Polaris 2015 RZR 900 XC Edition Service Manual Download Page 89

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3.23

9925723 R01 - 2015

RZR

900 Service Manual

PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT

Piston

Piston - Standard O.D. - Measured 90 degrees to pin,
0.51 in. (13 mm) up from piston skirt. See text.

3.6592 ± 0.0003" (92.950 ± 0.008 mm)

Piston Pin Bore I.D. (Standard)

0.7876" - 0.7878" (20.004 - 20.009 mm)

Piston Pin Bore I.D. (Service Limit)

0.7893" (20.05 mm)

Piston Pin

Piston Pin O.D. (Standard)

0.7872" - 0.7874" (19.995 - 20.000 mm)

Piston Pin O.D. (Service Limit)

0.7866" (19.98 mm)

Piston Ring

Installed
Gap

Top Ring (Standard)

0.008" - 0.014" (0.20 - 0.36 mm)

Top Ring (Service Limit)

0.020" (0.5 mm)

Second Ring (Standard)

0.015" - 0.025" (0.37 - 0.63 mm)

Second Ring (Service Limit)

0.028" (0.70 mm)

Oil Control Rails (Standard)

0.010" - 0.040" (0.25 - 1.02 mm)

Oil Control Rails (Service Limit)

0.059" (1.50 mm)

Ring to
Groove
Clearance

Top Ring (Standard)

0.0012" - 0.0037" (0.030 - 0.095 mm)

Second Ring (Standard)

0.0012" - 0.0030" (0.030 - 0.076 mm)

Service Limit

0.0047" (0.12 mm)

Connecting Rod

Connecting Rod Small End I.D. (Standard)

0.7879" - 0.7884" (20.015 - 20.025 mm)

Connecting Rod Small End I.D. (Service Limit)

0.7897" (20.06 mm)

1 - Marking

Connecting Rod Big End Bore I.D.

1.7318" - 1.7321" (43.989 - 43.996 mm)

2 - Marking

Connecting Rod Big End Bore I.D.

1.7321" - 1.7323" (43.996 - 44.003 mm)

3 - Marking

Connecting Rod Big End Bore I.D.

1.7323" - 1.7326" (44.003 - 44.010 mm)

Crankshaft

B - Marking

Main Journal O.D. (Standard)

1.6140" - 1.6143" (40.996 - 41.004 mm)

G - Marking

Main Journal O.D. (Standard)

1.6137" - 1.6140" (40.988 - 40.995 mm)

Y - Marking

Main Journal O.D. (Standard)

1.6134" - 1.6137" (40.980 - 40.987 mm)

Main Journal O.D. (Service Limit)

1.6126" (40.960 mm)

B - Marking

Rod Journal O.D. (Standard)

1.6118" - 1.6122" (40.942 - 40.950 mm)

G - Marking

Rod Journal O.D. (Standard)

1.6115" - 1.6118" (40.934 - 40.941 mm)

Y - Marking

Rod Journal O.D. (Standard)

1.6112" - 1.6115" (40.926 - 40.933 mm)

Rod Journal O.D. (Service Limit)

1.6104" (40.906 mm)

Crankshaft Runout Limit (PTO and MAG)

Less than 0.001" (0.025 mm)

Auxiliary Sprocket Installed Depth

4.9527" ± 0.0078" (125.8 ± 0.2 mm)

Balance Shaft

Bearing Journal O.D. (Standard)

1.4939" - 1.4946" (37.946 - 37.962 mm)

Bearing Journal O.D. (Service Limit)

1.4921" (37.900 mm)

ENGINE / COOLING SYSTEM

Summary of Contents for 2015 RZR 900 XC Edition

Page 1: ...n authorized dealer for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please provide any feedback you may have regarding this manual Authorized dealers can submit feedback using Ask Polaris Click on Ask Polaris and then click on Service Manual Service Literature Question Consumers please provide your feedback in writing to ...

Page 2: ...tor bystander or person s inspecting or servicing the vehicle CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage NOTE NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders d...

Page 3: ...y Vac Registered Trademark of Neward Enterprises Inc Torx Registered Trademark of Textron Hilliard Trademark of the Hilliard Corporation Warn Trademark of Warn Industries FOX Registered Trademark of FOX RACING SHOX RydeFX Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www polarisindustries com purchased from www purepolaris com or by contacting the ne...

Page 4: ......

Page 5: ...1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE COOLING SYSTEM 4 FUEL SYSTEM 5 PVT SYSTEM 6 TRANSMISSION 7 FINAL DRIVE 8 STEERING SUSPENSION 9 BRAKE SYSTEM 10 BODY FRAME 11 ELECTRICAL ...

Page 6: ......

Page 7: ... NUMBER LOCATION 1 3 MISC INFORMATION 1 4 PUBLICATION NUMBERS 1 4 REPLACEMENT KEYS 1 5 SPECIAL TOOLS 1 6 GENERAL SPECIFICATIONS 1 10 RZR 900 RZR 900 EPS SPECIFICATIONS 1 10 RZR 900 XC SPECIFICATIONS 1 12 RZR S 900 SPECIFICATIONS 1 14 MISC SPECIFICATIONS AND CHARTS 1 16 MASTER TORQUE TABLE 1 16 CONVERSION TABLE 1 19 STANDARD BOLT TORQUE SPECIFICATION 1 20 METRIC BOLT TORQUE SPECIFICATION 1 20 SAE T...

Page 8: ...ured versions of models not including the base First 3 digits and 10th digit are used in model number only They are not used with the 17 digit VIN Digits 1 through 8 determine Digital Wrench calibration Vehicle Identification Number VIN Designation 2015 Example 4XARH57A0F3000000 WORLD MFG ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE ENGINE SIZE ENGINE MODIFIER CATEGORY CHECK DIGIT ...

Page 9: ...identification number VIN and the engine serial number The VIN can be found stamped on a portion of the left rear upper frame and also on a decal on the front frame support behind the lower shock mounting location The engine serial number can be found on a decal applied to the front of the engine crankcase or stamped into the crankcase on the PTO side of the engine GENERAL INFORMATION 1 ...

Page 10: ... OWNER S MANUAL PARTS MANUAL 2015 RZR 900 EPS 50 9925322 9925324 2015 RZR 900 XC 9925631 9925324 2015 RZR S 900 EPS 60 9925322 9925792 NOTE When ordering service parts be sure to use the correct parts manual Polaris factory publications can be found at www polaris com or purchased from www purepolaris com GENERAL INFORMATION ...

Page 11: ... made from the original key To identify which series the key is take the first two digits on the original key and refer to the chart to the right for the proper part number SERIES PART NUMBER 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 GENERAL INFORMATION 1 ...

Page 12: ...ls listed or depicted are mandatory while other tools may be 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 Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com GENERAL INFORMATION ...

Page 13: ...Test Tool 2871056 Driven Clutch Puller 2871226 Clutch Bushing Replacement Tool Kit 2871282 Transmission Seal Driver 50 MM 2871351 IFP Depth Tool 2871358 B Drive Clutch Holding Fixture 2871702 Shaft Drive Transmission and Front Gearcase Tool Kit 2871745 Static Timing Light Harness 2872085 Drive Clutch Puller 2872608 Roll Pin Removal Tool 27 2876389 Combination Pliers 2877408 Spanner Wrench Clutch S...

Page 14: ...t PU 48951 CV Boot Clamp Pliers Stepless PU 49466 Relay Bypass PU 50105 Oil Filter Wrench PU 50296 Battery Tester PU 50338 Hydrometer PU 50518 Clutch Compressor PU 50562 Engine Stand Adapter PU 50563 Cylinder Holding Camshaft Timing Plate PU 50564 Water Pump Seal Installer PU 50565 Oil Pressure Gauge Adapter 1 2 NPT PU 50566 Transmission Nut Socket PU 50578 Clutch Spider Nut Socket PU 50624 Rollin...

Page 15: ... 8 PU 51024 Shock Rod Holding Tool PU 51039 Gas Shock Fill Tool PV 1253 Valve Spring Compressor PV 43513 A Valve Spring Compressor Adapter PV 43526 Connector Test Kit PV 43531 Oil Presure gauge PV 43568 Fluke Multimeter PV 43570 Piston Ring Compressor Pliers PV 48656 Fuel Pressure Gauge Adapter PW 47053 Bench Mount Engine Stand PW 47054 Engine Stand Adapter Sleeve 2 3 8 GENERAL INFORMATION 1 ...

Page 16: ... 271 8 cm Width 50 127cm Height 69 5 176 5cm Wheel Base 79 200 cm Ground Clearance 10 11 25 4 27 9 cm Dry Weight 1148 lbs 521 kg Gross Vehicle Weight 1969 lbs 893 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 336 4 kg Includes riders cargo and accessories Hitch Towing Capacity 1500 lbs 680 kg Hitch Tongue Capacity 150 lbs 68 kg GENERAL INFORMATION ...

Page 17: ...FI Fuel Pump Chassis EPS if appl Circuit Breaker 20A Cooling Fan Fuses 10A EFI 10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Sequence In Line Shift P R N L H Transmission Gear Ratios High Low Reverse 10 4 1 18 8 1 22 92 1 Front Gearcase Lubricant Requirement Demand Drive 7 5 oz 222 ml Transmission Lubricant Requirement ...

Page 18: ...th 55 139 7 cm Height 70 5 179 cm Wheel Base 79 200 cm Ground Clearance 12 5 31 75 cm Dry Weight 1247 lbs 566 kg Gross Vehicle Weight 2068 lbs 938 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 336 kg Includes riders cargo and accessories Hitch Towing Capacity 1500 lbs 680 kg Hitch Tongue Capacity 150 lbs 68 kg GENERAL INFORMATION ...

Page 19: ...l Pump Chassis EPS Circuit Breaker 20A Cooling Fan Fuses 10A EFI 10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Sequence In Line Shift P R N L H Transmission Gear Ratios High Low Reverse 10 4 1 18 8 1 22 92 1 Front Gearcase Lubricant Requirement Demand Drive 7 5 oz 222 ml Transmission Lubricant Requirement Full Synthetic AGL 44 ...

Page 20: ...h 60 152 4 cm Height 72 182 9 cm Wheel Base 79 200 cm Ground Clearance 12 5 31 75 cm Dry Weight 1208 lbs 548 kg Gross Vehicle Weight 2029 lbs 920 kg Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 336 kg Includes riders cargo and accessories Hitch Towing Capacity 1500 lbs 680 kg Hitch Tongue Capacity 150 lbs 68 kg GENERAL INFORMATION ...

Page 21: ...hassis EPS if appl Circuit Breaker 20A Cooling Fan Fuses 10A EFI 10A Key 10A Term 10A Accessory 10A Drive 15A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Sequence In Line Shift P R N L H Transmission Gear Ratios High Low Reverse 10 4 1 18 8 1 22 92 1 Front Gearcase Lubricant Requirement Demand Drive 7 5 oz 222 ml Transmission Lubricant Requirement Full Synthetic...

Page 22: ...taining Bolt 9 ft lb 12 Nm Crankcase Bolts M10 Torque in sequence Step 1 9 ft lb 12 Nm Step 2 21 ft lb 28 Nm Step 3 Tighten add n 90 Crankcase Bolts M8 26 ft lb 35 Nm ITEM TORQUE Crankcase Bolts M6 9 ft lb 12 Nm Crankcase Oil Gallery Plug 11 ft lbs 15 Nm Cylinder Head Bolts Torque in sequence Step 1 9 ft lbs 12 Nm Step 2 26 ft lb 35 Nm Step 3 Additional 180 Step 4 M6 bolts 7 ft lb 10 Nm Differenti...

Page 23: ...lb 11 Nm Seat Belt Mounting Fasteners 40 ft lbs 54 Nm Seat Fasteners 4 ft lb 5 Nm Seat Frame Fasteners front 14 ft lb 19 Nm ITEM TORQUE Seat Frame Fasteners rear 30 ft lb 41 Nm Shift Cable Bracket Bolts 17 ft lb 23 Nm Shift Cable Jam Nut 18 ft lb 24 Nm Shift Cable Mounting Fasteners 13 ft lb 18 Nm Shock Mounting Fasteners 42 ft lb 57 Nm Skid Plate Fasteners 8 ft lbs 11 Nm Spark Plug 7 ft lbs 10 Nm...

Page 24: ...Nm Transmission Shift Fork Screws 10 ft lb 14 Nm Transmission Snorkel Tube Locking Screw 10 ft lb 14 Nm Valve Cover Bolts 7 ft lbs 10 Nm Visor Mounting Screws 8 ft lb 11 Nm Voltage Regulator Fasteners 5 ft lb 7 Nm Water Pump Impeller 7 ft lb 10 Nm Apply Loctite 204 to bolt threads Water Pump Cover Bolts 7 ft lb 10 Nm Apply Loctite 204 to bolt threads Wheel Lug Nuts Aluminum 120 ft lbs 163 Nm Steel...

Page 25: ...mi x 1 6 km km x 0 6214 mile ounces oz x 28 35 grams g fluid ounces fl oz x 29 57 cubic centimeters cc cubic centimeters cc x 03381 fluid ounces grams g x 0 035 ounces pounds lb x 0 454 kg kilogram kg x 2 2046 lbs cubic inches cu in x 16 387 cc cubic centimeters cc x 0 061 cubic inches US quarts x 0 946 liters L liters L x 1 057 US quarts US gallons x 3 785 liters L liters L x 0 264 US gallons PSI...

Page 26: ...16 20 35 48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 Metric Bolt Torque Specification BOLT SIZE GRADE 4 6 4 8 8 8 8 9 10 9 12 9 FT LBS NM DRY THREADS M3 0 3 0 5 0 5 0 7 1 1 3 1 5 2 1 5 2 M4 0 8 1 1 1 1 5 2 3 3 4 5 4 5 M5 1 5 2 5 2 3 4 5 6 6 5 9 7 5 10 M6 3 4 4 5 5 7 5 10 11 15 13 18 M8 7 9 5 10 13 18 25 26 35 33 45 M10 14 19 18 25 37 50 55 75 63 85 M12 26 35 33 45 63 85...

Page 27: ... 1 2 12 1 27 64 12 28 4 6 mm 1 3 4 5 1 9 16 1 4 20 7 1 3 4 12 1 43 64 1 4 28 3 2 4 1 2 1 25 32 5 16 18 F 2 12 1 59 64 5 16 24 I 2 1 4 4 1 2 2 1 32 3 8 16 O 2 1 2 4 2 1 4 3 8 24 Q 2 3 4 4 2 1 2 7 16 14 U 3 4 2 3 4 7 16 20 25 64 Metric Tap Drill Sizes TAP SIZE DRILL SIZE DECIMAL NEAREST FRACTION 3 x 50 39 0 0995 3 32 3 x 60 3 32 0 0937 3 32 4 x 70 30 0 1285 1 8 4 x 75 1 8 0 125 1 8 5 x 80 19 0 166 1...

