 093 Top Out Piston Orifice 0 098 SHOCK DESIGN DETAILS Travel 6 22 Extended Length 21 34 IFP Location 3 40 Nitrogen Pressure 200 psi Gas Shock Oil...

Page 175: ... these procedures 1 Safety Glasses 2 Latex Gloves 3 Lint Free Towels 4 Assembly Lube lithium based grease 5 Loctite 271 6 12 Tie Wrap Zip Tie 7 MAPP Gas or Propane Torch 8 1 834 TC Seal Kit 9 5wt Shock Fluid Special Tools Required Body Holding Tool PN 2871071 Charging Needle PN 7052069 A Gas Shock Recharging Kit PN 2200421 FOX Shock IFP Tool PN 2871351 Seal Installation Bullet Tool PN 2201640 PN 2...

Page 176: ...he shock If your shock has polyurethane bushings and sleeves remove them from both ends of the shock Fig 1 5 Note and record the setting on the Compression Adjuster Screw Using the Flat Blade Screwdriver count the clicks as you turn the adjuster clockwise until it stops Fig 2 Once you have written this number down turn the screw all the way counterclockwise until it stops 6 Clean the entire shock ...

Page 177: ...oir tube using the IFP Depth Setting Tool and place it on a clean lint free towel Remove the shock from the vise and pour shock oil from body and reservoir tubes into a proper disposal container DO NOT RE USE OLD SHOCK OIL 18 Using the 1 8 Hex Tool remove the IFP bleed screw from the IFP 19 Clean the body tube reservoir tube and the IFP using solvent Dry with compressed air in a well ventilated ar...

Page 178: ... area If compressed air is not available dry parts using clean lint free paper towels and let sit in a well ventilated area to allow the remaining solvent to evaporate 3 Use a scribe or dental pick to remove the o ring seal from the IFP 4 Use a scribe or dental pick to remove the o ring seals from the reservoir end cap 5 Install the new well lubricated o rings into the bearing housing Correct plac...

Page 179: ...lbs using the torque wrench and 9 16 socket Remove shaft assembly from vise and set it aside on a clean lint free paper towel 5 Clamp the body cap of the shock securely in the vise with the open end of the body facing up 6 Using the flat blade screwdriver turn the compression adjuster screw counter clockwise until it stops turning 7 Lubricate the new IFP o ring with an ample amount of assembly lub...

Page 180: ...surface of the oil during this process 19 Bring the damping piston up until it is approximately 1 4 below the surface of the oil Using the mallet give 2 3 sharp blows to the eyelet driving the damping piston down into the shock body This opens the valves on the damping piston You will see the released air bubbles come to the surface of the oil 20 Add oil to the body tube until the surface of the o...

Page 181: ...en Safety Needle using a smooth straight motion Keep the reservoir as straight as possible to prevent the safety needle from bending As the safety needle is pulled free from the FOX air valve a popping sound should be heard 35 Install the button head screw into the FOX air valve using a 3 32 hex key 36 Remove the shock from the vise 37 Clean all oil residue from the shock and reservoir with solven...

Page 182: ...NOTES BODY STEERING SUSPENSION 5 38 ...

Page 183: ...DRIVE BELT CLUTCHES 6 8 DRIVE CLUTCH SERVICE 6 9 SPRING SPECIFICATIONS 6 9 SHIFT WEIGHTS 6 10 NON BRAKING EXPLODED VIEW RZR 6 11 EBS EXPLODED VIEW RZR S 6 11 CLUTCH DISASSEMBLY 6 12 SPIDER REMOVAL 6 12 ROLLER PIN AND THRUST WASHER INSPECTION 6 13 BUTTON TO TOWER CLEARANCE INSPECTION 6 14 SHIFT WEIGHT INSPECTION 6 14 BEARING INSPECTION 6 14 CLUTCH INSPECTION 6 15 MOVEABLE SHEAVE BUSHING INSPECTION ...

Page 184: ...This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive belt rotates low in the drive clutch sheaves As engine RPM increases centrifugal force causes the drive belt to be forced upward on drive clutch sheaves TOOL DESCRIPTION PART NUMBER Drive Clutch Puller Short PA 48595 Clutch Holding Wrench 9314177 Cl...

Page 185: ...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 186: ...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 187: ...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 188: ...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 189: ...5 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 re...

Page 190: ...le 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 driven sheave clockwise 3 The belt then should be able to be pushed down into and between the sheaves PVT Break In Drive Belt Clutches A prope...

