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Polaris 2009 Sportsman XP 850, Service Manual

The Polaris 2009 Sportsman XP 850 Service Manual is an essential tool for ATV enthusiasts. This comprehensive manual provides detailed instructions and maintenance guidelines to keep your vehicle running smoothly. Download it for free from our website and unlock the potential of your Sportsman XP 850.

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5.2

ENGINE

CRANKSHAFT / CAM CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46
CAM CHAIN / SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46
CRANKCASE INSPECTION (LOWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46
CRANKSHAFT INSPECTION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46
CONNECTING ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47
CONNECTING ROD BIG END BEARING SELECTION  . . . . . . . . . . . . . . . . . . . . . . . . 5.48
PISTON / PISTON RING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48
PISTON RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
PISTON PIN BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50
HONING - IMPORTANT INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50

ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5.51

CRANKCASE PREPARATION - UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51
PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52
PISTON / CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52
CRANKSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.53
OIL PASSAGE TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.53
CRANKCASE ASSEMBLY - UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.54
BALANCE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.55
BALANCE SHAFT TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.56
CRANKCASE PREPARATION (LOWER)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.57
CRANKCASE SEALANT AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.58
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.59

WATER PUMP  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5.59

WATER PUMP IMPELLER REMOVAL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.59
MECHANICAL SEAL / COUPLER SHAFT & BEARING REPLACEMENT  . . . . . . . . . . 5.59

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5.60

ENGINE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.60

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Summary of Contents for 2009 Sportsman XP 850

Page 1: ...TION 1 3 PUBLICATION NUMBERS 1 3 REPLACEMENT KEYS 1 3 SPECIAL TOOLS 1 3 SPECIFICATIONS 1 4 GENERAL 2009 SPORTSMAN XP 850 1 4 GENERAL 2009 SPORTSMAN XP 850 EPS 1 4 DETAILED 2009 SPORTSMAN XP 850 XP 850 EPS 1 5 MISC SPECIFICATIONS AND CHARTS 1 6 CONVERSION TABLE 1 6 STANDARD TORQUE SPECIFICATIONS 1 7 SAE TAP DRILL SIZES 1 8 METRIC TAP DRILL SIZES 1 8 DECIMAL EQUIVALENTS 1 8 GLOSSARY OF TERMS 1 9 P a...

Page 2: ...ound stamped on the lower frame rail on the front LH side of the ATV see Figure 1 1 The engine serial number can be found on top of the engine located on the valve cover see Figure 1 2 Machine Model Number Identification Year Designation Basic Chassis Designation EngineDesignation Emissions Model Option A 0 9 Z N 8 5 A L 4 X A Z N 8 5 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 17 Wor...

Page 3: ...d or depicted are mandatory while other tools maybe substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may order special tools through Polaris official tool supplier SPX Corporation by phone at 1 800 328 6657 or on line at http polaris spx com YEAR MODEL MODEL NO OWNER S MANUAL PN PARTS MANUAL PN 2009 SPORTSMA...

Page 4: ...acity 120 lbs 54 kg Rear Rack Capacity 240 lbs 109 kg Max Weight Capacity 575 lbs 261 kg Towing Capacity 1500 lbs 680 kg Unbraked Trailer Towing Capacity EU 1913 6 lbs 868 kg Hitch Tongue Weight 150 lbs 68 kg Category Dimension Length 83 25 in 211 5 cm Width 47 6 in 121 cm Height 50 75 in 129 cm Wheel Base 53 in 135 cm Ground Clearance 11 6 in 29 5 cm Turning Radius 84 in 213 cm unloaded Dry Weigh...

Page 5: ... 365 Instrumentation Multifunction Instrument Cluster DC Outlet Standard Relays Located in Relay Fuse Box Chassis Start Solenoid Fan EFI Bumper Lights Circuit Breaker Fan Motor 20A Fuses Located in Relay Fuse Box Lights 20A Drive 20A Accessory 20A EFI 20A Unswitched 10A EPS 30A Drivetrain Transmission Type Automatic PVT In Line H L N R P Transmission Fluid Type Fluid Capacity Synthetic Sportsman X...

Page 6: ...1 6 GENERAL INFORMATION MISC SPECIFICATIONS AND CHARTS Conversion Table C to F 9 5 C 32 F F to C 5 9 F 32 C P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 7: ...ecifications 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 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 8: ...1 8 GENERAL INFORMATION SAE Tap Drill Sizes Metric Tap Drill Sizes Decimal Equivalents P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 9: ...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 square inch Left or R...

Page 10: ...NOTES GENERAL INFORMATION 1 10 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 11: ...SION LUBRICATION 2 17 FRONT GEARCASE LUBRICATION 2 18 FRONT GEARCASE ADC FLUID 2 19 REAR GEARCASE LUBRICATION 2 20 COOLING SYSTEM 2 21 COOLANT LEVEL INSPECTION 2 21 COOLING SYSTEM HOSES COOLANT STRENGTH COOLANT TYPE 2 22 PVT FINAL DRIVE WHEEL AND TIRE 2 23 PVT DRYING DRIVE BELT REMOVAL 2 23 DRIVE SHAFT BOOT INSPECTION 2 23 WHEEL AND HUB TORQUE TABLE 2 24 WHEEL REMOVAL INSTALLATION 2 24 TIRE PRESSU...

Page 12: ...evel begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Break In Period The break in period consists of the first 20 hours of operation Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Drive vehicle slowly at first while varying the throttle ...

Page 13: ...ring Unit if equipped Daily Inspect daily clean often Head Lights Tail Lights 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 20 H Monthly 200 320 Check terminals clean test E Engine Oil Change Break in Period 20 H 1 M Perform a break in oil change at one month or ...

Page 14: ...ansmission Fluid 12 M 1000 1600 Change Fluid E Fuel System 100 H 12 M 1000 1600 Check for leaks at tank cap fuel lines fuel pump replace lines every two years Engine Mounts 100 H 12 M 1000 1600 Inspect Exhaust Pipe Silencer 100 H 12 M 1000 1600 Inspect E Spark Plug 100 H 12 M 1000 1600 Inspect replace as needed Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease t...

Page 15: ...Apply a maximum of 3 pumps of grease at each of these areas Item Recommended Lube Method Frequency Front Propshaft Yoke Polaris Premium U Joint Grease Grease fittings 3 pumps maximum every 500 miles 800 km Grease before long periods of storage and after pressure washing or submerging the ATV Front Rear A Arms Rear Bearing Carrier P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 16: ...first 20 hours of operation 100 hours thereafter Change more often 25 hours in severe duty conditions or short trip cold weather operation 2 Transmission Synthetic Sportsman XP Transmission Fluid Add fluid until it is visible at the fill hole threads Check level every 25 hours change fluid yearly 3 Engine Coolant Polaris 60 40 Coolant Maintain coolant level in coolant reservoir bottle Check level ...

Page 17: ... 5 Front Gearcase Polaris Premium LT Demand Drive Fluid Add fluid until it is visible at the fill hole threads Check level every 25 hours change fluid yearly or 1000 mi 6 Rear Gearcase Polaris ATV Angle Drive Fluid ADF Add fluid until it is visible at the fill hole threads Check level every 25 hours change fluid yearly 7 Brake Fluid Polaris DOT 4 Brake Fluid Maintain fluid level in both master cyl...

Page 18: ...t Gallon 6 count Grease Specialized Lubricants 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 Additives Sealants Thread Locking Agents Misc 2870585 L...

Page 19: ...ener torques listed in each chapter Controls Check handlebar controls for proper operation positioning and adjustment FUEL SYSTEM AND AIR INTAKE Fuel System Always stop the engine and refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck...

Page 20: ...he throttle cable if worn kinked or damaged Electronic Throttle Control Switch ETC Throttle Cable Adjustment NOTE Sportsman XP requires a new adjustment procedure 1 Slide the boot back far enough to expose the inline cable adjuster sleeve and loosen the adjuster locknut 2 Remove the 4 screws and cover from the RH control 3 With handlebars centered and wheels pointing forward slowly turn the adjust...

Page 21: ...ter screen off of main element Clean the pre filter with hot soapy water 5 Rinse and dry thoroughly 6 Inspect pre filter screen for tears or damage 7 Inspect main filter and replace if necessary If the filter has been soaked with fuel or oil it must be replaced Installation 8 Inspect airbox cover seal for damage It should adhere tightly to the cover and seal all the way around Replace seal as need...

Page 22: ...ange engine oil and filter at the intervals outlined in the Periodic Maintenance Chart Always change the oil filter whenever changing the engine oil 1 Position the ATV on a level surface 2 Place the transmission in park 3 Start engine and allow it to run for two to three minutes until the engine is warm 4 Stop the engine 5 Clean the area around the drain plug 6 Place a drain pan beneath the engine...

Page 23: ...dipstick and fill engine with 1 75 qts 1 66 L of the recommended engine oil 15 Start the engine and allow it to idle for one to two minutes 16 Stop the engine and check for leaks 17 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 18 Dispose of used oil and filter properly Engine Breather Hose Be sure engine breather hose is route...

Page 24: ...lling the tab out while pulling down on the connector 9 Loosen the hose clamp retaining the intake boot to the intake plenum and remove the boot 10 Lift up on the air box and turn it sideways to gain access to the valve cover bolts 11 Remove the spark plug wires and spark plugs 12 Remove the 6 valve cover bolts and valve cover 13 Remove PVT cover so the engine can be rotated see Drive Belt Removal...

Page 25: ...versing this procedure Start the engine to ensure proper valve adjustment was performed Compression and Leakdown Tests NOTE This engine does NOT have decompression components Compression readings will vary in proportion to cranking speed during the test Smooth idle generally indicates good compression Low engine compression is rarely a factor in running condition problems above idle speed Abnormal...

Page 26: ...eat Steps 3 and 4 see WARNING 7 Stop the engine and allow the silencer to cool Reinstall the clean out plug Engine Mount Fastener Torque Check engine mounting fasteners and ensure they are tight Also inspect the condition of the rubber mounts If rubber mounts are cracked or show signs of fatigue replace them WARNING Do not perform clean out immediately after the engine has been run as the exhaust ...

Page 27: ...ue to specification Transmission Fluid Change Access the drain plug through the rear right hand wheel well The plastic skid plate can be removed for better access to the drain plug 1 Remove the fill plug refer to Transmission Fluid Level Check 2 Place a drain pan under the transmission drain plug 3 Remove the drain plug and allow fluid to drain completely 4 Clean the drain plug magnetic surface 5 ...

Page 28: ...install the fill plug and torque to specification Front Gearcase Fluid Change The drain plug is located on the bottom side of the front gearcase Access the drain plug through the access hole in the front skid plate 1 Remove the fill plug refer to Front Gearcase Fluid Level Check 2 Place a drain pan under the front gearcase drain plug 3 Remove the drain plug and allow fluid to drain completely 4 Cl...

Page 29: ...r suction device to remove it from the reservoir NOTE Debris in the reservoir may result in inadequate bleeding and reduced performance of the system 5 Begin the bleeding process by filling reservoir to the MAX level with clean ADC Front Drive Fluid 6 Locate bleeder valves found on each side of the front gearcase and remove the protective caps 7 Attach a clean clear hose to one of the bleeder valv...

Page 30: ...e The drain plug is located on the bottom right hand side of the rear gearcase Access the drain plug from the rear right hand side of the ATV 1 Remove the fill plug refer to Rear Gearcase Fluid Level Check 2 Place a drain pan under the rear gearcase drain plug 3 Remove the drain plug and allow the fluid to drain completely 4 Clean the drain plug magnetic surface 5 Reinstall drain plug with a new O...

Page 31: ...erating temperature the coolant level should be between the MAX and MIN marks on the coolant recovery bottle If not perform the following procedure 1 Position the vehicle on a level surface 2 View the coolant level in the recovery bottle The coolant level can be viewed from inside the front right wheel well 3 If the coolant level is below the MIN line on the bottle remove the front rack assembly t...

Page 32: ...tifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection Do not use tap water straight antifreeze or straight water in the system Tap water contains minerals and impurities which build up in the system Straight water or antifreeze may cause the system to freeze corrode or overheat NOTE For further information on the engine cooling system refer to...

Page 33: ...t slippage If the belt slips repeat the process Drive Belt Removal Refer to Chapter 7 Clutching PVT for more detail 1 Elevate vehicle and remove the left rear wheel 2 Remove the lower left hand frame support 3 Remove the 11 screws retaining the outer PVT cover Pull the PVT cover out the LH wheel well 4 Insert the belt removal tool PN 2877408 into the driven clutch tool included with vehicle s tool...

Page 34: ...on 4 Install the wheel nuts and finger tighten them to align the center of the wheel holes with the center of the tapered nuts IMPORTANT It is possible to torque the wheel nut on a steel rim without the nut being centered in the hole Be sure to center the wheel nuts before applying torque to prevent wheel nuts from coming loose 5 Carefully lower the vehicle to the ground 6 Torque the wheel nuts an...

Page 35: ...re Pressure Inspection PSI Cold Front Rear 7 psi 48 kPa 5 psi 34 5 kPa WARNING Operating an ATV with worn tires will increase the possibility of the vehicle skidding and possible loss of control Worn tires can cause an accident Always replace tires when the tread depth measures 1 8 3 cm or less CAUTION Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle Im...

Page 36: ... petroleum jelly 5 Place the spacers on top of the battery terminals Be sure they are placed between the battery terminal and cable s 6 Connect and tighten the positive red battery cable first followed by the negative black battery cable 7 Verify cables are properly routed and fasteners are tight NOTE The cables should be safely tucked away at the front of the battery 8 Reinstall the seat Spark Pl...

Page 37: ...all amount of anti seize compound to the spark plug threads 6 Install spark plugs and torque to specification 7 Make sure the high tension leads are retained by the airbox 8 Reinstall the shift linkage upper right hand side panel and seat Engine Chassis Ground Periodically inspect the electrical ground cable attachments Cables and connections should be tight and corrosion free Inspect the battery ...

Page 38: ... power steering unit can be accessed through the front left wheel well by removing the mud guard Frequently clean the areas around and on top of the power steering unit to allow for proper cooling IMPORTANT Be sure to clean these areas thoroughly after riding through muddy conditions WARNING Due to the critical nature of the procedures outlined in this chapter Polaris recommends steering component...

Page 39: ... vehicle on a smooth level surface 2 Set handlebars in a straight ahead position and secure handlebars in this position NOTE The steering post frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 3 Tie a length of string between two stands as shown in the following illustration Position the stands so the string is...

Page 40: ...ENSION Suspension Inspection Compress and release the suspension Damping should be smooth throughout the range of travel Check all suspension components and mounting fasteners for wear or damage Inspect each shock body for leakage Suspension Spring Pre Load Adjustment The front and rear shock absorber springs are adjustable Rotate the adjuster cam either direction to increase or decrease spring te...

Page 41: ...ake master cylinder reservoir Add fluid to the indicated level Use Polaris DOT 4 Brake Fluid PN 2872189 Check brake system for fluid leaks excessive travel or spongy feel Check brake pads for wear damage or looseness Check surface condition of the disc Inspect thickness of brake pad friction material Brake Pad Inspection Inspect brake pad friction material for excessive wear Hose Fitting Inspectio...

Page 42: ... located underneath the front rack assembly see Figure 2 31 Check the effectiveness of the auxiliary brake by applying approximately 50 lbs 23 kg of downward force on the pedal If brake pedal requires an excessive amount of travel to operate inspect brake pads pedal linkage springs rear master cylinder and hoses for wear damage or leakage Replace components as needed Foot Brake P a r t S h a r k c...