Page 28: ...10 mm 0 3937 13 32 0 4063 27 64 0 4219 11 mm 0 4331 7 16 0 4375 29 64 0 4531 15 32 0 4688 12 mm 0 4724 31 64 0 4844 1 2 0 500 13 mm 0 5118 33 64 0 5156 17 32 0 5313 35 64 0 5469 14 mm 0 5512 9 16 0 5625 37 64 0 5781 15 mm 0 5906 19 32 0 5938 39 64 0 6094 5 8 0 625 16 mm 0 6299 FRACTION DECIMAL MM TO INCHES 41 64 0 6406 21 32 0 6563 17 mm 0 6693 43 64 0 6719 11 16 0 6875 45 64 0 7031 18 mm 0 7087 2...

Page 29: ...UEL LINES 2 11 THROTTLE PEDAL INSPECTION 2 11 ENGINE SYSTEM 2 12 ENGINE AIR FILTER SERVICE 2 12 INTAKE DUCT INSPECTION 2 12 AIR BOX FILTER ASSEMBLY VIEW 2 13 ENGINE OIL LEVEL 2 14 ENGINE OIL AND FILTER CHANGE 2 15 CRANKCASE BREATHER HOSE INSPECTION 2 16 ENGINE CYLINDER LEAK DOWN TEST 2 16 VALVE CLEARANCE INSPECTION 2 16 TRANSMISSION AND FRONT GEARCASE 2 19 SPECIFICATION CHART 2 19 TRANSMISSION LUB...

Page 30: ...AGE 2 28 BATTERY CHARGING 2 29 BATTERY REMOVAL 2 29 BATTERY INSTALLATION 2 30 ENGINE CHASSIS GROUND 2 30 SPARK PLUG SERVICE 2 31 STEERING SYSTEM 2 32 STEERING INSPECTION 2 32 STEERING WHEEL FREE PLAY 2 32 TIE ROD END WHEEL HUB INSPECTION 2 32 WHEEL TOE ALIGNMENT INSPECTION 2 33 WHEEL TOE ADJUSTMENT 2 34 SUSPENSION SYSTEM 2 35 SPRING ADJUSTMENT 2 35 SPRING ADJUSTMENT FOX 2 35 SHOCK COMPRESSION ADJU...

Page 31: ...the oil sump or crankcase Change oil immediately 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 Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these compone...

Page 32: ... leaks and abrasion Parking Brake Cable Adjustment INT L 25 H Inspect adjust tension after first 25 hours E Air Filter Weekly Inspect replace as needed E Engine Breather 25 H Monthly 150 250 Inspect clean Battery 25 H Monthly 250 400 Check terminals clean test E Engine Oil Filter Change Break In Period 25 H 1 M Perform a break in oil and filter change at 25 hours or one month perform every 50 hour...

Page 33: ...l surfaces Cooling Hoses 100 H 12 M 1000 1600 Inspect for leaks pressure test system Engine Mounts 100 H 12 M 1000 1600 Inspect torque to specification Exhaust Silencer Pipe 100 H 12 M 1000 1600 Inspect Wiring 100 H 12 M 1000 1600 Inspect for wear routing security inspect connectors subjected to water mud etc Clutches Drive and Driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Front Whe...

Page 34: ...emove cargo box panel and add oil to proper level on dipstick Perform a break in oil and filter change at 25 hrs or one month perform every 50 hrs thereafter Engine Coolant Reservoir 4 Radiator Cap 5 Radiator 6 Polaris 50 50 Coolant Remove hood panel Maintain coolant level in coolant reservoir bottle and radiator Check level daily change coolant every two years More often under severe use such as ...

Page 35: ...ing pre ride inspection change fluid every two years Front Gearcase Polaris Demand Drive Add lubricant until it is visible at the fill hole threads 2 7 5 oz 222 mL Initial level check at 25 hours or 1 month Change lubricant at 100 hours or every 12 months whichever comes first Transmission Polaris AGL Add lubricant until it is visible at the fill hole threads 3 More often under severe use such as ...

Page 36: ...horoughly washing or submerging the vehicle Apply grease until all traces of water has been purged out at each of these areas Prop Shaft Yokes Grease middle and rear fittings 2 Polaris Premium U Joint Grease Front Stabilizer Bar Bushings 50 and XC Grease the fitting on each side 3 Polaris All Season Grease Rear Stabilizer Bar Bushings Grease 2 fittings 4 through the skid plate access holes on each...

Page 37: ...evel at the recovery bottle Drive Shaft Boots Inspect inner and outer boots for tears or damage on both front and rear drive shafts Check all front and rear suspension components for wear or damage Shift Cable Inspection Adjustment Shift cable adjustment may be necessary if symptoms include No gear position or AWD display on instrument cluster Ratcheting noise on deceleration Inability to engage i...

Page 38: ...n the fuel when the engine is hot Severe burns may result Fuel Tank Vent Line Symptoms of a restricted fuel tank vent include the following collapsing fuel tank engine miss or hesitation loss of engine performance or high exhaust temperatures 1 Remove the seats and the engine service panel 2 Check the fuel tank vent line for signs of wear deterioration or damage Replace vent line if necessary 3 Be...

Page 39: ...s panel Check the line and quick connect fitting for signs of wear deterioration damage or leakage Replace line if necessary 3 Be sure fuel lines are routed and retained properly IMPORTANT Lines should not be kinked or pinched Throttle Pedal Inspection This vehicle is equipped with a Pedal Position Sensor 1 used to detect when the throttle pedal 2 is pushed or released The throttle pedal should mo...

Page 40: ... away any deposits with a clean shop towel NOTE If the filter has been soaked with fuel or oil it must be replaced 5 Inspect the air filter and replace if necessary NOTE DO NOT attempt to clean the air filter 6 Place the air filter into the air box and reinstall the air box cover NOTE Be sure the lower tabs on the air box cover are properly engaged into the airbox 7 Engage the cover straps 8 Reins...

Page 41: ...0 Service Manual Copyright 2014 Polaris Industries Inc Air Box Filter Assembly View 1 Intake Airbox Hose 6 Airbox Clips 2 Drain Cap 7 Vent Hose 3 Airbox 8 Intake Tubes 4 Air Filter 9 Engine Intake Housing 5 Airbox Cover MAINTENANCE ...

Page 42: ...w it to cool down before removing the dipstick 3 Remove the access panel between the seats to access the dipstick 4 Unlock the dipstick lever 1 Remove the dipstick and wipe it dry with a clean cloth 5 Reinstall the dipstick and push it into place Do not lock the dipstick NOTE Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent 6 Rem...

Page 43: ...edure Do not allow hot engine oil to come into contact with skin as serious burns may result 4 Place a drain pan under the engine crankcase and remove the drain plug 1 Allow the oil to drain completely 5 Remove the seats and engine service panel to access the oil filter 6 Using the Oil Filter Wrench PU 50105 turn the oil filter 2 counter clockwise to remove it Oil Filter Wrench PU 50105 2 5 64 mm ...

Page 44: ...rfill 19 When finished reinstall the oil fill cap oil dipstick and lock the lever 20 Reinstall the cargo box access panel engine service panel and seats 21 Dispose of used oil and filter properly Crankcase Breather Hose Inspection The engine crankcase is equipped with a breather hose Inspect the breather hose for possible kinks or wear The hose is form fitted for proper fit Follow the breather hos...

Page 45: ...ccess to valve cover as shown below 6 Remove the four T40 bolts retaining the valve cover 7 The engine will need to be rotated four times to inspect all eight valve clearances 1 Two valves can be measured at each camshaft lobe position 8 Rotate the drive clutch counter clockwise until the cam lobes 2 above the valves you are inspecting are facing up IMPORTANT Do not rotate the engine backwards The...

Page 46: ...d the four T40 bolts Torque bolts to specification Valve Cover Bolts 7 ft lbs 10 Nm 15 Install the spark plug wires back into their correct location 16 Install the push rivet that retains the heat shield to the frame cross member 17 Install the spark plug wires Ensure wires are installed on their proper cylinder spark plug and pushed down all the way so they engage onto the spark plugs NOTE The en...

Page 47: ...s routed properly and unobstructed Transmission Lubricant Level Check The fill plug is located on the rear portion of the transmission gearcase Access the fill plug at the rear of the vehicle Maintain lubricant level even with the bottom of the fill plug hole 1 Position vehicle on a level surface 2 Remove the fill plug 1 and check the lubricant level 3 If lubricant level is not even with bottom th...

Page 48: ...is positioned on a level surface when checking or changing the fluid Check vent hose to be sure it is routed properly and unobstructed Front Gearcase Fluid Level Check The fill plug is located on the bottom right side of the front gearcase Access the fill plug through the right front wheel well Maintain fluid level even with the bottom of the fill plug hole 1 Position vehicle on a level surface 2 ...

Page 49: ...ole Maintain the fluid level even with the bottom threads of the fill plug hole Recommended Front Gearcase Fluid Polaris Demand Drive PN 2877922 Quart Capacity 7 5 oz 222 mL 11 Reinstall the fill plug and torque to specification Front Gearcase Fill Drain Plug Torque 10 ft lbs 14 Nm 12 Check for leaks Dispose of used fluid properly MAINTENANCE ...

Page 50: ... straight water in the system Tap water contains minerals and impurities which build up in the system Straight water or antifreeze may cause the system to freeze corrode or overheat Recommended Coolant Polaris Premium Pre Mixed Antifreeze PN 2880514 Quart PN 2880513 Gallon Coolant Level Inspection The pressure cap 1 and recovery bottle 2 are located under the front hood of the vehicle The coolant ...

Page 51: ...r fins are clean to prevent overheating Cooling System Pressure Test Refer to ENGINE COOLING SYSTEM page Cooling System Hose Inspection 1 Inspect all vehicle hoses for cracks deterioration abrasion or leaks Replace if necessary 1 Recovery Bottle 2 Engine Hoses 3 Radiator Hoses 4 To Thermostat Housing 5 To Water Pump 6 To Radiator 2 Inspect all engine hoses for cracks deterioration abrasion or leak...

Page 52: ...ator are warm or hot Hot coolant can cause severe burns Allow engine and radiator to cool 2 Slowly remove the pressure cap to relieve any cooling system pressure 3 Place a suitable drain pan underneath the radiator fitting on the front right side of the vehicle 4 Drain the coolant from the radiator by removing the lower coolant hose from the radiator as shown 1 5 Allow coolant to drain completely ...

Page 53: ...d immediately Use the following instructions to dry it out before operating The PVT drain plug is located at the bottom of the outer clutch cover Access the drain plug through the left rear wheel well 1 Using a flat blade screwdriver remove the PVT drain plug 1 and O ring from the outer clutch cover 2 Allow the water to drain out completely 3 Reinstall the drain plug and O ring 4 Place the transmi...

Page 54: ...ve the wheel cap 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 Wheel Installation 1 Verify the transmission is still in PARK 2 Place the wheel in the correct position on the wheel hub 1 Be sure the valve stem 2 is toward the outside and rotation arrows on the tire poi...

Page 55: ...ossibility of the vehicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the usable tread depth has worn out Tire Pressure Remove the valve stem cap and check tire pressure using the tire pressure gauge included in the vehicle s tool kit CAUTION Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle Ti...

Page 56: ...ten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE Batteries must be fully charged before use or battery life will be red...

Page 57: ...harging if the battery becomes very warm to the touch Allow it to cool before resuming charging STATE OF CHARGE VOLTAGE DC ACTION CHARG E TIME 100 12 8 or more None check again in 3 months None Required 75 100 12 6 12 8 May need slight charge 3 6 hrs 50 75 12 3 12 6 Needs Charge 5 11 hrs 25 50 12 0 12 3 Needs Charge At least 13 hrs 0 25 12 0 or less Needs Charge At least 20 hrs NOTE Follow the cha...

Page 58: ...on Battery Hold Down Bracket 8 ft lb 11 Nm 3 Coat the terminals with dielectric grease or petroleum jelly 4 Connect and tighten the red positive cable s first Torque fasteners to specification Battery Terminal Fasteners 60 in lb 7 Nm 5 Connect and tighten the black negative cable s last 6 Verify that cables are properly routed and reinstall the driver s seat Engine Chassis Ground Inspect the groun...

Page 59: ...park plug socket with an extension 6 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes 7 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 8 Measure gap with a wire gauge Adjust gap if necessary by carefully bending the side electrode 9 If ne...

Page 60: ...y Check steering wheel for specified free play and operation 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of free play 4 If there is excessive free play or the steering feels rough inspect the following components Tie Rod Ends 1 Steering Shaft U Joints 2 Steering Rack 3 Tie Rod End Wheel Hub Inspection To check for play ...

Page 61: ...ent 3 Measure the distance between the marks at position 1 and record the measurement Call this measurement A 4 Rotate the tires 180 to position 2 by moving the vehicle forward Position chalk marks facing rearward even with the hub axle center line 5 Again measure the distance between the marks at position 2 and record Call this measurement B 6 Subtract measurement B from measurement A The differe...

Page 62: ...lowing precautions be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and may break To adjust toe alignment Hold tie rod end to keep it from rotating Loosen jam nuts at both end of the tie rod Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in Wheel Toe Alignment IMPORTANT When tight...

Page 63: ...otch of the adjustment will add 6 8 more preload to the spring over the primary position Spring Adjustment FOX The front and rear shocks have a spring adjustment Suspension springs may be adjusted to suit different riding conditions or vehicle payloads WARNING Uneven adjustment may cause poor handling of the vehicle which could result in an accident and serious injury or death Always adjust both t...

Page 64: ...ory setting 2 after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stability when operating without a load Shock Compression Adjustment FOX The compression damping adjustment is located on top of the shock Piggyback reservoir of each shock Turn the clicker adjuster knob to make damping adjustments NOTE When clicker adjuster is turned clockwise u...

Page 65: ...r 1 The level should be between the MAX and MIN level lines 4 If the fluid level is lower 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 wea...

Page 67: ...OOLING SYSTEM SPECIFICATIONS 3 12 COOLING SYSTEM PRESSURE TEST 3 12 RADIATOR CAP PRESSURE TEST 3 12 RADIATOR REMOVAL INSTALLATION 3 12 THERMOSTAT REPLACEMENT 3 13 COOLING SYSTEM BLEEDING 3 15 WATER PUMP REMOVAL 3 16 WATER PUMP SERVICE 3 16 WATER PUMP INSTALLATION 3 18 ENGINE SERVICE 3 20 LUBRICATION SPECIFICATIONS 3 20 ENGINE OIL PRESSURE TEST 3 20 ENGINE OIL FLOW CHART 3 21 ENGINE SPECIFICATIONS ...