Page 191: ...t to during operation it should always be inspected for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from the outer coil surfaces as shown Refer to the spring specification chart for specific free length measurements and tolerances Also check to see that spring coils are parallel to one another Distortion of the ...

Page 192: ...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 193: ...ing Lock Washer Bolt Flat Washer Cover Screws Button Pin Washers Roller Nut Shift Weight Bolt Non Braking Bearing Spacer Limiter Spider Button Washers Bearing Spring Cover Bearing Bushing Lock Washer Bolt Flat Washer Cover Screws Button Pin Washers Roller Nut Shift Weight Bolt One Way Bearing Spacer Spider Button ...

Page 194: ... area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or damaged 5 Remove and inspect the clutch spring See Drive Clutch Spring Specifications for spring inspection Spider Removal 1 Remove the limiter spacer from the shaft RZR Only 2 Install clutch in holding fixture PN 2871358 and loosen the spider counterclockwise using Clutch Spider Removal Tool ...

Page 195: ...s of three Also inspect to see if roller and bushing are separating Bushing must fit tightly in roller Use the Roller Pin Tool PN 2870910 to replace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation 2 Rubber backed buttons can be used in all RANGER clutches if the hollow roller pin is changed to the solid roller pin NOTE The rubber side o...

Page 196: ...ear or galling If weights or bolts are worn or broken replace in sets of three with new bolts NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See Roller Pin and Thrust Washer Inspection Bearing Inspection 1 Rotate the clutch bearing in both clockwise and counter clockwise directions RZR The non braking bearing should rotate in both directions on th...

Page 197: ...sher 4 off shaft Replace as an assembly if worn damaged or if problems were noted 5 Inspect surface of shaft for pitting grooves or damage Measure the outside diameter and compare to specifications Replace the drive clutch assembly if shaft is worn or damaged 6 Visually inspect PTFE thrust washer for damage Measure the thickness and compare to specification Replace if worn or damaged In mm Thrust ...

Page 198: ...pection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter 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 EBS Bushing Removal 5132028 1 Instructions 9915111 Additional Special Tools Qty Part Description Part 1 Clutch B...

Page 199: ...pter from puller rod Remove bushing from tool and discard Drive Clutch Bushing Installation 1 Place main adapter Item 8 on puller 2 Apply Loctite 609 evenly to bushing bore inside moveable sheave 3 Set bushing in place on sheave 4 Insert installation puller tool Item A B with A side down into center of bushing NOTE 800 EFI Clutch Use Bushing Tool PA 47336 5 With towers pointing upward slide sheave...

Page 200: ...er toward vise 4 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 5 Turn clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and clutch cover off rod Clutch Assembly NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly The Teflon...

Page 201: ... from the outside snap ring The driven clutch must be disassembled from the helix side 2 It is important to mark the position of the shaft cam cover and sheave before disassembly or use the X s on the components for reference This will aid in reassembly and helps to maintain clutch balance after reassembly 3 Remove the four screws that secure the cam helix assembly using a T25 Torx driver T Spider...

Page 202: ...ider assembly and spring B NOTE Spring is compression only and has no torsional wind 6 Remove the inside spider plate D and spider dampener E Inspect the spider dampener E for wear and replace if needed 7 Remove the E clips F washers G and the clutch rollers H Inspect the rollers for wear replace if worn 8 Remove the clutch assembly from the holding tool Remove the large outer retaining ring I and...

Page 203: ... Inspect the bearing for wear Spin the bearing if the bearing does not spin smoothly replace it To remove the bearing press the bearing off the shaft 13 Inspect the cam helix assembly bushing for wear If the bushing is worn or the shaft does not fit snug into the bushing replace the cam helix assembly K K M L PressShaftand Bearing Out Inspect Bearing Inspect Sheave Surface Inspect Bushing ...

Page 204: ...arrel for further tension if needed 7 Turn clutch sheave counterclockwise until bushing is removed and sheave comes free 8 Remove nut C left hand thread from puller rod and set aside 9 Remove adapters from puller 10 Remove bushing and removal tool from adapters Discard bushing EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 513250...

Page 205: ...tall left hand thread nut C onto puller rod and hand tighten against installation tool 7 Turn clutch sheave counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated 8 Remove nut C from puller rod and set aside 9 Remove installation tool and clutch sheave from puller Clutch Assembly 1 Install a new bearing onto the output shaft using a press 2 Install the sh...

