Polaris 2010 Ranger RZR 800 EFI Manual Download | Manualshive

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3.59

ENGINE

3

P

RELIMINAR

Y

V

ERS

ION

1.

After the engine is completely assembled and ready for
installation, the engine must be properly primed with
Polaris PS-4 PLUS Synthetic Engine Oil

(PN 2876244)

.

Fill the oil filter three-quarters full with Polaris PS-4 PLUS
Synthetic Engine Oil

(PN 2876244)

. Let the oil soak into

the filter for 8-10 minutes. Install the filter onto the engine.

2.

Remove primer plug from the engine. Install Oil System
Priming Adapter

(PU-45778)

into the oil plug hole. Push

3-5 oz. (approx.) of Polaris PS-4 PLUS engine oil into the
adapter or until resistance is felt. Remove the adapter.
Apply sealant to the plug threads. Install the plug and torque
to specification.

ENGINE INSTALLATION

Engine Assembly and Installation

Use the following procedure to reinstall the engine assembly.

Assemble the engine to the transmission on a work bench prior
to installation.

1.

Support the transmission / rear gearcase assembly while
setting the engine in place.

2.

Lightly tighten all fasteners evenly to eliminate any gaps
that may be present in the mounting areas.

3.

Torque fasteners to specification using a 2 part sequence.

• Torque fasteners to half of the specified torque value

• Then torque fasteners to the full specified torque value

Install the inner clutch cover, drive clutch, and driven clutch.
Torque to specification (see Chapter 6).

• Clean clutch sheaves thoroughly and inspect inlet and

outlet ducts for proper routing and sealing.

To install engine assembly, reverse the “Engine Removal”
procedure detailed earlier in this Chapter.

• Properly route all electrical harnesses for engine

assembly installation. Check for any possible rubbing
points of electrical wires.

• Carefully set the engine assembly into the vehicle while

installing the propshaft.

= T

Primer Plug Torque

18 ± 2 ft.lbs. (24.4 ± 2.71 Nm)

Fill 3/4 full

with PS-4 PLUS

PU-45778

= T

Engine / Transmission Mounting Fasteners

(2) Lower 3/8” Nuts: 40 ft. lbs. (54 Nm)

(4) Outer M8 Bolts: 28 ft. lbs. (38 Nm)

40 ft. lbs.

(54 Nm)

28 ft. lbs.

(38 Nm)

Plate is shown detached

from transmission for clarity

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Summary of Contents for 2010 Ranger RZR 800 EFI

Page 1: ...T KEYS 1 4 SPECIAL TOOLS 1 4 2009 GENERAL SPECIFICATIONS 1 5 GENERAL 2009 RANGER RZR RZR S INT L 1 5 DETAILED 2009 RANGER RZR 1 6 DETAILED 2009 RANGER RZR S INT L 1 7 2010 GENERAL SPECIFICATIONS 1 8 GENERAL 2010 RANGER RZR 1 8 DETAILED 2010 RANGER RZR 1 9 GENERAL 2010 RANGER RZR S INT L 1 10 DETAILED 2010 RANGER RZR S INT L 1 11 MISC SPECIFICATIONS AND CHARTS 1 12 CONVERSION TABLE 1 12 STANDARD TO...

Page 2: ... number VIN and the engine serial number The VIN can be found stamped on a portion of the front left frame rail close to the left front wheel see Figure 1 1 The engine serial number can be found on the sticker applied to the cylinder head on the side of engine see Figure 1 2 Machine Model Number Identification Model Year Designation Basic Chassis Designation Engine Designation Emissions Model Opti...

Page 3: ...atory while other tools maybe substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may order special tools through Polaris official tool supplier SPX Corporation by phone at 1 800 328 6657 or on line at http polaris spx com Model Model No Owner s Manual Parts Manual 2009 RANGER RZR R09VH76AD AG AH AM AO AS AZ 99...

Page 4: ...Height 68 5 in 174 cm Wheel Base 77 in 196 cm Ground Clearance 10 in 25 4 cm Dry Weight 945 lbs 429 kg Gross Vehicle Weight 1727 lbs 783 kg Front Storage Capacity 25 lbs 11 3 kg Cargo Box Dimension 42 in x 22 in 107 cm x 56 cm Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 336 4 kg Includesrider s cargo accessories and trailer tongue weight Hitch Towing Capacity 1500 lbs...

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

Page 6: ...9 cm Wheel Base 77 in 196 cm Ground Clearance 12 in 30 5 cm Dry Weight 1000 lbs 454 kg Gross Vehicle Weight 1782 lbs 808 kg Front Storage Capacity 25 lbs 11 3 kg Cargo Box Dimension 42 in x 22 in 107 cm x 56 cm Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 336 4 kg Includesrider s cargo accessories and trailer tongue weight Hitch Towing Capacity 1500 lbs 680 kg Hitch To...

Page 7: ...ays EFI Fan Circuit Breaker Fan Motor 20 Amp Fuses Chassis 20 Amp EFI 15 Amp Lights 15 Amp Accessory 15 Amp Speedo ECU 5 Amp Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio Front Rear High Low Rev 3 14 1 8 71 1 5 94 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 70 1 Shift Type In Line Shift H L N R P Front Gearcase Oil Requirements Polaris Demand Drive Plus 6 75 oz 200 ml Transmissi...

Page 8: ...t 68 5 in 174 cm Wheel Base 77 in 196 cm Ground Clearance 10 in 25 4 cm Dry Weight 945 lbs 429 kg Gross Vehicle Weight 1727 lbs 783 kg Front Storage Capacity 25 lbs 11 3 kg Cargo Box Dimension 42 in x 22 in 107 cm x 56 cm Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 336 4 kg Includesrider s cargo accessories and trailer tongue weight Hitch Towing Capacity 1500 lbs 680 ...

Page 9: ...Instrument Type Analog Speedometer with Multifunction LCD DC Outlet Standard 12 V Relays EFI Fan Circuit Breaker Fan Motor 20 Amp Fuses Chassis 20 Amp EFI 15 Amp Lights 15 Amp Accessory 15 Amp Speedo ECU 5 Amp Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio Front Rear High Low Rev 3 14 1 8 71 1 5 94 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 70 1 Shift Type In Line Shift H L N R ...

Page 10: ...n 179 cm Wheel Base 77 in 196 cm Ground Clearance 12 in 30 5 cm Dry Weight 1000 lbs 454 kg Gross Vehicle Weight 1782 lbs 808 kg Front Storage Capacity 25 lbs 11 3 kg Cargo Box Dimension 42 in x 22 in 107 cm x 56 cm Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 336 4 kg Includesrider s cargo accessories and trailer tongue weight Hitch Towing Capacity 1500 lbs 680 kg Hitc...

Page 11: ...rd 12 V Relays EFI Fan Circuit Breaker Fan Motor 20 Amp Fuses Chassis 20 Amp EFI 15 Amp Lights 15 Amp Accessory 15 Amp Speedo ECU 5 Amp Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio Front Rear High Low Rev 3 14 1 8 71 1 5 94 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 70 1 Shift Type In Line Shift H L N R P Front Gearcase Oil Requirements Polaris Demand Drive Plus 6 75 oz 200 ml...

Page 12: ...1 12 GENERAL INFORMATION P R E L I M I N A R Y V E R S I O N MISC SPECIFICATIONS AND CHARTS Conversion Table C to F 9 5 C 32 F F to C 5 9 F 32 C ...

Page 13: ...ue Specifications The following torque specifications are to be used only as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views or each manual section for torque values of fasteners before using standard torque ...

Page 14: ...1 14 GENERAL INFORMATION P R E L I M I N A R Y V E R S I O N SAE Tap Drill Sizes Metric Tap Drill Sizes Decimal Equivalents ...

Page 15: ... of one pound at the end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In lb 12 in lbs 1 ft lb kg 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...

Page 16: ...NOTES GENERAL INFORMATION 1 16 ...

Page 17: ... 14 ENGINE 2 16 ENGINE OIL LEVEL 2 16 ENGINE OIL AND FILTER SERVICE 2 17 ENGINE BREATHER HOSE INSPECTION 2 18 ENGINE AND TRANSMISSION MOUNT LOCATIONS 2 18 COMPRESSION AND LEAKDOWN TEST 2 18 EXHAUST SPARK ARRESTOR 2 18 TRANSMISSION AND GEARCASES 2 19 TRANSMISSION GEARCASE SPECIFICATION CHART 2 19 TRANSMISSION LUBRICATION 2 19 FRONT GEARCASE LUBRICATION 2 21 REAR GEARCASE LUBRICATION 2 22 COOLING SY...

Page 18: ...HUBS 2 30 TOE ALIGNMENT INSPECTION 2 30 TOE ADJUSTMENT 2 31 SUSPENSION RZR 2 31 SPRING PRELOAD ADJUSTMENT 2 31 SUSPENSION RZR S 2 32 SPRING PRELOAD ADJUSTMENT 2 32 SHOCK COMPRESSION ADJUSTMENT 2 32 BRAKE SYSTEM 2 33 BRAKE FLUID INSPECTION 2 33 BRAKE PAD DISC INSPECTION 2 33 BRAKE HOSE AND FITTING INSPECTION 2 33 MAINTENANCE LOG 2 34 ...

Page 19: ...if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Break In Period The break in period consists of the first 25 hours of operation or the time it takes to use 14 gallons 53 liters of fuel Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these...

Page 20: ...Inspect replace as needed Coolant Level Daily Check level daily change coolant every 2 years Head Lamp Tail Lamp Daily Check operation apply dielectric grease if replacing E Air Filter Weekly Inspect replace as needed Brake Pad Wear 10 H Monthly 100 160 Inspect periodically Battery 25 H Monthly 250 400 Check terminals clean test Front Gearcase Oil Demand Drive Plus 25 H Monthly 250 400 Inspect lev...

Page 21: ...el line rail and fuel pump Replace lines every two years E Spark Plug 100 H 12 M 600 1000 Inspect replace as needed E Engine Oil Filter Change 100 H 6 M 1000 1600 Perform a break in oil change at 25 hours or one month always replace oil filter when changing engine oil Drive Belt 100 H 12 M 1000 1600 Inspect replace as needed Radiator 100 H 12 M 1000 1600 Inspect clean external surfaces Cooling Hos...

Page 22: ...2 6 MAINTENANCE P R E L I M I N A R Y V E R S I O N COMPONENT INSPECTION SERVICE LOCATIONS Front and Rear View Standard RZR Shown Standard RZR Shown ...

Page 23: ...2 7 MAINTENANCE 2 P R E L I M I N A R Y V E R S I O N RH and LH Side Views Standard RZR Only Standard RZR Shown Standard RZR Shown ...

Page 24: ... ATV Gearcase Lubricant 2 5 Gal 2 Count 2876160 ATV Angle Drive Fluid 8 oz 12 Count 2872276 ATV Angle Drive Fluid 2 5 Gal 2 Count 2877922 Demand Drive Plus Quart 2877923 Demand Drive Plus 2 5 Gallon 2870465 Oil Pump for 1 Gallon Jug 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 Cou...

Page 25: ...873602 Add lube to bottom of fill plug threads 24 oz 710 ml Change annually Transmission Transfer Case Page 2 7 AGL Synthetic Gearcase Lubricant PN 2873602 Add lube to bottom of level check plug threads 14 oz 414 ml Change annually Front Gearcase Page 2 7 Demand Drive Plus PN 2877922 Add fluid to bottom of fill plug threads 6 75 oz 200 ml Change annually Rear Gearcase Page 2 7 ATV Angle Drive Flui...

Page 26: ... wear or damage Frame Nuts Bolts and Fasteners Periodically inspect the torque of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each chapter Shift Cable Inspection Adjustment Shift cable adjustment may be necessary if symptoms include No AWD or gear position display on instrument cluster Ratcheting noi...

Page 27: ...the EFI System Vent Lines 1 Check fuel tank front gear case rear gear case and transmission vent lines for signs of wear deterioration damage or leakage Replace every two years 2 Be sure vent lines are routed properly and secured with cable ties IMPORTANT Ensure lines are not kinked or pinched WARNING Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and...

Page 28: ... until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle pedal NOTE While adjusting lightly move the throttle pedal in and out 6 Re tighten the jam nut 7 Apply a small amount of grease to the inside of the boot and slide it over the cable adjuster to its original position Throttle Cable Replacement 1 Place the vehicle in PARK and stop the engine 2 Remove the seats and rear service panel...

Page 29: ...ute the cable over the upper A arm and between the front left hand drive shaft and frame and between the front gearcase and frame 18 Install the front upper cable clamp making sure to allow enough cable slack to attach the cable bracket to the frame support 19 Open the front lower cable retainer place over the cable and reinstall retainer into the frame hole 20 Route the cable through the retainer...

Page 30: ...3 Install the throttle body cover and PVT inlet duct 34 Verify the vehicle is still in PARK 35 Start the engine and allow it to warm up 36 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 1 8 1 5 3 mm If freeplay is correct proceed to next step If adjustment is required refer to Throttle Freeplay Adjustment procedure 37 Using a 10 mm o...

Page 31: ...eriods Installation 1 Clean the air box thoroughly 2 Place the filter ring over the end of the filter and install the filter into the air box Be sure the filter fits tightly in the air box NOTE Apply a small amount of general purpose grease to the sealing edges of the filter and the air box cap seal before installing 3 Install air box cap and secure with clips Cap Seal Air Filter Secure Clips Cap ...

Page 32: ...p the angle and depth of dipstick consistent 7 Remove the dipstick and check the oil level Maintain the oil level in the SAFE range Add oil as indicated by the level on the dipstick Do not overfill see NOTE below NOTE Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Proper level indication is determined on the upper surface of the...

Page 33: ...g on new filter with a film of fresh engine oil Check to make sure the O ring is in good condition 13 Installnew filter and turn by hand until filter gasket contacts the sealing surface then turn an additional 1 2 turn 14 Remove dipstick and fill sump with 2 quarts 1 9 l of PS 4 PLUS 2W 50 Synthetic Engine Oil PN 2876244 15 Verify the transmission is still positioned in PARK P 16 Start the engine ...

Page 34: ...se high pressure leakage testers as crankshaft seals may dislodge and leak Exhaust Spark Arrestor Periodically clean spark arrestor to remove accumulated carbon 1 Remove the retaining screw and remove the arrestor from the end of the silencer 2 Use a non synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm 3 Inspect the screen for wear and damage Replace i...

Page 35: ...lug hole 5 Reinstall the level check plug and torque to 30 45 in lbs 3 5 Nm 6 Reinstall the fill plug and torque to 40 50 ft lbs 54 68 Nm GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN LEVEL CHECK PLUG TORQUE Transmission Main Gearcase AGL Synthetic ATV Gearcase Lubricant 24 oz 710 ml 40 50 ft lbs 54 68 Nm 30 45 in lbs 3 5 Nm Transmission Transfer Case AGL Synthetic ATV Gearcase Lubricant 14 o...

Page 36: ... transfer case drain plug 3 Remove the drain plug and allow to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with a new o ring and torque to 30 45 in lbs 3 5 Nm 6 Add the recommended fluid through the fill plug hole until it begins to flow out the check plug hole Do not overfill 7 Reinstall the level check plug and torque to 30 45 in lbs 3 5 Nm 8 Reinstall the fill plug and to...

Page 37: ...e fill plug and torque to 8 10 ft lbs 11 14 Nm Lubricant Change The drain plug is located on the bottom of the gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug and allow fluid to drain completely 4 Clean the drain plug Inspect the O ring and replace if damaged 5 Reinstall the drain plug torque to 8 10 ft lbs 11 14 Nm 6 Add the recommended fluid Maint...

Page 38: ...g 2 Place a drain pan under the drain plug 3 Remove the drain plug and allow the lubricant to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with new O ring and torque to 30 45 in lbs 3 5 Nm 6 Add the recommended lubricant Maintain the fluid level even with the bottom threads of the fill plug hole 7 Reinstall the fill plug and torque to 40 50 ft lbs 54 68 Nm 8 Check for leaks D...