Page 68: ...3 59 CONNECTING ROD INSPECTION 3 59 ENGINE ASSEMBLY LOWER END 3 61 BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS 3 61 CONNECTING ROD BEARING SELECTION 3 62 CRANKSHAFT MAIN BEARING SELECTION 3 62 UPPER CRANKCASE PREPARATION 3 63 PISTON RING INSTALLATION 3 63 PISTON CONNECTING ROD ASSEMBLY 3 64 CYLINDER PISTON INSTALLATION 3 65 CRANKSHAFT INSTALLATION 3 66 BALANCE SHAFT INSTALLATION 3 67 LOWE...

Page 69: ...alve Spring Compressor PV 43513 A Valve Spring Compressor Adapter PV 43531 Oil Pressure Gauge PV 43570 1 Piston Ring Compressor Pliers PW 47053 Bench Mount Engine Stand Adapter Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com Lubrication Specifications Oil Capacity 2 5 Quarts 2 4 L Oil Filter Wrench PU 50105 or 2 5 64 mm Oil Filter 2540086 Oil Type Ambient Te...

Page 76: ...ue Values ITEM TORQUE ITEM TORQUE 1 Exhaust Head Pipe 7 Exhaust Gasket 2 Head Pipe Gasket 8 Spark Arrestor 3 Heat Shields 9 Spark Arrestor Fastener 8 ft lb 11 Nm 4 Head Pipe Bolts 18 ft lb 24 Nm 10 Muffler Shield Fasteners 10 ft lb 14 Nm 5 Push Rivet 11 Muffler Rubber Mounts 6 Muffler 12 Exhaust Spring ENGINE COOLING SYSTEM ...

Page 77: ... divider panel 4 5 Disconnect both taillights and remove ten Torx fasteners 5 retaining the rear fascia 6 Remove the three springs 6 two retaining the muffler to the head pipe and one spring retaining the muffler to the chassis 7 Remove the six exhaust head pipe fasteners 7 8 Remove the exhaust from the vehicle 9 To install reverse procedure Torque fasteners to specification Exhaust Head Pipe Fast...

Page 78: ...cool before removing the pressure cap 2 Remove the pressure cap from the radiator and pressure test the cooling system using a commercially available tester 3 The system must maintain 10 PSI for five minutes or longer If pressure loss is evident within five minutes check the radiator all cooling system hoses clamps and water pump seal for signs of leaking Radiator Cap Pressure Test 1 Open the fron...

Page 79: ...2 and disconnect the coolant reservoir hose 3 7 Lift radiator up to disengage it from its lower mounting points Tilt top of radiator outward and remove the radiator from the vehicle 8 Separate the fan motor assembly from the radiator Inspect fan blades for damage 9 Reverse this procedure for installation Be sure to properly fill and bleed cooling system see Chapter 3 Cooling System Bleeding Proced...

Page 80: ... 5 Remove the two bolts 4 that retain the thermostat cover to the engine 6 Remove the thermostat cover seal 5 and thermostat 6 from the engine NOTE Thermostat has a pop off relief to allow the bypass system to operate until the thermostat opens 7 Clean the thermostat mating surfaces on the engine and thermostat cover 8 Install a new thermostat and seal into the cover and install the cover onto the...

Page 81: ...he reservoir to the MAX line 4 Remove the radiator pressure cap 2 and add the necessary amount of Polaris Premium Antifreeze to the radiator 5 Remove the cargo box engine access panel 6 Open the bleed screw 3 to allow any trapped air to escape 7 Tighten the bleed screw to specification top off coolant and properly install the pressure cap Coolant Bleed Screw 89 in lb 10 Nm 8 Start the engine and a...

Page 82: ...lts for installation 8 Remove the water pump from the engine by gently twisting and rocking the water pump housing while pulling outward 9 Plug the water pump drive access hole in the engine block with a clean shop towel Water Pump Service NOTE The water pump cover gasket can be replaced while the water pump housing is still installed in the engine 1 Remove water pump assembly see Chapter 3 Water ...

Page 83: ...y install the water pump shaft and two washers into the housing 13 Place water pump drive tab vertically into a soft jaw vice Install a NEW mechanical seal into the water pump housing using special tool PU 50564 Press the new mechanical seal in until it is flush with the housing 14 Rotate the water pump shaft after seal installation to verify free movement 15 Place impeller onto the water pump sha...

Page 84: ...18 9 Bolt 13 Washers 17 Oil Seal 10 Loctite 204 14 Drive Tab 18 Impeller 11 Mechanical Seal 15 Water Pump Shaft 19 Washer 12 O Rings 16 Water Pump Housing Water Pump Installation 1 Replace the two sealing o rings 1 on the water pump housing NOTE Always use NEW o rings each time the water pump is removed 2 Lubricate new o rings 1 with clean engine oil 3 Remove the shop towel from the water pump dri...

Page 85: ...aligned properly during installation or severe engine or water pump damage will occur 7 Slide water pump into engine crankcase Be sure water pump is fully seated and the drive tab and slot are properly aligned 8 Install the three water pump mounting bolts 5 6 noting location of the shorter bolt Torque bolts to specification Water Pump Mounting Bolts 7 ft lb 10 Nm Apply Loctite 204 to bolt threads ...

Page 86: ...auge Adapter PU 50565 to the Oil Pressure Gauge PV 43531 Oil Pressure Gauge PV 43531 Oil Pressure Gauge Adapter PU 50565 2 Clean the area around the main oil gallery plug 1 located in the upper crankcase on the MAG side of the engine 3 Remove the plug and insert the oil pressure adapter 4 Start engine and allow it to reach operating temperature Monitor the gauge NOTE Test results are based on the ...

Page 88: ... Width Intake Standard 0 0393 0 0039 1 0 0 10 mm Valve Seat Contacting Width Intake Service Limit 0 0551 1 4 mm Valve Seat Contacting Width Exhaust Standard 0 0590 0 0039 1 5 0 10 mm Valve Seat Contacting Width Exhaust Service Limit 0 0748 1 9 mm Valve Seat Angles 30 0 1 5 45 0 0 5 60 0 1 5 Valve Guide Valve Guide Inner Diameter 0 2165 0 2171 5 500 5 515 mm Valve Valve Lash Cold Intake 0 006 0 002...

Page 89: ...ecting Rod Connecting Rod Small End I D Standard 0 7879 0 7884 20 015 20 025 mm Connecting Rod Small End I D Service Limit 0 7897 20 06 mm 1 Marking Connecting Rod Big End Bore I D 1 7318 1 7321 43 989 43 996 mm 2 Marking Connecting Rod Big End Bore I D 1 7321 1 7323 43 996 44 003 mm 3 Marking Connecting Rod Big End Bore I D 1 7323 1 7326 44 003 44 010 mm Crankshaft B Marking Main Journal O D Stan...

Page 90: ... the frame on the front only The rear of the engine is mounted to the transmission To replace the isolators 1 Slightly lift and secure the engine using an engine lift 2 Remove the engine isolator bolts securing the mount to the engine bracket 3 Remove the fasteners retaining the isolator bracket to the frame and remove the isolator 4 To install reverse the procedure Tighten fasteners to specificat...

Page 91: ...e fuel rail while holding a clean rag over the valve 4 Remove the seat and ECU cover panel 5 Remove the four screws mounting the ECU to the divider panel 2 and disconnect the harness plugs from the ECU 3 6 Remove the nine screws 4 for the air intake housing cover over the air box 7 Remove the six plastic rivets 5 retaining the engine divider panel and push the clamp retaining the main harness ECU ...

Page 92: ... the air box to the frame bracket and loosen the clamp on the air box duct Remove the air box from vehicle 13 Remove the 22 screws retaining the cargo box panel 14 Remove the ignition coil by disconnecting the wiring leads and removing the two mounting bolts Remove the spark plug caps 15 Disconnect the following electrical components 9 TMAP 10 Electronic Throttle Control 11 Taillight Harness 12 En...

Page 93: ...he way towards the driver s seat 18 Disconnect the two fuel rail mounting bolts and move the fuel rail off to the driver s side CAUTION Be careful not to pinch or kink the fuel rail 19 Remove the four fasteners retaining the intake manifold to the engine 20 and the one retaining the bottom of the intake manifold to the transmission bracket 21 20 Remove the PVTouter cover 21 Remove the belt and dri...

Page 94: ...th engine mounting fastener removal 26 Remove the six engine to transmission mounting bolts 27 Remove the four bolts retaining the engine to the front engine mount 28 Remove the engine from the frame Engine Installation 1 Carefully install the engine in the frame 2 Install the four bolts retaining the engine to the front engine mount Torque bolts to specification Engine Mounting Bolts front 40 ft ...

Page 95: ...ositive and negative cables going to the starter Torque fasteners to specification Starter Cable Fasteners 30 in lb 4 Nm 7 Install the seven bolts retaining the inner clutch cover Torque bolts to specification Inner Clutch Cover Fasteners 10 ft lb 14 Nm 8 Install the drive clutch on the vehicle Torque mounting bolt to specification Drive Clutch Bolt 96 ft lb 130 Nm 9 Install the driven clutch and ...

Page 96: ...eners To Engine 17 ft lb 23 Nm Lower 22 ft lb 30 Nm 12 Install the two fuel rail mounting fasteners Torque fasteners to specification Fuel Rail Mounting Fasteners 7 ft lb 10 Nm 13 Route the harness and install the three harness clamps on the intake manifold 2 14 Install the three fasteners retaining the harness to the intake manifold 3 and two fasteners retaining the harness by the transmission 4 ...

Page 97: ... Connect the wiring leads and spark plug caps Torque mounting bolts to specification Ignition Coil Mounting Bolts 75 in lb 9 Nm 17 Install the 22 Torx screws retaining the cargo box panel Torque screws to specification Cargo Box Screws 8 ft lb 11 Nm 18 Install the two bolts mounting the air box to the frame bracket 13 and tighten the clamp on the air box duct 14 Also tighten the PVT intake clamp 1...

Page 98: ...ing the frame support bar above the engine Torque Bolts to Specification Frame Support Bolts 22 ft lb 30 Nm 22 Install the six plastic rivets retaining the engine divider panel 18 and install the clamp retaining the main harness ECU leads 19 to the panel 23 Install the nine screws for the air intake housing cover over the air box 20 Torque fasteners to specification Intake Housing Cover Screws 8 f...

Page 99: ... Synthetic 4 Cycle Engine Oil Never substitute or mix oil brands Serious engine damage and voiding of warranty can result Do not operate at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts 1 Fill fuel tank with unleaded fuel which has a minimum pump octane number of 87 R M 2 2 Refer to Ch...

Page 100: ...nd valve cover seal 3 if oil leaks are evident 3 Remove the spark plugs 4 Stuff spark plug holes with clean shop towels to prevent any debris from falling into the combustion chamber Camshaft Removal NOTE The camshafts can be removed with the engine installed in the chassis 1 Rotate the engine so the PTO cylinder is at Top Dead Center TDC to relieve most of the valve spring pressure The camshaft l...

Page 101: ...7 Remove the remaining bolt from each camshaft sprocket 8 Lift the chain and sprockets off the camshafts to allow each sprocket to be removed 9 Using a paperclip or other tool hold cam chain up NOTE The crankcase has a built in lower guide to prevent the chain from falling off the crankshaft 10 Evenly loosen the four bolts retaining each rear camshaft carrier 10 and carefully lift the carriers off...

Page 102: ... point on the lobe using a micrometer Compare to specification NOTE Replace camshafts if damaged or if any part is worn past the service limit Camshaft Lobe Height Intake 1 5256 0015 38 75 040 mm Service Limit 1 5220 38 66 mm Exhaust 1 4961 0015 38 00 040 mm Service Limit 1 4925 37 91 mm 3 Visually inspect each camshaft journal for scoring wear or damage 4 Measure the diameter of the camshaft jour...

Page 103: ...072 mm Service Limit 0039 10 mm Cylinder Head Removal NOTE The cylinder head can be serviced with the engine installed in the chassis 1 Disconnect coolant hose from thermostat housing if connected 2 Remove the two outer M6 bolts 1 that retain the cylinder head 2 to the cylinder 3 Loosen the six cylinder head bolts 3 evenly 1 8 turn at a time until all are loose 4 Remove and discard the cylinder he...

Page 104: ...head 1 at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface If warp exceeds the service limit replace the cylinder head Cylinder Head Warp Limit 0039 0 10 mm Cylinder Head Disassembly WARNING Wear eye protection during cylinder head disassembly and reassembly or when working with the valve springs NOTE Keep mated parts tog...

Page 105: ...up the cylinder head and push the valve 7 out keeping it in order for reassembly in the same valve guide 7 Repeat the previous steps to remove the remaining valves 8 Clean the combustion chamber and head gasket surface Valve Inspection 1 Remove all carbon from valves with a soft wire wheel or brush 2 Check valve face for runout pitting and burnt spots To check for bent valve stems mount valve in a...

Page 106: ...D 0 2165 0 2171 5 500 5 515 mm 7 Be sure to measure each guide and valve combination individually NOTE The valve guides cannot be replaced Combustion Chamber Cleaning WARNING Wear eye protection during combustion chamber cleaning 1 Clean all accumulated carbon deposits from combustion chambers and valve seat area 1 NOTE Carbon Clean Fuel Treatment 2871326 can be used to help remove carbon deposits...

Page 107: ...ence of the seat and the seat must be the proper width all the way around If seat is uneven compression leakage will result If seat is too wide seat pressure is reduced causing carbon accumulation and possible compression loss If seat is too narrow heat transfer from valve to seat is reduced The valve may overheat and warp resulting in burnt valves Renewing Valve Seats 1 Install pilot into valve g...

Page 108: ... the proper width If the indicated seat contact is at the top edge of the valve face and contacts the margin area 3 it is too high on the valve face Use the 30 cutter to lower the valve seat If too low use the 60 cutter to raise the seat When contact area is centered on the valve face measure seat width If the seat is too wide or uneven use both top and bottom cutters to narrow the seat If the sea...

Page 109: ...ine oil and apply oil or water based lapping compound to the face of the valve NOTE Lapping is not required if an interference angle reconditioning method is used 10 Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem 11 Rotate the valve rapidly back and forth until the cut sounds smooth Lift the valve slightly off of the se...

Page 110: ...lywheel contains powerful magnets Use caution when removing and installing the stator cover DO NOT place fingers between cover and crankcase at any time during the removal installation process or injury could result 2 Carefully pry the stator cover off the engine using the two pry areas as shown below 3 Inspect the condition of the stator windings 1 and output wires 2 If replacement is required re...