Page 206: ...sheave assembly on both sides The flat side of the roller pin faces downward when the shaft side is laying flat on the bench 7 Install the spring pins C to secure the roller pins Install until flush with sheave surface 8 Install the spring over the shaft 9 Install the 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 ...

Page 207: ...ith the skip tooth on the shaft 12 Place the clutch into Clutch Compression Tool PN 8700220 Using Compression Extensions PN PS 45909 press down on the top of the spider assembly pushing the spider onto the shaft 13 Slowly compress the spider into place If the spider appears to bind while compressing stop and make sure the skip tooth on the shaft and the spider are aligned Once the spider passes th...

Page 208: ...ssembly 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 moveable sheave belt face with both hands and the helix will release 15 Use a T25 Torx driver to install the four screws and torque to specification T T25 Torx 42 52 in lbs 4 75 5 88 Nm Press Down to Loosen He...

Page 209: ... Compression Thrust Washer Cam Helix T25 Retaining Ring Roller Pin Slotted Ball E Clips Spring Spider Dampener Outer Spider Spider Insert Stationary Sheave Bearing Spring Pin Moveable Sheave Clutch Shaft Roller Retaining Ring Screws ...

Page 210: ...mpression Extensions PN PS 45909 apply and hold downward pressure on the outer spring retainer Carefully remove the snap ring Remember the outer spring retainer contains strong spring pressure NOTE Spring is compression only and has no torsional wind Stationary Moveable Inner Compression Spring Outer Retaining Spring Retainer Ring Spacer Spring Retainer Secondary Sheave Secondary Sheave CAUTION We...

Page 211: ...pring retainer from the inner sheave Inspect for wear and replace as needed 8 Check the rollers in the stationary sheave for wear If rollers are worn a new driven clutch assembly may be needed 9 Inspect the bearings inside the moveable sheave A B C E D C E B D Inspect for Abnormal Wear Moveable Sheave Bearing Inspection Replace the bearing if more brass than Teflon is visible on the bearing Inspec...

Page 212: ...er if removed Do not apply oil or grease to the bearings 2 Align the X marks on each of the sheaves during reassembly 3 Install the spring into the inner retainer 4 Install the spacer over the shaft 5 Install the outer retainer on top of the spring 6 Place the clutch into Clutch Compression Tool PN 8700220 Using Compression Extensions PN PS 45909 apply and hold downward pressure on the outer sprin...

Page 213: ...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 214: ...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 215: ...HILLIARD 7 14 CENTRALIZED HILLIARD EXPLODED VIEW 7 14 AWD DIAGNOSIS 7 16 GEARCASE REMOVAL 7 17 GEARCASE DISASSEMBLY INSPECTION 7 17 GEARCASE ASSEMBLY INSPECTION 7 19 BACKLASH THRUST PLATE ADJUSTMENT 7 21 GEARCASE INSTALLATION 7 22 REAR BEARING CARRIER 7 23 BEARING CARRIER INSPECTION REMOVAL 7 23 BEARING REPLACEMENT 7 24 BEARING CARRIER BUSHING REPLACEMENT 7 24 BEARING CARRIER INSTALLATION 7 25 REA...

Page 216: ...nt 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 earless type PU 48951 Axle Boot Clamp Tool 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...

Page 217: ...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 218: ... excess compound 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 Insta...

Page 219: ...tion 9 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions T Front Caliper Mounting Bolts 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 42 5 ft lbs 58 Nm 42 5 ft lbs 58 Nm T Wheel Hub Castle Nut 80 f...

Page 220: ...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 221: ...rate the outer CV joint from the drive shaft NOTE If using a brass drift be sure to tap on the inner race of the joint only 4 Make sure the circlip remains on the shaft and not left in the joint Discard the circlip as it will be replaced 5 Remove the small clamp and boot from the drive shaft IMPORTANT If the grease in the joint is obviously contaminated with water and or dirt the joint should be r...

Page 222: ...ced hammer or brass drift to separate the plunging joint from the drive shaft NOTE If using a brass drift be sure to tap on the inner race of the joint only 5 Make sure the circlip remains on the shaft and not left in the joint Discard the circlip 6 Remove the boot from the drive shaft IMPORTANT If the grease in the joint is obviously contaminated with water and or dirt the joint should be replace...

Page 223: ... lips into the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 19 Install and secure the small clamp on the boot using the earless clamp pliers 20 Pull out on the drive shaft to center the joint in the housing Slide a straight O ring pick or a small slotted screw driver between the large end of the boot and the joint housing and lift up to equalize the air pre...