Page 39: ...o disengage from the grommets 3 View the coolant level in the recovery bottle 4 If the coolant level is below the MIN line inspect the coolant level in the radiator NOTE If overheating is evident allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system 5 Remove the pressure cap Using a funnel add coolant to the top of the filler neck 6 ...

Page 40: ...ble drain pan underneath the radiator fitting on the front RH side of the vehicle 4 Drain the coolant from the radiator by removing the lower coolant hose from the radiator as shown Properly dispose of the coolant 5 Allow coolant to completely drain CAUTION Do not over tighten hose clamps at radiator or radiator fitting may distort causing a restriction to coolant flow Radiator hose clamp torque i...

Page 41: ...l is required remove the cotter pin and loosen the hub nut slightly 4 Elevate the appropriate side of the vehicle by placing a suitable stand under the frame 5 Remove the wheel nuts and remove the wheel 6 If hub removal is required remove the hub nut and washers Wheel Installation 1 Verify the transmission is still in PARK P 2 Install the wheel hub washers and hub nut if previously removed 3 Place...

Page 42: ...haft boots for damage tears wear or leaking grease If the rubber boots exhibit any of these symptoms replace the boot s Refer to Chapter 7 for drive shaft boot replacement CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear On vehicles with tapered rear wheel nuts make sure tapered end of nut goes into taper on wheel Wheel Nuts 4 Hub Nut Use a new cotter pin N...

Page 43: ...ult in a shorter life It can also hinder vehicle performance Follow the battery charging procedure before installing the battery 1 Ensure the battery is fully charged 2 Place the battery in the battery holder and secure with rubber strap 3 Coat the terminals with dielectric grease or petroleum jelly 4 Connect and tighten the red positive cable first 5 Connect and tighten the black negative cable l...

Page 44: ...than 12 8 volts charge the battery at 1 2 amps or less until battery voltage is 12 8 VDC or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for battery charging directions When using a constant current charger follow the guidelines in the following table Spark Plug Service 1 Remove both driver and passenger seats 2 Remove the rear service panel 3 The P...

Page 45: ...tter pins Replace any worn or damaged steering components Steering should move freely through the entire range of travel without binding Check routing of all cables hoses and wiring to be sure the steering mechanism is not restricted or limited NOTE Whenever steering components are replaced check front end alignment Steering Wheel Freeplay Check the steering wheel for specified freeplay and operat...

Page 46: ...the steering wheel in this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible NOTE It is important that the height of both marks be equally positioned in order to get an accurate measurement 4 Measure the distance between the marks and record the measurement Call this measurement A 5 Rotate...

Page 47: ...ings are adjustable by rotating the adjustment cam to change spring tension preload Suspension Spring Adjustment 1 Position the vehicle on a level surface and stop the engine 2 Raise and safely support the front or rear of the vehicle off the ground to allow the suspension to fully extend NOTE The tires should not be touching the ground 3 To adjust the suspension rotate the adjustment cam clockwis...

Page 48: ... each shock Use a flat blade screwdriver to make damping adjustments NOTE When the adjuster screw is turned clockwise until it stops the damping is in the fully closed position Turn the clicker clockwise to increase compression damping Turn the clicker counter clockwise to decrease compression damping NOTE The factory setting is 8 clicks from closed see Compression Adjustment Table WARNING Uneven ...

Page 49: ...than the MIN level line add brake fluid until it reaches the MAX level line 5 Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings Brake Pad Disc Inspection 1 Check the brake pads for wear damage or looseness 2 Inspect the brake pad wear surface for excessive wear 3 Pads shoul...

Page 50: ...2 34 MAINTENANCE P R E L I M I N A R Y V E R S I O N MAINTENANCE LOG Service Date Hours Miles km Service Performed Comments Dealer Technician ...

Page 51: ...TION WARP 3 26 VALVE SEAL SPRING SERVICE ON ENGINE 3 26 CYLINDER HEAD DISASSEMBLY 3 27 VALVE INSPECTION 3 28 COMBUSTION CHAMBER 3 29 VALVE SEAT RECONDITIONING 3 29 CYLINDER HEAD REASSEMBLY 3 31 VALVE SEALING TEST 3 32 CYLINDER REMOVAL 3 32 VALVE LIFTER REMOVAL INSPECTION 3 32 PISTON REMOVAL 3 33 CYLINDER INSPECTION 3 34 CYLINDER HONE SELECTION AND HONING PROCEDURE 3 35 HONING TO DEGLAZE CLEANING T...

Page 52: ...3 2 ENGINE P R E L I M I N A R Y V E R S I O N ENGINE SPECIFICATIONS Crankcase Exploded Views ...

Page 53: ...3 3 ENGINE 3 P R E L I M I N A R Y V E R S I O N Oil Pump Water Pump Engine Cover Exploded View ...

Page 54: ...3 4 ENGINE P R E L I M I N A R Y V E R S I O N Stator Cover Starter Water Pump Oil Filter Pressure Relief Exploded View ...

Page 55: ...3 5 ENGINE 3 P R E L I M I N A R Y V E R S I O N Cylinder Cylinder Head Piston Exploded View ...

Page 56: ...3 6 ENGINE P R E L I M I N A R Y V E R S I O N Engine EFI Sensors Valve Cover General Component Exploded View NOTE See Chapter 4 for more information on the EFI System ...

Page 57: ...0 3 Nm Crankcase Bolt Tighten Sequence Lubricate threads and between washer and underside of bolt with engine oil Torque in sequence to spec provided allow the gasket to set for 1 minute then tighten in sequence 90 1 4 turn 35 4 ft lbs 47 5 5 5 Nm 90 1 4 turn Cylinder Head Bolt Tighten Sequence ...

Page 58: ...18 2 24 5 2 7 Magneto Cover 6 mm 96 3 10 85 0 35 Oil Baffle Weldment 5 mm 60 6 6 8 0 68 Oil Drain Bolt Crankcase 12 mm 192 24 21 7 2 7 16 21 7 Oil Fill Tube Bolt 5 mm 50 5 5 64 0 56 Oil Filter Pipe Fitting 20 mm 35 4 47 5 5 4 Oil Pick Up 5 mm 60 6 6 8 0 68 Oil Pressure Relief Plug 10 mm 22 2 30 3 Oil Pump Housing Screw 6 mm 84 8 9 50 0 90 Rocker Arm 8 mm 22 2 30 3 Rocker Cover 6 mm 84 8 9 5 0 9 Sp...

Page 59: ... Balance Counter Balance End Play 0 005 0 127 mm Cylinder Head Cylinder Head Surface warp limit 0 00394 0 1 mm Cylinder Head Standard height 3 478 88 35 mm Valve Seat Valve Seat Contacting Width Intake 0 0472 0 00787 0 0039 1 20 0 20 0 10mm Valve Seat Contacting Width Exhaust 0 0591 0 00787 0 0039 1 50 0 20 0 10 mm Valve Seat Angle 45 5 0 255 Valve Guide Valve Guide Inner diameter 0 2367 0 00029 6...

Page 60: ... 00047 0 00024 0 012 0 006 mm Piston Pin Degree of Fit Piston pin must be push fit by hand at 68 F 20 C Piston Connecting Rod Crankshaft Engine Specifications Main Components Piston Connecting Rod EH076OLE022 EH076OLE072 Piston Ring Installed Gap Top Ring Standard 0 0059 0 0138 0 15 0 35 mm Top Ring Limit 15 Leakdown Second Ring Standard 0 0098 0 0197 0 25 0 50 mm Second Ring Limit 15 Leakdown Oil...

Page 61: ... 2870390 PISTON SUPPORT BLOCK PU 45497 1 CAM GEAR SPRING INSTALLATION KIT PU 45497 2 CAM GEAR TOOTH ALIGNMENT TOOL PU 45498 CAM SPANNER WRENCH PU 45838 GEAR HOLDER PA 44995 WATER PUMP MECHANICAL SEAL INSTALLER PU 45543 UNIVERSAL DRIVER HANDLE PA 45483 MAIN SEAL INSTALLER PU 45658 CRANKSHAFT MAIN SEAL SAVER PA 45401 WATER PUMP SEAL SAVER 2870975 MITY VAC PRESSURE TEST TOOL PU 45778 OIL SYSTEM PRIMI...

Page 62: ... a commercially available pressure tester 3 The system must maintain 10 psi for five minutes or longer If pressure loss is evident within five minutes check the radiator hoses clamps and water pump seals for leakage Pressure Cap Test 1 Remove pressure cap and test cap using a commercially available pressure cap tester 2 The pressure cap relief pressure is 13 psi Replace cap if it does not meet thi...

Page 63: ...le Engine Inlet Hose Engine Outlet Hose Radiator Radiator Shroud Radiator Pressure Cap Fan Motor Water Pump Cover Thermostat Housing Outlet Hose Inlet Hose Filler Neck To Filler Neck To Bottle Coolant Flow Diagram Radiator Recovery Bottle Engine Water Pump Engine Thermostat Housing Filler Neck ...

Page 64: ...gh the system 7 Slightly loosen the bleed screw C on the thermostat cover to let air escape If no air is present a steady stream of coolant will stream out If air is present the screw will bubble and sputter as the air escapes 8 Tighten the bleed screw to 70 10 in lbs 8 1 13 Nm on the thermostat housing and properly install the pressure cap 9 Squeeze the coolant lines by hand to help purge the sys...

Page 65: ...Cylinder Head Cylinder Piston Rings Rocker Arms Water Pump The following components require engine removal for service Flywheel Alternator Stator Counterbalance Shaft or Bearings Gear Train Components Camshaft Oil Pump Oil Pump Drive Gear Connecting Rod Crankshaft Crankshaft Main Bearings Crankcase Oil Pressure Test 1 Remove blind plug sender from left side of crankcase 2 Insert a 1 8 NPT oil pres...

Page 66: ...his point the oil is supplied to the main oil galley through a crankcase passage Oil is then diverted three ways from the main oil galley with the first path entering the camshaft bores onto the rear balance shaft journal and then draining back into the crankcase sump The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump The third oil path f...

Page 67: ...rated allow it to cool down before attempting to perform any work 2 Clean work area 3 Thoroughly clean the engine and chassis 4 Drain appropriate lubricant s If servicing the engine drain engine oil If servicing the transmission drain the lubricant from the main gearcase and transfer case If servicing the rear gearcase drain the gearcase lubricant 5 Remove the driver and passenger seats see Chapte...

Page 68: ...ark plugs and disconnect the ignition coil harness 17 Remove the vent lines from the upper bolt in frame brace andplugventlinestopreventfluidleakageduringremoval 18 Remove the 6 fasteners retaining the upper bolt in frame brace and remove it from the vehicle with the ignition coil and PVT duct attached 19 Remove the upper nut and grommet from the stabilizer bar linkage on both sides of the vehicle...

Page 69: ...t being excessively bent or kinked while removed from the vehicle 26 Mark the fuel injector harnesses to identify MAG and PTO harness connections to aid during reassembly Disconnect the fuel injector harnesses NOTE The Bosch harness connector and locking spring is bonded to the fuel injectors with an epoxy mix DO NOT attempt to disconnect the Bosch connector from the fuel injectors Damage will occ...

Page 70: ...ngine installation see Chapter 2 Shift Cable Inspection Adjustment 30 Disconnect the transmission gear indicator switch harness 31 Disconnect the CPS harness 32 Disconnect the stator alternator harness 33 Disconnect the transmission speed sensor harness 34 Remove the castle nuts from both rear wheel hubs Lower Jam Nut Mark Upper Jam Nut Gear Switch Connector CPS Connector Stator Connector Speed Se...

Page 71: ...8 Disconnect the engine coolant temperature ECT sensor harness 39 Loosen the hose clamp and remove the lower coolant hose from the water pump cover inlet and drain coolant into a suitable container 40 Remove the filler neck pressure cap to relieve the cooling system vacuum NOTE Use a portable wet vac or syphon to prevent any coolant from spilling 41 Remove the upper coolant hose from the thermosta...

Page 72: ...ng the engine transmission rear gearcase assembly 47 Using an engine hoist hook a chain between the engine transmission mounting plate and the transmission rear gearcase mounting plate NOTE Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components 48 Lift the front portion of the assembly out first to al...

Page 73: ... assembly has been removed from the vehicle the engine and transmission will need to be separated to allow engine servicing Use the following procedure to separate the engine from the assembly 1 Remove the drive belt drive clutch and driven clutch see Chapter 6 2 Remove the 6 fasteners retaining the inner clutch cover to the engine and transmission 3 Remove only the 4 outer fasteners retaining the...

Page 74: ...A R Y V E R S I O N ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Push Rods Hydraulic Lifters Valves Cylinder Head Valve Seals Springs Spring Retainers Rocker Arms Retainer Locks keepers Valve Spring Seats ...

Page 75: ...ually checked for straightness while they are installed in the engine by rotating them with the valve closed Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness 5 If the push rod A is visibly bent it should be replaced Cylinder Head Removal NOTE The cargo box assembly and the upper frame bolt in brace must be removed to allow enough clearan...

Page 76: ...ready removed the valve cover rocker arms and pushrods align the cylinder to be worked on at top dead center TDC Install the Valve Pressure Hose PU 45652 into the spark plug hole Hook the hose to an air compressor and supply 50 to 100 psi to the hose This will seat the valves during valve spring removal Do not remove air from the hose at anytime until reassembly is completed 2 Using the Valve Spri...

Page 77: ...if measurement is out of specification 4 Remove valve guide seals IMPORTANT It is recommended to replace seals whenever the cylinder head is disassembled Hardened cracked or worn valve seals will cause excessive oil consumption and carbon buildup 5 Mark the valves with a white pen Remove the valves from the cylinder head This will ensure that the valves are properly placed during engine reassembly...

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

Page 79: ...be replaced Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Reconditioning Kit PN 2200634 Abrasive stone seat reconditioning equipment can also be used Keep all valves in order with their respective seat NOTE Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the ent...

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

Page 81: ... Head Reassembly NOTE Assemble the valves one at a time to maintain proper order 1 Apply engine oil to valve guides and seats 2 Coat valve stem with molybdenum disulfide grease or PS 4 PLUS Synthetic engine oil 3 Install valve carefully with a rotating motion to avoid damaging valve seal 4 Valve seals should be installed after the valves are in the head to avoid valve seal damage Install new valve...

Page 82: ...on Support Block PN 2870390 Valve Lifter Removal Inspection 1 Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand 2 Thoroughly clean the lifters in cleaning solvent and wipe them with a clean lint free cloth 3 Mark the lifters with a white pen if using the lifters for reassembly This will ensure that the lifters are properly placed duri...

Page 83: ... radial tension 3 Remove top compression ring Using a piston ring pliers Carefully expand ring and lift it off the piston CAUTION Do not expand the ring more than the amount necessary to remove it from the piston or the ring may break By hand Placing both thumbs as shown spread the ring open and push up on the opposite side Do not scratch the ring lands 4 Repeat procedure for second ring 5 Remove ...

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

Page 85: ...cylinder wear or damage is excessive it will be necessary to replace the cylinder The cylinders are lined with a nicasil coating and are not repairable Hone only enough to de glaze the outer layer of the cylinder bore IMPORTANT Clean the cylinder after honing If cylinder wear or damage is excessive it will be necessary to replace the cylinder The cylinders are lined with a nicasil coating and are ...

Page 86: ... 2 Measure piston pin O D Replace piston and or piston pin if out of tolerance 3 Measure connecting rod small end ID Piston to Cylinder Clearance See 800 EFI Engine Service Specifications on page 3 9 Piston O D See 800 EFI Engine Service Specifications on page 3 9 Piston Pin Bore See 800 EFI Engine Service Specifications on page 3 9 5 mm Piston Piston Pin Piston Pin O D See 800 EFI Engine Service ...