Page 111: ...ler Leave them all attached to the water pump housing 2 Remove the three gold colored bolts 1 retaining the water pump housing to the engine Note the location of the shorter bolt 3 Remove the water pump assembly from the engine by using a twisting motion as you pull out on the housing 4 If water pump service is required impeller or mechanical seal refer to ENGINE COOLING SYSTEM Flywheel Removal NO...

Page 112: ...lutch can be serviced with the engine installed in the chassis 7 Remove the stator cover and flywheel see Chapter 3 Flywheel Removal page 3 45 8 Place flywheel on a work bench with the one way clutch facing up Grasp clutch gear and rotate clockwise It should turn smoothly without binding 9 Rotate one way gear counterclockwise The gear should immediately lock in position and not slip 10 Inspect the...

Page 113: ...arter gear as an assembly Starter One Way Clutch Assembly 1 Install one way clutch in clutch hub with flange of clutch 1 engaged in recess 2 Clean screw threads in flywheel to remove all oil or grease 3 Place one way clutch on flywheel and install the three screws Torque screws to specification One Way Clutch Retaining Screws 106 in lbs 12 Nm 4 Reassemble starter one way clutch and gear using the ...

Page 114: ...kcase drain plug 2 to drain any oil remaining in the engine 3 Remove the oil filter 4 Install the Cylinder Holding Camshaft Timing Plate 3 PU 50563 onto the cylinder The cylinder holding tool retains the cylinder and pistons when the engine is rotated 5 Rotate engine to access the crankcase sump cover 6 Remove the thirteen M6 5 and three M8 6 bolts retaining the sump cover 4 to the crankcase 7 Rem...

Page 115: ...t NOTE If unable to extract the dowel pins from the oil pump the oil pump sprocket must be removed Access the sprocket bolt by removing the case plug 11 Lift the oil pump drive chain and remove the oil pump 12 Visually inspect the oil pump and drive sprocket 12 for wear or damage Replace oil pump drive chain and sprocket if worn or damaged If any part of the oil pump is damaged the entire assembly...

Page 116: ...t M10 bolts 17 Tap on the lower crankcase in reinforced areas with a soft faced hammer to loosen Carefully lift up and remove the lower crankcase half Balance Shaft Removal Inspection 1 Perform Crankcase Disassembly Inspection procedure 2 Note timing marks on balance shaft and crankshaft drive gears Shafts must be properly timed upon assembly 3 Carefully rotate the balance shaft 1 and remove it fr...

Page 117: ...Removal Inspection 1 Perform Crankcase Disassembly Inspection procedure 2 Perform Balance Shaft Removal Inspection procedure 3 For ease of assembly mark each connecting rod and end cap 4 Loosen remove and discard the four connecting rod bolts 1 Remove the end caps from the crankshaft 5 Carefully lift the crankshaft 2 out of the crankcase 6 Remove the cam chain 3 PTO main seal 4 and oil pump drive ...

Page 118: ...stand or lathe Measure crankshaft runout where indicated and replace if runout exceeds maximum listed below Crankshaft Maximum Runout 001 0 025 mm 12 Visually inspect surface of crankshaft main and connecting rod journals Replace crankshaft if any journal is scratched or pitted 13 Measure each main journal and connecting rod journal in two locations 90 degrees apart Replace crankshaft if any journ...

Page 119: ...Standard 1 6118 1 6122 40 942 40 950 mm Service Limit 1 6104 40 906 mm G Main Bearing Standard 1 6137 1 6140 40 988 40 995 mm Service Limit 1 6126 40 960 mm Connecting Rod Bearing Standard 1 6115 1 6118 40 934 40 941 mm Service Limit 1 6104 40 906 mm Y Main Bearing Standard 1 6134 1 6137 40 980 40 987 mm Service Limit 1 6126 40 960 mm Connecting Rod Bearing Standard 1 6112 1 6115 40 926 40 933 mm ...

Page 120: ...used 4 Be sure oil passages are clean and free of any cleaning solvent see Chapter 3 Engine Oil Flow Chart page 3 21 5 Remove and discard the plain bearings located in the upper crankcase 2 lower crankcase 3 and connecting rods 4 Replace the crankcase assembly if a bearing bore is galled or if bearing inserts have rotated in the case Refer to bearing selection procedures upon assembly NOTE Always ...

Page 121: ...3 Remove the Cylinder Holding Camshaft Timing Plate PU 50563 from the cylinder 4 Carefully lift the cylinder and pistons from the upper crankcase 5 Remove the piston connecting rod assemblies from the cylinder NOTE If the pistons are to be reused mark the pistons so they are reassembled in the same cylinder bore and direction from which they were removed MAG PTO Cylinder Inspection 1 Lay a straigh...

Page 122: ...der must be replaced Cylinder Taper Service Limit 0 001 025 mm Cylinder Out of Round Service Limit 0 001 025 mm Standard Bore Size 3 6614 0003 93 mm 008 mm Piston Disassembly Inspection NOTE New pistons are directional intake vs exhaust but can be placed in either cylinder 1 Note location of the piston circlip gap 1 at the top 12 00 position or bottom 6 00 position 2 Remove piston circlip and push...

Page 123: ...0 7866 19 98 mm Piston Ring Removal 1 Carefully remove top compression ring 1 by hand or using a ring removal pliers CAUTION DO NOTexpand the ring more than necessary to remove it from the piston or the ring may break or lose radial tension Piston ring pliers Carefully expand ring and lift it off the piston By hand Placing both thumbs on the ring ends spread the ring open and push up on opposite s...

Page 124: ...ylinder 2 Use the piston to push the ring squarely into cylinder as shown below 2 Measure installed gap with a feeler gauge 3 at both the top and bottom of the cylinder NOTE A difference between top and bottom end gap measurements is a general indication of cylinder taper wear The cylinder should be measured for taper and out of round 3 If the installed gap measurement exceeds the service limit re...

Page 125: ...g Rod Inspection 1 Inspect the small end and big end of connecting rod and matching rod cap for damage galling of surface or pitting 2 Measure small end I D in two directions as shown Record measurements and compare to specifications Replace connecting rod if worn past the service limit specification Connecting Rod Small End I D 0 7879 0 7884 20 015 20 025 mm Service Limit 0 7897 20 06 mm 3 Instal...

Page 126: ...he connecting rod closest to the small bore end This number represents the bore diameter 7 The table below lists the big end bore diameter specifications Connecting Rod Big End Bore Diameters 1 2 3 1 7318 1 7321 43 989 43 996 mm 1 7321 1 7323 43 996 44 003 mm 1 7323 1 7326 44 003 44 010 mm 8 Whether using new connecting rods or re installing the original ones refer to the bearing selection chart p...

Page 127: ...dustries Inc ENGINE ASSEMBLY LOWER END Bearing Selection Identification Letters and Numbers 1 Connecting Rod Bearing Identification Number 1 digit 2 Crankcase Bearing Identification Number 6 digits 3 Crankshaft Bearing Identification Letters 6 letters ENGINE COOLING SYSTEM ...

Page 128: ...ng for each connecting rod Bearing Selection Chart Rod Bearings CRANKSHAFT Rod Code B G Y 1 Blue Blue Green 2 Blue Green Yellow 3 Green Yellow Yellow Crankshaft Main Bearing Selection In order to select the proper main bearings for the crankshaft you must reference the six numbers on the crankcase 1 and match that up with the main journal letters on the crankshaft 2 In this example you would use t...

Page 129: ...and trace the oil paths through the crankcase and cylinder 6 Flush all oil passages with solvent and then warm soapy water Rinse with clear warm water and dry with compressed air 7 Be sure passages are clean and dry before assembling the upper crankcase Piston Ring Installation NOTE Apply clean engine oil to all ring surfaces and ring lands upon installation Always check piston ring installed gap ...

Page 130: ...al tension Severe engine damage may result if circlips are re used or deformed during installation 2 Install a new circlip 1 on one side of piston with gap at the top 12 00 position or bottom 6 00 position NOTE Never re use a piston pin circlip If reinstalling the original connecting rods orientate the rods the same as when removed If new connecting rods are being installed they can be installed e...

Page 131: ... cylinder sleeve 2 Verify that all ring end gaps 3 are correctly located on each piston see Chapter 3 Piston Ring Installation page 3 63 3 Note the piston orientation mark arrow located on top of the piston Arrow should point toward the exhaust side NOTE Orientation arrow is also located on the bottom side of piston as an additional reference 4 Carefully compress the piston rings with your fingers...

Page 132: ...ces of upper crankcase main bearings connecting rods and connecting rod caps 3 Align tab of new main bearing 1 with the slot in main bearing bore of crankcase Press bearing insert firmly into place Repeat for all main bearings 4 Align tab of new connecting rod bearings 2 with the slot in the connecting rod stem and connecting rod end cap Press bearing insert firmly into place Repeat for the other ...

Page 133: ...gs made upon disassembly 13 Install new bolts and tighten evenly until snug 14 Torque connecting rod bolts to specification 9 Connecting Rod Bolts Step 1 9 ft lb 12 Nm Step 2 22 ft lb 30 Nm Step 3 Tighten add n 90 Balance Shaft Installation 1 Clean the upper crankcase balance shaft bearing bore surfaces 2 Align tab of new balance shaft bearings 1 with the slot in each bearing bore of crankcase Pre...

Page 134: ...d 5 Refer to Oil Flow Chart at the beginning of this chapter and trace the oil paths through the crankcase and cylinder 6 Flush all oil passages with solvent and then warm soapy water Rinse with clear warm water and dry with compressed air 7 Be sure passages are clean and dry before assembling the crankcase Crankcase Assembly 1 Check to be sure the PTO crankshaft seal is resting properly in the up...

Page 135: ...gaps 9 Install the eight M10 5 one M6 6 and two M8 7 lower crankcase bolts Tighten all bolts lightly by hand NOTE Install new M10 lower crankcase bolts 10 Torque lower crankcase bolts in sequence to specification Repeat sequence to verify final torque Lower Crankcase Bolts M10 Bolts Torque in sequence Step 1 9 ft lb 12 Nm Step 2 21 ft lb 28 Nm Step 3 Tighten add n 90 M8 Bolts 26 ft lb 35 Nm M6 Bol...

Page 136: ...hain and install the oil pump 17 Install dowel pins 10 into oil pump mounting holes 18 Install the three bolts 13 that retain oil pump 12 to the crankcase Torque mounting bolts to specification Oil Pump Mounting Bolts 7 ft lbs 10 Nm 19 Reinstall oil pump pick up 11 if previously removed Torque mounting screws to specification Oil Pump Pick Up Retaining Screws 7 ft lb 10 Nm 20 Clean the gasket seal...

Page 137: ...stick 22 Install the oil sump cover 15 onto the crankcase 23 Install the thirteen M6 16 and three M8 bolts that retain the oil sump cover 17 to the crankcase 24 Torque the oil sump cover bolts in sequence to specification Repeat the sequence to verify final torque Oil Sump Cover Bolts M6 Bolts 9 ft lb 12 Nm M8 Bolts 26 ft lb 35 Nm 25 Reinstall the crankcase drain plug if previously removed Torque ...

Page 138: ... reinstall the flywheel key 2 Clean taper of crankshaft to remove all oil or grease 3 Clean flywheel taper to remove all oil or grease 4 Align flywheel key way with key and install the flywheel seating it fully on taper 5 Install flywheel retaining bolt Using a commercially available strap wrench hold the flywheel and torque the flywheel retaining bolt 2 to specification NOTE If the Cylinder Holdi...

Page 139: ...or cover gasket over alignment pins CAUTION The flywheel contains powerful magnets Use caution when removing and installing the stator cover DO NOT place fingers between cover and crankcase at any time during the removal installation process or injury could result 3 Install stator cover and thirteen screws Torque screws in sequence to specification Stator Cover Screws 9 ft lb 12 Nm ENGINE COOLING ...

Page 140: ... and square with the guide NOTE Valve seals should be installed AFTER the valves are in the head to avoid valve seal damage 5 Dip the valve spring 3 and retainer 4 in clean engine oil 6 Install the valve spring with widely spaced coils 6 on the top and tightly spaced coils 7 facing down toward the cylinder head NOTE Valve springs to be installed with paint mark facing up 7 Place the valve retainer...

Page 141: ...g If any valve train components were replaced refer to Valve Clearance Adjustment page 3 82 Valve Sealing Test 1 Clean and dry the combustion chamber area 1 2 Pour a small amount of clean solvent into each intake port 2 and check for leakage around the valves The valve seats should hold fluid with no seepage 3 Repeat for exhaust valves by pouring fluid into each exhaust port 3 ENGINE COOLING SYSTE...

Page 142: ...all residue The head gasket must be installed clean and dry free from oil or grease NOTE Do not touch sealing surfaces of gasket 4 Guide cam chain 2 through a new head gasket 3 and install the gasket on the cylinder locating it on the alignment pins 5 Carefully set the cylinder head 4 in place on alignment pins 6 Install new bolts and finger tighten the six cylinder head bolts 5 evenly 7 Install a...

Page 143: ...e used as a TDC reference 2 Reference the intake and exhaust markings made during disassembly If installing new camshafts or if camshafts were not marked you can reference the part number stamped on the end of the shafts Intake Camshaft PN 1204583 Exhaust Camshaft PN 1204584 3 Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS 4 engine oil prior to installation 4 Carefully i...

Page 144: ...s into the chain with the I and E marks facing out 11 Install the sprockets onto the camshafts and align the sprocket marks with the valve cover gasket surface see sprocket timing illustration NOTE Intake cam sprocket should have I marks aligned with gasket surface and the exhaust cam sprocket should have E marks aligned with gasket surface Install the exhaust cam sprocket first opposite the cam c...

Page 145: ...ect position 14 If timing marks are not aligned remove sprockets and correct alignment 15 Remove the Cylinder Holding Camshaft Timing Plate PU 50563 from the end of the camshafts 16 Apply Polaris PS 4 engine oil to the cam chain tensioner bore prior to assembly 17 Rotate the engine using the flywheel and install the remaining bolt in each camshaft sprocket Hold camshafts in place with an open end ...

Page 146: ...draulic cam chain tensioner 13 into the cylinder and torque to specification Cam Chain Tensioner 29 ft lb 40 Nm 22 Torque the camshaft carriers bolts in sequence to specification Camshaft Carrier Bolts 7 ft lb 10 Nm 23 Rotate crankshaft through two revolutions and verify camshaft timing is correct ENGINE COOLING SYSTEM ...

Page 147: ... Copyright 2014 Polaris Industries Inc Camshaft Timing Quick Reference 1 Intake Cam 4 Align Exhaust Marks With Surface 2 Exhaust Cam 5 CPS Mounting Hole 3 Align Intake Marks With Surface 6 Align Flywheel Mark in Mounting Hole ENGINE COOLING SYSTEM ...