Page 43: ...2 33 MAINTENANCE 2 MAINTENANCE LOG Service Date Hours Miles km Service Performed Comments Dealer Technician 20 Hours 1 Month Break In 100 6 Months P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 44: ...NOTES MAINTENANCE 2 34 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 45: ...HROTTLE POSITION SENSOR TPS 3 19 TPS RESISTANCE TESTS TPS TESTER KIT 3 19 CHECKING TPS READING 3 20 TPS ADJUSTMENT 3 21 TPS REPLACEMENT 3 22 ENGINE COOLANT TEMPERATURE SENSOR ECT 3 22 ECT SENSOR TEST 3 22 ECT SENSOR REPLACEMENT 3 23 IGNITION COIL 3 23 IGNITION COIL TESTS 3 23 IGNITION COIL AND HT LEAD REPLACEMENT 3 24 EFI DIAGNOSTICS 3 25 INSTRUMENT CLUSTER TROUBLE CODE DISPLAY 3 25 FUEL SYSTEM TR...

Page 46: ...erial number PU 47471 Digital Wrench SmartLink Module Kit PU 47470 PU 47469 PU 47468 PU 47470 Digital Wrench PC Interface Cable PU 47469 Digital Wrench Vehicle Interface Cable PU 47468 Digital Wrench SmartLink Module WARNING Gasoline is extremely flammable and explosive under certain conditions EFI components are under high pressure Verify system pressure has been relieved before disassembly Never...

Page 47: ...ains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench diagnostic software Polaris dealers can also order the following separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 This kit is available to Polaris dealers through our tool supplier SPX 1 800 328 6657 Digital Wrench Diagnostic Connector The diagno...

Page 48: ...e PFA Nut Pressure Regulator PFA Gasket Fuel Tank Assembly Tank Vent Electrical Connector Fuel Pump Float Arm Rollover Valve Fuel Flow Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line Fuel Rail Fuel Injectors Pressure Regulator Fuel Tank P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 49: ...he sensor bench tests pass disconnect the connector at the ECU and perform a continuity check between the sensor connector and the appropriate pin at the ECU connector all connections for that sensor Wiring resistance should be less than one 1 ohm 5 If the resistance is high or open a wiring harness inspection is required including a thorough inspection of the ECU connector for contamination or da...

Page 50: ...ntrol IAC 4 Crankshaft Position Sensor CPS 5 Fuel Injectors 6 Fuel Rail 7 Fuel Line quick connect 8 Fuel Pump Regulator Fuel Gauge Sender inside fuel tank 9 Engine Coolant Temperature Sensor ECT 10 Throttle Position Sensor TPS 11 Throttle Body 12 Ignition Coil 1 2 3 4 5 6 9 11 10 8 7 Located in the Fuel Tank Asm 12 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 51: ...behind the frame support 4 Crankshaft Position Sensor CPS Located in the top portion of the magneto cover on the front of the engine 5 Fuel Injectors Located in the Integrated Air Fuel Manifold IAFM 6 Fuel Rail Fuel Pressure Valve Attached to the top portion of the fuel injectors Located on the PTO end of the fuel rail 7 Fuel Line Quick Connect Located between the injector fuel rail and the fuel t...

Page 52: ...ow the thermostat housing just above the throttle body 10 Throttle Position Sensor TPS Located on the MAG end front of the throttle body 11 Throttle Body Attached between the IAFM and the intake plenum 12 Ignition Coil Located on the RH side of the airbox The high tension leads are retained by the airbox Fuel Pump Fuel Pump Assembly ECT TPS Throttle Body Intake IAFM Plenum Ignition Coil P a r t S ...

Page 53: ...l occurs every other crankshaft revolution or once for each 4 stroke cycle The total amount of fuel needed for one firing of a cylinder is injected during each cycle When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for intake ai...

Page 54: ...inimum of 7 0 volts to operate The memory in the ECU is operational the moment the battery cables are connected To prevent engine over speed and possible failure an RPM limiting feature is programmed into the ECU If the maximum RPM limit 8000 is exceeded the ECU suppresses the injection signals cutting off the fuel flow This process repeats it self in rapid succession limiting operation to the pre...

Page 55: ...temptingto start the vehicle FUEL PUMP Operation NOTE All EFI units utilize quick connect fuel lines An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank This assembly includes the fuel pump regulator and fuel gauge sender The pump is rated for a minimum output of 25 liters per hour at 43 psi and has a non serviceable preliminary 65 micron filter When...

Page 56: ...ce the fuel pump tank assembly 5 If the pump did not activate Step 4 disconnect the plug from the fuel pump Connect a DC voltmeter across terminals A and C in the plug on the vehicle harness side Turn on the key switch and observe voltage to ensure a minimum of 7 volts is present NOTE If the voltage was below 7 VDC test battery ignition switch EFI relay and wiring harness 6 If the reading is betwe...

Page 57: ...NT Be sure to cover the fuel tank inlet with a shop towel prior to front cab and fuel tank removal see Chapter 9 Front Cab 6 Remove the 4 screws from the bottom of the right hand footwell 7 Remove the 2 fuel tank mounting screws located on the upper portion of the fuel tank 8 Remove the vent line from the fitting on top of the fuel tank 9 Disconnect the fuel pump electrical harness 10 While holdin...

Page 58: ...he regulator is a sealed non serviceable assembly If it is faulty the fuel tank assembly must be replaced Refer to the Fuel Pump Tank Assembly Replacement procedure FUEL INJECTORS Operation Overview The fuel injectors mount into the Integrated Air Fuel Manifold IAFM and the fuel rail attaches to the top end of them Replaceable O rings on both ends of the injector prevent external fuel leaks and al...

Page 59: ...cing the test leads on each pin of the injector Resistance specification is 13 8Ω 15 2Ω 20 C 68 F Fuel Injector Replacement NOTE Engine must be cool Depressurize the fuel system if possible 1 Remove the seat and both upper side panels see Chapter 9 Seat and Side Panels 2 Remove the 2 screws retaining the lower portion of the air box 3 Remove the hose from the breaker valve located on top of the va...

Page 60: ...he sensor fails or becomes disconnected for any reason the engine will stop running CPS Test The crankshaft position sensor is a sealed non serviceable assembly If fault code diagnosis indicates a problem with the CPS test and correct as follows 1 Remove the seat and left hand side panel 2 Locate and disconnect the CPS harness connector on the left side of the vehicle just below the ECU 3 Connect ...

Page 61: ... oil on the O ring to aid installation 4 Torque the retaining bolt to specification IDLE AIR CONTROL VALVE IAC Operation Overview The Idle Air Control IAC is used to stabilize the idle quality of the engine at cold start up and after warm up operations Mounted in front of the engine the IAC contains 1 stepper motor which receives varying voltage signal pulses from the ECU These pulses determine th...

Page 62: ...hand frame support 6 Remove the 4 bolts retaining the upper right hand frame support Pull the support forward and down to remove it from the vehicle 7 Disconnect vehicle harness from IAC 8 Remove the 3 Phillips head mounting screws and remove the IAC from the housing 9 Install the new IAC and torque the mounting screws to 17 7 in lbs 2 Nm 10 Reconnect vehicle harness to IAC 11 Reinstall the thrott...

Page 63: ...st leads connected and the meter set to the ohms scale observe the reading at the following pin locations of the TPS TPS Tester Kit The throttle position sensor TPS reading can be checked by using the TPS Tester Kit 2201519 Set up the TPS Tester Kit 2201519 according to the instructions that accompanied the tester Make sure the 9 volt battery is new The correct position of the throttle body stop s...

Page 64: ...g 1 Remove the seat and upper left hand side panel see Chapter 9 Seat and Side Panels 2 Assemble the TPS Tester according to the instructions Refer to TPS Tester Kit for proper set up and testing Verify the 9 volt tester battery is new 3 Disconnect vehicle harness from TPS 4 Plug the TPS Tester harness in the TPS harness 5 Set your voltmeter to read Vdc Connect the red voltmeter probe into the R t...

Page 65: ...aining the intake plenum and throttle body 3 Position the throttle body to access the TPS screws 4 Make sure the TPS Tester harness is still connected to the TPS harness 5 Loosen the TPS mounting screws 6 Rotate the TPS until your voltmeter reads 700 050 volts see Figure 3 20 7 Retighten TPS mounting screws and torque to specification 8 Verify voltage reading did not change If voltage reading chan...

Page 66: ...re The engine temperature sensor is a Negative Temperature Coefficient NTC type sensor as the temperature increases the resistance decreases Coolant passes through the cylinder and by the sensor probe varying a resistance reading which is relayed to the ECU This signal is processed by the ECU and compared to its programming for determining the fuel and ignition requirements during operation The EC...

Page 67: ...oth gap creates an interrupt input signal corresponding to specific crankshaft position This signal serves as a reference for the control of ignition timing The ECU then calculates the time interval between the consecutive pulses and determines when to trigger the voltage spike that induces the voltage from the primary to the secondary coil windings to fire the spark plugs Ignition Coil Tests The ...

Page 68: ...he ignition coil 5 Using a T20 driver remove the screw retaining the ignition coil to the airbox 6 Remove the coil assembly and disconnect the high tension leads by pulling on the coil side end caps 7 Install the new high tension leads NOTE Be sure to install the PTO long wire on the coil terminal nearest the airbox 8 Install the coil assembly and securely tighten the mounting screw 9 Upon assembl...

Page 69: ...er FMI 7 Use the Diagnostic Trouble Code Table as a reference 8 Press and hold the MODE button to cycle through all currently active trouble codes NOTE On vehicles equipped with power steering the power steering MIL LED will illuminate and blink in place of the Check Engine MIL if there is a diagnostic problem with the power steering system FMI SPN MIL PS MIL DIAGNOSTIC TROUBLE CODE TABLE Componen...

Page 70: ...to B 634 3 Driver Circuit Grounded 634 4 Position Out of Range 634 7 Starter Enable Circuit Driver Circuit Open Grounded 1321 5 Driver Circuit Short to B 1321 3 Driver Circuit Grounded 1321 4 Chassis Relay Driver Circuit Open Grounded 520208 5 Driver Circuit Short to B 520208 3 Driver Circuit Grounded 520208 4 All Wheel Drive Control AWD Driver Circuit Open Grounded 520207 5 Driver Circuit Short t...

Page 71: ...ications Transmit Error No TX Message for 2 Seconds 520227 2 Vehicle Speed This is applicable when the EPAS module gets the vehicle speed from the ECM Received Vehicle Speed Has Error 84 19 Engine Speed This is applicable when the EPAS module gets the engine speed from the ECM Received Engine Speed Has Error 190 19 Battery Voltage Too High 168 3 Too Low 168 4 Position Encoder Error 520228 11 EPAS ...

Page 72: ...or or disconnected wiring Throttle stop screw tampering Poor Idle Symptom Idle Too High If greater than 1400 RPM when engine is warm Throttle stop screw tampering Throttle cable sticking improperly adjusted routed incorrectly Failed sensor or disconnected wiring IAC stuck or inoperative Intake air leak Symptom Idle Too Low if less than 1100 RPM when engine is warm Plugged air filter Leaking inject...

Page 73: ...3 29 ELECTRONIC FUEL INJECTION 3 EFI SYSTEM BREAK OUT DIAGRAMS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 74: ...3 30 ELECTRONIC FUEL INJECTION Fuel Injector Circuit PTO Fuel Injector Circuit MAG P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 75: ...3 31 ELECTRONIC FUEL INJECTION 3 Idle Air Control IAC Circuit Crankshaft Position Sensor CPS Circuit P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 76: ...EL INJECTION Fuel Pump Fuel Level Sensor Circuit Wire Color Functions Wire Color Function BROWN Ground VT WHT Fuel Level Sender Signal RED BLUE EFI Relay Output Battery Voltage P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 77: ...3 33 ELECTRONIC FUEL INJECTION 3 Fuel Pump Circuit Fuel Gauge Circuit P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 78: ...3 34 ELECTRONIC FUEL INJECTION Engine Coolant Temperature Sensor ECT Circuit Throttle Position Sensor TPS Circuit P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 79: ...3 35 ELECTRONIC FUEL INJECTION 3 Intake Air Temperature Manifold Absolute Pressure Sensor T MAP Circuit Diagnostic Connector Circuit P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 80: ...3 36 ELECTRONIC FUEL INJECTION Diagnostic Connector Circuit EPS Models P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 81: ... 4 RADIATOR CLEANING 4 4 COOLANT DRAIN RADIATOR REMOVAL 4 4 WATER PUMP SERVICE 4 6 WATER PUMP IMPELLER REMOVAL 4 6 WATER PUMP MECHANICAL SEAL REPLACEMENT 4 7 WATER PUMP SHAFT BEARING REPLACEMENT 4 8 STATOR COVER INSTALLATION 4 9 WATER PUMP ASSEMBLY TORQUE SPECIFICATIONS 4 10 STATOR COVER ASSEMBLY TORQUE SPECIFICATIONS 4 11 THERMOSTAT 4 12 REMOVAL INSTALLATION 4 12 TROUBLESHOOTING 4 12 P a r t S h ...

Page 82: ...t dissipation resulting in possible engine damage Polaris Premium 60 40 Antifreeze Coolant is recommended for use in all cooling systems and comes pre mixed and ready to use PART NUMBER TOOL DESCRIPTION 2870975 Mity Vac Pressure Test Tool PA 44995 A Water Pump Mechanical Seal Installer PA 49378 Water Pump Bearing and Coupler Press Tool PA 49316 Water Pump Drive Nut Flywheel Puller TORQUE SPECIFICA...

Page 83: ...W ECT Sensor 17 ft lbs 23 Nm Resistance Reading Idle Condition Approx Reading Ohms Temperature Engine Shut Off 70 Ω 3 284 F 140 C Hot Lamp On engine misfire above idle 90 Ω 3 266 F 130 C Hot Lamp Blinking 100 Ω 3 257 F 125 C Fan On 215 Ω 3 203 F 95 C Fan Off 240 Ω 3 192 F 89 C Room Temperature 2 5k Ω 3 68 F 20 C System Capacity 2 qts 1 9 l Radiator Cap Relief Pressure 13 PSI P a r t S h a r k c o ...

Page 84: ...ystem fill the radiator first before filling the recovery bottle 10 Any air remaining in the system should continue to bleed out through the recovery bottle 11 Repeat this procedure if you are still having difficulty bleeding the system RADIATOR Radiator Cleaning 1 Check radiator air passages for restrictions or damage 2 Carefully straighten any bent radiator fins 3 Remove any obstructions with co...

Page 85: ... room for the radiator to tilt back during removal 7 Remove the 2 fasteners retaining the upper portion of the radiator to the frame 8 Disconnect the fan motor 9 Tilt the radiator back and lift upward to allow the lower grommets to clear the frame support holes Remove the radiator from the vehicle out the right hand side through the wheel well Take care not to damage the cooling fins during remova...

Page 86: ...the vehicle 3 Place a drain pan under the front portion of the engine 4 Slide the spring clamp back and remove the coolant inlet hose from the water pump housing 5 Slowly drain the coolant into the drain pan Dispose of used coolant properly 6 Remove the coolant by pass hose from the water pump cover fitting 7 Remove the 10 cover screws A and pump cover B 8 Remove gasket impeller bolt washer and im...

Page 87: ... block C positioned inside the stator housing as shown Do not attempt to press water pump shaft out of stator housing without first supporting the cover by the stator boss or cover may be damaged 6 Press shaft down until flush with end of mechanical seal or until the seal spring starts to compress 7 Select a suitable arbor D and press the shaft through the seal until the shaft assembly is removed ...