Page 87: ...on ring installed gap after re boring a cylinder or when installing new rings A re bored cylinder should always be scrubbed thoroughly with hot soapy water rinsed and dried completely Wipe cylinder bore with oil immediately to remove residue and prevent rust Starter Drive Bendix Removal Inspection 1 Remove stator housing bolts and remove housing 2 Remove the flywheel nut and washer Install Flywhee...

Page 88: ...ywheel Puller PN 2871043 and remove flywheel A 4 Use caution when removing the wire holddown B and the stator assembly D Do not tap or bump the gear stator housing cover or the stator This could cause the seal around the gear stator housing cover and the crankcase to break causing a leak 5 Remove the bendix E if necessary Engine Crankcase Disassembly Inspection 1 Remove the stator cover A and wate...

Page 89: ...holddown plate H and the woodruff key I from the crankshaft The stator does not have to be removed at this point 6 Remove the gear stator housing bolts and remove the gear stator housing cover J and gasket from the crankcase Be sure to catch the excess oil from the crankcase 7 Note the positions of the gears in the photo CAUTION Do not thread the puller bolts into the flywheel more than 1 4 or sta...

Page 90: ...and check to make sure there is spring tension offsetting the teeth between the two gears If there is no tension check the springs inside of the cam gear assembly 11 The cam gear assembly contains three loaded springs To open the cam gear assembly Place the cam gear on a flat surface with the timing mark side facing up While holding both gears together lightly work a small flathead screwdriver bet...

Page 91: ...s procedure with all three tapered pins Do not push the pins too far through or the springs will pop out NOTE Do not remove the tapered pins at this time 17 Note in photograph that the Tapered Pins PU 45497 1 are below flush with end of the springs This helps to align the three gear tabs during the next step 18 Line up the two gears using the timing marks and the three gear tabs that were referenc...

Page 92: ...ing mark NOTE For ease of installing the Cam Gear Alignment Tool PU 45497 2 use a twisting motion when pushing down on the tool 21 To remove the balance shaft gear the flat side of the camshaft P must face the balance shaft gear To rotate the camshaft use the Cam Spanner Wrench PU 45498 to rotate the camshaft so the flat side of the camshaft faces the balance shaft gear NOTE This Cam Spanner Wrenc...

Page 93: ...ate the water oil pump gear S so that all four bolts are visible though the gear Remove the four bolts with a hex wrench Pull out the pump 27 Inspect the oil pump rotors for wear Mark the rotors with a white pen to ensure upon reassembly that the correct sides of the rotors are installed and mesh with the same edges as previously installed NOTE If replacing the old rotors new replacement rotors wi...

Page 94: ... dowel in first If the valve is installed incorrectly oil pressure and oil priming problems will occur 31 Carefully press the gear off the assembly while supporting the housing assembly 32 Remove the snap ring from the assembly Place the housing in a support and press out the bearing shaft assembly 33 Place the shaft in a press to remove the bearing T 22 2 ft lbs 30 3 Nm 22 2 ft lbs 30 3 Nm Chamfe...

Page 95: ... housing 37 Remove thrust plate U 38 Remove PTO end engine mount Remove crankcase bolts Tap on the reinforced areas on the cases using soft hammer Carefully separate the two crankcase halves NOTE Only remove the oil baffle if the baffle is damaged When removing the oil baffle bolts use a heat gun to heat the bolts and loosen the Loctite This will prevent any possible damage to the bolts or to the ...

Page 96: ...ecommended to replace the bearings anytime the engine is disassembled Camshaft Inspection 1 Thoroughly clean the cam shaft 2 Visually inspect each cam lobe for wear chafing or damage 3 Measure height of each cam lobe using a micrometer Compare to specification W V In mm Cam Lobe Height Intake Std 800 EFI 1 334 33 867 mm 800 H O EFI 1 357 34 477 mm Exhaust std 800 EFI 1 334 33 867 mm 800 H O EFI 1 ...

Page 97: ...orque to specification 2 Install oil baffle weldment B Torque bolts to specification 3 Install the balance shaft Inspect balance shaft clearance C in both gearcase halves Rotate balance shaft to ensure there is clearance between it and the oil baffle weldment In mm Camshaft Journal O D A Mag 1 654 00039 42 010 mm B Ctr 1 634 00039 41 50 010 mm C PTO 1 614 00039 41 010 mm In mm Camshaft Journal Bor...

Page 98: ...lve NOTE Do not apply sealant to cam relief hole E 7 Assemble the crankcase halves Apply LocTite 242 PN 2871949 to the threads and pipe sealant to the bolt flanges Torque bolts to specification following torque pattern at beginning of this chapter 8 Lubricate cam lobes and valve lifters with Moly Lube Grease 9 Lubricate lifters with engine oil and install in the original order as removed in disass...

Page 99: ...es to ensure proper alignment of the pistons to the connecting rods upon assembly Partially install the piston pins into the pistons NOTE To help align the pistons slide a rod that is close to the same diameter as the wrist pin holes to properly align them in the cylinder 14 Position cylinder and piston assemblies onto the connecting rods and push the piston pins through the piston and connecting ...

Page 100: ...ft NOTE The application of lubrication aids in priming the oil pump during initial engine start up 19 Align the bolt holes and install oil pump assembly into crankcase Rotate the rotors in the housing during installation as this checks for binding if new rotors are used NOTE For assembly of the gears the cam gear and the crankshaft gear are stamped with This Side Out This indicates the side of the...

Page 101: ...250 F 121 C on a hot plate J 23 Use extreme caution when removing the crankshaft gear from the hot plate Use a pair of pliers and leather gloves when handling the crankshaft gear 24 Install the crankshaft gear I onto the crankshaft NOTE For assembly of the gears the cam gear and the crankshaft gear are stamped with This Side Out This indicates the side of the gear that faces outward or away from t...

Page 102: ...ear NOTE If the timing mark on the camshaft gear does not align properly remove the camshaft gear and tool Use the Cam Spanner Wrench PU 45498 to rotate the cam to the proper position NOTE Cam Spanner Wrench PU 45498 is only needed to rotate the camshaft when the entire valve train is assembled 27 Reinstall the camshaft gear so the timing marks are properly aligned Install the washer and bolt Torq...

Page 103: ...mp seal N with the seal lip facing out towards the crankcase Use of a hydraulic press is recommended for this procedure 29 Install a new crankshaft seal P into the gear stator housing cover Use the Universal Driver Handle PU 45543 and the Main Seal Installer PA 45483 to seat the crankshaft seal into place NOTE Install the crankshaft seal P with the seal lip facing out towards the crankcase 30 Once...

Page 104: ...ealant PN 2871557 to the outside edges of the crankcase halves see arrows where the crankcases mate see the following photos This helps to prevent coolant leakage 35 Install the gear stator housing gasket onto he crankcase 36 Secure the gear stator housing cover to the crankcase with the cover bolts Torque bolts in proper sequence to specification Remove seal protectors from the shaft ends once th...

Page 105: ...a new nylok nut Q Torque the nut to specification 39 Install water pump cover R with new O ring seal Torque bolts to specification in proper sequence see Page 3 4 40 Sparingly apply Starter Drive Grease PN 2871423 to the starter drive Install the starter bendix NOTE There are thrust washers on both sides of starter drive T Water Pump Impeller Nut Torque 108 6 in lbs 6 8 0 68 Nm P Q T Water Pump Ho...

Page 106: ...roperly under the wire hold down bracket 3 Install the flywheel washer nut and key Torque flywheel nut to specification 4 Install stator housing with new o rings Torque the bolts to specification and follow proper bolt torque sequence at the beginning of this chapter Cylinder Head Reassembly NOTE Before reassembly clean the bolts and bolt holes with Primer N PN 2874275 to remove any debris This wi...

Page 107: ...stall into lifters 5 Lubricate rockers E with engine oil 6 Verify pushrods are engaged in lifters 7 Install rockers Be sure that tab of fulcrum F is seated in head stand off Torque bolts to specification T Cylinder Head Bolt Torque Initial setting 35 4 ft lbs 47 5 5 5 Nm Allow to set for 1 minute then turn additional 90 1 4 turn Torque Bolts In Sequence C D T Rocker Arm Bolt Torque 22 2 ft lbs 30 ...

Page 108: ...orque bolts in sequence to specification 11 Install thermostat J new O ring and thermostat housing Torque to specification 12 Install temperature sender K and torque to specification Oil Pump Priming T Breather Bolt Toque 20 5 in lbs 2 5 0 55 Nm T Rocker Cover Bolt Torque 84 8 in lbs 9 5 0 9 Nm 20 5 in lbs 2 5 55 Nm G H I T Thermostat Housing Bolt Torque 84 8 in lbs 9 5 0 9 Nm T Temperature Sender...

Page 109: ... gearcase assembly while setting the engine in place 2 Lightly tighten all fasteners evenly to eliminate any gaps that may be present in the mounting areas 3 Torque fasteners to specification using a 2 part sequence Torque fasteners to half of the specified torque value Then torque fasteners to the full specified torque value Install the inner clutch cover drive clutch and driven clutch Torque to ...

Page 110: ...2 2 Check oil level indicated on dipstick Add oil if necessary Refer to Chapter 2 Engine Oil Level 3 Drive slowly at first to gradually bring engine up to operating temperature 4 Vary throttle positions Do not operate at sustained idle or sustained high speed 5 Perform regular checks on fluid levels controls and all important bolt torques 6 Pull only light loads during initial break in 7 Change oi...

Page 111: ...ter motor does not turn Engine seized rusted or mechanical failure Engine Runs But Will Not Idle Restricted fuel supply Low compression Crankcase breather restricted Engine Idles But Will Not Accelerate Spark plug fouled weak spark Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Incorrect ignition timing Restricted exhaust system Cam worn excessively...

Page 112: ...witch circuit faulty Poor connections in ignition system Ignition timing incorrect Sheared flywheel key Cooling System Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiator lines pump or water jacket accident damage Lean mixture v...

Page 113: ...L SENDER TEST 4 20 FUEL PUMP TEST 4 21 FUEL PUMP REPLACEMENT 4 22 FUEL TANK REMOVAL 4 22 FUEL TANK INSTALLATION 4 24 THROTTLE POSITION SENSOR TPS 4 25 TPS LEARN FUNCTION 4 25 TPS TESTER REGULATOR 4 25 CHECKING TPS READING 4 26 TPS ADJUSTMENT REPLACEMENT 4 27 ENGINE COOLANT TEMPERATURE SENSOR ECT 4 28 ECT SENSOR TEST REPLACEMENT 4 28 IGNITION COIL 4 29 IGNITION COIL TESTS 4 29 IGNITION COIL HT LEAD...

Page 114: ...re burns may result Do not overfill the tank The tank is at full capacity when the fuel reaches the bottom of the filler neck Leave room for expansion of fuel Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Do not smoke or allow open flames or sparks in or near the area where ...

Page 115: ...ers equipped with a CD drive and serial port connection and is designed to replace multiple shop tools often used to test EFI components It also includes step by step diagnostic procedures to aid technician repair and troubleshooting IMPORTANT If the PC you are using is not equipped with a 9 pin serial port a USB to serial port adaptor will be necessary A USB to serial port adaptor can be purchase...

Page 116: ...small quantities can cause significant problems Do not use compressed air if the system is open Cover any parts removed and wrap any open joints with plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Clean any connector before opening to prevent dirt from entering the system Although every precaution has b...

Page 117: ...Air Temperature Barometric Air Pressure Sensor T BAP 3 Crankshaft Position Sensor CPS 4 Fuel Injectors 5 Fuel Filter 6 Fuel Pump Regulator Gauge Sender Asm Located in tank as an assembly 7 Fuel Rail 8 Engine Coolant Sensor ECT 9 Throttle Position Sensor TPS 10 Throttle Body 11 Ignition Coil 12 Spark Plugs 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 118: ...rankshaft Position Sensor CPS Located in the magneto cover between the engine and transmission 4 Fuel Injectors Fuel Rail Attached to the fuel rail located in the intake track of the cylinder head 5 Fuel Pump Regulator Fuel Gauge Sender Assembly Located under the passenger seat and in the fuel tank as a complete assembly ECU T BAP CPS Fuel Fuel Rail Injectors Fuel Pump Assembly Located in Fuel Tan...

Page 119: ...sor TPS Located on the right hand side of the throttle body 8 Engine Coolant Temperature Sensor ECT Located in the cylinder head next to the thermostat housing The sensor can be accessed with the driver and passenger seats and rear service panel removed 9 Ignition Coil Located behind the driver s seat and rear service panel just above the PVT cover Throttle Body TPS ECT Ignition Coil ...

Page 120: ...ANK Exploded View Rear Tank Bracket Screw Pad Fuel Tank Front Tank Bracket Gasket Cap Hi Temp Flex Conduit Fuel Pump Asm Screw Pad Quick Connect Fuel Line Fuel Flow Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line Fuel Rail Fuel Injectors Pressure Regulator Fuel Tank ...

Page 121: ...EFI Operation Overview The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions The ignition and injection functions are electronically controlled monitored and continually corrected during operation to maintain peak performance The central component of the system is the Bosch Engine Control Unit ECU which manages system operation det...

Page 122: ...igital Wrench Diagnostic Software dealer only ELECTRONIC CONTROL UNIT ECU Operation Overview The ECU is the brain or central processing computer of the entire EFI fuel ignition management system During operation sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECU Signals to the ECU include ignition on off crankshaft position and speed RPM t...

Page 123: ...djustment procedure if required For the purpose of troubleshooting a known good ECU from another Polaris RANGER RZR EFI of the same model may be used without system or engine component damage ECU Replacement 1 Remove the 2 retaining screws holding the ECU 2 With the Ignition turned off disconnect the wire harness from the ECU 3 To install reverse the procedures and tighten screws to specification ...

Page 124: ...signal corresponding to specific crankshaft position for PTO cylinder This signal serves as a reference for the control of ignition timing by the ECU Synchronization of the CPS and crankshaft position takes place during the first two revolutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine ...

Page 125: ... the CPS the rear portion of the exhaust system and the mounting bracket between the transmission and rear gearcase will need to be removed 3 Remove the exhaust pipe between the elbow pipe and the exhaust silencer Remove the exhaust silencer 4 Remove the 3 bolts retaining the front portion of the mounting bracket to the transmission Retain the bolts washers and spacers for installation 5 Remove th...

Page 126: ...when the transmission and rear gearcase are installed in the vehicle 1 Clean bolt threads with solvent and allow them to dry Coat the circumference of the first 4 threads of the bolts with Loctite before installing the bolts 2 Reinstall mounting bracket and hand tighten the 7 bolts 3 Torque ALL mounting bracket bolts to specification T CPS Retaining Bolt Torque 25 in lbs 2 8 Nm Remove Bracket This...

Page 127: ...l tool and attach an extension to the torque wrench Torque the bottom bolt that attaches the bracket to the rear gearcase through the hole in the frame support Bottom Rear Gearcase Bolt NOTE Special Tool is not required for this torque 6 Using special tool PA 48873 torque the upper 2 bolts retaining the mounting bracket to the rear gearcase Place the torque wrench through the rear exhaust silencer...

Page 128: ...olt that attaches the bracket to the front side of the rear gearcase Front Rear Gearcase Bolt NOTE A multi directional torque wrench is required in this application because of the limited access to this bolt Check with the manufacturer of your torque wrench to see if it can be used to tighten left hand threaded bolts ...

Page 129: ...for operational vibration indicating that they are opening and closing When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration NOTE Do not apply voltage directly to th...

Page 130: ... of the fuel injector s by measuring between the two harness pin terminals Fuel Injector Replacement 1 Be sure the engine has cooled enough to work on 2 Place a suitable container below the quick connect plug at the end of the fuel rail Hold a shop rag over the plug and remove it to depressurize the fuel system 3 Remove the exhaust pipe between the exhaust silencer and the elbow pipe to allow bett...