Page 148: ...n the end of the shafts Intake Camshaft 1 PN 1204583 Exhaust Camshaft 2 PN 1204584 2 Lubricate the camshaft bearing journal surfaces with Polaris PS 4 engine oil prior to installation 3 Carefully install the camshafts into the cylinder head The PTO camshaft lobes 3 should face out as shown 4 Carefully install the rear camshaft carriers onto the camshafts Carrier openings should face each other whe...

Page 149: ...TION If performing this procedure with the cylinder head installed on the engine cover the spark plug holes and the cam chain opening to prevent a valve adjustment shim from falling into the cylinder or crankcase 11 Record the 3 digit number on the bottom of the tappet 8 12 Reference the valve clearance measurement recorded for that valve along with the 3 digit tappet number 13 Refer to the approp...

Page 150: ... 532 535 538 540 542 545 0 376 0 400 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 401 0 425 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 426 0 450 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518...

Page 151: ...522 525 528 530 532 535 538 540 542 0 401 0 425 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 426 0 450 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 0 451 0 475 465 468 470 472 475 478 480 482 485 488 490 492 495 ...

Page 152: ...ication Spark Plugs 7 ft lbs 10 Nm 3 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 4 Inspect the valve cover seal 3 and replace if necessary 5 Replace the isolators 2 around each T40 bolt 6 Install the four valve cover shoulder bolts 1 and isolators using a T40 driver 7 Torque valve cover bolts to specification Valve Cover Bolts 7 ft lbs 10 Nm ENGINE COOLING SYS...

Page 153: ...le Restricted fuel supply Low compression Crankcase breather restricted Engine Idles But Will Not Accelerate Spark plug fouled weak spark Obstruction in air intake Air box removed reinstall all intake components Incorrect ignition timing Restricted exhaust system Cam worn excessively Engine Has Low Power Spark plug fouled Cylinder piston ring or valve wear or damage check compression PVT not opera...

Page 154: ...m Ignition timing incorrect Sheared flywheel key Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiator lines pump or water jacket accident damage Lean mixture vents fuel pump or fuel valve Fuel pump output weak Electrical malfunct...

Page 155: ... 4 11 OPERATION OVERVIEW 4 11 FUEL INJECTOR TROUBLESHOOTING 4 11 FUEL INJECTOR TEST 4 12 FUEL INJECTOR REPLACEMENT 4 12 FUEL TANK 4 15 FUEL TANK ASSEMBLY VIEW 4 15 FUEL LINE REMOVAL INSTALLATION 4 16 FUEL TANK REMOVAL 4 16 FUEL TANK INSTALLATION 4 18 FUEL PUMP 4 20 OPERATION OVERVIEW 4 20 FUEL SENDER TEST 4 20 FUEL PUMP TEST 4 21 FUEL PUMP REPLACEMENT 4 22 T MAP SENSOR 4 25 OPERATION OVERVIEW 4 25...

Page 156: ...L WRENCH DIAGNOSTIC SOFTWARE OVERVIEW 4 40 SPECIAL TOOLS ALSO REFER TO THE BEGINNING OF THIS CHAPTER 4 40 DIGITAL WRENCH SOFTWARE VERSION AND UPDATE ID 4 41 DIGITAL WRENCH UPDATES 4 41 DIGITAL WRENCH COMMUNICATION ERRORS 4 42 DIGITAL WRENCH DIAGNOSTIC CONNECTOR 4 42 GUIDED DIAGNOSTICS 4 42 DIGITAL WRENCH SERIAL NUMBER LOCATION 4 43 DIGITAL WRENCH FEATURE MAP 4 44 ECU REPLACEMENT 4 45 ECU REPROGRAM...

Page 157: ...rial number interface cable USB serial adapter cable and Smartlink Module Kit Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com Torque Specifications CPS Retaining Fastener 9 ft lb 12 Nm ETC Mounting Bolts 7 ft lb 10 Nm Fuel Pump PFA Nut 70 ft lbs 95 Nm Fuel Rail Mounting Screws 7 ft lb 10 Nm Hose Clamp Ducting 35 in lb 4 Nm Intake Manifold Mounting Fasteners ...

Page 158: ... they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Clean any connector before opening to prevent dirt from entering the system Although every precaution has been taken to prevent water intrusion failure avoid direct water or spray contact with system components Do not disconnect or reconnect the wiring harness connec...

Page 159: ...ctronic Control Unit ECU 7 Fuel Pump Regulator 2 Crankshaft Position Sensor CPS 8 Fuel Level Sender 3 Engine Coolant Temperature Sensor ECT 9 Fuel Filter 4 Throttle Body Electronic Throttle Control ETC 10 Fuel Supply Line 5 Fuel Injectors 11 TMAP Sensor 6 Fuel Rail Regulator 12 Engine Coolant Temp Sensor FUEL SYSTEM ...

Page 160: ...shaft Position Sensor CPS 3 Located on top of the stator cover Temperature and Manifold Absolute Pressure TMAP Sensor 4 Located on top of the intake manifold Engine Coolant Temperature ECT Sensor 5 Located right by the thermostat housing The sensor can be accessed by removing the intake manifold Throttle Body Assembly 6 Located between the intake duct and the intake manifold Fuel Injectors 7 Locat...

Page 161: ...25723 R01 2015 RZR 900 Service Manual Copyright 2014 Polaris Industries Inc Fuel Rail 8 Located on top of the intake manifold Fuel Pump Fuel Regulator Fuel Sender 9 Located under the passenger seat FUEL SYSTEM ...

Page 162: ...n This range can vary depending on fuel requirements The controlled injection of the fuel occurs every other crankshaft revolution or once for each 4 stroke cycle When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for intake air t...

Page 163: ...operational the moment the battery cables are connected To prevent engine over speed and possible failure an RPM limiting feature is programmed into the ECU If the maximum RPM limit is exceeded the ECU suppresses the injection signals cutting off the fuel flow and retards the ignition timing This process repeats it self in rapid succession limiting operation to the preset maximum RPM Limit 8300 EC...

Page 164: ... until the connectors are free from the ECU NOTE Upon removing the ECU connectors you should hear a click when the connectors are fully open 5 Remove the ECU from the vehicle 6 To install reverse the procedure and tighten the ECU mounting screws to specification ECU Mounting Screws 24 in lb 3 Nm NOTE Upon installing the ECU connectors you should hear a click when the connectors are fully closed FU...

Page 165: ...ation indicating that they are opening and closing When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration NOTE Do not apply voltage directly to the fuel injector s Ex...

Page 166: ...g between the two pin terminals 2 Fuel Injector Resistance Specification 11 4 12 6 Ω NOTE Be sure to connect the PTO harness lead to the PTO injector and the MAG harness lead to the MAG injector to ensure proper engine operation Fuel Injector Replacement CAUTION Be sure the engine has cooled enough to work on 1 Remove the cargo box assembly see Chapter 10 Cargo Box Removal page 10 14 2 Loosen the ...

Page 167: ... aid installation 10 Install the new injector s into the fuel rail 11 Thoroughly clean the area around the fuel injector ports on the throttle body 12 Lightly lubricate the injector O rings and reinstall the fuel rail injector assembly into the throttle body 13 Install the fuel rail mounting screws and torque to specification Fuel Rail Mounting Screws 7 ft lb 10 Nm 14 Reinstall the fuel line to th...

Page 168: ...e sure the air box boots fully seat onto the dual throttle body before tightening the hose clamps 16 Hose Clamps 35 in lb 4 Nm Intake Plenum Mount Screw 22 ft lb 30 Nm 20 Reinstall the breather into the air box and tighten the hose clamps retaining the air box to the throttle body assembly 21 Reinstall the two screws retaining the air box assembly 22 Position the intake hose onto the air box and t...

Page 169: ...e Manual Copyright 2014 Polaris Industries Inc FUEL TANK Fuel Tank Assembly View 1 PFA Nut 5 Preliminary Filter 2 Fuel Sender Float Arm 6 Fuel Tank Vent 3 PFA Gasket replace if removed 7 Fuel Tank Assembly 4 Fuel Pump Regulator FUEL SYSTEM ...

Page 170: ... is fastened Fuel Tank Removal NOTE Syphon as much fuel from the tank as possible before attempting to remove it from the vehicle WARNING Always wear safety goggles when working with high pressure or flammable fluids Failure to do so could result in serious injury or complications 1 Remove the driver and passenger seats 2 Disconnect the negative and positive battery cables from the battery located...

Page 171: ...x to keep out of the way 7 Push the shifter boot 6 so it is no longer attached to the console Remove the console from the vehicle 8 Remove the two bolts 7 retaining the front and two rear bolts 8 retaining the rear of the seat base frame Remove the two T40 Torx screws 9 retaining the front of the seat base frame Remove the rear seat base assembly from the vehicle 9 Remove the T40 Torx screw 10 ret...

Page 172: ...rly into the lower fuel tank mount 2 Reinstall the fuel tank bracket and fasteners 3 Install the vent line onto the tank fitting 4 Reinstall the block off panel Secure with plastic rivets and torque screws to specification Block off Panel Screws 8 ft lb 11 Nm 5 Install the seat base frame and torque fasteners to specification Seat Base Frame Fasteners 8 ft lb 11 Nm 6 Install regulator and fuse box...

Page 173: ...cker panel and all body fasteners 11 Connect the fuel line and fuel pump electrical harness Verify connections are secure 12 Install the battery and battery bracket Torque fasteners to specification Battery Bracket Fasteners 8 ft lb 11 Nm 13 Install both seats and test the fuel pump by turning the ignition key ON and listening for the fuel pump to activate Check fuel line fittings for leaks FUEL S...

Page 174: ...f the pump preventing the continued delivery of fuel in these instances If the key switch is not promptly turned to the start position If the engine fails to start If 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 f...

Page 175: ...ignition switch ECU fuel pump and pressure regulator are working properly Turn the key switch off and depress the valve button on the tester to relieve the system pressure Fuel Pressure 58 2 psi 400 14 kPa NOTE If the fuel pressure is out of specification replace the fuel pump assembly 6 If the pump did not activate Step 5 disconnect the harness connector from the fuel pump Connect a DC voltmeter ...

Page 176: ...pump and or clogging of internal fuel filters 4 Ensure that static has been discharged by touching a ground source such as the engine or frame 5 While holding a shop towel over the fuel line connectors disconnect the fuel supply line 2 from the pump CAUTION It is possible for pressurized fuel to be present when disconnecting the fuel line It is recommended to allow the vehicle to sit for a period ...

Page 177: ... fuel Do not use water or any other chemicals to remove debris 11 Remove new fuel pump assembly 5 gasket 6 and PFA nut 7 from packaging Use care not to bend float arm 8 during un packaging Do not lift or carry fuel pump assembly by the float arm 12 Use cleaning wipes provided to clean fuel tank surface and threads 9 Remove all debris grease and oil Allow surfaces to dry completely 13 Install new P...

Page 178: ...que wrench Fuel Pump PFA Nut 70 ft lbs 95 Nm 19 Verify alignment of fuel pump and tank orientation marks 20 Connect the fuel supply line to the pump see Chapter 2 Fuel Lines page 2 11 for specific installation procedures NOTE Be sure to engage the retainers on each fuel line until each snaps into place Pull on fuel lines lightly to confirm connection 21 Install the fuel tank vent line onto the tan...

Page 179: ...ogramming for determining the fuel and ignition requirements during engine operation The T MAP provides the ECU with engine load data TMAP Test Replacement The T MAP is a non serviceable item and can only be tested using Digital Wrench If the sensor is faulty it must be replaced NOTE This sensor should only be tested using Digital Wrench Diagnostic Software dealer only To replace the TMAP sensor 1...

Page 180: ...missing tooth creates an interrupt input signal corresponding to specific crankshaft position 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 fo...

Page 181: ...hapter 4 CPS Replacement page 4 27 4 If the resistance is incorrect follow the CPS Replacement page 4 27 procedure CPS Replacement 1 Access the CPS harness from the right rear side of the vehicle 2 Disconnect the CPS harness connector 3 Remove CPS retaining bolt 1 and remove the sensor 2 from the stator cover 4 Remove CPS wire lead from wire clip 3 5 Install new sensor using a light coating of oil...

Page 182: ...ned or tampered with in any way All operating and control functions within the ETC are pre set No internal servicing or adjustments may be performed If a problem is encountered and you determine the ETC to be faulty contact the Polaris Service Department for specific handling instructions Do not replace the ETC without factory authorization Use Digital Wrench to perform all troubleshooting of this...

Page 183: ...ndustries Inc 5 Remove the ETC housing and gasket 4 from intake plenum 6 Reverse these steps for installation Torque the ETC housing retaining bolts and intake boot clamp to specification ETC Housing Retaining Bolts 7 ft lb 10 Nm Intake Boot Clamp 35 in lb 4 Nm FUEL SYSTEM ...

Page 184: ...tion sensor 1 is located on the top of the accelerator pedal lever PPS Test The PPS can be tested utilizing Digital Wrench by verifying that the throttle position readout varies as the pedal is pressed Reference the Data Display section and be sure Throttle Position is displayed Throttle Position should display as follows Key on for less than 10 seconds and pedal released 2 8 Key on for more than ...

Page 185: ... is being pushed Active Brake pedal is being pushed Inactive Brake pedal released open circuit or faulty switch Cam Sensor Signal Status Indicates if the ECU is seeing a hall effect signal from the cam sensor Yes Camshaft is turning No No signal from camshaft sensor engine not running Cooling Fan Relay Driver ECU control of the cooling fan relay Active ECU is grounding the cooling fan relay Fan sh...

Page 186: ...e 4 7 ms Unit is start up enrichment or under rapid acceleration Intake Air Temperature Measures air temperature at the TMAP sensor varies should be close to ambient air temperature Warm engine at idle may cause reading to be higher Manifold Absolute Pressure Measures air pressure inside the intake manifold on the TMAP sensor Reading will be high at key on and wide open throttle Reading will be lo...

Page 187: ...as started Check throttle body and connections Cycle the key switch Throttle Position How far open the throttle plate is 0 100 At warm idle this can range from 0 3 Throttle Limp home Operation Condition ETC error and ECU is limiting speed Yes There is an error in the throttle control and the vehicle is limiting No Normal Operation Turf Mode Switch Input Input to ECU to indicate if turf mode is swi...

Page 188: ...splayed use the MODE button to toggle until CK ENG displays on the information display area 2 Press and hold the MODE button to enter the diagnostics code menu 3 A set of three numbers will appear in the information area The first number located far left can range from 0 to 9 This number represents the total number of trouble code present example 2 means there are 3 codes present The second number...