Page 224: ...all the upper ball joint end into the front bearing carrier 5 Installthe upperpinch boltand torque to 17 ft lbs 23 Nm 6 Apply grease to drive shaft axle splines 7 Install front wheel hub assembly cone washers and hand tighten the castle nut Install washers with domed side out 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...

Page 225: ...ve the retaining screw 3 Remove the Torx screws retaining the center console to access the propshaft 4 Slide prop shaft back far enough to remove it from the front gearcase input shaft 5 Pull sharply forward to remove it from transmission shaft NOTE You may have to loosen the front gearcase mounting bolts to allow for propshaft removal T Wheel Hub Castle Nut 80 ft lbs 108 Nm T Front Caliper Mounti...

Page 226: ...f grease fitting and mark inner and outer yoke for correct re positioning during installation 2 Support inner yoke as shown and drive outer yoke down bearing cap out with a soft face hammer 3 Support U joint in vise as shown and drive inner yoke down to remove remaining bearing caps 4 Force U joint cross to one side and lift out of inner yoke Assembly 1 Install new bearing caps in yoke by hand Car...

Page 227: ...ust 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 6 Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown 7 When installation is complete yokes must pivot freely in all directions without binding If the joint is stiff or binding tap the yok...

Page 228: ...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 229: ...n the ring gear and roll cage are spinning vehicle is moving the energized coil and armature plate will apply drag to the roll cage that indexes the rollers inside ring gear to an engagement position While in the engagement position the front drive will be in an over running condition not engaged until the rear wheels loose traction Once the rear wheels begin to loose traction the front drive will...

Page 230: ...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 231: ...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 232: ...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 233: ...atches 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...

Page 234: ...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 235: ... is 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 he...

Page 236: ...e vehicle 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 in...

Page 237: ...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 238: ...aring 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 603 retaining compound to the outer circumference of the new bearing race and carefully press the new bearing into the bearing carri...

Page 239: ...s 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 Bolts Upper 33 ft lbs 45 Nm Lower 38 ft 52 Nm 33 ft lbs 45 Nm 38 ft lbs 52 Nm Out Cone Washers Wheel Hub T Rear Caliper Mounting Bolts 18 ft lbs 24 Nm CAU...

Page 240: ...ve 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 Nuts Steel Wheels 27 ft lbs 37 Nm Aluminum Wheels 90 ft lb...

Page 241: ...the axle splines and CV boots for any damage Outer CV Joint Boot Replacement 1 Using a side cutters cut away and discard the boot clamps 2 Remove the large end of the boot from the CV joint and slide the boot down the shaft 3 Clean the grease from the face of the joint 4 Place the drive shaft in a soft jawed vise 5 Using a soft faced hammer or brass drift strike the inner race of the joint to driv...

Page 242: ...assembly 11 Slide the small boot clamp and boot small end first onto the drive shaft and position the boot in it s groove machined in the shaft 12 Install a NEW circlip on the end of the shaft 13 Grease the joint with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s inner race Pack the ball tracks and outer face f...

Page 243: ...using and shaft Make sure the boot is not dimpled or collapsed 19 Install and tighten the large clamp using the Axle Boot Clamp Tool PU 48951 20 While pulling out on the CV shaft fully extend the CV joint and slide a straight O ring pick or a small slotted screw driver between the small end of the boot and the shaft This will allow the air pressure to equalize in the CV boot in the position that t...

Page 244: ...e in the joint is obviously contaminated with water and or dirt the joint should be replaced 8 Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly 9 Visually inspect the joint for damage Replace if needed 10 Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly...

Page 245: ...l surfaces and place the excess grease in the boot 19 Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 20 Install and tighten the small clamp using the Axle Boot Clamp Tool PU 48951 21 Pull out on the drive shaft to center the joint in the housing Slide a straight O ring pick or a small slotted sc...

Page 246: ...r 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 bearing carrier REAR SHAFT CV Joint Plunging Spring Ring Gear Side Boot Kit Wheel Side Boot Kit Joint Spring Ring Large Clamp Grease Pack Small Clamp Spring Ring Large Clamp Grease Pack RZR SHAFT RZR S SHAFT Apply...

Page 247: ...nstall 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 Bolts Upper 33 ft lbs 45 Nm Lower 38 ft lbs 52 Nm 33 ft lbs 45 Nm 38 ft lbs 52 Nm Out Cone Washers Wheel Hub 18 ft lbs 24 Nm T Rear Caliper Mounting Bolts 18 ft lbs 24 Nm CAUTION New bolts have a pre applied locking agent whi...