Page 88: ...t Bearing Replacement procedure 10 Press pump shaft bearing assembly into housing until firmly seated 11 Turn cover over and drive new mechanical seal squarely into housing using seal installer 12 Install impeller Torque bolt to 10 lb ft 13 5 Nm 13 Rotate impeller and check for smooth rotation Water Pump Shaft Bearing Replacement 1 Press new shaft bearing assembly from kit into cover from stator s...

Page 89: ...the 12 00 position 3 Install new O rings on the plastic coolant pipe Lubricate the O rings with P80 rubber lubricant or lithium grease 4 Carefully install the stator cover 5 Check the water pump coupler engagement by turning the impeller bolt with a ratchet and 10 mm deep well socket 6 Refer to the following pages for stator cover assembly and torque information CAUTION Be sure bearing is fully se...

Page 90: ...EM Water Pump Assembly Torque Specifications 10 ft lbs 89 in lbs 10 Nm Stator wire routing See procedure 89 in lbs 10 Nm 13 5 Nm 89 in lbs 10 Nm See procedure TORQUE SEQUENCE P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 91: ... contact cement to hold damper rubber A on water pump coupler nut B during stator cover installation A B Crankshaft Position Sensor CPS 89 in lbs 10 Nm Coolant Fitting 1 8 NPTF Coolant Pipe TORQUE SEQUENCE 89 in lbs 10 Nm Lubricate New O Rings P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 92: ...ir 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 fuel system restriction Fuel pump output weak Electrical malfunction Water pump failure Loose impeller Engine Coolant Temperature Sensor failure Coolin...

Page 93: ...FORMATION 5 21 ENGINE REMOVAL 5 21 ENGINE INSTALLATION NOTES 5 25 ENGINE DISASSEMBLY AND INSPECTION 5 26 VALVE COVER BREATHER VALVE 5 26 ROCKER CARRIER CAMSHAFT REMOVAL 5 26 ROCKER ARM ROCKER ARM SHAFT INSPECTION 5 27 CAMSHAFT CAMSHAFT BORE INSPECTION 5 28 CYLINDER HEAD REMOVAL 5 28 CYLINDER HEAD CLEANING 5 28 CYLINDER HEAD WARP INSPECTION 5 29 CYLINDER HEAD DISASSEMBLY 5 29 VALVE INSPECTION 5 30 ...

Page 94: ... IMPORTANT INFORMATION 5 50 ENGINE ASSEMBLY 5 51 CRANKCASE PREPARATION UPPER 5 51 PISTON RING INSTALLATION 5 51 PISTON CONNECTING ROD ASSEMBLY 5 52 PISTON CONNECTING ROD INSTALLATION 5 52 CRANKSHAFT INSTALLATION 5 53 OIL PASSAGE TUBE 5 53 CRANKCASE ASSEMBLY UPPER 5 54 BALANCE SHAFT INSTALLATION 5 55 BALANCE SHAFT TIMING 5 56 CRANKCASE PREPARATION LOWER 5 57 CRANKCASE SEALANT AND TORQUE VALUES 5 58...

Page 95: ...MP DRIVE NUT PULLER PA 49316 FUEL PRESSURE TEST ADAPTOR PS 48762 MITY VAC PRESSURE TEST TOOL 2870975 OIL FILTER WRENCH PU 50105 PISTON RING COMPRESSOR PLIERS PV 43570 1 PISTON RING COMPRESSOR BAND 87mm PV 43570 3 UNIVERSAL DRIVER HANDLE PU 45543 VALVE SPRING COMPRESSOR PV 1253 or PV 4019 Quick Release VALVE SPRING COMPRESSOR ADAPTOR PV 43513 A WATER PUMP BEARING AND COUPLER PRESS PA 49378 WATER PU...

Page 96: ...ecting Tube lower crankcase to upper crankcase PTO End MAG End Balance Shaft Bearings Mag end cylinder head bolt passage exhaust side Holes in rocker arm shafts feed rocker arms and rollers Balance Shaft Bearings Upper crankcase Upper Crankcase Main Oil Gallery Cam chain tensioner Carrier bolt passages feed Center and PTO camshaft main journals P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 97: ... Seat Contacting Width Exhaust 0 047 0 008 0 0039 1 20 0 20 mm Valve Seat Angle 45 5 0 25 Valve Guide Valve Guide Inner diameter 0 217 0005 0 0 5 52 012 0 0 mm Valve Guide Protrusion Above Head Intake 0 361 0 010 9 18 0 25 mm Valve Guide Protrusion Above Head Exhaust 0 276 0 010 7 00 0 25 mm Valve Valve Lash Cold Intake 0 006 152 mm 0 025 mm Valve Lash Cold Exhaust 0 009 228 mm 0 025 mm Valve Marg...

Page 98: ...d 0 008 0 014 0 20 0 36 mm Top Ring Service Limit 0 016 0 41 mm Second Ring Standard 0 014 0 024 0 36 0 61 mm Second Ring Service Limit 0 032 0 81 mm Oil Ring Rails Standard 0 020 0 010 0 51 0 25 mm Oil Ring Rails Service Limit 0 032 0 81 mm Ring to Groove Clearance Top Ring Standard 0 0024 0 0008 0 060 0 020 mm Second Ring Standard 0 0028 0 0008 0 070 0 020 mm Connecting Rod Connecting Rod Small ...

Page 99: ...STATOR COVER STARTER GEAR 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 89 lb in 10 Nm 14 lb ft 19 Nm 13 lb ft 18 Nm 89 lb in 10 Nm 9 lb ft 12 Nm 89 lb in 10 Nm 26 lb ft 35 Nm 90 see procedure 13 lb ft 18 Nm 89 lb in 10 Nm 1 2 3 4 5 6 7 8 16 14 11 17 15 13 12 10 9 8 6 5 18 4 3 2 1 CRANKCASE M9 26 lb ft 35 Nm M6 89 lb in 10 Nm 7 19 20 6 5 4 3 2 1 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 100: ...5 8 ENGINE Valve Cover Breather Valve 1 2 3 4 5 6 89 lb in 10 Nm Apply All Purpose Grease Torque Pattern 89 lb in 10 Nm 44 lb in 5 Nm P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 101: ...e Pattern 26 mm 1 mm 4 Torque to 13 lb ft 18 Nm Slots must be vertical and face OUT 89 0 lb in 10 Nm 1 2 3 4 5 6 7 8 9 10 following torque pattern 1 Crankshaft at TDC MAG cylinder 2 Camshaft pin at 10 00 position 89 0 lb in 10 Nm P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 102: ...18 1 5 lb ft 25 2 Nm Step 2 18 lb in 2 Nm Step 1 Align dowel locators to Step 5 89 lb in 10 Nm Step 3 18 lb in 2 Nm Step 6 89 lb in 10 Nm Step 4 18 lb in 2 Nm Step 7 89 lb in 10 Nm cylinder head holes IAFM Torque Sequence P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 103: ...5 11 ENGINE 5 Valve Spring Height Detail Free Length 47 26 mm 1 861 in Combustion chamber top Combustion chamber top Top Bottom P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 104: ...nal 60 120 mm Paint tolerance mark see text gap at top Install NEW rod bolts if disassembled Match stamp on rod and cap or rear of engine Rod stamp can face front Rod has no offset or bottom NOTE Pistons can be installed in either orientation as they are symmetric P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 105: ...ft Main Journal O D Connecting Rod Journal O D 45 015 mm 01 1 7722 0004 Runout Limit 001 025 mm 54 98 mm 01 2 1646 0004 Refer to bearing selection procedure and chart on page 5 48 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 106: ... 89 lb in 10 Nm M6 x 20 89 lb in 10 Nm M6 x 35 26 lb ft 35 Nm M9 x 115 Sealant Application Apply light film of engine oil to flange and threads of all M9 crankcase bolts 26 lb ft 35 Nm M9 x 160 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 107: ...e procedure 10 Nm Detail balance shaft end cap Use tool PA 49320 and bearing See removal procedure Piston must be removed installed through top of cylinder as an assembly with connecting rod attached P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 108: ...ft Timing at TDC on MAG Cylinder Pin Washer Install before pin Split Gear Springs Drive Gear Bearing retaining ring OUT Press on inner race only Replace if removed Bearing Press on inner race only Replace if removed P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 109: ... Pattern 106 lb in 12 Nm M6x16 all outer screws M6x20 106 lb in 12 Nm 21 lb ft 28 Nm Oil Pump Cover Ensure tab is visible Install new gasket to verify assembly 21 lb ft 28 Nm 6 8 lb in 69 89 Nm M3 end cap screws 12 lb ft 16 Nm Fill 89 lb in 10 Nm 89 lb in 10 Nm P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 110: ...mp coupler nut B during stator cover installation A B 74 lb ft 100 Nm 35 lb in 4 Nm Crankshaft Position Sensor CPS 89 lb in 10 Nm M6 x 16 89 lb in 10 Nm M6 x 20 Key Coolant 89 lb in 10 Nm Fitting O Ring 1 8 NPTF Coolant Pipe Sealant bead should face the cover P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 111: ... Water Pump Coupler Stator Flywheel 10 lb ft 89 lb in 10 Nm Stator wire routing See procedure 89 lb in 10 Nm 13 5 Nm 89 lb in 10 Nm See procedure Torque Sequence 1 2 3 4 5 6 7 8 9 10 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 112: ...5 20 ENGINE Drive Coupler Rear Starter Gear Torque Sequence 14 lb ft 19 Nm P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 113: ...e crankcase differences can be easily recognized by their physical appearance A dull dark gray color identifies the NiCaSil plated A shinny metallic color identifies the iron lined The crankcase differences can also be identified by viewing the engine designation portion of the vehicle s model number NiCaSil Plated A09ZN85 Iron Lined A09ZN8X Engine Removal IMPORTANT Some engine repair procedures c...

Page 114: ... from the main harness Pull down on the connector while pulling the connector tab out 13 Disconnect the harness and ground wire from the ignition coil located on the right side of the air box 14 Remove the 2 screws from the rear portion of the air box disconnect the intake boot from the intake plenum and remove the air box from the vehicle 15 Depressurize the fuel system at the fuel valve Disconne...

Page 115: ...CPS wire harnesses 21 Use the Roll Pin Removal Tool PN 2872608 to drive out the roll pin from the front propshaft Pull the shaft back towards the transmission to remove it from the front gearcase input shaft then pull it forward to remove it from the transmission output shaft 22 Remove all bolts from both sides retaining the engine to the transmission 23 Remove the top bolt from the RH engine isol...

Page 116: ...located on the throttle body Remove the throttle body and IAC mount plate as an assembly with the throttle cable still attached to the throttle body NOTE Do not allow throttle body to hang from the throttle cable 29 Set the assembly on top of the front cab support Insert a clean shop towel into each intake track of the engine to prevent debris from entering 30 Disconnect the fuel injectors at the ...

Page 117: ...Install the springs retaining the pipe to the silencer 5 Torque the exhaust retaining nuts to specification Bleed Cooling System 1 Remove radiator cap and slowly add coolant to top of filler neck 2 Fill coolant reservoir tank to full mark 3 Install radiator cap and squeeze coolant lines to force air out of system 4 Again remove radiator cap and slowly add coolant to top of fill neck 5 Alternately ...

Page 118: ...direction of rotation until pin A is facing UP Rotate cam another 60 to the 10 00 position to relieve valve spring pressure from camshaft lobes 2 Remove cam chain tensioner bolts evenly and remove tensioner Note TOP marked on plate for assembly 3 Remove sprocket bolt and lift chain and sprocket off camshaft Secure cam chain with a wire if cylinder head will not be removed 4 Loosen all cam carrier ...

Page 119: ... be minimal Roll a smooth flat rod across the roller applying firm downward pressure on roller while observing roller movement Roller should turn smoothly without binding Replace rocker arm if roller surface is damaged or if roller does not turn smoothly 4 Measure I D of rocker arms and O D of rocker arm shafts Measure shaft bore in cam carrier Compare to specifications See Engine Specifications E...

Page 120: ... at a time following the pattern below 6 5 etc until all are loose Remove all bolts cylinder head and gasket NOTE Head can be removed from cylinder crankcase without removing cam carrier C but the center two cylinder head bolts cannot be removed from the head unless carrier is removed Cylinder Head Cleaning Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon 3...

Page 121: ...k parts or place them in a rack as you remove them Valve Spring Compressor PV 1253 or PV 4019 with adapter PV 43513 A 1 Compress valve spring and remove split keepers B 2 Remove compressor then remove top retainer spring and seal C Discard seals Repeat for all remaining valves 3 Clean combustion chamber and head gasket surface 4 Measure free length of each spring with a Vernier caliper and compare...

Page 122: ...er in three places then rotate 90 degrees and measure again six measurements total Compare to specifications 6 Measure valve guide 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 stemto guide clearance NOTE The valve guides cannot be replaced Be su...

Page 123: ...from camshaft side of head to proper installed height Note difference between intake and exhaust guide height below 5 Ream or hone new valve guides to size to obtain specified stem to guide clearance Ream from combustion chamber side of head 6 Clean cylinder head thoroughly with clean solvent 7 Inspect valve seats and recondition if necessary CAUTION Replacement of valve guides requires an oven sp...

Page 124: ...erence of the seat rotate the pilot 180 and make another light cut If the cutter now contacts the uncut portion of the seat check the pilot Look for burrs nicks or runout If the pilot is bent it must be replaced If the contact area of the cutter is in the same place the valve guide is distorted from improper installation If the contact area of the initial cut is greater than 75 continue to cut the...

Page 125: ...reconditioning method is used 10 Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem 11 Rotate the valve rapidly back and forth until the cut sounds smooth Lift the valve slightly off of the seat rotate 1 4 turn and repeat the lapping process Do this four to five times until the valve is fully seated and repeat process for t...

Page 126: ...es NOTE To prevent damage to the valve seals do not compress the valve spring more than necessary to install the keepers A small magnet can be used to aid installation 10 Repeat procedure for remaining valves When all valves are installed tap lightly with soft faced hammer on the end of the valves to seat the split keepers Valve Sealing Test 1 Clean and dry the combustion chamber area A 2 Pour a s...

Page 127: ...engaged in slots Secure cam chain with a wire so it will not fall into crankcase 6 Thread cam chain through a new head gasket and install gasket locating it on the alignment pins 7 Set cylinder head in place on alignment pins Apply engine oil to threads and flange of the 6 main cylinder head bolts 8 Tighten main head bolts finger tight then install the two 6mm outer bolts CYLINDER HEAD TORQUE PROC...

Page 128: ...arrier Installation 1 Loosen all valve adjuster lock nuts 2 Turn adjuster screws out counterclockwise until they lightly seat against rocker arm NOTE DO NOT force screws against rocker arm The adjuster pivot ball may be damaged if forced 3 Rotate crankshaft in direction of rotation until Top Dead Center mark B on flywheel is aligned with crankcase parting line C This is TDC for MAG side cylinder 4...

Page 129: ... two sprocket marks with valve cover gasket surface 6 Slide sprocket onto camshaft aligning slot in sprocket with pin 7 Screw in the sprocket bolt finger tight Sprocket bolt must be tightened fully after cam chain tensioner is installed 8 Verify flywheel TDC mark is still aligned be sure the crankshaft has not rotated from TDC and that sprocket marks are aligned with gasket surface note that cam c...