Page 189: ...P0117 Temperature Too High 16 P0217 Engine Overheat Shutdown 0 P1217 System Power Battery Potential Power Input Voltage Too High 168 3 P0563 C1063 Voltage Too Low 4 P0562 C1064 Engine Speed This is applicable when the EPS module gets the engine speed from the ECM Error in Engine Speed Computation 190 31 P121C Received Engine Speed Has Error 19 C1066 Engine Speed Error in Engine Speed Computation 4...

Page 190: ...P0222 Signal Out of Range 2 P0221 All Wheel Drive Control Circuit AWD Driver Circuit Open Grounded 520207 5 P1836 Driver Circuit Short to B 3 P1835 Driver Circuit Grounded 4 P1834 Steering Over Current Shut Down Current Above Normal or Grounded 520221 6 C1050 Steering Excessive Current Error Current Above Normal or Grounded 520222 6 C1051 Steering Torque Partial Failure Condition Exists 520223 31 ...

Page 191: ...ignal Error 8 P151B Deactivated power stages due to 5V sensor supply error 31 P153F Throttle Body Control Return Spring Check Failed Condition Exists 520278 31 P151C Throttle Body Control Adaptation Aborted Condition Exists 520279 31 P151D Throttle Body Control Limp Home Position Check Failed Condition Exists 520280 31 P151E Throttle Body Control Mechanical Stop Adaptation Failure Condition Exists...

Page 192: ...ator Sensor Synchronicity Fault Sensor Difference Exceeds Limit Condition Exists 520308 31 P1533 ECU Fault ICO Condition Exists 520309 31 P1534 ECU Fault Hardware Disruption Condition Exists 520311 31 P1537 Oxygen Sensor 1 Data Erratic Intermittent or Incorrect 3056 2 P0130 Voltage Above Normal or Shorted to High Source 3 P0132 Voltage Below Normal or Shorted to Low Source 4 P0131 Oxygen Sensor He...

Page 193: ...ce bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug Injector failure Poor Idle Symptom Idle Too High if 1400 RPM when warm Throttle stop screw tampering Throttle cable sticking improperly adjusted routed incorrectly Faulty electrical connection Symptom Idle Too Low if 1100 RPM when warm Plugged air filter L...

Page 194: ...erform guided diagnostic procedures Create customer service account records Perform output state control tests some models Special Tools also refer to the beginning of this chapter DIGITAL WRENCH DIAGNOSTIC SOFTWARE PART NUMBER Digital Wrench Diagnostic Kit PU 47063 B PU 47063 B listed above INCLUDES Digital Wrench Software PU 48731 Standard Interface Cable PU 47151 SmartLink Module Kit PU 47471 U...

Page 195: ...tes are released for Digital Wrench via the Internet at http polaris diagsys com The Digital Wrench website can also be accessed through the dealer website at www polarisdealers com NOTE Only authorized Polaris dealers and distributors can access the dealer website 1 Log on to www polarisdealers com 2 Locate the Service and Warranty drop down menu 3 Click on Digital Wrench Updates 4 The Digital Wr...

Page 196: ...tal Wrench use 1 Assemble the SmartLink Module and attach the PC Interface Cable to your laptop 2 Remove the protective cap from the Digital Wrench connector 3 Connect the Vehicle Interface Cable to the Digital Wrench diagnostic connector 4 Turn the ignition key to the ON position select the appropriate vehicle and wait for the status to display Connected in the lower left corner of the screen 5 O...

Page 197: ... 900 Service Manual Copyright 2014 Polaris Industries Inc Digital Wrench Serial Number Location Open the configuration screen by clicking on the wrench icon The serial number is located on the right side of the screen FUEL SYSTEM ...

Page 198: ...sor and ECU information in a grid meter or chart format Enter customer and vehicle information and view ECU Identification View information from the main ECU sensors Load the Vehicle Home Page Set up data capture and record functions Open the Software Configuration Screen Perform specialized testing and adjustment functions service reports Run the Help System Open the ASSERT ASK form Prints the cu...

Page 199: ...gital Wrench A laptop that is used by a variety of people and in several applications around the dealership is more 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 Chapter 4 Digital Wrench Updates page 4 41 CLOSE NON ESSENTIAL PROGRA...

Page 200: ...eed to the Integrity Check and obtain a Request Code 8 Copy CTRL C the Request Code that will be required on the dealer website in the next step DO NOT CLOSE Digital Wrench or the Request Code will be invalid NOTE All characters are letters there are no numbers in a request code NOTE Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen 9 Go to www polarisdealer...

Page 201: ...ar in the upper left corner of the screen Copy this key exactly as it appears 13 Enter or paste the Authorization Key in the box located on the Digital Wrench screen Click the Continue button and follow instructions provided on the screen to complete reprogramming procedure 14 At this point the reflash process will begin Do not touch the vehicle or PC during the process 15 Once the ECU reprogrammi...

Page 202: ...nload the app Android Device Minimum Specifications Minimum operating system Android 3 1 Honeycomb or higher Android 4 0 or higher preferred Dual core processor 2 GB internal memory external microSD 32 or 64 GB slot 500 MB RAM Rear facing camera with minimum 3 0 mega pixel resolution with auto continuous focus Video Microphone and Voice to text capable Internet and Bluetooth wireless technology ca...

Page 203: ...REAK IN DRIVE BELT CLUTCHES 5 10 DRIVE CLUTCH SERVICE 5 11 DRIVE CLUTCH ASSEMBLY VIEW 5 11 DRIVE CLUTCH DISASSEMBLY 5 12 BEARING INSPECTION 5 13 SHIFT WEIGHT INSPECTION 5 14 BUTTON TO TOWER CLEARANCE 5 14 SPIDER REMOVAL 5 15 ROLLER PIN AND THRUST WASHER INSPECTION 5 15 DRIVE CLUTCH INSPECTION 5 16 MOVEABLE SHEAVE BUSHING INSPECTION 5 17 BUSHING SERVICE 5 17 DRIVE CLUTCH ASSEMBLY 5 19 DRIVEN CLUTCH...

Page 204: ...Holding Wrench PU 50518 Driven Clutch Compression Tool PU 50578 Spider Jam Nut Socket Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com Torque Specifications ITEM TORQUE Clutch Cover Retaining Screws Outer 54 in lb 5 Nm Drive Clutch Cover Plate 8 ft lb 11 Nm Drive Clutch Retaining Bolt 96 ft lb 130 Nm Drive Clutch Spider 290 ft lb 393 Nm Apply 0 4 mL Loctite 6...

Page 205: ...lack 7044317 1800 3700 6000 12000 26 49 1323271 Black Red 7044263 Black 7044317 non EBS Driven Spring has white letters on it that start with 210498 EBS Models ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING Meters Feet 0 1800 0 6000 26 55 1322982 Black Red 7044263 Black 7044318 1800 3700 6000 12000 26 49 1323271 Black Red 7044263 Black 7044318 EBS Driven Spring has white letters on it that start...

Page 206: ...rst to the engine power curve then to average riding conditions and the vehicle s intended usage Therefore modifications or variations of components at random are never recommended Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning Drive Clutch Operation Drive clutches primarily sense engine RPM The two major components w...

Page 207: ...ect the PVT system is similar to a power governor Rather than vary throttle position as a conventional governor does the PVT system changes engine load requirements by either upshifting or backshifting Maintenance Inspection Under normal use the PVT system will provide years of trouble free operation Periodic inspection and maintenance is required to keep the system operating at peak performance T...

Page 208: ... and Ducting Components 1 Clutch Duct Intake Assembly 10 Bracket Cover Guard 2 Clamp Worm 11 Air Inlet Duct 3 Bolt and Washer 12 Screw 4 Cover Assembly Outer 13 Screw 5 O Ring 14 Nut Nylok 6 Drain Plug Cover 15 Bracket Belt Screen 7 Seal Cover 16 Hose Air Outlet 8 Screw 17 Seal Cover 9 Cover Assembly PVT SYSTEM ...

Page 209: ...nd exhaust ducts by loosening the clamps 2 retaining the ducts to the inner clutch cover 3 Remove the drive belt see Chapter 5 Belt Removal page 5 9 4 Remove the Driven Clutch retaining bolt 3 5 Remove the Drive Clutch retaining bolt 4 6 Remove the seven fasteners retaining the inner clutch cover to the engine and transmission 7 Remove the inner clutch cover from the vehicle PVT SYSTEM ...

Page 210: ... 14 Nm 3 Install the Drive Clutch Torque mounting bolt to specification Drive Clutch Bolt 96 ft lb 130 Nm 4 Install the Driven Clutch Torque mounting bolt to specification Driven Clutch Bolt 38 ft lb 52 Nm 5 Install the drive belt 6 Install the PVT intake and exhaust ducts to the inner clutch cover Torque clamps to specification Duct Clamps 12 ft lb 16 Nm 7 Install the eight screws retaining the o...

Page 211: ... outer clutch cover outward as shown below to access the drive belt NOTE Removal of left rear wheel or left rear shock is NOT necessary for belt replacement 4 Mark the drive belt direction of rotation so that it can be installed in the same direction 5 EBS Models ONLY Insert clutch spreader tool 2877408 2 into the driven clutch as shown tool included with vehicle s tool kit NOTE Make sure the tool...

Page 212: ...th the clutch spreader tool installed 2877408 loop the belt over the drive clutch and over the driven clutch 2 Rotate the driven clutch and walk the belt into the clutch 3 Remove the clutch spreader tool from driven clutch 4 Rotate spin the driven clutch and belt approximately 5 7 times to properly seat the belt in the driven clutch 5 Install the outer clutch cover and eight screws Torque screws t...

Page 213: ... Washers 11 Washer 3 Needle Bearing non EBS models One Way Clutch EBS models 12 Button 4 Spacer 13 Jam Nut 250 ft lb 339 Nm Apply 0 1 mL Loctite 620 5 Bushing 14 Limiter Spacer 6 Moveable Sheave 15 Clutch Spring 7 Spider 290 ft lb 393 Nm Apply 0 4 mL Loctite 620 16 Cover Bushing 8 Shift Weight 17 Cover 9 Bolt 20 in lb 2 Nm 18 Cover Bolt 8 ft lb 11 Nm PVT SYSTEM ...

Page 214: ...t the clutch will not be in balance and the assembly MUST be replaced 3 Remove cover bolts evenly in a cross pattern and remove cover plate 4 Inspect cover bushing 1 The outer cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing Cover Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing R...

Page 215: ... Clutch Spring Specifications Part Number 7044263 Color Black Red Free Length 3 219 81 76 mm Spring Wire Diameter 0 177 4 50 mm Bearing Inspection Needle Bearing Inspection non EBS clutch 1 Rotate the clutch bearing in both clockwise and counter clockwise directions The non braking needle bearing should rotate in both directions on the shaft with only a slight amount of drag 2 Verify there is no b...

Page 216: ...lts and nuts CAUTION The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clutch assembly NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See Drive Clutch Roller Pin and Button Service Button to Tower Clearance 1 Inspect the button to tower clearance as shown Replace the spider buttons if clearance is be...

Page 217: ...1358 A 2 Loosen and remove the spider 2 counterclockwise using Clutch Spider Removal Installation Tool PN 2870341 Spider Removal Installation Tool 2870341 Clutch Holding Fixture 2871358 A Roller Pin and Thrust Washer Inspection 1 Inspect all rollers roller bushings and roller pins by pulling a flat metal rod across the roller 2 Turn roller with your finger If you notice resistance galling or flat ...

Page 218: ...he moveable clutch sheave 3 Lift thrust washers 5 and bearing 6 off the shaft Replace as an assembly if worn damaged or if operational problems were noted prior to disassembly 4 Inspect surface of shaft for pitting grooves or damage Measure the outside diameter and compare to specifications Replace the drive clutch assembly if shaft is worn or damaged Shaft Diameter Standard 1 3725 1 3712 34 8615 ...

Page 219: ...Clutch Bushing Tool Kit 2201379 ITEM QTY PART TOOL DESCRIPTION A B 1 5132027 EBS Puller Tool C 1 5132501 EBS Puller Nut D 1 5132029 EBS Main Adapter E 1 5132028 EBS Bushing Removal Tool Instructions 1 9915111 Instructions Additional Special Tools QTY PART TOOL DESCRIPTION 1 2871226 Clutch Bushing Replacement Tool Kit 1 2870386 Piston Pin Puller Clutch Bushing Replacement Tool Kit PN 2871226 ITEM Q...

Page 220: ...to center of sheave with A side toward sheave NOTE Use Bushing Tool PA 47336 8 Install nut C onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Using a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear 9 Turn sheave counterclockwise on puller rod until it comes free Lift sheave off puller 10 Remove nut from...

Page 221: ... Working from inside of cover insert new bushing and bushing installation tool into center of clutch cover 31 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 32 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 33 Turn clutch cover counterclockwise on puller rod until bushing is seated 34 Remove nut from puller rod ...

Page 222: ... Asm 6 Jam Nut 7 Spider 6 Install clutch onto holding fixture PN 2871358 A and secure in a bench vice Tighten the spider 9 using Clutch Spider Tool PN 2870341 Torque spider to specification Spider Assembly 290 ft lb 393 Nm Apply 0 4 mL Loctite 620 7 Apply 0 1mL of Loctite 620 and 0 1mL of Loctite 7088 Primer in 90 apart to the threads of the spider jamb nut Install spider jamb nut onto stationary ...

Page 223: ... not in alignment upon assembly the clutch will not be in balance and the drive clutch assembly must be replaced 10 Install the limiter spacer 11 and the clutch spring 12 CAUTION DO NOT reassemble the drive clutch without the limiter spacer Belt life will be greatly reduced 11 Install the drive clutch cover 13 Be sure all alignment marts are in alignment 12 Install cover bolts and torque in a cros...

Page 224: ...ris Industries Inc DRIVEN CLUTCH SERVICE EBS Assembly View 1 Snap Ring 8 Spring 2 Bearing 9 Spider Insert 3 Stationary Sheave 10 Spider Dampener 4 Pin 11 E Clip 5 Roller 12 Washer 6 Moveable Sheave 13 Helix Cam 7 Clutch Shaft 14 Helix Screws 48 in lb 5 Nm PVT SYSTEM ...

Page 225: ...isassembly of the driven clutch from the outside snap ring The driven clutch must be disassembled from the helix side 2 It is important to mark the position of the shaft cam cover and sheave before disassembly or use the X s on the components for reference This will aid in assembly and maintains clutch balance 3 Remove the four screws 1 that secure the cam helix assembly using a T25 Torx driver 4 ...