Page 131: ...s shown previous in this procedure 7 Thoroughly clean the area around the fuel injectors including the throttle body manifold 8 Using a 6mm hex wrench loosen the fuel rail mounting screw from the cylinder head Carefully pull the rail away from the injectors and remove the injector s from the cylinder head along with the harness 9 Reverse the previous procedures to install the new injector s and re...

Page 132: ... the engine is stopped with the key switch on as in the case of an accident In these situations the check engine light will go on but will turn off after 4 cranking revolutions if system function is OK Once the engine is running the fuel pump remains on Fuel Sender Test If the fuel gauge reading on the instrument cluster is not working or if the display reading differs in large comparison to the f...

Page 133: ...ion replace the fuel pump assembly 6 If the pump did not activate Step 3 disconnect the harness connector 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 the battery ignition switch relay s wiring harness and ECU 7 ...

Page 134: ...hon as much fuel from the tank as possible before attempting to remove it from the vehicle 1 Remove the driver and passenger seats along with the rear service panel 2 Disconnect the negative battery cable from the battery located under the driver s seat 3 While holding a shop towel over the fuel line connector disconnect the quick connect fuel line from the fuel pump NOTE A small amount of fuel ma...

Page 135: ...rivets and 4 Torx screws retaining the RH rocker panel and remove panel from the vehicle 9 Remove the lower bolt retaining the seat belt mechanism near the rear RH portion of the fuel tank Once removed place the mechanism in the rear cargo box to keep it out of the way 10 Remove the 3 Torx fasteners from the rear RH fender well and remove the fender well from the vehicle NOTE Lift fender well up o...

Page 136: ...l the rear RH fender well and secure with fasteners 4 Reinstall the seat belt mechanism and secure the lower bolt 5 Reinstall the RH rocker panel and all 15 fasteners 6 Reinstall the rear seat base and secure with the 2 fasteners 7 Reinstall the push rivets into the rear of the center console 8 Install the fuel line and vent hose and verify they are secure 9 Reconnect the fuel pump electrical harn...

Page 137: ...last successfully learned point and the Check Engine or MIL indicator will illuminate Performing the TPS Adjustment procedure will remedy this problem TPS Tester Regulator The TPS reading can be checked by using the Throttle Position Sensor TPS Tester 2201519 A IMPORTANT TPS Tester 2201519 A replaces the existing TPS tester PU 47082 which included the 4010264 regulator If your dealership has PU 47...

Page 138: ...mps that secure the throttle body in the intake boot and intake adaptor This will allow you to rotate the throttle body to access the TPS or allow you to remove the throttle body to perform this procedure 4 Assemble the TPS Tester according to the instructions Refer to TPS Tester Regulator for proper set up and testing Verify the 9 volt tester battery is new 5 Disconnect the vehicle chassis harnes...

Page 139: ...ecification see Figure 4 28 4 Retighten the mounting screw and verify the voltage did not change If the voltage changed repeat steps 2 4 5 Reconnect the TPS harness to the vehicle chassis harness TPS Replacement NOTE The correct position of the TPS angle on the throttle body is established and set at the factory If the TPS is replaced repositioned or loosened it must be recalibrated Refer to the T...

Page 140: ...or any reason the engine temperature sensor circuit is interrupted the fan will default to ON ECT Sensor Test To quickly rule out other components and wiring related to the ECT disconnect the harness from the ECT The fan should turn on This indicates all other components are working properly Refer to Chapter 10 for ECT testing Polaris dealers can also test the sensor by using the Digital Wrench Di...

Page 141: ...il windings to fire the spark plugs Ignition Coil Tests The ignition coil can be tested by using an ohm meter Use the following illustration and specification table to test the ignition coil Primary Test Secondary Test Ignition Coil HT Lead Replacement 1 Remove the driver and passenger seats 2 Remove the rear service panel to access the ignition coil 3 Disconnect the ignition coil harness and remo...

Page 142: ...00 26 Vehicle Speed Sensor Implausible Yes P1121 27 TPS Set Error Yes P0113 41 Intake Air Temp Sensor Open or Short Circuit to Sensor Voltage ECU Yes P0112 41 Intake Air Temp Sensor Short Circuit to Ground Yes P0117 42 Engine Temperature Sensor Circuit Short To Ground Yes P0118 42 Engine Temperature Sensor Circuit Open or Short to Battery Yes P0107 45 Barometric Pressure Sensor Circuit Low Input Y...

Page 143: ...h idle poor fuel economy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug TPS setting incorrect Injector failure Poor Idle Symptom Idle Too High If greater than 1300 RPM when engine is warm Throttle stop screw set incorrect Throttle cable sticking improperly adjuste...

Page 144: ...he original ECU is transferred to the replacement ECU Refer to procedure and carefullyfollow all instructions provided in Digital Wrench Guided Diagnostic Available Guided diagnostics are available within Digital Wrench for all supported Trouble Codes that is any fault that will turn on the Check Engine indicator In addition guided diagnostics are also available for many other electrical sub syste...

Page 145: ...ght side of the screen Digital Wrench Version and Update ID Knowing what Digital Wrench version and update is installed will help determine which updates are required NOTE Versions and updates are subject to change 1 Open the Digital Wrench software Locate the version ID shown on the lower right side of the Digital Wrench start up screen 2 In this case the version number is 3 1 with a 03 13 09 upd...

Page 146: ...d is newer than your current version and update see Digital Wrench Version and Update ID download the file 7 Click on the link shown above save the file to your hard disk and then double click the icon to start the update process NOTE Do not run or open the file from where they are Select save and download them to your PC before running the install 8 When the update is complete the version shown o...

Page 147: ...4 35 ELECTRONIC FUEL INJECTION 4 P R E L I M I N A R Y V E R S I O N Digital Wrench Feature Map ...

Page 148: ...e likely to cause a reprogramming problem than one dedicated to Digital Wrench diagnostics only OBTAINING THE LATEST UPDATE Reprogramming updates are provided periodically and contain the most recent calibrations see Digital Wrench Updates CLOSE NON ESSENTIAL PROGRAMS Polaris recommends that you DO NOT install non essential programs on a Service Department laptop Camera detection software Virus Sc...

Page 149: ...duct line and vehicle description by selecting the Change Vehicle Type icon 5 Select the Special Tests icon 6 Select Engine Controller Reprogramming 7 Select the file you want to load into the ECU then click the Continue icon to proceed to the Integrity Check 8 Follow the on screen instructions and connect a 9V battery to the reflash battery connector located off the main diagnostic connector Clic...

Page 150: ...m the list that you selected previously while in Digital Wrench Enter the VIN along with the customer s name and address When completed click the Authorize button once to proceed 13 An Authorization Key will appear in the upper left corner of the screen Copy CTRL C this key exactly as it appears 14 Enter or paste CTRL C the Authorization Key in the box located on the Digital Wrench screen Click th...

Page 151: ... E R S I O N 15 At this point the reflash process will begin Do not touch the vehicle or PC during the process 16 Once the ECU reprogramming procedure is complete click the Finish button on the screen Verify the reflash was a success by starting the vehicle ...

Page 152: ...NOTES ELECTRONIC FUEL INJECTION 4 40 ...

Page 153: ... ASSEMBLY REMOVAL 5 15 STEERING ASSEMBLY 5 16 EXPLODED VIEW RZR RZR S 5 16 EXPLODED VIEW RZR S INT L 5 17 STEERING WHEEL REMOVAL 5 18 STEERING SHAFT REMOVAL BEARING REPLACEMENT 5 18 WHEEL HUBS 5 19 FRONT A ARMS 5 20 REMOVAL REPLACEMENT 5 20 EXPLODED VIEW 5 21 BALL JOINT SERVICE 5 22 FRONT STABILIZER BAR RZR RZR S INT L 5 23 SWAY BAR LINKAGE STABILIZER BAR REMOVAL 5 23 EXPLODED VIEW 5 24 REAR A ARM...

Page 154: ...arrier 38 ft lbs 52 Nm Upper LH RH Rear Bearing Carrier 33 ft lbs 45 Nm Outer Tie Rod to Bearing Housing 42 5 ft lbs 58 Nm Front Ball Joint Pinch Bolts 17 ft lbs 23 Nm Front Upper Lower Shock Bolt 27 33 ft lbs 37 45 Nm Rear Upper Lower Shock Bolt 27 33 ft lbs 37 45 Nm Front Wheel Hub Castle Nut 80 ft lbs 108 Nm Rear Wheel Hub Castle Nut 80 ft lbs 108 Nm Wheel Nuts Cast Rims Wheel Nuts Steel Rims 9...

Page 155: ...ith four 5 16 18 bolts and 5 16 18 nuts Tighten bolts to 16 18 ft lbs 22 24 Nm Fasten the two self tapping screws to the rear inner portion of the bracket on each side Tighten screws to 15 ft lbs 20 Nm 3 Place the straps from the safety net over the front coupler posts 4 Fasten the front of the cab frame to the base brackets and secure with four 3 8 16 x 1 1 4 screws and 3 8 16 Nyloc nuts Tighten ...

Page 156: ...ws to the rear inner portion of the bracket on each side Tighten screws to 15 ft lbs 20 Nm 3 Place the straps from the safety net over the front coupler posts Fasten the front of the cab frame to the base brackets and secure with four 3 8 16 x 1 1 4 screws and 3 8 16 Nyloc nuts Tighten screws to 25 28 ft lbs 34 38 Nm 4 Attach the upper side bars to the cab frame Do not fully tighten at this time F...

Page 157: ...R E L I M I N A R Y V E R S I O N BODY EXPLODED VIEWS Dash Instruments Controls RZR RZR S A Instrument Cluster Speedo B Headlight Switch C 2WD AWD Switch D 12 Volt Accessory Receptacle E Speedometer Mode Button F Key Switch C D E F B A ...

Page 158: ... H L G A Instrument Cluster B Headlight Switch MY09 C 2WD AWD TURF Switch D 12 Volt Accessory Receptacle E Speedometer Mode Button F Key Switch G Hazard Switch H Turn Indicator I Horn MY09 J Turn Signal Switch MY09 K Turn Signal Cover MY09 L Switch Turn Lights Horn MY10 MODEL YEAR 2010 Dash Instruments MODEL YEAR 2009 Dash Instruments ...

Page 159: ...light Radiator O Ring Front Bumper Support Front Bumper Winch Pocket T25 Screw T27 Screw T27 Screw T30 Screws Washers Bumper Retaining Bracket Bulb Screen Radiator Screen MY10 MY09 MY10 MY09 Cover Winch Pocket Cover RH Tail Light Rear Bumper Speed T25 Screws T27 Screws T27 Screw LH Tail Light Nuts ...

Page 160: ...N Hood Front Body Work Center Hood Panel Hood Dash Front Bumper Front RH Fender Flair Front LH Fender Flair Winch Pocket Cover Push Rivets Push Rivets T27 Screws Reflector 1 4 Turn Latch Grommet Washer Hood Pad Push Rivet Push Rivet T27 Screws T27 Screws T25 Screws ...

Page 161: ...pring Lever Latch Body Grommets Seat Seat Back Seat Bottom Hoop Tube Nuts 41 57 in lbs 4 6 6 4 Nm 48 in lbs 5 4 Nm 41 57 in lbs 4 6 6 4 Nm Driver 3 Point Seat Belt Rear Seat Base Latch Seat Passenger Seat 3 Point Seat Belt 3 Point Seat Belt Plunger 35 ft lbs 47 Nm 35 ft lbs 47 Nm 35 ft lbs 47 Nm 35 ft lbs 47 Nm 35 ft lbs 47 Nm ...

Page 162: ...LH Rocker Lower Floor Rear Front Push Rivets U Type Support Bracket Rear Support Bracket Push Rivets Support Bracket Front Support Bracket Self Tapping Screws Self Tapping Screws Self Tapping Screw T27 Screws T27 Screws Nuts T27 Screws Self Tapping Screw Plastic Dart T27 Screws Torx Screws Upper Floor T27 Screw ...

Page 163: ...LH Fender Flair Fender Rear LH Fender Cargo Box Tie Down Bracket Panel Divider Rear RH Panel Divider Rear Main Service Panel Supports Heat Shield Grommet Push Rivets Rivets T27 Tie Down Bracket Torx Screw Bolts T25 Screws T25 Screws Torx Nut Torx Screw Nut Screws Screws T27 Screws 1 4 Turn Latch Storage Cover Seal T27 Screws Push Rivet Foil Tie Down Ring MY09 Only ...

Page 164: ...2 BODY STEERING SUSPENSION P R E L I M I N A R Y V E R S I O N Chassis Main Frame Main Frame Bolt In Brace Skid Plate Rear Bumper Support 15 ft lbs 20 Nm 15 ft lbs 20 Nm 17 ft lbs 23 Nm 6 8 ft lbs 8 11 Nm ...

Page 165: ... Lift the panel upward and towards the front of the vehicle to remove it Front Bumper 1 Remove the 4 push rivets from the sides of the front bumper 2 Remove the 6 Torx screws retaining the upper middle and lower portion of the bumper 3 Disconnect the front head lamp connectors and remove the front bumper from the vehicle Rear Bumper 1 Remove the 4 Torx screws retaining the upper portion of the rea...

Page 166: ...ssembly to allow dash removal Refer to CAB FRAME Assembly Removal for assembly torque specifications 4 Remove the 8 push rivets that attach the dash assembly to the rocker panels on each side 5 Remove the 2 Torx screws and 2 push rivets that retain the front and rear portions of the dash assembly and remove the dash assembly from the vehicle Front Fender Flair Removal 1 If dash is installed remove...

Page 167: ...f the rocker panels to the rear fenders 3 Remove the 3 push rivets or 8 T27 screws RZR S and remove the fender flair from the rear fender 4 Remove the 3 Torx screws from the bottom side of the fender and the upper push rivet from the top side Remove the fender from the vehicle 5 Remove the 4 fasteners that retain the tie down brackets to the cargo box and remove from vehicle Cargo Box Assembly Rem...

Page 168: ...t Tube Steering Shaft Cotter Pin Gear Box Bearing Bushing Oil Locking Shock Asm Asm 17 ft lbs 23 Nm 17 ft lbs 23 Nm 12 14 ft lbs 16 19 Nm Nut 42 5 ft lbs 58 Nm 42 5 ft lbs 58 Nm 12 14 ft lbs 16 19 Nm 27 33 ft lbs 37 45 Nm 25 31 ft lbs 34 42 Nm 23 ft lbs 31 Nm 23 ft lbs 31 Nm 7 ft lbs 10 Nm 12 ft lbs 16 Nm Bushing Thick Washer Thin Washer Thick Washers Thin Washer Thin Washer Spacer ...

Page 169: ...t Cotter Pin Gear Box Bearing Bushing Oil Locking Shock Asm Asm 17 ft lbs 23 Nm 17 ft lbs 23 Nm 12 14 ft lbs 16 19 Nm Nut 42 5 ft lbs 58 Nm 42 5 ft lbs 58 Nm 12 14 ft lbs 16 19 Nm 27 33 ft lbs 37 45 Nm 25 31 ft lbs 34 42 Nm 23 ft lbs 31 Nm 23 ft lbs 31 Nm 7 ft lbs 10 Nm 12 ft lbs 16 Nm Bushing Thick Washer Thin Washer Thick Washers Thin Washer Thin Washer Spacer Screw Steering Lock Collar ...

Page 170: ...ngs out of the pivot tube using a drift punch 6 Inspect the pivot tube bearing surfaces for signs of excessive wear or damage 7 Slide a new lower bearing onto the steering shaft and install the steering shaft through the pivot tube NOTE Be sure the lower washers and spacers are still on the steering shaft 8 Slide a new upper bearing onto the steering shaft and press it into the pivot tube by hand ...