Page 130: ...p mark on tensioner cap plate faces UP 3 Push tensioner plunger in and hold 4 Rotate plate and gasket into position and start the inner bolt 5 Slowly draw bolts evenly until snug 6 Torque tensioner cap bolts 7 Rotate crankshaft through two revolutions and verify camshaft timing is correct 8 Torque camshaft sprocket bolt 9 Adjust valve clearance on all valves refer to Chapter 2 Maintenance B 89 lb ...

Page 131: ...Stator Cover Removed Parting Flywheel Crankshaft Camshaft Center line Tensioner Installed Crankshaft at TDC MAG Cylinder Flywheel key UP in line with crankshaft camshaft centerline or if flywheel is installed use TDC mark IMPORTANT Valve and or piston damage can occur if engine is rotated with camshaft incorrectly timed P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 132: ...D THREAD Turn CLOCKWISE to remove 6 Hold flywheel with Crankshaft Holding Tool PA 49318 and remove flywheel bolt NOTE The flywheel bolt has a LEFT HAND THREAD Turn CLOCKWISE to remove CAUTION The rotor contains powerful magnets Use caution when removing and installing the stator cover DO NOT place fingers between cover and crankcase at any time during the removal installation process or injury cou...

Page 133: ...sassembly 1 Remove oil pump cover plate screws Note location of two longer M6x20 screws for assembly These screws secure the pump 2 Remove three baffle plate screws A and plate 3 Slide pump off mounting boss in crankcase 4 Visually inspect pump rotors and drive gear for damage or debris NOTE Replace oil pump as an assembly and pressure relief valve if debris has entered pump or if pump damage is e...

Page 134: ... free play and compare to specification 8 Inspect inner rotor drive pin for wear or damage 9 Remove oil pressure relief from crankcase Replace if debris has entered or if oil pressure was outside of specified range T 20 2 ft lbs 27 3 Nm OIL PUMP DETAIL 6 8 lb in 69 89 Nm M3 end cap screws Gear must turn freely after assembly P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 135: ...s have no offset Piston Connecting Rod Removal 1 Some pistons may have an orientation marking Note the arrow A should face the MAG end of crankshaft NOTE Replacement pistons can be installed in either orientation as they are symmetric 2 Push connecting rod piston assembly out through top of cylinder bore of upper crankcase NOTE If pistons are to be reused mark them for assembly in same cylinder 3 ...

Page 136: ...d no detectable up and down movement Replace bearings if any of the above are present 5 Inspect gear teeth for damage Normal split gear alignment is approximately 1 2 tooth in the relaxed position as shown 6 Hold main gear A and rotate split gear counterclockwise viewed from gear end to compress springs Split gear should rotate and return freely and completely without binding Counterbalance Split ...

Page 137: ... Turn over on workbench Working through access holes D push back each spring until all three tabs of split gear are engaged and split gear seats to drive gear 6 Lay gear assembly on press plate with split gear side UP 7 Carefully align pin of balance shaft with slot in gear Press shaft into gear assembly until seated against washer 8 Lay new bearing retaining ring side down on open press plate so ...

Page 138: ...rnal B in two locations 90 degrees apart Record measurements for bearing selection on page 5 48 Calculate the difference between the two measurements for each journal to determine concentricity C Replace crankshaft if any journal is worn below the minimum diameter specification or if journal out of round exceeds maximum specification 3 Support crankshaft on V blocks or on centers in a crankshaft s...

Page 139: ...d cap on connecting rod without bearings and install bolts 9 Tighten bolts snug then torque to 24 lb ft 33 Nm 10 Using a dial bore gauge measure big end I D in two directions shown Record measurements Difference between measurements is concentricity Compare to specifications 11 Select appropriate bearing insert color from table page 5 48 NOTICE Do not apply heat to piston rings or a loss of radial...

Page 140: ...t procedure for second ring 3 Remove 3 piece oil control ring Remove top rail first then bottom rail then the expander Bearing Size Selection Chart In Millimeters Connecting rod journal must be within standard size limits as determined by crankshaft measurements See page 5 46 Con Rod Mark Red White Blue Yellow Con Rod Big End Bore Diameter 47 987mm 47 993mm 47 993mm 47 999mm 47 999mm 48 005mm 48 0...

Page 141: ...m gasket surface 2 Lay a straight edge across cylinders upper crankcase 3 Use a thickness gauge to measure gap between straightedge and gasket surface Measure at outer edges and center repeating measurements with straightedge laid diagonally 4 Inspect cylinder for wear scratches or damage IMPORTANT DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing See Honing Important Inf...

Page 142: ...lling new pistons and or piston rings DO NOT attempt to hone the NiCaSil cylinders A special process is required and improper honing or use of the wrong type of abrasive stone will result in irreversible cylinder wall damage Any change in surface finish should be followed by cylinder measurement and an inspection for wear If cylinders are damaged or worn beyond the service limit they can be re pla...

Page 143: ...s piston skirt 2 Rotate expander in groove until butt ends are on intake side of piston Ends must butt squarely together and must not overlap 3 Install bottom rail first then top rail with end gap located as shown at right 4 Install second ring with undercut facing bottom of piston Rotate ring to place end gap generally toward intake side of piston as shown below 5 Install top ring with 0 mark fac...

Page 144: ...the top or bottom Push the piston pin in both directions to make sure the clips are properly seated in the groove IMPORTANT Never re use a circlip that has been installed 6 Check to be sure rings rotate freely in the grooves Piston Connecting Rod Installation 1 Apply clean engine oil to piston assembly and cylinder walls of upper crankcase 2 Be sure ring end gaps are positioned at least 120 degree...

Page 145: ...shaft 6 Carefully lower crankshaft into upper crankcase Guide connecting rods onto rod journals of crankshaft as necessary 7 Adjust crankshaft seals so each is flush with end of crankcase 8 Clean threads of bolts and threads in connecting rod to remove all oil grease or assembly lubricant 9 Apply Loctite 262 Red to the end 5 threads of rod bolts 10 Install rod caps on rods with marks aligned 11 In...

Page 146: ...5 54 ENGINE Crankcase Assembly Upper 89 lb in See procedure 10 Nm Detail balance shaft end cap Use tool PA 49320 and bearing P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 147: ...tion 4 Install balance shaft placing tooth with single dot between two dots on crankshaft gear Align bearing locating ring in groove on crankcase and fully seat the shaft 5 Rotate crankshaft until SINGLE dot on crankshaft gear is visible 6 Align single dot of drive gear between two dots of balance gear 7 Align bearing locating ring in groove on crankcase and fully seat the shaft 8 Verify balance s...

Page 148: ...5 56 ENGINE Balance Shaft Timing P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 149: ...clear warm water and dry with compressed air Be sure passages are clean and dry before assembling the lower crankcase Assemble parts in order A J Torque Pattern 106 lb in 12 Nm M6x16 all outer screws M6x20 106 lb in 12 Nm 21 lb ft 28 Nm Oil Pump Cover Ensure tab is visible to verify assembly 21 lb ft 28 Nm 6 8 lb in 69 89 Nm M3 end cap screws 12 lb ft 16 Nm 89 lb in 10 Nm 89 lb in 10 Nm A B D E F ...

Page 150: ...Torque Pattern 89 lb in 10 Nm M6 x 20 89 lb in 10 Nm M6 x 35 26 lb ft 35 Nm M9 x 115 26 lb ft 35 Nm M9 x 160 Sealant Application Apply a light film of engine oil to flange and threads of M9 crankcase bolts P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 151: ...all lightly by hand 11 Inspect mating surfaces to be sure they are joined properly Investigate the cause of any gaps 12 Torque all crankcase in sequence shown on page 5 58 to final torque value then repeat the sequence to verify final torque 13 Install cylinder head page 5 35 WATER PUMP Water Pump Impeller Removal IMPORTANT Water pump impeller removal is not required to remove the stator cover If ...

Page 152: ...r Dead battery Starter motor does not turn Engine seized rusted or mechanical failure Engine Runs But Will Not Idle Restricted fuel system Low compression valves incorrectly adjusted Crankcase breather restricted Engine Idles But Will Not Accelerate Spark plug fouled weak spark Broken throttle cable Air intake obstructed Air box removed reinstall all intake components Reverse speed limiter limitin...

Page 153: ...t valve or stuck valve Valve spring broken or weak Rocker arm sticking Backfiring Fouled spark plug or incorrect plug or plug gap Speed limiter system malfunction Exhaust system air leaks Ignition system faulty Spark plug cap cracked broken Ignition coil faulty Ignition switch circuit faulty Poor connections in ignition system Ignition timing incorrect Sheared flywheel key Valve sticking P a r t S...

Page 154: ...NOTES ENGINE 5 62 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 155: ...KAGE GEAR SELECTOR 6 2 SHIFT LINKAGE INSPECTION 6 2 GEAR SELECTOR REMOVAL 6 2 TRANSMISSION SERVICE 6 3 TRANSMISSION REMOVAL 6 3 TRANSMISSION DISASSEMBLY 6 4 TRANSMISSION SHAFT SERVICE 6 8 TRANSMISSION ASSEMBLY 6 10 TRANSMISSION INSTALLATION 6 14 TRANSMISSION EXPLODED VIEW 6 16 TROUBLESHOOTING 6 18 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 156: ...rod out of the snap linkage at the gear selector 3 Remove the retaining screw from the back side and pull the gear selector out from the frame support as an assembly NOTE Remove RH frame support to ease removal ITEM TORQUE VALUE Transmission Fill Plug 10 14 ft lbs 14 19 Nm Transmission Drain Plug 10 14 ft lbs 14 19 Nm Transmission Case Screws 15 20 ft lbs 20 27 Nm Oil Deflector Plate Screws 7 10 f...

Page 157: ...taining the rear propshaft to the rear gearcase input shaft Slide the shaft off the transmission output shaft and out from the vehicle 10 Disconnect the wheel speed sensor located on the lower right hand side of the transmission 11 Disconnect the gear selector switch from the top of the transmission 12 Disconnect the linkage rod from the gear selector 13 Remove the high tension leads from the engi...

Page 158: ...e front propshaft from the transmission shaft 22 Once you have cleared the coupler carefully lift the transmission assembly out the right side the of vehicle Transmission Disassembly 1 Remove the drive belt drive clutch and driven clutch see Chapter 7 PVT SYSTEM SERVICE Disassembly 2 Remove the 10 screws that secure the inner PVT cover to the transmission case and remove the cover 3 Remove 2 retai...

Page 159: ...ove the bolts retaining the transmission cover 8 Carefully lift up on the cover Use a soft faced hammer to tap on the input shaft and rear output shaft to ease cover removal 9 Lift up on the rear output shaft assembly and remove the front output shaft assembly 10 Remove the 2 screws retaining the oil deflector plate Thread bolts in pin holes Coupler Primary Shaft Input Shaft Output Shaft Rear Outp...

Page 160: ... up on each end of the shift fork and rotate the fork out of the shift shaft cam 15 Repeat the previous step to remove the lower shift fork 16 Remove the input shaft assembly and reverse shaft assembly together from the transmission 17 If servicing either shaft assembly remove the reverse silent chain and separate the shaft assemblies Compensator Assembly Rear Output Shaft Park Shaft Rail Shift Sh...

Page 161: ...ch 20 Remove the retaining ring and washer from the cam shift shaft Remove the nut bellcrank and washer from the bellcrank shift shaft 21 Remove both shift shafts from the transmission as an assembly Lightly tap on each shaft to ease removal Washer Snap Ring Detent Plug Bellcrank Washer Washer Retaining Ring P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 162: ...vice Use the exploded views within this section when servicing the transmission shafts Shaft bearings can be serviced using an arbor press Input Shaft Primary Shaft Rear Output Shaft Reverse Shaft P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 163: ...washers and place them into the belleville cup upon assembly as shown The UP stamping on each washer should face out when assembling the washer stack Cam Shift Shaft Bellcrank Shift Shaft Belleville Washers UP Marking Cup P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 164: ...e 3 If the cam shift shaft was disassembled install the detent gear with the step facing the O ring NOTE Both shift shafts have skip tooth keyed splines for assembly purposes 4 If the bellcrank shift shaft was disassembled install the gear sector with the step facing the O ring 5 Install new O rings on both shift shafts and lubricate prior to installation Step Replace O Ring Step Replace O Ring P ...

Page 165: ...ue to specification 10 Install the washer and a new retaining ring onto the cam shift shaft The retaining ring should be tight on the shaft 11 Install the transmission switch washer and snap ring 12 Install the detent plug and torque to specification 13 Assemble the input shaft and reverse shaft with the lower shift fork and park pawl installed 14 Place the assembly into the transmission housing m...

Page 166: ...l shaft assembly into the transmission case Apply grease to the primary shaft shim s and place them into the transmission cover 23 Carefully install the transmission cover onto the transmission Apply even pressure to cover while setting into place A soft faced hammer can be used once the cover is started and aligned IMPORTANT Take care not to damage seals during cover installation 24 Install the r...

Page 167: ...be clean to ensure adhesion of new silicone sealant 32 Be sure to flame treat the inner PVT cover prior to applying silicone to ensure good adhesion Pass the flame of a propane torch back and forth quickly over the area where the silicone is to be applied 2 3 inches from the flame tip is recommended Do not hold the torch too close to the surface Keep the torch moving to prevent damage 33 Apply RTV...

Page 168: ...ion shaft 6 Line up the engine and transmission couplers as shown 7 Slide the transmission forward to engage the couplers NOTE Be sure the front propshaft is still attached to the transmission shaft before installing the bolts 8 Start the 7 bolts that retain the transmission to the engine NOTE Mount the engine to chassis ground with bolt as shown 9 Torque the transmission to engine bolts in two st...

Page 169: ...tion 17 Add the recommended amount of lubricant through the fill plug hole Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission Do not overfill 18 Reinstall fill plug with a new O ring and torque to specification T Transmission Through Bolt Fasteners 18 ft lbs 24 Nm T Transmission Torx Head Mounting Screw 36 ft lbs 49 Nm T Upper Right Hand Frame Support Bo...

Page 170: ...ply LoctiteTM 2760 to the bolt threads 115 125 ft lbs 156 170 Nm 7 10 ft lbs 9 14 Nm 10 14 ft lbs 14 19 Nm 15 ft lbs 20 Nm 10 14 ft lbs 14 19 Nm 15 20 ft lbs 20 27 Nm 10 14 ft lbs 14 19 Nm 50 60 ft lbs 68 81 Nm 7 10 ft lbs 9 14 Nm 17 23 ft lbs 23 31 Nm P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 171: ... 1 Washer Thrust 68 1 Rail Park Shaft 22 1 Washer Thrust 69 1 Engagement Dog Low 23 2 Shim 70 1 Engagement Dog Reverse Low 24 1 Shim 71 1 Bushing Sleeve 25 1 Washer Thrust 72 1 Shaft Compensator 26 1 Shim 73 1 Shift Fork 27 1 Shim 74 1 Engagement Dog High 28 6 Washer Belleville 75 2 Pipe Knock 29 1 Washer Thrust 76 1 Shift Fork 30 1 Collar 77 1 Switch Shaft 31 3 Ball Bearing 78 1 PTL Subassembly 3...

Page 172: ...on components NOTE To determine if shifting difficulty is caused by an internal transmission problem isolate the transmission by disconnecting linkage rod from transmission bellcrank Manually select each gear range at the transmission bellcrank and test ride vehicle If it functions properly the problem is outside the transmission If transmission problem remains disassemble transmission and inspect...