Page 226: ...e the spider assembly and spring 3 NOTE Spring is compression only and has no torsional wind 7 Remove the inside spider plate 4 and spider dampener 5 Inspect the spider dampener for wear and replace if needed 8 Remove the E clips 6 washers 7 and the clutch rollers 8 Inspect the rollers for wear replace if worn 9 Remove the clutch assembly from the holding tool 10 Press out the spring pins 9 in the...

Page 227: ...pect the bearing 12 for wear Spin the bearing if the bearing does not spin smoothly replace it To replace the bearing remove the snap ring 13 from the end of the shaft and press the bearing off the shaft 14 Inspect the cam helix assembly bushing 14 for wear If the bushing is worn or the shaft does not fit snug into the bushing replace the cam helix assembly 15 Inspect the sheaves for excessive wea...

Page 228: ... 90 Driven Clutch Cover Bushing Removal Tool 8 1 5020632 Main Puller Adapter 9 1 5010279 Adapter Reducer 10 1 5020633 Number Two Puller Adapter NOTE Bushings are installed at the factory using Loctite 648 In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing Clean all residual Loctite from bushing bore prior to installing new bushing Clutch Bushing R...

Page 229: ...stallation tool 2 and install assembly into sheave 16 Install left hand thread nut C onto puller rod and hand tighten against installation tool 17 Turn clutch sheave counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated 18 Remove nut C from puller rod and set aside 19 Remove installation tool and clutch sheave from puller Clutch Assembly 1 Install a new ...

Page 230: ...oth sides 5 Install the roller pin into the sheave assembly on both sides The flat side of the roller pin faces downward when the shaft side is laying flat on the bench 6 Install the spring pins C to secure the roller pins Install until flush with sheave surface 7 Install the spring over the shaft 8 Install the clutch rollers D onto each side of the outside spider Install the washers E and E clips...

Page 231: ...ushing the spider onto the shaft 13 Slowly compress the spider into place If the spider appears to bind while compressing stop and make sure the skip tooth on the shaft and the spider are aligned Once the spider passes the retaining ring notch on 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...

Page 232: ...R01 2015 RZR 900 Service Manual Copyright 2014 Polaris Industries Inc 15 Use a T25 Torx driver to install the four helix retaining screws 1 and torque to specification Helix Retaining Screws 48 in lb 5 Nm PVT SYSTEM ...

Page 233: ...ht 2014 Polaris Industries Inc DRIVEN CLUTCH SERVICE NON EBS Driven Clutch Assembly View non EBS 1 Stationary Sheave 6 Moveable Sheave 2 Thrust Washer 7 Spring 3 Roller 8 Spring Cup 4 Washer 9 Retaining Ring 5 E clip 10 Torx Screw 12 ft lb 16 Nm PVT SYSTEM ...

Page 234: ... clutch from the transmission input shaft and install it on a universal clutch compressor PU 50518 Spin the tool down until it touches the spring cup 5 Remove the five Torx screws 1 that secure the spring cover to the inner clutch sheave 6 Turn the compression tool handle counter clockwise to relieve spring pressure and remove the compressor tool from the clutch assembly 7 Remove the spring cover ...

Page 235: ...mission input shaft splines 14 Lube splines with a light film of grease Do not lubricate the bearings Driven Clutch Assembly 1 Align the X marks on each of the sheaves during reassembly 2 Assemble the clutch sheaves 3 Position the spring spring cup and retaining ring into moveable sheave Do not apply oil or grease to the bearings 4 Place the clutch into the universal clutch compressor Apply and ho...

Page 236: ...d operating range Incorrect drive clutch spring too high of rate Install correct recommended spring Drive clutch shift weights incorrect for application too light Install correct recommended shift weights Drive clutch binding Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Driv...

Page 237: ...in Owner s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Find leak and repair as necessary Operator error Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt slippage Belt worn out Replace belt Water ingestion Inspect and seal PVTsystem Belt contaminated with oil or grease Inspect and clean PVT noise Be...

Page 238: ...cle overturn Climbing over large objects from a stopped position Shift the transmission to Low carefully use fast aggressive brief throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVTsystem Remove the PVT drain plug Shift the transmission to neutral Using the throttle vary the engine ...

Page 239: ...ANSMISSION SERVICE 6 6 TRANSMISSION REMOVAL 6 6 TRANSMISSION INSTALLATION 6 11 TRANSMISSION DISASSEMBLY 6 14 DIFFERENTIAL OPERATION TURF MODE MODELS ONLY 6 18 PLANETARY DIFFERENTIAL DISASSEMBLY TURF MODE MODELS ONLY 6 20 PLANETARY DIFFERENTIAL BUSHING REPLACEMENT TURF MODE MODELS ONLY 6 21 PLANETARY DIFFERENTIAL ASSEMBLY TURF MODE MODELS ONLY 6 23 GEAR SHAFT BEARING INSPECTION 6 24 TRANSMISSION AS...

Page 240: ... Stabilizer Bar Linkage Rear 40 ft lbs 54 Nm Transmission Case Screws 20 ft lbs 27 Nm Transmission Fill Drain Plugs 14 ft lbs 19 Nm Transmission Mount Bracket Fasteners rear 22 ft lb 30 Nm Transmission Mount Isolator Bolt rear 33 ft lb 45 Nm Transmission Snorkel Tube Locking Screw 10 ft lb 14 Nm Special Tools PART NUMBER TOOL DESCRIPTION PA 50231 Snorkel Tool 2871698 Part of 2871702 Kit Rear Outpu...

Page 241: ... 64 ft lb 87 Nm Step 3 5 ft lb 7 Nm Step 4 7 44 ft lb 60 Nm See sequence in illustrations below 3 Transmission Bracket Bolts Step 1 2 64 ft lb 87 Nm Step 3 5 ft lb 7 Nm Step 4 7 44 ft lb 60 Nm See sequence in illustrations below 2 Transmission Isolator Fasteners 33 ft lb 45 Nm 4 Transmission Mount Bracket Fasteners 22 ft lb 30 Nm TRANSMISSION ...

Page 242: ...rx driver Remove the console from the vehicle 2 Remove the clip and washer retaining the shift cable to the shift lever and disconnect the cable end from the lever 3 Remove the retaining ring 5 and slide the shift lever 6 off the mounting bracket and out from the frame 4 Remove both bushings 7 from the shift lever and service as needed Shift Lever Installation Perform the removal steps in reverse ...

Page 243: ...ivot bushings and dust boot 2 Replace if worn or damaged 3 If adjustment is required loosen the lower jam nut 4 and pull the cable out of the mount 3 to move the upper jam nut 5 4 Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK 5 Thread the upper or lower jam nut as required to obtain proper cable adjustment NOTE This procedure may ...

Page 244: ...edure Always wear eye protection 1 Disconnect the negative battery cable from the battery 2 Remove the nine screw for the dog house cover over the air box 3 Loosen the clamp 1 for the PVT intake 4 Remove the four screws mounting the engine and PVT intake vents 5 Remove the two bolts 2 retaining the air box to the frame support and loosen the clamp 3 from the air box to the intake 6 Remove the 22 c...

Page 245: ...ake manifold and two fasteners retaining the harness by the transmission switch 9 Remove the three harness clamps 12 on the intake manifold Move the main harness out of the way towards the driver s seat 10 Disconnect the two fuel rail mounting bolts and move the fuel rail off to the driver s side CAUTION Be careful not to pinch or kink the fuel rail 11 Remove the four fasteners 13 retaining the in...

Page 246: ...ssion Lubrication page 2 19 15 Remove the stabilizer bar mounting bolt and nut 15 from both sides Discard nuts and replace with new upon assembly 16 Remove the fasteners 16 attaching the upper control arms to the bearing carriers left and right side Discard nuts and replace with new upon assembly Allow the radius rods swing downward 17 Pivot the control arms downward and maneuver the drive shafts ...

Page 247: ...N 2872085 CAUTION Use the correct puller to prevent damage to the end of the crankshaft 22 Remove seven bolts retaining the inner clutch cover 23 Remove vent hose 17 from transmission 24 Remove the gear position switch connector 18 speed sensor connector 19 crankshaft position sensor connector 20 shift bracket bolts and shift bracket 21 shift cable clevis pin and washer 22 from the transmission 25...

Page 248: ... the frame Remove the fasteners 26 that attach the rear mount to the transmission Remove the mount assembly from the vehicle 29 Slide transmission towards the rear of the vehicle Lift and rotate the top of the transmission towards the left side of the vehicle With the help of an assistant remove transmission from the left rear wheel well area NOTE Remove the grease zerk from the left rear upper co...

Page 249: ... the rear mount Torque fasteners to specification Rear Transmission Isolator Fasteners 33 ft lb 45 Nm 5 Install the two rear exhaust springs securing the muffler to the rear transmission mounting bracket 6 Install the Clutch Center Distance Tool PU 50658 onto the crankshaft and transmission input shaft to properly position the clutch center distance IMPORTANT Tool should bottom out on the transmis...

Page 250: ... Nm 12 Remove the clutch center distance tool 13 Remove the spacer or support between the vehicle frame and engine 14 Install and properly route the gear position switch connector 4 speed sensor connector 5 crankshaft position sensor connector 6 shift bracket and shift bracket bolts 7 shift cable clevis pin and washer 8 onto the transmission 15 Torque the two shift cable bracket bolts to specifica...

Page 251: ...e splines of the drive shaft with the transmission splines Push inward on the control arm assembly until the rear drive shafts lock into the transmission splines 22 Install new fasteners 12 retaining the upper control arms to the bearing carriers on each side Torque to specification 23 Install the stabilizer bar link mounting bolts and new nuts 13 Torque to specification 24 Install rear wheels and...

Page 252: ...ter as a reference 1 Place transmission in High gear before disassembly 2 Drain and properly dispose of the transmission lubricant see Chapter 2 Transmission Lubrication page 2 19 3 Remove the bell crank nut 1 and bell crank 2 4 Remove E clip 3 that retains spring and flat washers 4 and gear switch 5 Remove the switch 5 Remove the sector cover bolts 6 and remove the sector cover 7 NOTE Removal can...

Page 253: ...the designated pry points indicated by the black arrows in the illus tration below CAUTION Do not pry on case sealing surfaces Use only the designated pry points on the transmission 12 Lift up on the shift shaft rail 16 and move the rail assembly rearward to allow the shift fork pins 17 to be removed from the shift drum 18 Remove the shift drum from the transmission housing 13 Remove the shift sha...

Page 254: ...e the longer screw 24 that locks the snorkel tube 18 Remove all seals from the gearcase halves and clean the cases in preparation for assembly Gear Cluster Disassembly 19 Remove the bearing from the reverse shaft using a bearing puller Remove the retaining ring and slide the washers high gear and needle bearing off the reverse shaft 1 Bearing 6 Needle Bearing 2 Reverse Shaft 7 Engagement Dog 3 Ret...

Page 255: ...e shift shaft rail remove the snap ring 25 from the end of the shift rail on either side CAUTION Use caution when disassembling the shift rail The compressed springs on the shift rail may pop off causing eye or face injury Snorkel Shaft Removal Disassembly CAUTION The pinion shaft must be removed prior to removing the snorkel shaft assembly Failure to remove pinion shaft will result in damage to t...

Page 256: ...he snorkel shaft Differential Operation Turf Mode Models Only Transmissions equipped with Turf Mode have two traction operational modes Differential Lock and Differential Unlock Locking the rear differential is beneficial in low traction and rough terrain conditions Unlocking the rear differential makes maneuvering easier and minimizes damage to terrain When Differential Unlock is selected the rea...

Page 257: ...r turns When Differential Lock is selected power is removed from the electrical solenoid allowing the solenoid plunger to retract Spring tension moves the shift fork back into place and mates the engagement dog to the side gear that is part of the planetary differential assembly This locks the rear differential as a solid rear axle increasing traction TRANSMISSION ...

Page 258: ... to disassembly 2 Remove the six screws retaining the differential cover and remove the cover 3 Remove the six planet gears and each side gear assembly from the ring gear 4 Inspect the female side gear A male side gear B planet gears C and ring gear D Replace components or bushings as needed Bushing replacement can be performed on all necessary differential components If bushing replacement is req...

Page 259: ...mbly procedure Ring Gear Bushing Replacement 1 Press the old bushing out of the ring gear 2 Thoroughly clean the bore of the ring gear and check for any unwanted burs 3 Press the new bushing into the ring gear housing 4 Install the bushing to the specified depth as shown Planet Gear Bushing Replacement 5 Press the old bushing out of the planet gear 6 Thoroughly clean the bore of the planet gear an...

Page 260: ...cover 9 Thoroughly clean the bore of the differential cover and check for any unwanted burs 10 Press the new bushing into the differential cover 11 Install the bushing to the specified depth as shown Female Side Gear Bushing Replacement 12 Locate the bushing split Using a small chisel or flat blade screwdriver peel back and remove the old bushing from the side gear being careful not to damage the ...

Page 261: ...ly 1 Thoroughly clean the differential components 2 Assemble the side gears and place them onto the ring gear along with the six planet gears 3 Align and install the differential cover using the previously made scribe marks 4 Apply Loctite 2760 to cover screws 5 Install screws hand tight Place assembly in soft jaw vise and torque to specification Differential Cover Screws 22 ft lb 30 Nm TRANSMISSI...

Page 263: ...nto the snorkel shaft flush to the shoulder install the washer and new retaining ring 3 Press the gear back towards the retaining ring Avoid excessive force so the retaining ring is not damaged or pre stressed significantly NOTE Failure to press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service 4 Apply a small amount of whi...

Page 264: ...r retaining screws 9 Using a 5 mm Allen wrench install only the three screws 15 that secure the pinion shaft assembly as shown below Leave the longer locking screw 16 out at this point Torque the bearing cover retaining screws to specification Bearing Cover Retaining Screws 10 ft lb 14 Nm IMPORTANT DO NOT install the longer screw Installing the longer screw will lock the snorkel tube and not allow...

Page 265: ...el shaft clockwise to the next notch 4th notch 14 Once the backlash is set apply Loctite 242 to the threads and install the locking screw to secure the snorkel tube Torque the locking screw to specification Snorkel Locking Screw 10 ft lb 14 Nm Transmission Assembly NOTE The snorkel shaft and pinion shaft must be installed prior to transmission assembly The snorkel shaft cannot be installed after a...

Page 266: ... the shift shaft rail 31 and shift forks into the transmission housing as an assembly Be sure the shift forks are engaged into the engagement dogs NOTE Shift fork pins should be offset towards the input shaft as shown above 32 21 Inspect the shift drum for any damage or wear Inspect the splines of the shift drum 22 Install the shift drum into the transmission housing Lift up on the shift shaft rai...