Page 248: ... fasteners and mount bolt and remove bracket from vehicle 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...

Page 249: ...he 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 t...

Page 250: ...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 ge...

Page 251: ...n 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 252: ...e transmission 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 A...

Page 253: ...t Rear 1 16 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 N A 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 23 27 ft ...

Page 254: ...Bearing Bearing Front Tire Washers 27 ft lbs 37 Nm 80 ft lbs 108 Nm Ring Carrier Steel Front Rim Aluminum Wheel Nuts 90 ft lbs 122 Nm Studs Wheel Nuts Rear Rim Castle Nut Cotter Pin Cone Wheel Hub Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Rear Tire Washers 27 ft lbs 37 Nm 80 ft lbs 108 Nm Ring Carrier Steel Rear Rim Aluminum Wheel Nuts 90 ft lbs 122 Nm Studs ...

Page 255: ...NT 8 3 TRANSMISSION SERVICE 8 4 TRANSMISSION REMOVAL SERVICE NOTES 8 4 TRANSFER CASE DISASSEMBLY 8 4 TRANSFER CASE REASSEMBLY 8 7 TRANSMISSION SHIFT HOUSING DISASSEMBLY 8 9 TRANSMISSION SHIFT HOUSING REASSEMBLY 8 14 TROUBLESHOOTING 8 19 TROUBLESHOOTING CHECKLIST 8 19 TRANSMISSION EXPLODED VIEWS 8 20 SHIFT HOUSING TRANSFER CASE EXPLODED VIEW 8 20 ...

Page 256: ... 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 257: ... 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 258: ... 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 259: ...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 260: ...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 261: ... 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 262: ... 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 263: ...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 264: ...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 265: ... 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 266: ...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 267: ...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 268: ...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 269: ... 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 270: ...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 271: ... 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 272: ...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 273: ...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 274: ...8 20 TRANSMISSION TRANSMISSION EXPLODED VIEWS Shift Housing Transfer Case Exploded View Transfer Case Shift Housing ...

Page 275: ...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 276: ...4 6 mm Rear Brake Disc Thickness 188 4 78 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 277: ...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 278: ...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 279: ...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 280: ...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 281: ...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 282: ...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 283: ... 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 284: ... 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 285: ... 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 286: ...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 287: ...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 288: ...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 289: ...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 290: ...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 291: ...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 292: ... 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 293: ...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 294: ...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 295: ...ST 5 FUEL GAUGE DISPLAY NOT WORKING 10 13 TEST 6 GEAR INDICATOR NOT WORKING TRANSMISSION SWITCH 10 13 ALL WHEEL DRIVE COIL 10 14 GEAR POSITION INDICATOR SWITCH 10 14 SPEED SENSOR 10 14 HEAD LIGHTS 10 15 HEADLIGHT ADJUSTMENT 10 15 HEADLAMP BULB REPLACEMENT 10 15 HEADLAMP HOUSING REMOVAL 10 16 HEADLAMP HOUSING INSTALLATION 10 16 TAIL BRAKE LIGHTS 10 16 BULB REPLACEMENT 10 16 COOLING SYSTEM SCHEMATIC...

Page 296: ...BLY 10 25 BRUSH INSPECTION REPLACEMENT 10 26 ARMATURE TESTING 10 27 STARTER REASSEMBLY INSTALLATION 10 27 STARTER DRIVE 10 28 STARTER SOLENOID BENCH TEST 10 29 STARTER SOLENOID OPERATION 10 29 STARTER EXPLODED VIEW 10 30 STARTING SYSTEM TESTING FLOW CHART 10 31 ELECTRICAL BREAKOUT DIAGRAMS 10 32 12V KEY ON POWER CIRCUIT 10 32 STARTING SYSTEM CIRCUIT 10 32 INSTRUMENT CLUSTER CIRCUIT 10 33 TRANSMISS...

Page 297: ...nd resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is used when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc and the position of the decimal point For resistance readings isolate the component to be tested Disconnect it from the wiring harness...

Page 298: ...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 299: ...tor This indicator 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...

Page 300: ...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 301: ...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 302: ...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 programmed Mi...

Page 303: ...e 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 mount more easily 2 ...

Page 304: ... 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 305: ...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 PIN CONNECTOR FROM SPEEDOMETER ONNECT WIRES FROM TEST LIGHT TO SENSOR PIN CONNECTOR AS SHOWN AT RIGHT USING THE ALL 3ENSOR 0ROBE ARNESS 0 OR JUMPER LEADS 2EMOVE THE SPEED SENSOR FROM THE TRA...