Page 173: ...VAL 7 9 BELT INSPECTION 7 10 BELT INSTALLATION 7 10 PVT BREAK IN DRIVE BELT CLUTCHES 7 10 DRIVE CLUTCH SERVICE 7 11 SPRING SPECIFICATIONS 7 11 EXPLODED VIEW 7 12 CLUTCH DISASSEMBLY 7 12 SPIDER REMOVAL 7 13 ROLLER PIN AND THRUST WASHER INSPECTION 7 14 BUTTON TO TOWER CLEARANCE INSPECTION 7 14 SHIFT WEIGHT INSPECTION 7 14 BEARING INSPECTION 7 15 CLUTCH INSPECTION 7 15 MOVEABLE SHEAVE BUSHING INSPECT...

Page 174: ...nning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive belt rotates low in the drive clutch sheaves As engine RPM increases centrifugal force causes the drive belt to be forced upward on drive clutch sheaves TOOL DESCRIPTION PART NUMBER Drive Clutch Puller Short PA 48595 Clutch Holding Wrench 9314177 Clutch Holding Fixture 2871358 A Drive Clutch Spider...

Page 175: ...ttle position as a conventional governor does the PVT system changes engine load requirements by either upshifting or backshifting PVT Break In Drive Belt Clutches A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and drive belt by operating at slower speeds during the 10 hour break in period as recommended see Chapter 5 Engine ...

Page 176: ...lt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Towing Pushing at low RPM low ground speed Use Low only Plowing snow dirt etc utility use Use Low only Stuck in mud or snow Shift the transmission to Low carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may c...

Page 177: ...M SERVICE PVT Sealing and Ducting Components Outer Clutch Cover Inner Clutch Cover Drain Plug O Ring Outer Seal Clamps Cover Screws Outlet Duct Air Inlet Duct Boot Boot Boot Clamps Screws P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 178: ...t harnesses from the rear cab and remove the rear cab to allow access to the PVT system for disassembly 4 Remove the 11 screws retaining the outer PVT cover 5 Using care pull the outer PVT cover out the left hand wheel well 6 Mark the drive belt direction of rotation and remove drive belt see DRIVE BELT Belt Removal steps 8 10 7 Loosen the clamps and remove the PVT outlet duct from the inner PVT c...

Page 179: ...h surfaces thoroughly in preparation for assembly Assembly 1 Inspect the inner PVT cover Replace if cracked or damaged The mating surface must be clean to ensure adhesion of new silicone sealant 2 Be sure to flame treat the inner PVT cover prior to applying silicone to ensure good adhesion Pass the flame of a propane torch back and forth quickly over the area where the silicone is to be applied 2 ...

Page 180: ...BELT Belt Installation steps 1 3 12 Install the PVT outlet duct Align the duct with the inner PVT cover properly before tightening the hose clamps 13 Replace the outer PVT cover seal 14 Reinstall outer PVT cover and secure with screws Torque screws to specification 15 Reinstall the rear cab tail light bulbs and fasteners 16 Reinstall the lower left hand frame support and torque bolts to specificat...

Page 181: ...hand wheel well 7 Mark the drive belt direction of rotation so that it can be installed in the same direction 8 Insert the belt removal tool PN 2877408 into the driven clutch as shown tool included with vehicle s tool kit NOTE Make sure the tool is square with the moveable sheave surface of the driven clutch 9 Rotate the tool towards the clutch to open the sheaves 10 Walk the belt out of the drive...

Page 182: ...ve belt as shown so the Polaris label can be read 3 Rotate the driven sheave and walk the belt into the driven clutch 4 Replace the outer PVT cover seal 5 Reinstall outer PVT cover and secure with screws Torque screws to specification 6 Reinstall the lower left hand frame support and torque bolts to specification 7 Install the left rear wheel and torque wheel nuts to specification 8 Lower the ATV ...

Page 183: ...mits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from the outer coil surfaces as shown Refer to the spring specification chart for specific free length measurements and tolerances Also check to see that spring coils are parallel to one another Distortion of the spring indicates stress fatigue requiring replacement CAUTION Never ...

Page 184: ...er bolts evenly in a cross pattern and remove cover plate 4 Inspect cover bushing A The outer cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing Washers Bearing Spring Cover Bearing Bushing Lock Washer Bolt Flat Washer Cover Bolts Pin Washers Roller Nut Shift Weight Bolt One Way Bearing Spacer Spider Buttons Limiter Cover Bushing...

Page 185: ...urn the Spider Removal Tool in a clockwise direction to remove NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly Be sure to note the number and thickness of these washers Moveable Sheave Bushing Inspection 4 Inspect the Teflon coating on the moveable sheave bushing Inspect Shaft 2871358 A Image is for reference only Actual holding...

Page 186: ... pin is changed to the solid roller pin NOTE The rubber side of the button is positioned toward the solid roller pin Button To Tower Clearance Inspection 1 Inspect for any clearance between spider button to tower If clearance exists replace all buttons and inspect surface of towers See Spider Removal procedure 2 Inspect sheave surfaces Replace the entire clutch if worn damaged or cracked Shift Wei...

Page 187: ...rom cover plate side with only a slight amount of drag When rotated clockwise the one way bearing should lock to the shaft without slipping 2 Verify there is no binding or rough spots If problems are noted continue with disassembly Clutch Inspection NOTE Remove cover spring and spider following instructions for drive clutch removal then proceed as follows 1 Remove the moveable sheave spacer sleeve...

Page 188: ... Bushing Inspection Inspect the Teflon coating arrow on the moveable sheave bushing Inspect both sheaves for signs of wear grooving or cracking De glaze sheave surfaces with a 3M Scotch Brite Pad if needed In mm Shaft Diameter Standard 1 3745 1 375 Service Limit 1 3730 In mm PTFE Washer Thickness Standard 030 76mm Service Limit 025 64mm Moveable Sheave Bushing Inspection Replace the cover bushing ...

Page 189: ... toward sheave EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBSBushingRemovalTool 5132028 1 Instructions 9915111 Additional Special Tools Qty Part Description Part 1 Clutch Bushing Replacement Tool Kit 2871226 1 Piston Pin Puller 2870386 Item Qty Part Description Part 2 1 P 90 Drive Driv...

Page 190: ...de 9 Remove sheave from puller 10 Remove installation tool Cover Bushing Removal 1 Install main adapter Item 8 on puller 2 Install adapter reducer Item 9 3 From outside of clutch cover insert removal tool Item 3 into cover bushing 4 With inside of cover toward vise slide cover onto puller 5 Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed 6 Turn clutch ...

Page 191: ... using the holding fixture and spider tool Torque with smooth motion to avoid damage to the stationary sheave IMPORTANT The clutch shaft has left hand threads Be sure to turn the Spider Removal Tool in a counter clockwise direction to reinstall 5 Install the limiter spacer over the shaft and on top of spider 6 Install shift weights using new lock nuts on the bolts 7 Reinstall clutch spring 8 Reins...

Page 192: ...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 4 Place the clutch into the Clutch Compression Tool PN 8700220 Using Compression Extensions PN PS 45909 press down on top of the spider assembly compressing the spider onto the shaft Remove snap ring A and slowly release the assembly 5 Rem...

Page 193: ... wear replace if worn 8 Remove the clutch assembly from the holding tool Remove the large outer retaining ring I and the inner retaining ring J 9 Press out the spring pins K in the inner sheave 10 Pull out the clutch roller pins L and rollers M 11 Press the shaft and bearing out of the outer sheave using a press E D H G F I J K K M L PressShaftand Bearing Out Inspect Bearing P a r t S h a r k c o ...

Page 194: ...ite from bushing bore prior to installing new bushing Inspect Sheave Surface Inspect Bushing EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBSBushingRemovalTool 5132028 1 Instructions 9915111 Additional Special Tools Qty Part Description Part 1 Clutch Bushing Replacement Tool Kit 2871226 ...

Page 195: ... puller rod and set aside 9 Remove adapters from puller 10 Remove bushing and removal tool from adapters Discard bushing Clutch Bushing Installation 1 Install puller adapter Item 10 onto puller 2 Install adapter Item 9 onto puller 3 Apply Loctite 609 evenly to bushing bore inside moveable sheave 4 Install sheave face down on puller 5 Install new bushing on installation tool Item 2 and install asse...

Page 196: ...heave 3 Install the small and large retaining rings into the outer sheave above the bearing 4 Line up the X on the moveable sheave with the X on the stationary sheave or use the marks previously used Put the sheaves together 5 Install the roller A onto the roller pin B on both sides Align X s A B P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 197: ...each side of the outside spider Install the washers E and E clips F to secure the rollers The rollers should spin freely 10 Install the spider dampener G inside the outer spider and install the inside spider plate H 11 Install the spider assembly onto the shaft with the retaining ring on top of the spider NOTE Use the marks previously made to align the skip tooth spider or use the X on top of the ...

Page 198: ...4 Install the cam helix assembly over the shaft Line up the X on the cam X on spider and X on the stationary sheave or use the marks previously made before disassembly NOTE If the cam assembly helix is difficult to install be sure the sheaves are aligned To align the sheaves place the clutch assembly on a flat surface with the cam assembly helix side down Press down on the moveable sheave belt fac...

Page 199: ...Washer Cam Helix T25 Retaining Ring Roller Pin Slotted Ball E Ring Spring Spider Dampener Outer Spider Spider Insert Stationary Sheave Bearing Spring Pin Moveable Sheave Clutch Shaft Roller Retaining Ring Screws P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 200: ...o high spring rate Driveclutch shiftweightsincorrectforapplication too light Drive clutch binding Driven clutch binding Clutch sheaves greasy belt slipage Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable caus...

Page 201: ...g 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 separated thin spots loose belt Broken or worn clutch components cover h...

Page 202: ...NOTES CLUTCHING PVT 7 30 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 203: ...NSPECTION 8 16 GEARCASE ASSEMBLY 8 20 SETTING RING GEAR BACKLASH 8 22 GEARCASE INSTALLATION 8 23 ADC SYSTEM FLUID BLEEDING 8 25 REAR BEARING CARRIER 8 26 INSPECTION REMOVAL 8 26 BEARING REPLACEMENT 8 27 BUSHING REPLACEMENT 8 28 INSTALLATION 8 28 REAR DRIVE SHAFT 8 30 REMOVAL 8 30 INSTALLATION 8 31 DRIVE SHAFT SERVICE 8 32 DRIVE SHAFT CV JOINT HANDLING TIPS 8 32 OUTER CV JOINT BOOT REPLACEMENT 8 32...

Page 204: ... 75 ft lbs 102 Nm Steel Wheels Tapered Nut Short 45 ft lbs 61 Nm Item Specification Wheel Hub Retaining Nuts front and rear 80 ft lbs 108 Nm Steering Post to Bulkhead 20 ft lbs 27 Nm Steering Post to Gearcase 22 ft lbs 30 Nm Tie Rod to Bearing Carrier Tie Rod to Steering Frog 44 ft lbs 60 Nm Brake Caliper Mount Bolts 37 ft lbs 50 Nm Shock Mounting Bolts 37 ft lbs 50 Nm Front Ball Joint Pinch Bolts...

Page 205: ...ont Tire Washers See Page 8 2 for Torque Value 80 ft lbs 108 Nm Ring Aluminum Rim Front Steel Rim Hub Cover Dust Cover Wheel Nuts Rear Valve Castle Nut Cotter Pin Cone Wheel Hub Stud Brake Disc Retaining Sealed Ball Bearing Bearing Carrier Rear Tire Washers See Page 8 2 for Torque Value 80 ft lbs 108 Nm Ring Aluminum Rim Rear Steel Rim Hub Cover Dust Cover P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8...

Page 206: ...e brake line Use wire to hang caliper to prevent damage to the brake line 6 Remove the front wheel hub assembly 7 Remove the cotter pin from the bottom of the tie rod end 8 Hold the top of the rod end with a 13 mm open end wrench and remove the nut from the bottom 9 Remove the steering tie rod from the bearing carrier 10 Remove the upper and lower ball joint pinch bolts 11 Using a soft faced hamme...

Page 207: ...an arbor press and remove the bearing by pressing it out from the back side 3 Inspect the bearing carrier housing for scratches wear or damage Replace front bearing carrier if damaged Bearing Installation 4 Thoroughly clean the front bearing carrier housing and the outer race on the new bearing Be sure that all oil residue has been removed from each surface 5 Support the bottom of the bearing carr...

Page 208: ...side facing out toward the castle nut 5 Install the brake caliper and torque the new mounting bolts to specification 6 Install the steering tie rod end onto the front bearing carrier Torque fastener to specification and install a new cotter pin T Pinch Bolts 21 ft lbs 28 Nm Out Cone Washers Wheel Hub Castle Nut T Front Caliper Mounting Bolts 37 ft lbs 50 Nm CAUTION New bolts have a pre applied loc...

Page 209: ...3 Remove the cotter pin and loosen the front wheel hub castle nut Remove the nut and 2 cone washers from the front wheel hub assembly 4 Remove the 2 brake caliper mounting bolts and caliper 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 front wheel hub assembly T Wheel Hub Castle Nut 80 ft lbs 108 Nm T Wheel Nuts Steel Wh...

Page 210: ...epairing the drive shaft Installation 1 Install a new spring ring on the end of the drive shaft and apply an anti seize compound to the splines 2 Align the splines of the drive shaft with the front gearcase and reinstall the drive shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 3 Install the drive shaft into the front bearing carrier 4 Refer to the FRONT BEARIN...

Page 211: ...output shaft then slide it up onto the front gearcase input shaft verify pin holes are aligned 2 Using Roll Pin Tool PN 2872608 install a NEW roll pin spring pin into the propshaft 3 Reinstall the footwell side panel and seat see Chapter 9 PROPSHAFT U JOINT SERVICE Disassembly 1 Remove internal or external snap ring from bearing caps NOTE If yoke or bearing is removed cross bearing must be replace...

Page 212: ...or fully seat the bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled 4 Install snap ring to contain bearing cap just installed Repeat procedure for other side 5 Install outer yoke aligning marks made at disassembly and repeat Steps 1 3 to install bearing caps on outer yoke 6 Seat all bearing caps against snap rings by supporting cross shaft a...

Page 213: ...r Screw 2 11 Cap Plug 2 31 Thrust Button Assembly 1 12 Bolt M6 3 32 Thrust Plate 1 13 Screw M6 6 33 Pinion Gear 1 14 Fill Plug 1 34 Armature Plate AWD 1 15 Cap Screw M6 4 35 Armature Plate ADC 1 16 Screw M4 4 36 AWD Coil 1 17 Set Screw M6 1 37 Piston 2 18 Cover Housing 1 38 Pump Assembly 1 19 Pinion Cover 1 39 Vent 1 20 Clutch Pack Assembly 2 40 Drain Plug Magnetic 1 3 7 4 5 8 9 10 12 18 14 16 17 ...

Page 214: ...d coil and armature plate will apply drag to the roll cage that indexes the rollers inside the 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 lose traction Once the rear wheels begin to lose traction the front drive will engage by coupling the output hubs to the ring gear via the rollers Th...

Page 215: ...t is present at the input shaft coil 1 Operation is controlled by the ECU grounding and ungrounding the coil The coil s magnetic field attracts a splined armature plate 2 on the pinion input shaft 4 The energized splined armature plate attracts the unsplined eccentric cam 3 which begins to turn with the input shaft The eccentric cam drives a hydraulic piston pump assembly 5 The pressure created by...

Page 216: ...the coil area as indicated in Step 5 A wear band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation 5 Check to make sure the AWD 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 If the top of the coil is above the surface of the U shaped insert it raises the arm...