Page 171: ...lts Retaining Sealed Ball Bearing Bearing Front Tire Washers 27 ft lbs 37 Nm 80 ft lbs 108 Nm Ring Carrier Steel Front Rim Aluminum Wheel Nuts 90 ft lbs 122 Nm Studs Wheel Nuts Rear Rim Castle Nut Cotter Pin Cone Wheel Hub Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Rear Tire Washers 27 ft lbs 37 Nm 80 ft lbs 108 Nm Ring Carrier Steel Rear Rim Aluminum Wheel Nuts 90 ft lbs 122 Nm Studs ...

Page 172: ...bolt to 17 ft lbs 23 Nm 13 Attach shock to A arm with spacer D and fastener A see FRONT STABILIZER BAR Exploded View Torque lower shock bolt to 27 33 ft lbs 37 45 Nm 14 Remove the lower ball joint pinch bolt E from the front bearing carrier 15 Using a soft face hammer tap on bearing carrier to loosen the lower A arm ball joint end while pushing downward on the lower A arm Completely remove the bal...

Page 173: ... Pinch Bearing CV Shield Bushings 33 ft lbs 45 Nm Pivot Tube Bushing Grease Zerk Ball Joint Carrier Bolts Zerk 17 ft lbs 23 Nm 33 ft lbs 45 Nm Pivot Tube Upper A arm Lower A arm Grease Screws Ball Joint Pinch Bearing CV Shield Bushings 33 ft lbs 45 Nm Grease Ball Joint Carrier Bolts Zerk 17 ft lbs 23 Nm 33 ft lbs 45 Nm Pivot Zerk Tube Pivot Tube Bushings ...

Page 174: ...ng process 4 Use a press and correct size driver to remove the ball joint from the A arm NOTE The driver must fit the ball joint housing in the A arm This will allow the ball joint to be properly pressed out of the A arm without damaging the A arm Ball Joint Upper A arm Retaining Ring Standard RZR Shown 1 75 in 1 375 in 3 49 cm 3 in 7 62 cm Driver Dimensions Outside diameter of driver cannot be an...

Page 175: ...iew on page 5 24 3 Remove the bolts that attach the upper portion of the linkages to the sway bar clamps and remove the linkages from the vehicle see Exploded View on page 5 24 4 Inspect the linkage assemblies for signs of excessive wear or damage Replace linkage assembly if damaged 5 Reverse the procedure for installation Torque the linkage fasteners to 27 33 ft lbs 37 45 Nm Stabilizer Bar Remova...

Page 176: ...acket 8 Remove the 4 bolts retaining the upper radiator mount bracket and remove the bracket from the frame 9 Lift up on the stabilizer bar and remove it from the vehicle 10 Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed 11 Reverse the procedure for installation Torque the linkage fasteners to 27 33 ft lbs 37 45 Nm Exploded View Filler Neck Recovery Bottle M...

Page 177: ... upper A arm from the vehicle 3 Examine A arm and bearing carrier bushings and pivot tubes see Exploded View on page 5 27 Replace if worn Discard hardware 4 If not replacing the A arm thoroughly clean the a arm and pivot tubes 5 Insert new A arm bushings and pivot tubes into new A arm Lower A arm Removal RZR 1 While holding the stabilizer bar linkage remove the lower nut retaining the linkage to t...

Page 178: ...remove the lower A arm from the vehicle see previous illustration 5 Examine A arm and bearing carrier bushings and pivot tubes see Exploded View Replace if worn Discard hardware 6 If not replacing the A arm thoroughly clean the a arm and pivot tubes 7 Insert new A arm bushings and pivot tubes into the new A arm Installation 1 Install lower A arm assembly onto vehicle frame Torque new fasteners to ...

Page 179: ... 33 ft lbs 45 Nm Pivot Tube Carrier Pivot 33 ft lbs 45 Nm Grease Zerk Shield 38 ft lbs 52 Nm Tube 33 ft lbs 45 Nm Bushings Pivot Tube Pivot Tube Bushings Upper A arm Lower A arm Screws Bearing CV Bushings 33 ft lbs 45 Nm Pivot Tube Carrier Pivot 33 ft lbs 45 Nm Grease Zerk Shield 38 ft lbs 52 Nm Tube 33 ft lbs 45 Nm Bushings Pivot Tube Bushings Pivot Tube ...

Page 180: ...ge bushing on each side of the vehicle 3 Remove the 4 fasteners retaining the stabilizer bar bracket to the frame 4 Remove the stabilizer bar and bracket from the frame as an assembly 5 Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed 6 Inspect the rubber bushings on the linkage rod and replace if needed 7 Reverse the procedure for installation Torque the stab...

Page 181: ...retaining the stabilizer bar to the linkage on each side of the vehicle 3 Remove the 4 fasteners retaining the stabilizer bar to the bracket 4 Remove the stabilizer bar from the bracket bracket can remain attached to the frame 5 Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed 6 Reverse the procedure for installation Torque the stabilizer bolts to 18 ft lbs 24...

Page 182: ...RINGS RZR Exploded View Shock Removal Installation 1 Elevate the vehicle off the ground to relieve the suspension load 2 Remove the upper and lower fasteners retaining the shock and remove the shock from the vehicle 3 Reverse the procedure to reinstall the shock Torque new fasteners to 27 33 ft lbs 37 45 Nm Shock Replacement 1 Using a spring compressor compress the shock spring far enough to remov...

Page 183: ...t 4 1 Reservoir 18 1 Bearing External 5 Shock Oil 2870995 19 1 Bearing External 6 1 Decal 20 2 Retaining Ring Wire 7 2 Bearing 21 1 Spring Guide 8 4 Retaining Ring 22 1 Piston Damping 9 1 Eyelet 23 1 Reservoir End Cap Asm 10 1 Spacer 24 1 Retaining Ring Wire 11 1 Piston Asm Floating IFP 25 1 Damping Adjust Asm Piston 12 1 Valving Asm 26 1 Damping Adjust Asm Concentric Adjuster 13 1 Bearing Asm 27 ...

Page 184: ...EBOUND 1 300 x 0 008 1 250 x 0 006 1 300 x 0 008 1 250 x 0 006 0 800 x 0 004 1 250 x 0 008 1 250 x 0 008 1 100 x 0 006 1 100 x 0 006 1 000 x 0 006 1 000 x 0 006 0 900 x 0 008 0 900 x 0 010 0 800 x 0 010 0 800 x 0 010 0 700 x 0 010 0 700 x 0 010 0 620 x 093 Back Up 1 125 x 093 Top Out Piston Orifice 0 098 SHOCK DESIGN DETAILS Travel 6 22 Extended Length 21 34 IFP Location 3 40 Nitrogen Pressure 200...

Page 185: ... protection during these procedures 1 Safety Glasses 2 Latex Gloves 3 Lint Free Towels 4 Assembly Lube lithium based grease 5 Loctite 271 6 12 Tie Wrap Zip Tie 7 MAPP Gas or Propane Torch 8 1 834 TC Seal Kit 9 5wt Shock Fluid Special Tools Required Body Holding Tool PN 2871071 Charging Needle PN 7052069 A Gas Shock Recharging Kit PN 2200421 FOX Shock IFP Tool PN 2871351 Seal Installation Bullet To...

Page 186: ...rom both ends of the shock If your shock has polyurethane bushings and sleeves remove them from both ends of the shock Fig 1 5 Note and record the setting on the Compression Adjuster Screw Using the Flat Blade Screwdriver count the clicks as you turn the adjuster clockwise until it stops Fig 2 Once you have written this number down turn the screw all the way counterclockwise until it stops 6 Clean...

Page 187: ... out of the reservoir tube using the IFP Depth Setting Tool and place it on a clean lint free towel Remove the shock from the vise and pour shock oil from body and reservoir tubes into a proper disposal container DO NOT RE USE OLD SHOCK OIL 18 Using the 1 8 Hex Tool remove the IFP bleed screw from the IFP 19 Clean the body tube reservoir tube and the IFP using solvent Dry with compressed air in a ...

Page 188: ... a well ventilated area If compressed air is not available dry parts using clean lint free paper towels and let sit in a well ventilated area to allow the remaining solvent to evaporate 3 Use a scribe or dental pick to remove the o ring seal from the IFP 4 Use a scribe or dental pick to remove the o ring seals from the reservoir end cap 5 Install the new well lubricated o rings into the bearing ho...

Page 189: ... the nut to 22 ft lbs using the torque wrench and 9 16 socket Remove shaft assembly from vise and set it aside on a clean lint free paper towel 5 Clamp the body cap of the shock securely in the vise with the open end of the body facing up 6 Using the flat blade screwdriver turn the compression adjuster screw counter clockwise until it stops turning 7 Lubricate the new IFP o ring with an ample amou...

Page 190: ...ast 1 4 below the surface of the oil during this process 19 Bring the damping piston up until it is approximately 1 4 below the surface of the oil Using the mallet give 2 3 sharp blows to the eyelet driving the damping piston down into the shock body This opens the valves on the damping piston You will see the released air bubbles come to the surface of the oil 20 Add oil to the body tube until th...

Page 191: ...rom the FOX Nitrogen Safety Needle using a smooth straight motion Keep the reservoir as straight as possible to prevent the safety needle from bending As the safety needle is pulled free from the FOX air valve a popping sound should be heard 35 Install the button head screw into the FOX air valve using a 3 32 hex key 36 Remove the shock from the vise 37 Clean all oil residue from the shock and res...

Page 192: ...NOTES BODY STEERING SUSPENSION 5 40 ...

Page 193: ...9 2009 SHIFT WEIGHTS 6 10 2010 SHIFT WEIGHTS 6 11 2009 NON BRAKING EXPLODED VIEW RZR 6 12 2009 EBS EXPLODED VIEW RZR S 6 12 2010 NON BRAKING EXPLODED VIEW RZR RZR S 6 13 CLUTCH DISASSEMBLY 6 13 SPIDER REMOVAL 6 14 ROLLER PIN AND THRUST WASHER INSPECTION 6 15 BUTTON TO TOWER CLEARANCE INSPECTION 6 15 SHIFT WEIGHT INSPECTION 6 15 BEARING INSPECTION 6 16 CLUTCH INSPECTION 6 16 MOVEABLE SHEAVE BUSHING...

Page 194: ...d contacts the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive belt rotates low in the drive clutch sheaves As engine RPM increases centrifugal force causes the drive belt to be forced upward on drive clutch sheaves TOOL DESCRIPTION PART NUMBER Drive Clutch Puller Short PA 48595 Clutch...

Page 195: ... 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 hours as recommended see Chapter 3 Engine Break In Period for break in example Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period Main...

Page 196: ...ent temperatures Warm engine at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Towing Pushing at low RPM or low ground speed Use Low only Plowing snow dirt etc utility use Use Low ...

Page 197: ...push rivets and 2 fasteners retaining the rear seat base and remove the seat base from vehicle to allow clutch cover removal 4 Loosen the hose clamp on the clutch outlet duct 5 Remove outer clutch cover screws and remove the clutch cover 6 Mark the drive belt direction of rotation and remove drive belt see DRIVE BELT Belt Removal 7 Remove the driven clutch retaining bolt and driven clutch Inner Cl...

Page 198: ...on transmission input shaft 3 Apply RTV silicone sealant to outside edge of inner clutch cover to engine seal to ensure a water tight fit between the seal and the cover Surfaces must be clean to ensure adhesion of silicone sealant 4 Reinstall cover and tighten rear cover bolts just enough to hold it in place 5 Fit lip of inner cover seal A to engine Install seal retainer plate and tighten screws s...

Page 199: ... Reinstall outer clutch cover and secure with screws Torque to 45 50 in lbs 5 5 6 Nm 16 Install the clutch cover outlet duct and tighten the clamps DRIVE BELT Belt Removal 1 Remove outer clutch cover as described in PVT Disassembly 2 Mark the drive belt direction of rotation so that it can be installed in the same direction NOTE Belt is normally positioned so that the part number can be easily rea...

Page 200: ...e causes Belt Installation NOTE Be sure to position belt in the same position as when removed or so part number is easily read 1 Loop belt over the drive clutch and over top of the driven sheave 2 While pushing down on top of belt turn the back or moveable driven sheave clockwise 3 The belt then should be able to be pushed down into and between the sheaves PVT Break In Drive Belt Clutches A proper...

Page 201: ...it should always be inspected for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from the outer coil surfaces as shown Refer to the spring specification chart for specific free length measurements and tolerances Also check to see that spring coils are parallel to one another Distortion of the spring indicates stres...

Page 202: ... the PVT system These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance clutch balance and shifting pattern ...

Page 203: ...r the PVT system These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance clutch balance and shifting pattern ...

Page 204: ...ing Cover Bearing Bushing Lock Washer Bolt Flat Washer Cover Screws Button Pin Washers Roller Nut Shift Weight Bolt Non Braking Bearing Spacer Limiter Spider Button Washers Bearing Spring Cover Bearing Bushing Lock Washer Bolt Flat Washer Cover Screws Button Pin Washers Roller Nut Shift Weight Bolt One Way Bearing Spacer Spider Button ...

Page 205: ...ning the spider during clutch assembly 3 Remove cover 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 Screws Button Pin Washers Roller Nut Shift Weight Bolt ...

Page 206: ...al Tool PN 2870341 NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly Be sure to note the number and thickness of these washers Moveable Sheave Bushing Inspection 3 Inspect the Teflon coating on the moveable sheave bushing Clutch Holding Fixture PN 2871358 Spider Removal Tool PN 2870341 Inspect Shaft Moveable Sheave Bushing Inspect...

Page 207: ...in all RANGER clutches if the hollow roller pin is changed to the solid roller pin NOTE The rubber side of the button is positioned toward the solid roller pin Button To Tower Clearance Inspection 1 Inspect for any clearance between spider button to tower If clearance exists replace all buttons and inspect surface of towers See Spider Removal procedure 2 Inspect sheave surfaces Replace the entire ...

Page 208: ... only a slight amount of drag 2009 RZR S The one way bearing should rotate clockwise when viewed from cover plate side with only a slight amount of drag When rotated counter 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 followin...

Page 209: ...lace if worn or damaged Moveable Sheave Bushing Inspection Inspect the Teflon coating arrow on the moveable sheave bushing Inspect both sheaves for signs of wear grooving or cracking De glaze sheave surfaces with a 3M Scotch Brite Pad if needed In mm Shaft Diameter Standard 1 3745 1 375 Service Limit 1 3730 In mm PTFE Washer Thickness Standard 030 76mm Service Limit 025 64mm Moveable Sheave Bushin...

Page 210: ...A B into center of sheave with A side toward sheave EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBSBushingRemovalTool 5132028 1 Instructions 9915111 Additional Special Tools Qty Part Description Part 1 Clutch Bushing Replacement Tool Kit 2871226 1 Piston Pin Puller 2870386 Item Qty Part...

Page 211: ... 8 Remove nut from puller rod and set aside 9 Remove sheave from puller 10 Remove installation tool Cover Bushing Removal 1 Install main adapter Item 8 on puller 2 Install adapter reducer Item 9 3 From outside of clutch cover insert removal tool Item 3 into cover bushing 4 With inside of cover toward vise slide cover onto puller 5 Install nut onto puller rod and hand tighten Turn puller barrel to ...

Page 212: ...arks that were made earlier in moveable sheave 4 Torque spider to specification using the holding fixture and spider tool Torque with smooth motion to avoid damage to the stationary sheave 5 Install limiter spacer over the shaft and on top of spider 2009 RZR Only 6 Install shift weights using new lock nuts on the bolts 7 Reinstall clutch spring 8 Reinstall cover aligning X mark with other marks 9 ...

Page 213: ...ssembly or use the X s on the components for reference This will aid in reassembly and helps to maintain clutch balance after reassembly 3 Remove the four screws that secure the cam helix assembly using a T25 Torx driver 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 sh...