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Page 307: ...11 725 7 50 1 6 5 7 5 1 67 57 5 1 7851 6 7 2 25 217 18 7 21 9 2 7 7 2 6 8 1 725 25 1 25 217 18 7 520 51 72 5281 5 5 6 2 7 67 6 1 5 25 3523 5 23 5 7 21 5 5 72 8 6 1 5 7 67µ 6 7 2 5 6 87 352 0 5 0 16 5 3 8 3803 60 1 5HG 9 RQVWDQW 5HG KLWH 9 6ZLWFKHG UH 2UDQJH 0RGH EXWWRQ 1 UHHQ OXH HOORZ 530 QSXW URZQ URXQG OXH KLWH QJLQH 2YHUKHDW 6ZLWFK 1 ON KLWH 0DOIXQFWLRQ QGLFDWRU 9LROHW KLWH XHO DXJH URZQ 5HG U...

Page 308: ...nections 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 Switch Resistance Value Table NOTE See Instrument Cluster Troubleshooting for additional switch circuit...

Page 309: ...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 310: ...lamp 3 Reconnect wire harness or re insert bulb if previously removed 4 Adjust headlights using the Headlight Adjustment procedure in this section TAIL BRAKE 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 or brake light does not work the bulb may need to be re...

Page 311: ...10 17 ELECTRICAL 10 COOLING SYSTEM SCHEMATIC Cooling System Break Out Diagram ...

Page 312: ...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 Chapter 4 E...

Page 313: ...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 314: ...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 315: ...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 316: ... 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 317: ...ts 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 w...

Page 318: ...t Voltage Test and a Load Test OCV Open Circuit Voltage Test Battery voltage should be checked with a digital multimeter Readings of 12 8 volts or less require further battery testing and charging See the following chart and Load Test NOTE Maintenance Free batteries should be kept at or near a full charge If the battery is stored or used in a partially charged condition hard crystal sulfation will...

Page 319: ...drive Faulty starter drive gears or starter motor gear Faulty flywheel gear or loose flywheel Voltage Drop Test The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 1...

Page 320: ...ct meter lead resistance 2 Measure resistance between insulated brush and starter housing Reading should be infinite OL Inspect insulation on brush wires for damage and repair or replace as necessary 3 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Slide brush end frame off end of starter NOTE The electrical input post must stay with the field coil...

Page 321: ...ading should be infinite no continuity 5 Check commutator bars for discoloration Bars discolored in pairs indicate shorted coils requiring replacement of the starter motor 6 Place armature in a growler Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1 8 3 cm above armature coil laminates Rotate armature 360 If hacksaw blade is drawn to armature on any pole the armature is s...

Page 322: ...ch of the starter bolts Torque the bottom bolt first to 9 ft lbs 12 Nm Then torque the top bolt to the same specification NOTE It is important to tighten the bottom starter bolt first circle as the bottom hole acts as a pilot hole to properly align the starter drive bendix with the flywheel This helps to prevent binding and starter damage Starter Drive If the garter spring is damaged the overrun c...

Page 323: ...d Bench Test Test the start solenoid by powering the solenoid via the 2 wire connection With the solenoid energized resistance should read about 0 5Ω 10 between terminal A and B If resistance measurement is out of specification replace the starter solenoid Starter Solenoid Operation To energize the Starter Solenoid the following must occur The brake must be applied to provide a ground path via the...

Page 324: ... 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 325: ...id 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 ...

Page 326: ...10 32 ELECTRICAL ELECTRICAL BREAKOUT DIAGRAMS 12V Key On Power Circuit Starting System Circuit ...

Page 327: ...10 33 ELECTRICAL 10 Instrument Cluster Circuit Transmission Switch Circuit ...

Page 328: ...10 34 ELECTRICAL Wheel Speed Sensor Circuit AWD Circuit ...

Page 329: ...10 35 ELECTRICAL 10 Fuel Gauge Display Circuit Cooling Fan Circuit ...

Page 330: ...10 36 ELECTRICAL Charging System Circuit ...

Page 331: ...WD 1 WIRE DIAGRAM 2009 RANGER RZR RZR S PAGE 1 OF 2 ...

Page 332: ...WD 2 WIRE DIAGRAM 2009 RANGER RZR RZR S PAGE 2 OF 2 ...

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Polaris 2009 Ranger RZR 800 EFI, Manual

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Summary of Contents for 2009 Ranger RZR 800 EFI

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