Page 217: ...oir and clear hose out from the frame so it can be removed with the front gearcase 7 Remove the cotter pin and nut from each tie rod end at the steering post frog 8 Remove the 2 bolts retaining the lower steering post bracket to the front gearcase 9 Remove the front cover and remove the 2 fasteners retaining the upper steering post bushing bracket 10 Lift the steering post assembly up from the fro...

Page 218: ...earcase Disassembly Inspection 1 Drain and properly dispose of used lubricant Remove any metal particles from the drain plug magnet 2 Remove the 4 screws retaining the piston pump assembly to the gearcase and remove the pump NOTE Piston pump assembly is a non serviceable item and should not be disassembled Replace as an assembly if found to be damaged or non working 3 Remove the 6 screws retaining...

Page 219: ...the front drive on deceleration are key indicators of burnt or broken down front drive fluid 6 Remove the armature plate Inspect the armature plate for distortion or other damage see AWD Diagnosis Replace as required 7 Remove the ring gear and roll cage from the gearcase as an assembly 8 Remove the male output hub assembly Inspect the bearings contact surfaces and splines for signs of wear or dama...

Page 220: ...individual part availability Most parts are to be replaced as an assembly or as a complete kit 13 Inspect the armature plate for a consistent wear pattern Uneven wear of the armature plate indicates a warped plate which may cause intermittent operation refer to AWD Diagnosis for inspection 14 Inspect the magnetic coil F in the cover plate assembly refer to AWD Diagnosis for inspection 15 Inspect t...

Page 221: ...equired replace the input cover as an assembly 20 Remove the 4 screws that retain the pump neck assembly to the main gearcase 21 Remove the neck and input shaft assembly from the main gearcase 22 Inspect the pinion gear N for chipped broken or missing teeth Inspect the input shaft bearing P for signs of wear The bearing can be replaced separate from the input shaft IMPORTANT Refer to the Electroni...

Page 222: ... main gearcase using new O rings Torque the screws to specification 6 Install the cam armature plate and input cover assembly with a new O ring 7 Torque the input cover screws to specification 8 Install the roll cage and rollers into the ring gear Insert the rollers as the roll cage is installed 9 Install the male output hub assembly into the main gearcase IMPORTANT Take care not to damage the sea...

Page 223: ...Lightly crimp the thrust pad to hold the pad on the cover plate during installation 15 Place the cover plate assembly on the main gearcase and install the 6 screws Torque screws to specification IMPORTANT Take care not to damage the seal lip or seal spring while installing the cover plate 16 Install the piston pump assembly with new O rings Torque the screws to specification IMPORTANT If the cover...

Page 224: ...ench turn the backlash screw out 3 4 turns Re apply Loctite 262 onto the bottom screw threads 3 Turn the screw in until it is lightly seated then turn the screw out 1 4 turn 4 Set the gearcase upright Rotate the input shaft at least 4 times This ensures the ring gear completes one full rotation 5 If a tight spot is felt during rotation loosen the backlash screw another 1 8 turn and perform step 4 ...

Page 225: ...ine and the 4 bolts that secure the front gearcase to frame Torque bolts to specification 5 Connect and route the AWD wire harness along the frame and install a plastic tie strap to attach it to the frame 6 Place the steering post and bearing into the front gearcase 7 Reinstall the upper steering post bushing bracket and torque the 2 fasteners to specification 36 ft lbs Install Vent Line 49 Nm T F...

Page 226: ... specification 14 Add the recommended amount of fluid through the fill hole Maintain the fluid level even with the bottom threads of the fill plug hole 15 Reinstall fill plug with a new O ring and torque to specification 16 Check for external leaks 17 If the ADC system was serviced it must be properly bled see ADC System Fluid Bleeding T Steering Post to Gearcase Bolts 22 ft lbs 30 Nm T Tie Rod to...

Page 227: ...of the bleeder valves 8 Slowly loosen the valve counter clockwise and allow fluid and trapped air to flow from the fitting IMPORTANT Do not allow ADC fluid in reservoir to drop below the MIN fill line Close bleeder valve before the fluid level drops below the MIN fill line Refilling an empty reservoir will result in air pockets becoming trapped 9 Close the valve when clean bubble free fluid begins...

Page 228: ...y 5 Remove the two brake caliper mounting 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 rotation Visually...

Page 229: ...ut from the back side 3 Inspect the bearing carrier housing for scratches wear or damage Replace rear bearing carrier if damaged Bearing Installation 4 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 5 Support the bottom of the bearing carrier housing 6 Apply Loctite 603 retaining compound to th...

Page 230: ...r fittings after it has been installed and the rear A arms have been attached Installation 1 Install drive shaft axle through the backside of the bearing carrier Be sure bushings and pivot tubes are installed 2 Install the fasteners that attach the rear bearing carrier to the upper and lower A arms Torque bolts to specification 3 Apply grease to drive shaft axle splines 4 Install rear wheel hub as...

Page 231: ...eel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly T Rear Caliper Mounting Bolts 37 ft lbs 50 Nm T Wheel Hub Castle Nut 80 ft lbs 108 Nm 37 ft lbs 50 Nm NEW Cone Washers 80 ft lbs 108 Nm Cotter Pin T ...

Page 232: ...ot 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 upper A arm to the rear bearing carrier 7 Tilt the top portion of the bearing carrier down and pull the rear drive shaft out from the bearing carrier CAUTION Serious injury may result if machine tips or falls Be sure machine is ...

Page 233: ...a new spring ring on the end of the drive shaft and apply an anti seize compound to the splines 2 Align the splines of the drive shaft with the rear gearcase and reinstall the drive shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 3 Install the drive shaft into the rear bearing carrier 4 Refer to the REAR BEARING CARRIER Installation procedure within this chapte...

Page 234: ...not to be used as a lever arm to position other suspension components Never use a hammer or sharp tools to remove or to install boot clamps Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned Refer to text for grease capacity of CV joints and CV joint boots Outer CV Joint Boot Replacement 1 Us...

Page 235: ...e balls and the splined hole in the joint s inner race Pack the ball tracks and outer face flush with grease Place any remaining grease into the boot NOTE The amount of grease that s provided is pre measured so use all the grease 14 Slide the joint onto the drive shaft splines and align the circlip with the lead in chamfer on the inner race of the joint 15 Use a soft faced hammer to tap the joint ...

Page 236: ...ion on the shaft 21 Install and tighten the small clamp on the boot using the Axle Boot Clamp Tool PU 48951 Inner Plunging 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 plunging 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 ...

Page 237: ...le in the joint s inner race Pack the ball tracks and outer face flush with grease Place any remaining grease into the boot NOTE The amount of grease that s provided is pre measured so use all the grease 14 Fully compress the joint and push the drive shaft firmly into the inner race 15 Align the circlip with the lead in chamfer 16 Use a soft faced hammer to tap the joint onto the drive shaft until...

Page 238: ...he 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 pressure in the boot 22 Position the boot lip in its groove Install and tighten the large clamp using the Axle Boot Clamp Tool PU 48951 Drive Shaft Exploded View Axle Boot Clamp Tool PU 48951 Axle Boot Clamp Tool PU 48951 REAR ...

Page 239: ...ler 3 Slide the shaft towards the transmission and pivot the propshaft down Slide the propshaft off the transmission output shaft and out from the vehicle Installation 1 Apply anti seize compound to all splines Slide propshaft back onto the transmission output shaft and then lift it up and align it with the rear gearcase input shaft coupler 2 Install the 4 bolts and torque to specification T Rear ...

Page 240: ...ssion output shaft and out from the vehicle 7 Remove the PVT outlet duct driven clutch drive clutch and inner PVT cover see Chapter 7 PVT SYSTEM SERVICE Disassembly 8 Remove the top retaining nut from each stabilizer bar linkage and rotate the stabilizer bar back out of the way 9 Remove the upper shock mounts from each side 10 Remove the brake line retainer and left rear brake caliper 11 Remove th...

Page 241: ... carrier Pivot the wheel hub and bearing carrier down to remove the drive shaft IMPORTANT Take care not to stretch the brake line while removing the drive shaft 15 Remove the drive shaft from the rear gearcase by pulling sharply 16 Remove the 4 through bolts retaining the rear gearcase to the frame 17 Remove the vent line from the rear gearcase 18 Pull the rear gearcase out between the transmissio...

Page 242: ... the main gearcase half and note the shim between the cover and the ring gear 4 Remove the ring gear from the main gearcase half 5 Inspect the ring gear teeth for chipped worn or broken teeth 6 Inspect the pinion 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 NOTE In the event damag...

Page 243: ...7 Thoroughly clean the pinion shaft 8 Support the pinion shaft and carefully press the new bearing on the shaft and install a NEW O ring see Figure 8 27 9 Remove the seals from each case half using a seal puller or other suitable method see Figure 8 28 10 Support the gearcase cover and press the bearing out Repeat this procedure on the main gearcase half see Figure 8 28 11 Thoroughly clean the gea...

Page 244: ...All Season Grease PN 2871322 upon assembly to prevent from damaging seals 2 Install the ring gear into the main gearcase 3 Install the shim previously removed onto the ring gear 4 Thoroughly clean the gearcase mating surfaces and be sure the alignment pins are in place 5 Apply Crankcase Sealant PN 2871557 to mating surfaces 6 Install the gearcase cover onto the main gearcase half 7 Install the cov...

Page 245: ...caliper mounting bolts to specification 10 Install the rear upper shock through bolts Torque bolts to specification 11 Install the rear stabilizer bar onto the linkage rods Torque the linkage retaining nuts to specification 12 Install the rear propshaft and torque bolts to specification 13 Reassemble the PVT system see Chapter 7 PVT SYSTEM SERVICE Assembly 14 Install the rear wheels and torque whe...

Page 246: ... Shaft 10T Straight Bevel 1 5 Locking Washer 1 15 Ring Gear 37T Straight Bevel 1 6 Dowel Pin 2 16 Vent Tube 1 7 Retaining Ring 1 17 Coupler 1 8 Shim 1 18 Triple Lip Seal 2 9 Plain Bearing 1 19 Triple Lip Seal 1 10 Ball Bearing 1 20 O Ring 1 1 2 3 4 5 7 8 9 10 13 14 15 16 17 18 19 20 12 10 14 ft lbs 14 19 Nm 6 90 110 ft lbs 122 149 Nm 15 20 ft lbs 20 27 Nm 11 11 18 10 14 ft lbs 14 19 Nm P a r t S h...

Page 247: ...EMOVAL INSTALLATION 9 4 MUD GUARDS 9 4 REMOVAL INSTALLATION 9 4 FOOTWELLS 9 4 REMOVAL INSTALLATION 9 4 FRONT CAB 9 5 REMOVAL 9 5 INSTALLATION 9 5 REAR RACK 9 6 REMOVAL INSTALLATION 9 6 REAR BUMPER COVERS 9 6 REMOVAL INSTALLATION 9 6 REAR CAB 9 6 REMOVAL INSTALLATION 9 6 HEADLIGHT POD 9 7 DISASSEMBLY REMOVAL 9 7 ASSEMBLY INSTALLATION 9 7 MAIN FRAME 9 8 FRAME SUPPORT EXPLODED VIEW 9 8 CHASSIS 9 9 BO...

Page 248: ...the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application SPECIAL TOOLS Plastic Push Rivet Removal Polaris ATVs use a two piece plastic push rivet to fasten most body components Using the Multi Function Pliers eases removal and prevents from damaging the push rivets and body components Multi Function Pliers Included in the tool kit the multi functio...

Page 249: ...crew and knob to allow removal 6 Reverse this procedure to reinstall components 7 When installing the seat start the front portion first then follow by installing the rear portion Be sure the under seat fasteners are fully engaged upon installation FRONT RACK Removal Installation 1 Release the front rack latches and remove the rack as an assembly 2 To reinstall the rack hold the rack as shown in t...

Page 250: ... reinstall the front bumper MUD GUARDS Removal Installation 1 Locate the mud guards in the front wheel well area 2 Remove the 4 push rivets from each mud guard and remove from them from the wheel well 3 Reverse this procedure to reinstall the mud guards FOOTWELLS Removal Installation 1 Remove the seat and upper side panel see SEAT AND SIDE PANELS 2 Remove the push rivets and screws that retain the...

Page 251: ... fuel fill hose inlet to prevent dirt or debris from entering the fuel tank 11 Carefully lift up and pull the front cab toward the rear of the ATV to clear in the headlight pod Installation 1 Carefully install the front cab onto the frame 2 Uncover the fuel fill hose inlet and attach the hose to the front cab Torque the upper hose clamp to specification 3 Install the push rivets retaining the fron...

Page 252: ...he frame see REAR CAB 3 Lift up on the rear cab and remove the bumper covers by sliding them off the rear bumper 4 Reverse this procedure to reinstall the covers REAR CAB Removal Installation 1 Remove the 10 push rivets and 4 Torx headed screws retaining the rear cab assembly 2 Remove the tail light bulbs from the tail lamps disconnect the tail light harnesses from the rear cab and remove the rear...

Page 253: ...ll vent line wire harness and throttle cable routing for reassembly purposes 6 Remove the lower pod from the vehicle Assembly Installation 1 Reverse the Disassembly Removal procedure NOTE Make sure to route all vent lines wire harness and throttle cable correctly into the lower headlight pod 2 When installing the headlight into the lower pod be sure to install the O rings prior to installing the h...

Page 254: ...9 8 BODY FRAME MAIN FRAME Frame Support Exploded View P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 255: ...9 9 BODY FRAME 9 CHASSIS Body Plastic Removed View P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 256: ...NOTES BODY FRAME 9 10 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 257: ...RING UNIT INSTALLATION 10 8 STEERING EXPLODED VIEW EPS MODELS 10 10 STEERING TIE ROD 10 11 TIE ROD TIE ROD END REPLACEMENT 10 11 FRONT A ARMS 10 12 EXPLODED VIEW 10 12 REMOVAL REPLACEMENT 10 13 BALL JOINT SERVICE 10 14 REMOVAL 10 14 INSTALLATION 10 15 REAR A ARMS 10 16 EXPLODED VIEW 10 16 REMOVAL INSTALLATION 10 17 REAR STABILIZER BAR 10 18 EXPLODED VIEW 10 18 LINKAGE REMOVAL INSTALLATION 10 19 ST...

Page 258: ...er handlebar blocks and remove them from the handlebar Item Specification Aluminum Wheels 75 ft lbs 102 Nm Steel Wheels 45 ft lbs 61 Nm Wheel Hub Retaining Nuts front and rear 80 ft lbs 108 Nm Steering Post to Bulkhead 20 ft lbs 27 Nm Steering Post to Gearcase 22 ft lbs 30 Nm Tie Rod Jam Nuts 12 ft lbs 16 Nm Tie Rod to Bearing Carrier Tie Rod to Steering Frog 44 ft lbs 60 Nm Handlebar Block Bolts ...

Page 259: ...pter 9 NOTE Make sure to route all vent lines wire harness and throttle cable correctly into the lower headlight pod STEERING Steering Post Removal 1 Remove the front rack and front cover see Chapter 9 2 Remove the upper and lower headlight pods from the handlebar bracket see Chapter 9 IMPORTANT Take note of all vent line wire harness and throttle cable routing for reassembly purposes 3 Remove the...

Page 260: ...NOTE Make sure to route all vent lines wire harness and throttle cable correctly into the lower headlight pod 2 When installing the headlight into the lower pod be sure to install the O rings prior to installing the headlight 3 Place the headlight into the lower pod mounting tabs and press firmly until the headlight snaps into place 4 Lift the O ring up and over the headlight mounting tab to secur...