Page 214: ...tch rollers H Inspect the rollers for wear replace if worn 8 Remove the clutch assembly from the holding tool Remove the large outer retaining ring I and 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 I...

Page 215: ...nd each bushing Clean all residual Loctite from bushing bore prior to installing new bushing Inspect Sheave Surface Inspect Bushing EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBSBushingRemovalTool 5132028 1 Instructions 9915111 Additional Special Tools Qty Part Description Part 1 Clutc...

Page 216: ... 8 Remove nut C left hand thread from puller rod and set aside 9 Remove adapters from puller 10 Remove bushing and removal tool from adapters Discard bushing 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 inst...

Page 217: ...tall the shaft bearing into the outer sheave 3 Install the small and large retaining rings into the outer sheave above the bearing 4 Line up the X on the moveable sheave with the X on the stationary sheave or use the marks previously used Put the sheaves together 5 Install the roller A onto the roller pin B on both sides Align X s A B ...

Page 218: ... 9 Install the clutch rollers D onto each side of the outside spider Install the washers E and E clips F to secure the rollers The rollers should 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 too...

Page 219: ... the shaft install the retaining ring 14 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 Pre...

Page 220: ...O N Exploded View Compression Thrust Washer Cam Helix T25 Retaining Ring Roller Pin Slotted Ball E Clips Spring Spider Dampener Outer Spider Spider Insert Stationary Sheave Bearing Spring Pin Moveable Sheave Clutch Shaft Roller Retaining Ring Screws ...

Page 221: ...ssion Tool PN 8700220 Using Compression Extensions PN PS 45909 apply and hold downward pressure on the outer spring retainer Carefully remove the snap ring Remember the outer spring retainer contains strong spring pressure NOTE Spring is compression only and has no torsional wind Stationary Moveable Inner Compression Spring Outer Retaining Spring Retainer Ring Spacer Spring Retainer Secondary Shea...

Page 222: ...emove the inner spring retainer from the inner sheave Inspect for wear and replace as needed 8 Check the rollers in the stationary sheave for wear If rollers are worn a new driven clutch assembly may be needed 9 Inspect the bearings inside the moveable sheave A B C E D C E B D Inspect for Abnormal Wear Moveable Sheave Bearing Inspection Replace the bearing if more brass than Teflon is visible on t...

Page 223: ...inner spring retainer if removed Do not apply oil or grease to the bearings 2 Align the X marks on each of the sheaves during reassembly 3 Install the spring into the inner retainer 4 Install the spacer over the shaft 5 Install the outer retainer on top of the spring 6 Place the clutch into Clutch Compression Tool PN 8700220 Using Compression Extensions PN PS 45909 apply and hold downward pressure...

Page 224: ...Incorrect drive clutch spring too high spring rate Drive clutchshift weightsincorrect forapplication too light Drive clutch binding Driven clutch binding Converter sheaves greasy belt slipage Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire ran...

Page 225: ...in Owner s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt slippage Belt worn out Water ingestion Belt contaminated with oil or grease Replace belt Inspect and seal PVT system Inspect and clean PVT noise B...

Page 226: ...NOTES CLUTCHING 6 34 ...

Page 227: ...SPECTION 7 19 BACKLASH THRUST PLATE ADJUSTMENT 7 21 GEARCASE INSTALLATION 7 22 REAR BEARING CARRIER 7 23 BEARING CARRIER INSPECTION REMOVAL 7 23 BEARING REPLACEMENT 7 24 BEARING CARRIER BUSHING REPLACEMENT 7 24 BEARING CARRIER INSTALLATION 7 25 REAR DRIVE SHAFT 7 26 DRIVE SHAFT REMOVAL 7 26 OUTER CV JOINT BOOT REPLACEMENT 7 27 INNER PLUNGING JOINT BOOT REPLACEMENT 7 30 DRIVE SHAFT EXPLODED VIEW 7 ...

Page 228: ...shers from the front wheel hub assembly 5 Remove the steering tie rod end fastener from the front bearing carrier PART NUMBER TOOL DESCRIPTION 2872608 Roller Pin Removal Tool 8700226 CV Boot Clamp Pliers earless type PU 48951 Axle Boot Clamp Tool ITEM NUT TYPE SPECIFICATION Aluminum Wheels Cast Lug Nut 1 90 ft lbs 122 Nm Steel Wheels Black Camo Flange Nut 2 27 ft lbs 37 Nm Front Hub Castle Nut 80 ...

Page 229: ...minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 12 Replace bearing if moisture dirt corrosion or roughness is evident Bearing Replacement Bearing Removal 1...

Page 230: ...using clean of any excess compound and install the snap ring Bearing Carrier Installation 1 Install drive shaft axle through the backside of the bearing carrier 2 Install the upper and lower ball joint ends into the front bearing carrier 3 Install pinch bolts and torque to 17 ft lbs 23 Nm 4 Apply grease to drive shaft axle splines 5 Install front wheel hub assembly cone washers and hand tighten th...

Page 231: ...l nuts to specification 10 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions T Front Caliper Mounting Bolts 30 ft lbs 40 Nm CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly T Tie Rod End Fastener 42 5 ft lbs 58 Nm 42 5 ft lbs 58 Nm T Wheel...

Page 232: ...caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 5 Remove the front wheel hub assembly 6 Remove the upper ball joint pinch bolt 7 Using a soft faced hammer lightly tap on the bearing carrier while removing the upper ball joint end 8 Remove the drive shaft from the front bearing carrier 9 With a short sharp jerk remove drive shaft from the front gearcase CAUTIO...

Page 233: ...rass drift to separate the outer CV joint from the drive shaft NOTE If using a brass drift be sure to tap on the inner race of the joint only 4 Make sure the circlip remains on the shaft and not left in the joint Discard the circlip as it will be replaced 5 Remove the small clamp and boot from the drive shaft IMPORTANT If the grease in the joint is obviously contaminated with water and or dirt the...

Page 234: ... faced hammer or brass drift to separate the plunging joint from the drive shaft NOTE If using a brass drift be sure to tap on the inner race of the joint only 5 Make sure the circlip remains on the shaft and not left in the joint Discard the circlip 6 Remove the boot from the drive shaft IMPORTANT If the grease in the joint is obviously contaminated with water and or dirt the joint should be repl...

Page 235: ...osition the boot lips into the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 19 Install and secure the small clamp on the boot using the earless clamp pliers 20 Pull out on the drive shaft to center the joint in the housing Slide a straight O ring pick or a small slotted screw driver between the large end of the boot and the joint housing and lift up to equa...

Page 236: ...ng carrier 4 Install the upper ball joint end into the front bearing carrier 5 Installthe upperpinch boltand torque to 17 ft lbs 23 Nm 6 Apply grease to drive shaft axle splines 7 Install front wheel hub assembly cone washers and hand tighten the castle nut Install washers with domed side out 8 Torque wheel hub nut to 80 ft lbs 108 Nm and install a NEW cotter pin Tighten nut slightly if necessary ...

Page 237: ...elector cap and remove the retaining screw 3 Remove the Torx screws retaining the center console to access the propshaft 4 Slide prop shaft back far enough to remove it from the front gearcase input shaft 5 Pull sharply forward to remove it from transmission shaft NOTE You may have to loosen the front gearcase mounting bolts to allow for propshaft removal T Wheel Hub Castle Nut 80 ft lbs 108 Nm T ...

Page 238: ...in Spring Pin upon reassembly 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 replaced Note orientation of grease fitting and mark inner and outer yoke for correct re positioning during installation 2 Support inner yoke as shown and drive outer yoke down bearing cap out with a soft face hammer ...

Page 239: ...ce bearing caps in 3 Using a suitable arbor fully seat the bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled 4 Install snap ring to contain bearing cap just installed Repeat procedure for other side 5 Install outer yoke aligning marks made at disassembly and repeat Steps 1 3 to install bearing caps on outer yoke 6 Seat all bearing caps again...

Page 240: ...l Cage 2 22 Thrust Button Assembly 6 Hub Sub Assembly Female 6 23 Dowel Pin 7 Hub Sub Assembly Male 1 24 Set Screw M6 8 Connector 1 25 Input Cover 9 Plastic Clip 1 26 Bearing 10 Thrust Plate 2 27 Spacer Pinion Cover Nylon 11 Armature Plate 6 28 Ball Bearing 12 Pinion 1 29 O Ring 13 Oil Seal 1 30 Hub Race Assembly Female 14 Grommet 1 31 Hub Race Assembly Male 15 O Ring Square 2 32 Nylon Spacer 16 A...

Page 241: ... gear and roll cage are spinning vehicle is moving the energized coil and armature plate will apply drag to the roll cage that indexes the rollers inside 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 ...

Page 242: ...an interrupted wear mark may indicate a warped plate which may cause intermittent operation See the following illustrations 5 Check to make sure the coil is seated in the U shaped insert that is pressed into the gearcase cover The top of the coil should be seated below the U shaped insert The U shaped insert controls the pole gap If the top of the coil is above the surface of the U shaped insert i...

Page 243: ... vent line from the front gearcase 6 Remove the 4 bolts securing the front gearcase to frame 7 Remove the gearcase from the front LH wheel well area and slide it between the upper and lower A arm Gearcase Disassembly Inspection 1 Drain and properly dispose of gearcase fluid Remove any metal particles from the drain plug magnet 2 Remove the 6 cover screws and remove the cover plate 3 Remove and ins...

Page 244: ...move the RH output hub assembly from the gearcase housing 7 Remove the 4 screws retaining the pinion shaft assembly and remove the assembly from the gearcase housing Inspect and clean the gearcase housing and replace the seal 8 Clean and inspect all parts Check for excessive wear or damage 9 Inspect the coil located in the cover plate assembly Refer to AWD Diagnosis for detailed inspection process...

Page 245: ...nicks burrs or scratches If damaged replace the roll cage assembly 14 Inspect clutch housing ring gear C for a consistent wear pattern Inspect the ring gear for chipped broken or missing teeth 15 Inspect both output hub assemblies Inspect the bearings and replace if needed Gearcase Assembly Inspection 1 As mentioned during gearcase disassembly section replace all O rings seals and worn components ...

Page 246: ...e new cover plate seal while installing the output hub 8 Place the thrust plate onto the adjuster button located in the cover plate assembly using a light film of grease to hold it in place 9 Install the RH output hub into the clutch housing assembly 10 While holding the hub flip the clutch housing over and install the armature plate Be sure the armature plate tabs are fully engaged into the roll ...

Page 247: ...lbs 10 15 Nm Backlash Thrust Plate Adjustment NOTE Ring gear backlash is set from the factory No adjustment is required unless the cover plate ring gear clutch housing or pinion gear assembly is replaced Adjustment is also required if the thrust plate adjustment screw is removed 1 Lay the gearcase on its side with the cover plate facing up NOTE The backlash adjustment screw is held in place with L...

Page 248: ...earcase back into the vehicle through the LH wheel well area between the upper and lower A arms 2 Install the propshaft assembly onto the front gearcase input shaft Use a NEW spring pin in the front propshaft 3 Install the 4 bolts that secure the front gearcase to the frame and torque to 30 ft lbs 41 Nm 4 Install the vent line 5 Connect the AWD wire harness 6 Refer to FRONT DRIVE SHAFT Drive Shaft...

Page 249: ...ers from the rear wheel hub assembly 5 Remove the two brake caliper attaching bolts CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 6 Remove the rear wheel hub assembly 7 Remove the bolts that attach the rear bearing carrier to the upper and lower A arms 8 Remove the bearing carrier from the rear drive shaft 9 Rotate bearing by hand an...

Page 250: ...ge Replace rear bearing carrier if damaged Bearing Installation 5 Thoroughly clean the rear bearing carrier housing and the outer race on the new bearing Be sure that all oil residue has been removed from each surface 6 Support the bottom of the bearing carrier housing 7 Apply Loctite 603 retaining compound to the outer circumference of the new bearing race and carefully press the new bearing into...

Page 251: ...nut Install washers with domed side out 5 Install brake caliper mounting bolts and torque to 18 ft lbs 24 Nm 6 Torque wheel hub nut to 80 ft lbs 108 Nm and install a NEW cotter pin Tighten nut slightly if necessary to align cotter pin holes T Rear Bearing Carrier Bolts Upper 33 ft lbs 45 Nm Lower 38 ft 52 Nm 33 ft lbs 45 Nm 38 ft lbs 52 Nm Out Cone Washers Wheel Hub T Rear Caliper Mounting Bolts 1...

Page 252: ...heel hub castle nut Remove the nut and 2 cone washers from the rear wheel hub assembly 4 Remove the two brake caliper attaching bolts CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 5 Remove the rear wheel hub assembly 6 Remove the bolt that attaches the rear bearing carrier to the upper A arm T Wheel Nuts Steel Wheels 27 ft lbs 37 Nm ...

Page 253: ...he seal 9 Inspect the axle splines and CV boots for any damage Outer CV Joint Boot Replacement 1 Using a side cutters cut away and discard the boot clamps 2 Remove the large end of the boot from the CV joint and slide the boot down the shaft 3 Clean the grease from the face of the joint 4 Place the drive shaft in a soft jawed vise 5 Using a soft faced hammer or brass drift strike the inner race of...

Page 254: ...grease prior to reassembly 11 Slide the small boot clamp and boot small end first onto the drive shaft and position the boot in it s groove machined in the shaft 12 Install a NEW circlip on the end of the shaft 13 Grease the joint with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s inner race Pack the ball track...

Page 255: ... into the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 19 Install and tighten the large clamp using the Axle Boot Clamp Tool PU 48951 20 While pulling out on the CV shaft slide a straight O ring pick or a small slotted screw driver between the small end of the boot and the shaft This will allow the air pressure to equalize in the CV boot in the position tha...

Page 256: ...RTANT If the grease in the joint is obviously contaminated with water and or dirt the joint should be replaced 8 Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly 9 Visually inspect the joint for damage Replace if needed 10 Clean the splines on the end of the shaft and apply a light coat of grease p...

Page 257: ... joint s external surfaces and place the excess grease in the boot 19 Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 20 Install and tighten the small clamp using the Axle Boot Clamp Tool PU 48951 21 Pull out on the drive shaft to center the joint in the housing Slide a straight O ring pick or a ...

Page 258: ... drive shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary NOTE Take care when installing the drive shaft to prevent damaging the seal 3 Slide the rear drive shaft into the rear bearing carrier REAR SHAFT CV Joint Plunging Spring Ring Gear Side Boot Kit Wheel Side Boot Kit Joint Spring Ring Large Clamp Grease Pack Small Clamp Spring Ring Large Clamp Grease Pack RZR...

Page 259: ...t lbs 108 Nm and install a NEW cotter pin Tighten nut slightly if necessary to align cotter pin holes 9 Install wheel and 4 wheel nuts Torque wheel nuts to specification T Rear Bearing Carrier Bolts Upper 33 ft lbs 45 Nm Lower 38 ft lbs 52 Nm 33 ft lbs 45 Nm 38 ft lbs 52 Nm Out Cone Washers Wheel Hub 18 ft lbs 24 Nm T Rear Caliper Mounting Bolts 18 ft lbs 24 Nm CAUTION New bolts have a pre applied...

Page 260: ...d mount bolt and remove bracket from vehicle 5 Remove the fasteners and bracket that secure the rear gearcase to the transmission 6 Remove the 4 fasteners and remove the rear mount from the rear gearcase 7 Pull the rear gearcase towards the rear of the vehicle to disengage it from the transmission NOTE If the splined coupler doesn t slide off the input shaft on the rear gearcase use a screwdriver ...

Page 261: ...him the gears In the event damage to the gears or housing requires replacement the entire assembly must be replaced 1 Drain and properly dispose of used gearcase fluid 2 Remove the remaining cover screws from the rear gearcase 3 Remove the ring gear axle spool assembly The bearings are a slip fit and will slide off the axel spool NOTE Record the thickness of the shim pack located under each bearin...