Page 261: ...RH 11 Upper Steering Bracket 4 Jam Nut RH 12 Upper Steering Bushing 5 Tie Rod Assembly 13 Carriage Bolt 6 Jam Nut LH 14 Nut 7 Rod End LH 15 Bolt 8 Washer 20 ft lbs 27 Nm 22 ft lbs 30 Nm 12 ft lbs 16 Nm 44 ft lbs 60 Nm 12 ft lbs 16 Nm 44 ft lbs 60 Nm 44 ft lbs 60 Nm 12 ft lbs 16 Nm 12 ft lbs 16 Nm P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 262: ...bar is removed 5 Remove the bolt retaining the upper steering post to the power steering unit 6 Remove the 2 fasteners retaining the upper steering post bushing bracket 7 Lift the upper steering post up from the power steering unit remove it from the chassis Upper Steering Post Installation 1 Reverse the Upper Steering Post Removal procedure to reinstall the steering post 2 Apply anti seize to the...

Page 263: ...e upper and lower headlight pods Power Steering Unit Removal 1 Remove the front rack and front cover see Chapter 9 2 Remove both front mud guards and right hand footwell see Chapter 9 3 Locate the power steering unit through the front left wheel well area 4 Remove the bolt retaining the upper steering post to the power steering unit 5 Remove the 2 fasteners retaining the upper steering post bushin...

Page 264: ...rame 12 Carefully lift the power steering unit up to disengage the lower steering coupler and remove it from the chassis Power Steering Unit Installation 1 Position the vehicle so the front wheels are pointing straight forward 2 Clean the lower steering post so the alignment mark is visible Mark the skip tooth spline on the lower power steering shaft 3 Apply anti seize to the shaft splines to aid ...

Page 265: ...l times to ensure the power steering doesn t bind If binding occurs Loosen the 4 mounting fasteners Move handlebars from left to right several times to position the power steering unit Torque the 4 mounting fasteners to specification and check the steering operation for binding again If no binding is present proceed if binding is still present repeat this procedure 14 Install both front mud guards...

Page 266: ...Power Steering Bracket LH 7 Rod End LH 19 Power Steering Bracket RH 8 Washer 20 Front Drive Bracket LH 9 Cotter Pin 21 Front Drive Bracket RH 10 Nut 22 Bolt 11 Upper Steering Bracket 23 Bolt 12 Upper Steering Bushing 20 ft lbs 27 Nm 22 ft lbs 30 Nm 12 ft lbs 16 Nm 44 ft lbs 60 Nm 12 ft lbs 16 Nm 44 ft lbs 60 Nm 44 ft lbs 60 Nm 12 ft lbs 16 Nm 12 ft lbs 16 Nm 44 ft lbs 60 Nm 22 ft lbs 30 Nm 15 ft l...

Page 267: ...ue jam nuts to specification 5 Install the new tie rod assembly C 6 Install the rod ends and fasteners B in the proper orientation see illustration 7 Torque the tie rod end fasteners to specification and install new cotter pins 8 Install the front wheel s and wheel nuts Torque wheel nuts to specification 9 Check wheel toe alignment and adjust as necessary see Chapter 2 CAUTION Serious injury may r...

Page 268: ...EF DESCRIPTION 1 Upper A arm 8 Bushing 2 Lower A arm 9 Pivot Shaft 3 Retaining Ring 10 Bolt 4 Ball Joint 11 Nut 5 Nut 12 CV Shield 6 Bolt 13 Screw 7 Grease Fitting 40 ft lbs 54 Nm 21 ft lbs 28 Nm 40 ft lbs 54 Nm 21 ft lbs 28 Nm P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 269: ...olt to 21 ft lbs 28 Nm 13 Attach shock to A arm with new fastener Torque lower shock bolt to 37 ft lbs 50 Nm 14 Remove the lower ball joint pinch bolt from the front bearing carrier see Figure 10 2 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 the bearing carrier 16 Rem...

Page 270: ...iver 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 Installation 1 Place the A arm in the correct position for ball joint installation Face the A arm end flat on top of the driver Carefully drive the ball joint into place until the ball joint 1 75 in 1 375 in 3 49 cm 3 in 7 62 cm Driver Dimensions Outsi...

Page 271: ...ll a new retaining ring 3 Reinstall the A arm see FRONT A ARMS Removal Replacement 4 Repeat the ball joint service procedure for any additional A arm ball joint replacements Press into the A arm in this direction Upper A arm Shown Place driver HERE to support A arm P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 272: ...ION REF DESCRIPTION 1 Bolt 7 Bolt 2 Nut 8 Lower A arm 3 Bushing 9 Bolt 4 Upper A arm 10 Pivot Shaft Upper 5 Grease Fitting 11 Pivot Shaft Lower 6 Pivot Shaft 12 Bushing Lower 45 ft lbs 61 Nm 40 ft lbs 54 Nm 45 ft lbs 61 Nm P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 273: ...e frame and remove the A arm from the vehicle 12 Examine A arm and bearing carrier bushings and pivot shafts see Exploded View Replace if worn and discard the hardware 13 If not replacing the A arm thoroughly clean the a arm and pivot shafts 14 Insert new bushings and pivot shafts into the new A arm Installation 1 Install upper and lower A arm assemblies onto the vehicle frame Torque new fasteners...

Page 274: ...SCRIPTION REF DESCRIPTION 1 Bolt 6 Nut 2 Stabilizer Bar Bracket 7 Linkage Stabilizer Bar 3 Bushing Stabilizer Bar 8 Bolt 4 Nut 9 Flat Washer 5 Stabilizer Bar 10 Bushing Linkage 17 ft lbs 23 Nm 22 ft lbs 30 Nm 37 ft lbs 50 Nm P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 275: ...he 2 exhaust springs from the rear portion of the exhaust silencer 2 Remove the 2 exhaust springs that retain the exhaust pipe to the silencer 3 Remove the exhaust silencer from the vehicle through the right rear wheel well NOTE Lift upward slightly on the exhaust pipe to allow for enough clearance to remove the silencer 4 Remove the 4 screws retaining the exhaust heat shield and remove the shield...

Page 276: ... 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 37 ft lbs 50 Nm Shock Spring Replacement 1 Using a spring compressor compress the shock spring far enough to remove the spring retainer 2 Remove the spring and adjusting cam fro...

Page 277: ...EMENT 11 6 BLEEDING PROCEDURE 11 6 HAND BRAKE MASTER CYLINDER 11 8 REMOVAL DISASSEMBLY INSTALLATION 11 8 BRAKE SWITCH REPLACEMENT 11 8 FOOT BRAKE MASTER CYLINDER 11 9 FOOT MASTER CYLINDER REMOVAL INSTALLATION 11 9 BRAKE PEDAL REMOVAL INSTALLATION 11 9 BRAKE PADS 11 10 PAD REMOVAL INSPECTION INSTALLATION 11 10 BRAKE BURNISHING PROCEDURE 11 11 CALIPER SERVICE 11 11 CALIPER REMOVAL DISASSEMBLY 11 11 ...

Page 278: ...ckness 040 1 mm Brake Disc Thickness 187 4 75 mm 167 4 24 mm Brake Disc Thickness Variance Between Measurements 002 051 mm Brake Disc Runout 010 254 mm Caliper Piston Diameter 1 250 31 75 mm 1 246 31 65 mm Caliper Bore Diameter 1 254 31 85 mm 1 256 31 90 mm TORQUE SPECIFICATIONS Item Torque ft lbs in lbs Torque Nm Caliper Mounting Bolts 37 50 Handlebar Master Cylinder Clamp Bolts 70 in lbs 7 9 Han...

Page 279: ...up 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 can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust Brake Noise Troubleshooting Possible Ca...

Page 280: ...pongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating port which is opened and closed by the master cylinder piston assembly As the temperature within the hydraulic system changes this port compensates for fluid expansion or contraction Due to the high temperatures created within the system during heavy braking it is very impo...

Page 281: ...ustment Set Screw Apply Polaris All Purpose Grease Apply Polaris DOT 4 Brake Fluid to Component 47 in lbs 5 3 Nm A B C D E F G H J K A Lever B Piston C Locking Lever D Primary Cup E O ring F Reservoir Cover G Pivot Pin H Piston Return Spring J Dust Boot K Lever Return Spring L Clamp M Retaining Ring N Locking Push On P Torx Screws Q Cover Screws R Brake Switch G L M N P Q 70 in lbs 8 Nm 7 in lbs 0...

Page 282: ...to fitting and place the other end in a container Be sure the hose fits tightly on fitting NOTE Install diaphragm and cover onto the hand master cylinder reservoir to prevent spills Do not tighten the cover 4 Slowly pump the hand brake lever until pressure builds and holds 5 While maintaining lever pressure open bleeder screw 6 Close bleeder screw and release brake lever NOTE Do not release lever ...

Page 283: ... container Be sure the hose fits tightly on fitting 6 Slowly pump the foot brake pedal until pressure builds and holds 7 While maintaining pedal pressure open bleeder screw 8 Close bleeder screw and release brake pedal NOTE Do not release pedal before bleeder screw is tight or air may be drawn into caliper 9 Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add...

Page 284: ...aster cylinder on handlebars Torque bolt furthest from the reservoir first followed by the bolt closest to the reservoir Torque clamp bolts to 70 in lbs 8 Nm NOTE Speed up brake bleeding by purging air before brake line is attached Fill with DOT 4 Brake Fluid and pump lever slowly 2 to 3 times with finger over the outlet end to purge master cylinder of air 2 Place new sealing washers on each side ...

Page 285: ...s needed 4 Reverse this procedure when reinstalling and torque mounting fasteners to specification 5 Reinstall the brake line and torque the banjo bolt with new sealing washers installed to specification 6 Bleed the master cylinder following the procedure outlined in the Brake Bleeding section of this chapter Brake Pedal Removal Installation 1 Remove the RH mud guard and footwell see Chapter 9 2 R...

Page 286: ...beyond the service limit Pad Installation 1 Lubricate mounting bracket pins and external slide pin O ring with a light film of Polaris Premium All Season Grease PN 2871423 2 Compress mounting bracket Install pads with friction material facing each other CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls Remove Caliper Front Cal...

Page 287: ...his procedure 10 times CALIPER SERVICE Caliper Removal 1 Loosen the 4 wheel nuts 2 Elevate and support the side of the ATV in which the caliper is being serviced 3 Remove the wheel nuts and wheel 4 Place a suitable container under the caliper to catch brake fluid draining from brake line Using a wrench loosen and remove brake line from the caliper 5 Remove 2 caliper mounting bolts and remove the c...

Page 288: ...liper 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 pad and disc as outlined in this chapter see Pad Inspection and Brake Disc Inspection Clean Components In mm Fr...

Page 289: ...rease Caliper Installation 1 Install caliper assembly over the brake disc and onto the bearing carrier Torque mounting bolts to specification 2 Install brake line and torque the banjo bolt fitting to specification 3 Perform brake bleeding procedure as outlined earlier in this chapter 4 Install the wheel and 4 wheel nuts Torque wheel nuts to specification In mm Front Calipers Caliper Piston O D Std...

Page 290: ...ication Disc Removal Replacement 1 Loosen the 4 wheel nuts 2 Elevate and support the side of the ATV in which the brake disc is being serviced 3 Remove the wheel nuts and wheel 4 Remove the cotter pin castle nut and cone washers In mm Brake Disc Thickness New 187 4 75 mm Service Limit 167 4 24 mm In mm Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements In mm Bra...

Page 291: ... are flush with the mating surface 10 Install wheel hub assembly cone washers and hand tighten the castle nut Install washers with domed side out 11 Install the brake caliper and torque the new mounting bolts to specification CAUTION Always use new wheel studs if removed from the wheel hub assembly Remove Rear Caliper Shown CAUTION New bolts have a pre applied locking agent which is destroyed upon...

Page 292: ...liper disc misaligned Caliper dirty or damaged Brake line damaged or lining ruptured Worn disc and or friction pads Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Lever Pedal Vibration Disc damaged Disc worn warped runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port plugged Brake lever or pedal binding or unable to r...

Page 293: ...MP ADJUSTMENT 12 18 HEADLIGHT BUMPER LAMP REPLACEMENT 12 19 TAIL BRAKE BULB REPLACEMENT 12 19 CHARGING SYSTEM 12 20 CHARGING SYSTEM DIAGRAM TESTING 12 20 CURRENT DRAW KEY OFF 12 20 BATTERY CHARGE TEST 12 20 STATOR ALTERNATOR TESTS 12 20 STATOR ALTERNATOR REMOVAL 12 21 STATOR ALTERNATOR INSTALLATION 12 22 BATTERY SERVICE 12 23 BATTERY REMOVAL INSTALLATION 12 23 BATTERY OFF SEASON STORAGE 12 23 BATT...

Page 294: ...6 KEY ON POWER CIRCUITS 12 38 CHASSIS POWER CIRCUITS 12 39 HEAD LAMP CIRCUITS 12 40 BRAKE LAMP CIRCUITS 12 41 ENGINE START COMMAND CIRCUITS 12 42 ECM WAKE UP COMMAND CIRCUITS 12 44 AWD ADC CIRCUITS 12 45 AWD ADC FUNCTION TESTS 12 47 RADIATOR FAN CIRCUIT 12 48 GEAR SELECTOR SWITCH CIRCUIT 12 50 GROUND SPEED SENSOR CIRCUIT 12 52 REVERSE OVERRIDE CIRCUIT 12 53 CONTROLLER AREA NETWORK CAN 12 54 OVERVI...

Page 295: ...roper jack for the test being performed i e 10A jack for current readings Refer to the Owner s Manual included with your meter for more information Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is acceptable for use when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to...

Page 296: ...view The instrument cluster displays critical vehicle information to the user Reference the following page for display functions and descriptions NOTE Some features are not applicable to all models P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 297: ...econds when the engine hours meet the hour threshold indicating when maintenance should be performed 9 Select Button Press and release to toggle through the information area fields The fields are Odometer tripmeter 1 tripmeter 2 engine hours and service interval The information area will also display any current Diagnostic Trouble Codes DTC if applicable NOTE Select button locked out when vehicle ...

Page 298: ...tion displayed in this area includes Odometer tripmeter 1 tripmeter 2 engine hours service interval engine Diagnostic Trouble Codes DTCs and power steering DTCs 1 Press and release the SELECT button on the instrument cluster or press and release the LH control REVERSE OVERRIDE button to toggle between the information displays NOTE DTC display modes can only be accessed using the SELECT button on t...

Page 299: ...ck The clock displays the time in a 12 hour or 24 hour format depending on whether the instrument cluster units are set to Standard or Metric on early build vehicles On later build vehicles change between 12 hour and 24 hour formats by performing the following procedure 1 Press and hold the MODE button until RPM is displayed 2 Toggle the SELECT button until the odometer is displayed 3 Press and ho...

Page 300: ...ic Mode Use the following procedure to display diagnostic trouble codes logged in the ECU if the check engine MIL is illuminated on the instrument cluster 1 Place the transmission in PARK 2 Push and release the SELECT button to toggle through the LCD display until the check engine MIL icon is flashing 3 When the check engine MIL icon is flashing a set of two numbers will appear on the LCD 4 The fi...

Page 301: ...s C and D A and F Turn the key to START There should be continuity between pins A and B C and D If any of the tests fail replace ignition switch assembly Instrument Cluster Pinouts FUNCTION PIN Battery Voltage Vdc 1 Ground 2 Run Stop Switch 3 CAN High 4 CAN Low 5 High Beam Input 20 Fuel Level Sensor 23 International Models Only Hazard Warning 10 Left Turn Signal 21 Right Turn Signal 22 Ignition Sw...