Page 262: ...arcase housing Replace the o ring in the gearcase cover 7 Remove the input shaft seal using a seal puller or other suitable method 8 Inspect the input shaft by rotating the assembly in the gearcase housing while checking for any looseness or roughness Inspect the pinion gear teeth for chipped worn or broken teeth If damaged replace the ring gear and pinion gear as a set NOTE In the event damage to...

Page 263: ...stall new seals on each side of the gearcase housing using a standard seal installer or other suitable method Install a new o ring in the gearcase cover 3 If removed install each axle spool bearing race using standard bearing installation tools and an arbor press WARNING Wear the appropriate safety equipment while installing bearing races to reduce the risk of injury ...

Page 264: ...en reinstalling the transmission to rear gearcase mount bracket it is extremely important to torque all 7 fasteners to specification Refer to the Installation procedure listed on page 4 14 NOTE Special tool PA 48873 will be required to torque the mounting bracket fasteners when the transmission and rear gearcase are installed in the vehicle Refer to the Installation procedure listed on page 4 14 2...

Page 265: ...15 Screw Flange Head 2 5 Mount Rear 1 16 Seal Oil 2 6 Nut Flanged 4 17 Screw Flange Head 4 7 Assembly Rear Housing RH 1 18 Screw 8 8 N A 1 19 Dowel 2 9 Assembly Tapered Roller Bearing 2 20 Plug Drain w O Ring 1 10 Shim 2 21 Plug Fill w O Ring 1 11 N A 1 1 2 3 4 5 6 7 9 10 7 13 14 15 16 17 18 19 20 12 21 30 45 in lbs 3 5 Nm 40 ft lbs 54 Nm 23 27 ft lbs 31 37 Nm 10 9 6 16 7 70 80 ft lbs 95 108 Nm 23...

Page 266: ...ar away from the engagement dogs that are attached to the differential gear assembly This unlocks the rear differential When Differential Lock is selected on the switch power is removed from the electrical solenoid allowing the solenoid plunger to retract Spring tension moves the shift yoke back into place and engages the clutch gear into the engagement dogs that are attached to the differential g...

Page 267: ...See REAR DRIVE SHAFT on page 7 26 2 Remove the exhaust pipe and exhaust silencer to allow for gearcase removal 3 Remove the 4 bolts retaining the rear rack cab frame to the rear suspension plate Remove the upper A arm bolts lower rear A arm bolts and plate 4 Remove the 2 rear gearcase mount bracket fasteners and mount bolt and remove bracket from vehicle Differential Clutch Gear IRS Axle Clutch Ge...

Page 268: ...arcase back further to disengage it 9 Remove the vent line and lift the rear gearcase upward and on its side to remove it from the vehicle Gearcase Disassembly IMPORTANT The pinion gear assembly is NOT intended to be disassembled from the case as it requires special OEM tooling in order to properly reassemble If there is any damage to the pinion gear bearings or case the entire gearcase assembly m...

Page 269: ... top portion of the differential assembly Inspect the bearing for smoothness and wear 6 Remove the shim s from the differential assembly Be sure to keep the shims together for reassembly 7 Remove the bearing from the lower portion of the differential assembly Inspect the bearing for smoothness and wear 8 Remove the shim s from the differential assembly Be sure to keep the shims together for reasse...

Page 270: ...he gearcase housing while checking for any looseness or roughness Inspect the pinion gear for chipped worn or broken teeth If damaged replace the gearcase assembly NOTE In the event damage to the gears pinion bearings or housing requires replacement the entire assembly must be replaced 13 Remove the differential solenoid from the gearcase if servicing the solenoid shift lever shift lever spring or...

Page 271: ...ck pin assembly from the gearcase housing 18 Carefully remove the shift yoke assembly from the gearcase cover 19 Inspect the shift lever A shift lever spring B shift return springs C shift yoke D and lock pin bushing E Inspect the components for excessive wear or damage and replace as needed NOTE The pinion shaft assembly is NOT intended to be disassembled from the case as it requires special OEM ...

Page 272: ...e the differential cover 3 Remove the upper differential gear 4 Use a scribe to mark the ring gear and differential case Remove the 8 bolts that secure the ring gear to the differential and allow the ring gear to slide down and off 5 Place the differential assembly upright Use a roll pin punch to remove the roll pin from the differential case 6 With the roll pin removed slide the cross pin out and...

Page 273: ...fferential gears and thrust washers and slide the cross pin into position with the hole side facing the hole in the differential case 4 Install a new roll pin 5 Install the upper differential gear and differential cover Apply Loctite 271 to the cover screws and torque the screws to specification 6 Install the ring gear and torque the retaining bolts to specification Thrust Gear Gears Washers Thrus...

Page 274: ... seal installer or other suitable method 4 Install a new O ring in the gearcase cover 5 Install a new pinion shaft seal using a standard seal installer or other suitable method 6 Install the original shim s previously removed onto the appropriate sides of the differential assembly Install the bearings by hand as they are a slip fit 7 If previously removed assembly the shift lever A shift lever spr...

Page 275: ...and tighten 11 Install the differential assembly into the gearcase housing and install a new lightly greased O ring onto the cover 12 Assemble the gearcase halves and install the bolts that secure the cover to the housing Torque the bolts in a criss cross pattern to 23 27 ft lbs 31 37 Nm 13 If previously removed install the differential solenoid Torque the solenoid to 30 40 ft lbs 41 54 Nm C O Rin...

Page 276: ...dure listed on page 4 14 NOTE Special tool PA 48873 will be required to torque the mounting bracket fasteners when the transmission and rear gearcase are installed in the vehicle Refer to the Installation procedure listed on page 4 14 2 Add Polaris ATV Angle Drive Fluid to rear gearcase Refer to maintenance information in Chapter 2 for more details Torque drain and fill plugs to specification Rear...

Page 277: ...aring Tapered Roller 1 10 Bearing Ball 2 29 Screw Flange Head 10 11 Plug Drain 1 30 Case Diff Cover Half 1 12 Shim Kit 2 31 Thrust Washer Pinion 2 13 Gear Clutch 1 32 Gear Diff Pinion Mate 2 14 Yoke Shift 1 33 Gear Diff Side 2 15 O Ring 1 34 Thrust Washer Side Gear 1 16 Cover Asm Rear 1 35 Case Diff Half 1 17 Screw 2 36 Pin Diff Cross 1 18 Seal Oil 2 37 Pin Spring 1 19 Screw Flanged 4 1 2 3 4 5 6 ...

Page 278: ...ining Sealed Ball Bearing Bearing Front Tire Washers 27 ft lbs 37 Nm 80 ft lbs 108 Nm Ring Carrier Steel Front Rim Aluminum Wheel Nuts 90 ft lbs 122 Nm Studs Wheel Nuts Rear Rim Castle Nut Cotter Pin Cone Wheel Hub Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Rear Tire Washers 27 ft lbs 37 Nm 80 ft lbs 108 Nm Ring Carrier Steel Rear Rim Aluminum Wheel Nuts 90 ft lbs 122 Nm Studs ...

Page 279: ...ABLE INSPECTION ADJUSTMENT 8 3 TRANSMISSION SERVICE 8 4 TRANSMISSION REMOVAL SERVICE NOTES 8 4 TRANSFER CASE DISASSEMBLY 8 4 TRANSFER CASE REASSEMBLY 8 7 TRANSMISSION SHIFT HOUSING DISASSEMBLY 8 9 TRANSMISSION SHIFT HOUSING REASSEMBLY 8 14 TROUBLESHOOTING 8 18 TROUBLESHOOTING CHECKLIST 8 18 2009 TRANSMISSION EXPLODED VIEW 8 19 2010 TRANSMISSION EXPLODED VIEW 8 20 ...

Page 280: ...ecification ITEM TORQUE VALUE Transmission Fill Plugs 40 50 ft lbs 54 67 Nm Transmission Drain Level Plugs 30 45 in lbs 0 2 0 3 Nm Transmission Case Screws 23 27 ft lbs 31 36 Nm Shift Cable Lever Screw 15 20 ft lbs 20 27 Nm Detent Sleeve Assembly 40 45 ft lbs 54 61 Nm Outer Detent Screw 23 27 ft lbs 31 37 Nm Drain Plugs Check Plug 30 45 in lbs 0 2 0 3 Nm Ground Speed Sensor Screw 130 155 in lbs 15...

Page 281: ...r jam nut 4 Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH H gear and PARK P 5 Thread the upper or lower jam nut as required to obtain proper cable adjustment NOTE This procedure may require a few attempts to obtain the proper adjustment 6 Once the proper adjustment is obtained place the shift cable and upper jam nut into the moun...

Page 282: ...ll instructions before beginning disassembly NOTE Exploded views are located at the end of this chapter for additional information 1 Place the transmission in the neutral position 2 Drain both the transfer case and transmission case halves 3 Remove the 7 bolts retaining the transmission and rear gearcase stabilizer bracket 4 Remove the connector tube bolts securing the rear gear case and transmiss...

Page 283: ...ng removal tools Discard removed bearings as they become damaged by the removal process 10 Remove the intermediate pinion shaft assembly from the housing Check bearings and gear teeth for wear or damage and replace as needed The shaft can be disassembled as shown using a press and standard bearing removal tools 11 Disassemble the output pinion shaft assembly by removing the retaining screws on the...

Page 284: ...aft can be disassembled as shown using a press and standard bearing removal tools 14 Remove the upper snap ring from the top side of the 21T main pinion gear and remove the gear 15 Remove the lower snap ring from under the gear 16 Remove the intermediate shaft seal using a seal puller or other suitable method ...

Page 285: ...ront output pinion shaft assembly NOTE Bearing is pressed onto the shaft 3 Install the shims bearing cup and alignment dowels into the retaining bracket 4 Install a new output shaft seal flush with the case Install the output pinion shaft assembly and bearing cup bracket assembly as shown Verify the alignment dowels are seated Torque the bracket screws evenly to specification T Output Pinion Shaft...

Page 286: ... round edge inward Install a new shaft seal flush with the surface the shims and bearing cup Apply a thin coat of sealant to the mating surfaces Apply lubricant to the seal lip 7 Install the transfer case cover Align the dowels 1 7 and insert the cover screws note position of the longest screw 4 Torque the screws evenly to specification in sequence as shown Apply Sealant PN 2871557 To Case Mating ...

Page 287: ...he transmission and 2 from the backside as shown NOTE Shift cable bracket removal is required 2 Place the transmission shift housing onto a flat surface as shown Lift the transmission case half straight up and remove NOTE Shaft components may catch during transmission case half disassembly Work slowly and deliberately to avoid component loss or damage 3 Remove the retaining ring and retaining plat...

Page 288: ... removal process damages the bearing 7 Remove the reverse idler snap ring upper washer gear needle bearing and lower washer from the idler shaft NOTE The reverse idler shaft is a non serviceable item and should not be pressed out of the housing 8 Remove the input shaft seal and clutch intermediate shaft seal using a seal puller or punch 9 Remove the 2 screws that attach the gear position sensor to...

Page 289: ... to fall into the shift housing 12 Remove the park reverse spacer from the clutch shaft 13 Pull back fully on gear selector arm to bring shift collar up and disengage the shift collar from the clutch yoke Lifting on the clutch shaft may aid in shift collar removal 14 Inspect the inner and outer gear teeth and splines on both ends of the shift collar for excessive wear or damage NOTE If servicing a...

Page 290: ...oth ends of the shift collar for excessive wear or damage 18 Remove the sliding shoes from the clutch yoke 19 Remove the clutch shaft assembly from the housing The forward gear assembly and bearings will remain on the shaft upon removal 20 Disassemble the clutch shaft as needed by removing both retaining rings and separating the high and low gears from the clutch shaft Inspect all parts for wear o...

Page 291: ...sion housing 25 Remove the transmission input shaft from the housing Inspect the shaft bearing and replace if required using a shop press Inspect the gears for damage and or wear Replace the shaft if required 26 Remove the screw from the end of the shift cable lever and remove the shifter assembly from the housing 27 Inspect the shifter assembly shaft and housing for excessive wear or damage Repla...

Page 292: ...the shift cable lever X facing out and torque the retaining screw to specification 3 Assemble the input shaft with new ball bearings if required NOTE Install new bearings and seals by pressing on the outer edge only 4 Install the input shaft assembly into the transmission housing 5 Install the clutch yoke into the shifter assembly Align the holes and install clutch yoke pivot pin 6 Install the piv...

Page 293: ...age the shift shoes onto the center groove of the shift collar Shifting the clutch shaft position may aid in shift collar installation Install the park reverse spacer on top of the shift collar as shown 11 Install the dent sleeve assembly ball spring and outer detent screw Use new O rings anytime these screws are removed Torque the detent sleeve assembly to specification TURN THE OUTER DETENT SCRE...

Page 294: ...cation 12 Complete the shift detent screw installation Torque the outer detent screws to specification 13 Install the reverse idler lower washer needle bearing gear upper washer and retaining ring onto the idler shaft 14 Install a new shaft bearing if required 15 Install the park flange and torque the 5 screws to specification Apply Lubricant to shift drum components T Gear Position Sensor Screws ...

Page 295: ... the case Apply lubricant to both seal lips 19 Place the transmission shift housing onto a flat surface as shown Apply a bead of crankcase sealant onto the mating surfaces Align the dowels and install the transmission case half onto the shift housing while rotating the input shaft using care not to damage the seal surfaces 20 Install the shift cable bracket 7 shift housing case screws to the front...

Page 296: ... ends Loose fasteners on selector box Worn rod ends clevis pins or pivot arm bushings Linkage rod adjustment and rod end positioning Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty is caused by an internal transmission problem isolate the transmission by disconnecting the shifter from transmission bellcrank Verify the engi...

Page 297: ...8 19 TRANSMISSION 8 P R E L I M I N A R Y V E R S I O N 2009 TRANSMISSION EXPLODED VIEW Shift Housing Transfer Case Exploded View Transfer Case Shift Housing ...

Page 298: ...8 20 TRANSMISSION P R E L I M I N A R Y V E R S I O N 2010 TRANSMISSION EXPLODED VIEW Shift Housing Transfer Case Exploded View Transfer Case Shift Housing ...

Page 299: ... BURNISHING PROCEDURE 9 8 FRONT CALIPER SERVICE 9 9 CALIPER EXPLODED VIEW 9 9 CALIPER REMOVAL 9 9 CALIPER DISASSEMBLY 9 10 CALIPER INSPECTION ASSEMBLY 9 11 CALIPER INSTALLATION 9 12 FRONT BRAKE DISC 9 13 DISC INSPECTION REPLACEMENT 9 13 REAR BRAKE PAD 9 14 PAD REMOVAL 9 14 PAD INSPECTION ASSEMBLY INSTALLATION 9 15 BRAKE BURNISHING PROCEDURE 9 15 REAR CALIPER SERVICE 9 16 CALIPER EXPLODED VIEW 9 16...

Page 300: ... Brake Disc Thickness 188 4 78 mm 170 4 32 mm Rear Brake Disc Runout 010 254 mm Item Torque ft lbs Torque Nm Front Caliper Mounting Bolts 30 40 Rear Caliper Mounting Bolts 18 24 Brake Line Flare 12 15 16 20 Brake Line Banjo Bolts Caliper Attachment 15 20 Brake Line Banjo Bolt Master Cylinder Attachment 15 20 Front Brake Disc to Hub Bolts 28 38 Rear Brake Disc to Hub Bolts 28 38 Brake Switch 12 15 ...

Page 301: ...OOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise Permatex Disc Brake Quiet PN 2872113 can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust Bra...

Page 302: ...em and cause the brakes to feel spongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating port 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 dur...