Page 302: ...rive mode and then test for continuity If any of the tests fail replace the RH throttle switch assembly OFF RUN LH SWITCH Function Test Use a multimeter to test for continuity when the LH switch is moved to the RUN position Move the switch to the RUN position and test If the test fails replace the LH control assembly ADC AWD 2x4 Switch Test 3 4 5 4x4 ADC 4x4 AWD 2x4 3 4 5 Off Run Switch Test F Lef...

Page 303: ...er to test for continuity with the 3 head lamp control outputs OFF LOW HIGH in the LH control assembly There should be no continuity on any pin when the headlamp switch is in the OFF position Move the switch to LOW There should be continuity between pins D and F Move the switch to HIGH There should be continuity between pins D and E If any of the tests fail replace the LH control assembly Reverse ...

Page 304: ...between the switch contacts and connector leads Replace the switch if no continuity or high resistance is found in any of the gear positions Resistor Module Function Test The resistor module relays a different resistance reading to the ECU depending on which gear is selected by the operator If the module fails the ECU will not be able to determine what gear the transmission is in NOTE Reference Ch...

Page 305: ...st the BROWN ground circuit Verify there is continuity between the circuit and chassis ground 4 If all circuits function remove the speed sensor from the transmission Verify the sensor is not damaged 5 Test the speed sensor using the following tools Hall Sensor Probe PN 2460761 Static Timing Light Tool PN 2871745 6 Connect the tools together as shown below 7 Insert the sensor probe s 3 terminals i...

Page 306: ... AWD functions Diagnosing System Failures Verify the ADC AWD switch is functional and that a minimum of 11 volts is present at the hub coil connection Verify the ADC AWD hub coil is functional Test the AWD hub coil using a multimeter Verify the wiring harness wiring connectors connector pins and grounds are undamaged clean and connected properly Verify continuity of wire connections with a known g...

Page 307: ...2 Vdc battery voltage DB RD ECU relay control circuit for relay coil ORG LH RUN switch supplied 12 Vdc battery voltage to relay coil WHT 12 Vdc Bus bar for Lights 20A Fuse Drive 20A Fuse Accessory 20A Fuse Fan Relay Color Function RD WHT 20A Circuit breaker protected 12 Vdc battery voltage ORG YEL ECU relay control circuit for relay coil RD WHT Constant 12 Vdc battery voltage to relay coil ORG BLK...

Page 308: ...N 20A fuse protected 12 Vdc battery voltage BRN Ground for relay coil DG Hi Low LH control 12 Vdc battery voltage to relay coil DG LH RH front bumper lights power Start Solenoid Relay Color Function RD WHT 20A circuit breaker protected 12 Vdc battery voltage BRN WHT ECU relay control for relay coil WHT RD Starter solenoid power BLU RD Key switched START relay coil power 12 Vdc battery voltage Powe...

Page 309: ...rotected Circuits 20A Circuit Breaker Fan Motor Starter Solenoid 20A EFI EFI Relay controlled circuits Ignition coil pack Fuel Pump Fuel Injectors 10A Unswitched Power ECU Fan Relay Driver Ignition Switch Instrument Cluster 30A EPAS Power Steering Relay Motor 20A Lights Front and rear tail lights Brake lights Head lights 20A Drive AWD Coil ADC Coil RH AWD ADC switch Winch Switch Power 20A Accessor...

Page 310: ...ght aim on the wall The most intense part of the headlight beam should be aimed 2 in 5 cm below the mark placed on the wall in Step 3 6 Loosen the adjustment screw at the rear of the headlamp 7 Adjust the beam to desired position Repeat the procedure to adjust the other headlight Bumper Lamp Adjustment 1 Loosen the Phillips screw located at the rear of the lamp 2 Tilt the lamp upward or downward 3...

Page 311: ...iring 2 Turn the lamp counterclockwise to remove it 3 Insert new the new lamp and turn it clockwise to secure it Reinstall the wire harness to the lamp NOTE Make sure the tab on the lamp locates properly in the housing Tail Brake Bulb Replacement Before replacing the bulb use a digital multimeter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present If a ta...

Page 312: ...ttery is fully charged and in good condition 2 With the engine running connect the multimeter to the positive and negative battery terminals 3 Test for Vdc with the multimeter 4 The meter display should read approximately 14 0 14 4 Vdc at idle 5 If the voltage is lower than 14 0 14 4 Vdc the alternator should be tested Stator Alternator Tests Three tests can be performed using a multimeter to dete...

Page 313: ...Y3 Y2 to Y3 5 Refer to the following table for approximate AC Voltage readings according to RPM Test each leg at the specified RPM in the table NOTE If one or more of the stator leg output AC voltage varies significantly from the specified value the stator may need to be replaced Stator Alternator Removal 1 Remove the fuel tank see Chapter 3 2 Remove the 4 screws retaining the engine skid plate an...

Page 314: ...se the following steps to ensure proper assembly 3 Torque the stator and wire guide bolts to specification 4 Install new O rings on the coolant pipe and lightly lubricate for ease of installation 5 Torque the 8 stator cover bolts to specification using the torque sequence provided CAUTION The flywheel contains powerful magnets Use caution when removing and installing the stator cover DO NOT place ...

Page 315: ... Battery tenders can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Testing Whenever a service complaint is related to either the starting or charging systems the battery should be checked first Following are two tests which can easily be made on a sealed Maintenance Free battery to determine its condi...

Page 316: ... s instructions for recharging Do not exceed 10 amps when charging the 4011224 battery NOTE Charge the battery using an automatic charger that will not exceed 14 6 Vdc An automatic charger will signal when charging is complete NOTE Allow the battery to stand disconnected for several hours after being properly charged If the voltage drops below 12 6 volts charging was ineffective or the battery nee...

Page 317: ...r motor Engine problem seized or binding can engine be rotated easily Starter Motor Turns Over Slowly Battery discharged Excessive circuit resistance poor connections see Voltage Drop Test Engine problem seized or binding can engine be rotated easily Faulty or worn brushes in starter motor Starter Motor Turns Engine Does Not Rotate Faulty starter drive Faulty starter drive gears or starter motor g...

Page 318: ...etaining the starter motor 5 Remove the engine oil dipstick to allow for starter motor removal 6 Remove the starter motor from the crankcase housing Reinstall the engine oil dipstick 7 Remove the key switch energize wire and battery cable from the starter solenoid Remove the starter motor assembly from the chassis 8 Install the new starter motor assembly by reversing this procedure 9 Be sure to in...

Page 319: ...G The following 4 diagnostic tests can be performed without using Digital Wrench Troubleshooting functions not listed here can be found using Digital Wrench Guided Diagnostics Instrument Cluster Key OFF No Power P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 320: ...12 28 ELECTRICAL Instrument Cluster Key ON No Power P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 321: ...12 29 ELECTRICAL 12 Instrument Cluster No High Beam Indicator P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 322: ...12 30 ELECTRICAL Instrument Cluster No Incorrect Fuel Level P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 323: ...12 31 ELECTRICAL 12 Instrument Cluster Circuit P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 324: ... mechanically coupled steering system The system is Polaris Digital Wrench compatible for simplified diagnostics and system troubleshooting through the vehicle s diagnostic port With the engine off and the key on the power steering unit will operate for up to five minutes After the five minutes you will need to either cycle the key switch or start the engine to regain power steering operation The ...

Page 325: ...connector will not positively engage or snap into place while in the wrong position but can still be installed If the connector is not installed correctly on a Sportsman XP the Power Steering Unit will not function This situation can be avoided by paying close attention when installing the 8 way connector If the 8 way is connected properly the vehicle should have assist with the key on EPS Trouble...

Page 326: ... will turn on at approximately 167 F 75 C If the regulator rectifier turns off verify the housing cooling fins are clean and free from debris and adequate airflow is present Wire Color Functions Wire Color Function RED Battery Voltage EPS Fuse Protected Voltage BROWN Ground YELLOW Stator AC Voltage Wires GRAY Fusible Link BLACK Starter Motor Ground P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 327: ...12 35 ELECTRICAL 12 Battery Charging Circuits P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 328: ...tions Wire Color Function RED Battery Voltage EPS Fuse Protected Voltage RED WHT Constant Battery Voltage RED BLK Unswitched Fuse Circuit Breaker Protected Battery Voltage RED GRN EFI Fuse Protected Battery Voltage P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 329: ...12 37 ELECTRICAL 12 Constant Power Circuits P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 330: ...L Key On Power Circuits Wire Color Functions Wire Color Function RED BLK Key On Battery Voltage ORANGE Key On Run Switch On Battery Voltage RED WHT Constant Battery Voltage P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 331: ...ry Voltage BROWN Ground ORANGE Key ON Run Switch On Battery Voltage RED BRN Lights Fuse Protected Battery Voltage WHITE Chassis Relay Output Battery Voltage RED GRN Drive Fuse Protected Battery Voltage ORG WHT Accessory Fuse Protected Battery Voltage P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 332: ...S ACTIVE WHEN THE HEADLAMP SWITCH IS IN LOW OR HIGH Wire Color Functions Wire Color Function RED BRN Lights Fuse Protected Battery Voltage BROWN Ground DARK GREEN Bumper Lights Power YELLOW Pod Light Power High Beam Indicator Power P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 333: ... ELECTRICAL 12 Brake Lamp Circuits Wire Color Functions Wire Color Function ORANGE Brake Signal Voltage BROWN Ground RED BRN Lights Fuse Protected Battery Voltage P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 334: ...ction RED Battery Voltage BROWN Ground ORANGE Key On Run Switch On Battery Voltage WHT RED Ignition Key Start Solenoid Battery Voltage DG WHT ECU Start Solenoid Ground Command Line WHITE Gear Selector Return Signal VIOLET ECU Sensor Ground P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 335: ...12 43 ELECTRICAL 12 Engine Start Command Circuits P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 336: ...ED BLU EFI Relay Output Battery Voltage GRN YEL ECM EFI Relay Coil Ground Command Line RED YEL ECM ECM Relay Coil Ground Command Line BLACK ECM Ignition Coil Ground Line CPS Ground BROWN Ground WHITE Ignition Coil Battery Voltage CPS AC Generator Voltage WHT BLK Fuel Injector ECM Ground Line Wire Color Functions Wire Color Function P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 337: ...ARE SENT TO THE ECU Wire Color Functions Wire Color Function RED GRN Drive Fuse Protected Battery Voltage BRN WHT ECM AWD Coil Ground Line BRN YEL ECM ADC Coil Ground Line GRAY RH Control 4x4 Command Signal BLK RED RH Control ADC Command Signal P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 338: ...12 46 ELECTRICAL AWD ADC Circuits P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 339: ... Function Tests The following diagnostic test can be performed before using Digital Wrench Troubleshooting functions not listed here can be found using Digital Wrench Guided Diagnostics P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 340: ...round BROWN Ground RED Battery Voltage RED WHT Constant Battery Voltage 10 AMP Circuit Breaker Protected Battery Voltage ORG BLK Relay Output Fan Power YELLOW Coolant Temp Sensor Signal VIOLET ECM Sensor Ground ORG YEL ECM Fan Relay Coil Ground P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 341: ...12 49 ELECTRICAL 12 Radiator Fan Circuit P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 342: ...rcuit NOTE DO NOT SPLICE OR CUT INTO THE CAN CIRCUITS Wire Color Functions Wire Color Function YELLOW CAN High Signal GREEN CAN Low Signal VIOLET ECM Sensor Ground WHITE Gear Selector Return Signal P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 343: ...12 51 ELECTRICAL 12 Gear Selector Switch Circuit P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 344: ... SPLICE OR CUT INTO THE CAN CIRCUITS Wire Color Functions Wire Color Function YELLOW CAN High Signal GREEN CAN Low Signal BROWN Ground ORANGE Key On Run Switch On Battery Voltage GRN RED Speed Sensor Return Signal P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 345: ...12 53 ELECTRICAL 12 Ground Speed Sensor Circuit Reverse Override Circuit P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 346: ...ms not working on the instrument cluster No engine speed displayed No vehicle speed displayed No gear position displayed Odometer Tripmeters not working Reverse override button does not toggle between display modes ECU monitored inputs are not displayed when DTCs or problems exist i e check engine LED engine overheat LED etc There is power at the Smart Link connector but it cannot connect to Digit...

Page 347: ...WD 3 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL PAGE 1 OF 2 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 348: ...WD 4 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL PAGE 2 OF 2 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 349: ...WD 6 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL AWD ADC P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 350: ...WD 8 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL BATTERY CHARGING P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 351: ...WD 10 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL BATTERY PLUS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 352: ...WD 12 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL BRAKE LAMPS START P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 353: ...WD 14 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL CHASSIS POWER P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 354: ...WD 16 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL COOLING FAN P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 355: ...WD 18 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL ECM WAKE UP P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 356: ...WD 20 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL EFI P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 357: ...WD 22 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL ENGINE CRANK P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 358: ...WD 24 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL EPS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 359: ...WD 26 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL FUEL PUMP LEVEL P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 360: ...WD 28 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL GEAR SENSOR P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 361: ...WD 30 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL GROUND SPEED SENSOR P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 362: ...WD 32 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL KEY ON POWER P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 363: ...WD 34 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL LIGHTS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 364: ...WD 35 WIRE DIAGRAM 2009 SPORTSMAN XP 850 INTL HAZARD LIGHTS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 365: ...WD 1 WIRE DIAGRAM 2009 SPORTSMAN XP 850 PAGE 1 OF 2 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 366: ...WD 2 WIRE DIAGRAM 2009 SPORTSMAN XP 850 PAGE 2 OF 2 P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 367: ...WD 5 WIRE DIAGRAM 2009 SPORTSMAN XP 850 AWD ADC P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 368: ...WD 7 WIRE DIAGRAM 2009 SPORTSMAN XP 850 BATTERY CHARGING P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 369: ...WD 9 WIRE DIAGRAM 2009 SPORTSMAN XP 850 BATTERY PLUS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 370: ...WD 11 WIRE DIAGRAM 2009 SPORTSMAN XP 850 BRAKE LAMPS START P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 371: ...WD 13 WIRE DIAGRAM 2009 SPORTSMAN XP 850 CHASSIS POWER P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 372: ...WD 15 WIRE DIAGRAM 2009 SPORTSMAN XP 850 COOLING FAN P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 373: ...WD 17 WIRE DIAGRAM 2009 SPORTSMAN XP 850 ECM WAKE UP P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 374: ...WD 19 WIRE DIAGRAM 2009 SPORTSMAN XP 850 EFI P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 375: ...WD 21 WIRE DIAGRAM 2009 SPORTSMAN XP 850 ENGINE CRANK P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 376: ...WD 23 WIRE DIAGRAM 2009 SPORTSMAN XP 850 EPS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 377: ...WD 25 WIRE DIAGRAM 2009 SPORTSMAN XP 850 FUEL PUMP LEVEL P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 378: ...WD 27 WIRE DIAGRAM 2009 SPORTSMAN XP 850 GEAR SENSOR P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 379: ...WD 29 WIRE DIAGRAM 2009 SPORTSMAN XP 850 GROUND SPEED SENSOR P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 380: ...WD 31 WIRE DIAGRAM 2009 SPORTSMAN XP 850 KEY ON POWER P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

Page 381: ...WD 33 WIRE DIAGRAM 2009 SPORTSMAN XP 850 HEADLAMPS P a r t S h a r k c o m 8 7 7 9 9 9 5 6 8 6 ...

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