Page 303: ...er to the frame Installation 1 Reverse Steps 1 5 for master cylinder installation Refer to the torque specifications in the illustration 2 After installing the foot brake check pedal freeplay Pedal freeplay should not exceed 090 2 286 mm BRAKE PEDAL LEVER Pedal Removal 1 Locate the brake pedal lever L and remove the master cylinder clevis pin B and clip A 2 Remove the E ring E from the pedal mount...

Page 304: ...er cylinder 7 Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir 8 Tighten bleeder screw securely and remove bleeder hose Torque bleeder screw to 47 in lbs 5 3 Nm 9 Repeat procedure Steps 5 8 for the remaining calipers 10 Add brake fluid to MAX level inside reservoir 11 Install master cylinder reservoir cover...

Page 305: ...ing a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 5 Push mounting bracket inward and slip outer brake pad past edge Remove the inner pad Pad Inspection 1 Measure the thickness of the pad material Replace pads if worn...

Page 306: ...turn counterclockwise 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap 7 Install wheel and torque wheel nuts Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop mach...

Page 307: ...ng the line Remove brake line from caliper 5 Loosen brake pad adjustment set screw 2 3 turns to allow brake pad removal after the caliper is removed A Socket Set Screw B Bleeder Screw C Caliper Assy D Boot E Square O ring thick F Square O ring thin G Piston H Caliper Mount I Brake Pads A B C D E F G H Apply Polaris All Purpose Grease Apply Polaris DOT 4 Brake Fluid to Component I 47 in lbs 5 3 Nm ...

Page 308: ...mble the caliper 5 Use low pressure compressed air to remove the pistons from the caliper 6 While holding the caliper and covering the pistons with a shop towel carefully apply compressed air to the brake line inlet to force the pistons out from the caliper IMPORTANT Do not remove the caliper pistons with a pliers The piston sealing surfaces will become damaged if a pliers is used 7 Once the pisto...

Page 309: ...ter and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads as outlined in this chapter Caliper Assembly 1 Install new O rings in the caliper body Be sure the grooves are clean and free of residue or brakes may drag upon assembly 2 Coat pistons with clean Polaris DOT 4 Brake Fluid Install pistons with a twisting motion while pushing inward Piston should slide in and o...

Page 310: ...ecification 6 Install brake line and tighten securely with a line wrench Torque the banjo bolt brake line s to the proper torque specification 7 Install the pad adjustment screw and turn until stationary pad contacts disc then back off 1 2 turn 8 Perform brake bleeding procedure as outlined earlier in this chapter 9 Install wheel and torque wheel nuts to specification NOTE If new brake pads are in...

Page 311: ...g surface and install new disc on wheel hub 5 Install new bolts and torque to 28 ft lbs 38 Nm 6 Install wheel hub assembly washers and castle nut Torque castle nut to 80 ft lbs 108 Nm and install a new cotter pin 7 Install front brake caliper see FRONT CALIPER SERVICE Follow the bleeding procedure outlined earlier in this chapter 8 Field test unit for proper braking action before putting into serv...

Page 312: ...nk or bend brake line 5 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 6 Push caliper mounting bracket inward and slip outer brake pad past the edge to remove 7 R...

Page 313: ...pad contacts the disc then back off 1 2 turn counterclockwise 6 Verify fluid level in reservoir is up to the MAX line inside reservoir and install reservoir cap 7 Install wheel and torque wheel nuts Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed t...

Page 314: ... 5 Loosen the brake pad adjustment set screw to allow brake pad removal after the caliper is removed 6 Remove the two caliper mounting bolts and remove the caliper A Brake Pad B Mount Bracket C Piston D Caliper Assy E Square Ring thick F Square Ring thin G Boot Pin Bushing H Boot Pin Seal I Bleeder Screw K Set Screw A B C D E F G H I K Apply Polaris DOT 4 Brake Fluid to Component Apply Polaris All...

Page 315: ... with brake cleaner or alcohol NOTE Be sure to clean seal grooves in caliper body Caliper Inspection 1 Inspect caliper body for nicks scratches or wear Measure bore size and compare to specifications Replace if damage is evident or if worn beyond service limit 2 Inspect piston for nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit 3 Inspect the brak...

Page 316: ...s Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease Caliper Installation 5 Install the rear caliper with the mounting bolts Torque mounting bolts to 18 ft lbs 24 Nm 6 Install brake line banjo bolt and torque to specification 7 Install the pad adjustment screw and turn until stationary pad contacts disc then back off 1 2 turn 8 Perform brake blee...

Page 317: ... surface and install new disc on wheel hub 5 Install new bolts and torque to 28 ft lbs 38 Nm 6 Install wheel hub assembly washers and castle nut Torque castle nut to 80 ft lbs 108 Nm and install a new cotter pin 7 Install rear brake caliper see REAR CALIPER SERVICE Follow the bleeding procedure outlined earlier in this chapter 8 Field test unit for proper braking action before putting into service...

Page 318: ...Worn or damaged master cylinder or components Damaged break pad noise insulator Brake pads dragging Brake caliper dragging Pedal Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port plugged Pad clearance set incorrectly Brake pedal binding or unable to return fully Residue build up under caliper seals Operator riding br...

Page 319: ... NO DISPLAY 10 13 TEST 3 VEHICLE SPEED SENSOR 10 13 TEST 4 NO AWD HUB SAFETY LIMITER 10 14 TEST 5 FUEL GAUGE DISPLAY NOT WORKING 10 15 TEST 6 GEAR INDICATOR NOT WORKING TRANSMISSION SWITCH 10 15 ALL WHEEL DRIVE COIL 10 16 GEAR POSITION INDICATOR SWITCH 10 16 SPEED SENSOR 10 16 HEAD LIGHTS 10 17 HEADLIGHT ADJUSTMENT 10 17 HEADLAMP BULB REPLACEMENT 10 17 HEADLAMP HOUSING REMOVAL INSTALLATION 10 18 T...

Page 320: ...PEN CIRCUIT VOLTAGE TEST 10 27 LOAD TEST 10 27 OFF SEASON STORAGE 10 27 STARTING SYSTEM 10 28 TROUBLESHOOTING 10 28 VOLTAGE DROP TEST 10 28 STARTER MOTOR REMOVAL DISASSEMBLY 10 28 BRUSH INSPECTION REPLACEMENT 10 29 ARMATURE TESTING 10 30 STARTER REASSEMBLY INSTALLATION 10 30 STARTER DRIVE 10 31 STARTER SOLENOID BENCH TEST 10 32 STARTER SOLENOID OPERATION 10 32 STARTER EXPLODED VIEW 10 33 STARTING ...

Page 321: ...th other meters may differ Pay attention to the prefix on the multimeter reading K M etc and the position of the decimal point For resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply Under Dash Components The following switches and components can be accessed underneath the instrument dash panel Speedometer Speedometer Mode Switch Digital Wre...

Page 322: ...mbly Turn the ignition key to ON LIGHTS There should be continuity between pins A E and F C and D Turn the ignition key to ON There should be continuity between pins C and D E and F Turn the ignition key to START There should be continuity between pins A and B C and D E and F Turn Signal Switch 2010 INT L Models 1 Disconnect the switch harness Green Blue Yellow Gray Red Red Yellow and Yellow Green...

Page 323: ...itch terminals Re test and replace switch if necessary AWD 2WD Switch 1 Disconnect the switch harness Grey Red White and Brown by depressing the connector lock and pulling on the connector Do not pull on the wiring 2 Test the switch connections and check for continuity at the pins shown in the illustration AWD 2WD TURF Switch INT L Models 1 Disconnect the switch harness Grey Red White Brown and Wh...

Page 324: ...RF mode a ground signal is provided to the ECU from the AWD 2WD TURF Switch Depending on engine speed and gear position criteria the ECU energizes the Rear Diff Solenoid Relay allowing it to enable the differential solenoid If the rear differential fails to switch from operational modes Check the solenoid and relay connectors Look for loose wires or bad connections Check for power from the relay c...

Page 325: ...r P Park 2 AWD Indicator This indicator illuminates when the AWD switch is in the AWD position 3 Engine Hour Display Indicator 4 Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan a...

Page 326: ...gine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Diagnostic Display Mode The wrench icon will display when the gauge is in the diagnostic mode To exit the diagnostic mode turn the key switch off and on Any movement of the tires will also cause the gauge to exit the diagnostic mode To enter the ...

Page 327: ...programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance NOTE The service interval is programmed to 50 hours at the factory To enable or disable the service interval 1 Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the...

Page 328: ...o display either standard or metric units of measurement 1 Enter the diagnostic mode 2 Toggle to the screen that displays either kilometers KM or miles MP 3 Press and hold the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set Viewing Diagnostic Codes Use the following procedure to view diagnostic blink codes failure cod...

Page 329: ...d is a serviceable part Instrument Cluster Installation 1 Spray a soap and water mixture onto the outer surface area of the instrument cluster This will help the instrument cluster slide into the rubber mount more easily 2 Be sure the rubber mount inside the dash is fully installed and that the indexing key on the rubber mount is lined up with the keyway in the dash 3 Hold the dash securely and in...

Page 330: ...10 12 ELECTRICAL P R E L I M I N A R Y V E R S I O N INSTRUMENT CLUSTER TROUBLESHOOTING TESTS TEST 1 No All Wheel Drive ...

Page 331: ...10 13 ELECTRICAL 10 P R E L I M I N A R Y V E R S I O N TEST 2 No Display TEST 3 Vehicle Speed Sensor ...

Page 332: ...10 14 ELECTRICAL P R E L I M I N A R Y V E R S I O N TEST 4 No AWD Hub Safety Limiter ...

Page 333: ...10 15 ELECTRICAL 10 P R E L I M I N A R Y V E R S I O N TEST 5 Fuel Gauge Display Not Working TEST 6 Gear Indicator Not Working Transmission Switch ...

Page 334: ...rify continuity of wire connections with a known good volt ohm meter IMPORTANT Verify all wires and wiring connections have been tested properly with a known good volt ohm meter before suspecting a component failure 80 of all electrical issues are caused by bad failed connections and grounds GEAR POSITION INDICATOR SWITCH Switch Resistance Value Table NOTE See Instrument Cluster Troubleshooting fo...

Page 335: ...orming this procedure 5 Adjust the beam to the desired position by loosening the adjustment screw A and moving the lamp to the appropriate height 6 Adjust the beam to desired position Repeat the procedure to adjust the other headlight Headlamp Bulb Replacement 1 Disconnect the headlamp bulb from the wiring harness Be sure to pull on the connector not on the wiring 2 Turn the lamp counterclockwise ...

Page 336: ...or re insert bulb if previously removed 4 Adjust headlights using the Headlight Adjustment procedure in this section TAIL BRAKE LIGHTS Bulb Replacement Before replacing the bulb s use a digital multi meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present If a tail light brake light or turn signal INT L Only does not work the bulb may need to be replace...

Page 337: ...10 19 ELECTRICAL 10 P R E L I M I N A R Y V E R S I O N COOLING SYSTEM SCHEMATIC Cooling System Break Out Diagram ...

Page 338: ...2 With the meter in the ohms mode place the meter leads onto the sensor contacts 3 Use the table Temperature Resistance table to determine if the sensor needs to be replaced NOTE If the coolant temperature sensor or circuit malfunctions the radiator fan will default to ON EFI DIAGNOSTICS EFI Component Testing All EFI component information and diagnostic testing procedures are located in Chapter 4 ...

Page 339: ... Amp power to Fan Motor output Red Fused 20 Amp constant battery power IN supply for EFI component operation EFI RELAY COLOR FUNCTION Orange Fused 15 amp constant battery power IN supply for EFI component operation Red White Key On battery power supply switched on by key switch enables power to relay Red Black EFI power output Switched by relay when ECU sends a signal on the GRY W wire closing the...

Page 340: ...AKER Operation Located in the fuse box under the dash the fuse panel provides overload protection for wiring and components such as the Instrument Cluster ECU EFI System Chassis Power Lights and Accessories A separate 20 amp circuit breaker protects the fan motor circuit ...

Page 341: ...ndicated 4 Shift transmission into neutral with the park brake on and start the engine With the engine running at idle observe meter readings 5 Increase engine RPM while observing ammeter and tachometer 6 Note RPM at which the battery starts to charge ammeter indication is positive 7 With lights and other electrical loads off the break even point should occur at approximately 1500 RPM or lower 8 W...

Page 342: ...of Each Stator Leg at Charging RPM 1 Set the selector dial to measure AC Voltage 2 Start the engine and let it idle 3 While holding the engine at a specified RPM separately measure the voltage across each leg of the stator by connecting the meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to Y3 4 Refer to the following table for approximate AC Voltage readings according to...

Page 343: ...nnector BLACK Ground 2 wire connector Open Circuit BLACK Ground 2 wire connector RED Battery 2 wire connector 2300mV to 2400mV BLACK Ground 2 wire connector Regulator Rectifier Case Closed Circuit continuity BLACK Ground 2 wire connector Any Phase Open Circuit AC 1 3 wire connector BLACK Ground 2 wire connector Open Circuit AC 2 3 wire connector BLACK Ground 2 wire connector 2200mV to 2300mV AC 3 ...

Page 344: ...s operating habits The battery will continually discharge if operated below the Break Even RPM Con tinued problems would call for battery inspection Yes Inspect the wiring harness between the panel and the stator for remove the recoil and flywheel Inspect the flywheel magnets stator coils and stator wires for damage No Check stator regulator ground battery and battery connections Also check wire c...

Page 345: ...determine its condition Open Circuit Voltage Test and a Load Test OCV Open Circuit Voltage Test Battery voltage should be checked with a digital multimeter Readings of 12 8 volts or less require further battery testing and charging See the following chart and Load Test NOTE Maintenance Free batteries should be kept at or near a full charge If the battery is stored or used in a partially charged co...

Page 346: ...e Faulty starter drive gears or starter motor gear Faulty flywheel gear or loose flywheel Voltage Drop Test The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 1 VDC...

Page 347: ...s Remember to subtract meter lead resistance 2 Measure resistance between insulated brush and starter housing Reading should be infinite OL Inspect insulation on brush wires for damage and repair or replace as necessary 3 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Slide brush end frame off end of starter NOTE The electrical input post must stay...

Page 348: ...ure shaft The reading should be infinite no continuity 5 Check commutator bars for discoloration Bars discolored in pairs indicate shorted coils requiring replacement of the starter motor 6 Place armature in a growler Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1 8 3 cm above armature coil laminates Rotate armature 360 If hacksaw blade is drawn to armature on any pole t...

Page 349: ...ase Hand tighten each of the starter bolts Torque the bottom bolt first to 9 ft lbs 12 Nm Then torque the top bolt to the same specification NOTE It is important to tighten the bottom starter bolt first circle as the bottom hole acts as a pilot hole to properly align the starter drive bendix with the flywheel This helps to prevent binding and starter damage Starter Drive If the garter spring is da...

Page 350: ...lenoid Bench Test Test the start solenoid by powering the solenoid using battery voltage for a maximum of 5 seconds With the solenoid energized resistance should read about 0 0 5Ω between terminals A and B If resistance measurement is out of specification replace the starter solenoid Starter Solenoid Operation To energize the Starter Solenoid the following must occur The brake must be applied to p...

Page 351: ...ing 2 Brush Spring 3 Thrust Washer 4 Gear Assembly 5 O Ring 6 Brush Complete 7 O Ring 8 Thrust Washer 9 Shaft Complete 10 Gear Assembly 11 Through Bolt 12 Cover 13 Stopper 14 Snap Ring 15 Washer 16 Flange Bolt 17 Thrust Washer 18 Flange Bushing Indicates Do not reuse Replace with new parts ...

Page 352: ... With the solenoid energized resistance should read about 0 5Ω 10 between the two terminals If resistance measurement is out of specification replace the starter solenoid see Starter Solenoid Bench Test Reconnect the solenoid Connect the tester black lead to the battery positive and the red lead to the solenoid end of the battery to solenoid wire Turn the ignition key to the start position Reading...

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