Page 267: ...haft seal 34 should be pressed in until it seats flush with the housing The rear output shaft seals 35 can be installed using a standard bushing installation tool Seals should be installed just past the case lead in chamfer 0 070 or 1 8 mm from outer face of bore 26 Thoroughly clean the shift shaft housing 27 Install the sector gear 16T onto the shift drum shaft Install the shift shaft assembly an...

Page 268: ...ghly 32 Apply Crankcase Sealant 3 Bond PN 2871557 onto the cover and transmission case mating surface 33 Install the sector cover and align the transmission case dowel with the alignment hole Install and torque the bolts to specification Sector Gear Cover Bolts 12 ft lb 16 Nm 34 Install the transmission drain plug and torque to specification Fill Drain Plug 14 ft lbs 19 Nm 35 Install the bellcrank...

Page 271: ...1 Sprocket Reverse 19 Retaining Ring Internal 62 Gear Low 20 Retaining Ring External 63 Engagement Dog 6 Face 21 Retaining Ring External 64 Gear High 22 Retaining Ring External 65 Shaft Pinion 11T 23 Retaining Ring External 66 Gear 46T 24 Washer Thrust 67 Gear Snorkel 13T 25 Washer Thrust 68 Shaft Shift 26 Shim 69 Weldment Rear Mount Bracket 27 Shim 70 Bracket Rear Mount 28 Bearing Needle Cage 71 ...

Page 273: ...17 Pin Spring 52 Gear Sector 31T 88 O Ring 18 Retaining Ring External 53 Pawl Detent 89 O Ring 19 Snap Ring 54 Star Detent 90 Seal Triple Lip 20 Retaining Ring External 55 Plate Park 12 Face 91 Seal Triple Lip 21 Retaining Ring External 56 Shaft Idler 29T 92 Seal Dual Lip 22 Retaining Ring Internal 57 Shaft Reverse 29T 93 Seal Triple Lip 23 Retaining Ring External 58 Shaft Front Output 95 Sensor S...

Page 274: ...hift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting the shift cable end from the transmission bellcrank Manually select each gear range at the transmission bellcrank and test ride vehicle If it functions properly the problem is ou...

Page 275: ... FRONT HALF SHAFT REMOVAL 7 10 FRONT HALF SHAFT INSTALLATION 7 11 REAR HALF SHAFT REMOVAL 7 12 REAR HALF SHAFT INSTALLATION 7 13 DRIVE SHAFT CV JOINT HANDLING TIPS 7 14 OUTER CV JOINT BOOT REPLACEMENT 7 15 INNER PLUNGING JOINT BOOT REPLACEMENT 7 17 PROP SHAFT REMOVAL 7 20 PROP SHAFT INSTALLATION 7 21 FRONT GEARCASE CENTRALIZED HILLIARD 7 22 FRONT GEARCASE ASSEMBLY VIEW 7 22 ALL WHEEL DRIVE OPERATI...

Page 276: ... Gearcase Fill Drain Plugs 10 ft lbs 14 Nm Front Gearcase Mounting Bolts 33 ft lbs 45 Nm Hub Castle Nut 110 ft lbs 149 Nm Tie Rod End Fastener 30 ft lbs 41 Nm 90 Wheel Lug Nuts Aluminum 120 ft lbs 163 Nm Steel 60 ft lb 81 Nm Special Tools PART NUMBER TOOL DESCRIPTION 2870026 CV Boot Clamp Pliers earless type 2872608 Roll Pin Removal Tool PU 48951 Axle Boot Clamp Tool Bosch Automotive Service Solut...

Page 277: ...d discard the two front brake caliper mounting bolts and remove the caliper from the brake disc see Chapter 9 Front Caliper Pad Removal page 9 16 CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 7 Remove the front wheel hub assembly 8 Remove and discard the upper and lower ball joint pinch bolts 4 9 Using a soft faced hammer lightly tap...

Page 278: ...the new bearing Be sure that all oil residue has been removed from each surface 2 Support the bottom of the bearing carrier housing CAUTION Use an arbor and press only on the outer race otherwise bearing damage may occur 3 Apply Loctite 603 retaining compound to the outer circumference of the new bearing 2 race and carefully press the new bearing into the bearing carrier housing NOTE Use care to n...

Page 279: ...ly 7 Install the steering tie rod end 4 onto the front bearing carrier NOTE Refer to the photos below to ensure proper placement of the tie rod end 8 Torque the tie rod end fastener 5 to specification and install a new cotter pin Tie Rod End Fastener 30 ft lbs 41 Nm 90 9 Torque wheel hub nut 6 to specification and install a new cotter pin 7 Tighten nut slightly if necessary to align cotter pin hol...

Page 280: ... caliper by the brake like Use wire or rope to hang the caliper to prevent brake line damage 6 Remove the fasteners 5 retaining the bearing carrier to the upper and lower control arms Swing radius rod down Discard the nut 7 Remove the rear wheel hub and brake disc assembly 8 Pull the bearing carrier out to remove from the vehicle 9 Rotate the bearing by hand and check for smooth rotation Visually ...

Page 281: ...wear or damage Replace rear bearing carrier if damaged 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 CAUTION Use an arbor and press only on the outer race or bearing damage may occur 7 Apply Loctite 603 retaining compound to the outer circu...

Page 282: ...control arms to the bearing carrier Torque bolts to specification Rear Bearing Carrier Mounting Fasteners 42 ft lb 57 Nm 3 Apply a small amount of anti seize to the drive shaft splines 4 Install rear wheel hub assembly 2 cone washers 3 and hand tighten the castle nut Install washers domed side out 5 Install the rear brake caliper assembly and new bolts 4 Torque bolts to specification Brake Caliper...

Page 283: ...t slightly if necessary to align cotter pin slot Hub Castle Nut 110 ft lbs 149 Nm 7 Install wheel and four wheel nuts finger tight Lower vehicle and torque wheel nuts to specification Wheel Lug Nuts Aluminum 120 ft lbs 163 Nm Steel 60 ft lb 81 Nm 8 Rotate wheel and check for smooth operation Bend both ends of the cotter pin around the end of the spindle FINAL DRIVE ...

Page 284: ...nut 2 Remove the nut and cone washers 3 from the front wheel hub assembly 4 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc see Chapter 9 Front Caliper Pad Removal page 9 16 CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 5 Remove the front wheel hub assembly 6 Remove and discard...

Page 285: ...Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 3 Install drive shaft into the front bearing carrier 4 Install the upper and lower ball joint ends into the front bearing carrier 5 Install new pinch bolts 3 and nuts Torque to specification Ball Joint Pinch Bolts 42 ft lb 57 Nm 6 Apply Anti Seize to drive shaft axle splines 7 Install front wheel hub assembly 4 cone was...

Page 286: ...king agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 10 Install wheel and four wheel nuts Torque wheel nuts to specification Wheel Nuts Aluminum 120 ft lbs 163 Nm Steel 60 ft lb 81 Nm 11 Rotate wheel and check for smooth operation Rear Half Shaft Removal 1 Remove the center cap 1 on the wheel 2 Remove the cotter pin 2 and loosen the castle nut 3 3 Sl...

Page 287: ...pe or wire to secure the bearing carrier 9 With a quick short jerk outward remove the half shaft from the transmission Rear Half Shaft Installation 1 If the half shaft is not being replaced install a new spring ring 1 on the half shaft Apply anti seize to the splines 2 2 Align splines of the half shaft with transmission splines and reinstall the half shaft by pushing in with a quick jerk 3 Install...

Page 288: ... the rim Drive Shaft CV Joint Handling Tips Care should be exercised during drive shaft removal or when servicing CV joints Drive shaft components are precision parts Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life The complete drive shaft and joint should be handled by getting hold of the interconnecting shaft to avoid disas...

Page 289: ...t Replacement 1 Use a side cutters to cut and discard the boot clamps 1 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 Using a soft faced hammer or brass drift strike the inner race of the joint to drive the joint off the drive shaft Be sure to tap evenly around the jo...

Page 290: ...nes on the end of the shaft and apply a light coat of grease prior to reassembly 10 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 11 Install a new circlip on the end of the shaft 12 Grease the joint with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls and the spli...

Page 291: ... equalize in the CV boot in the position that the joint will spend most of its life Before you remove your instrument be sure the small end of the boot is in its correct location on the shaft 20 Install and tighten the small clamp 4 on the boot using the appropriate clamp tool Axle Boot Clamp Tool PU 48951 or CV Boot Clamp Pliers 8700226 Inner Plunging Joint Boot Replacement 1 Use a side cutters t...

Page 292: ...ar patterns Intermixing the internal components could result in looseness binding and or premature failure of the joint IMPORTANT If the grease in the joint is obviously contaminated with water and or dirt the joint should be replaced 7 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 8 Visually in...

Page 293: ...ft until you reach the end of the splines and the joint locks in place 16 Pull on the joint to test that the circlip is seated and that the joint is securely fastened to the shaft 17 Remove excess grease from the plunging joint s external surfaces and place the excess grease in the boot 18 Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft Make ...

Page 294: ...ine if none are present between the front prop shaft yoke and the splines on the rear prop shaft for proper alignment on installation 7 Remove the two fasteners 4 retaining the prop shaft support bearing to the frame 8 While moving the prop shaft support bearing assembly rearward slide the front prop shaft 5 off the rear prop shaft 6 and remove it from the vehicle NOTE If difficulty is encountered...

Page 295: ...aring 5 Align the keyways on the front and rear prop shafts as shown and slide them together NOTE Paint marks are applied to the front and rear prop shafts to aid in shaft alignment and installation Reference these marks during installation 6 Install and torque the support bearing fasteners to specification Prop Shaft Support Bearing Fasteners 33 ft lb 45 Nm 7 Align the front prop shaft paint mark...

Page 296: ...ew 1 Seal 11 Ring Gear 2 Cover Plate 12 Spring 3 AWD Coil 13 Output Hub 4 Backlash Spacer 14 Bearing 5 Nylon Spacer 15 Gearcase Housing 6 Armature Plate 16 Drain Plug 10 ft lbs 14 Nm 7 Roller Cage 17 Fill Check Plug 10 ft lbs 14 Nm 8 Roller 18 Pinion Gear 9 Spring Retainer 19 Snap Ring 10 O ring 20 Cover Plate Screws 11 ft lbs 15 Nm FINAL DRIVE ...

Page 297: ...gaged while the wheels are spinning severe drive shaft and front gearcase damage could result AWD Engagement When the AWD switch is activated the AWD coil is powered by a 12 Vdc input which creates a magnetic field This magnetic field attracts an armature plate 1 that is keyed to the roll cage 2 When the ring gear 3 and roll cage are spinning vehicle is moving the energized coil and armature plate...

Page 298: ...nd inspect components 4 Inspect armature plate 3 for a consistent wear pattern There should be two distinct wear bands 4 If only one band of wear is present or if there is wear between the two bands inspect the coil area as indicated in Step 5 A wear band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation 5 Check to make sure the coil 5 is seated in th...

Page 299: ...hapter 7 Front Half Shaft Removal page 7 10 4 Remove the front section of the prop shaft see Chapter 7 Prop Shaft Removal page 7 20 5 Disconnect the wire harness for the front gearcase and remove the harness from the retaining dart 6 Remove the vent line from the front gearcase and plug vent line fitting 7 Remove the four bolts 4 securing the front gearcase to the frame 8 Rotate front of gearcase ...

Page 300: ...e assembly NOTE Nylon spacer is non serviceable and should not be removed 4 Remove and inspect the armature plate Refer to AWD Diagnosis page 7 24 for detailed inspection process 5 Remove the torsion spring retainer and torsion spring from the top of the ring gear 6 Remove the clutch housing ring gear and roll cage assembly from the gearcase housing FINAL DRIVE ...

Page 301: ...ed broken or missing teeth Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting 10 Inspect the AWD coil located in the outer cover plate assembly Refer to AWD Diagnosis page 7 24 for detailed inspection process Replace the cover plate seal and O ring 11 Remove the roll cage assembly and rollers from the clutch housing Use a shop towel to cover the housing in o...

Page 302: ...rts are to be replaced as an assembly or as a complete kit 13 Inspect clutch housing ring gear C for a consistent wear pattern Inspect the ring gear for chipped broken or missing teeth 14 Inspect the roll cage assembly B sliding surfaces and H springs The sliding surfaces must be clean and free of nicks burrs or scratches If damaged replace the roll cage assembly 15 Inspect both output hub assembl...

Page 303: ... a new pinion shaft seal into the pinion gear housing Using a universal seal installer press the new seal into the housing until the seal is just below the housing chamfer 4 Install the RH output hub into the gearcase housing 5 Carefully install the rollers into the roll cage assembly while installing the assembly into the clutch housing NOTE Install roll cage so that the ring gear grooves line up...

Page 304: ... armature plate Be sure all of the armature plate tabs are fully engaged into the roll cage assembly and that it is resting properly on the torsion spring retainer NOTE Verify armature plate tabs are in the roll cage slots and that it rests properly on the spring retainer 10 Carefully install the ring gear and roll cage assembly into the gearcase housing 11 Install a new O ring on the cover plate ...

Page 305: ...s and torque to specification Cover Plate Screws 11 ft lbs 15 Nm Front Gearcase Installation 1 Install the gearcase back into the vehicle through the LH wheel well area above the upper A arm 2 Lubricate the front gearcase splines with Anti Seize 3 Install the prop shaft onto the front gearcase input shaft Use a NEW spring pin in the front prop shaft 4 Install the four bolts 1 that secure the front...

Page 306: ...tallation page 7 11 and install both front drive shafts into the gearcase 8 Add the proper lubricant to the front gearcase Refer to Chapter 2 for fluid fill and change information Recommended Front Gearcase Fluid Polaris Demand Drive PN 2877922 Quart Capacity 7 5 oz 222 mL fill on a level surface to bottom of threads on the fill hole FINAL DRIVE ...

Page 307: ...EL HUBS Front Hub Assembly View 1 Wheel Cap 7 Wheel Hub 2 Wheel Nuts Aluminum 120 ft lbs 163 Nm Steel 60 ft lb 81 Nm 8 Brake Disc 3 Front Rim Aluminum shown 9 Studs 4 Cotter Pin 10 Retaining Ring 5 Castle Nut 110 ft lbs 149 Nm 11 Sealed Bearing 6 Cone Washer 12 Bearing Carrier FINAL DRIVE ...

Page 308: ...nc Rear Hub Assembly View 1 Wheel Cap 7 Wheel Hub 2 Wheel Nuts Aluminum 120 ft lbs 163 Nm Steel 60 ft lb 81 Nm 8 Brake Disc 3 Rear Rim Aluminum shown 9 Studs 4 Cotter Pin 10 Retaining Ring 5 Castle Nut 110 ft lbs 149 Nm 11 Sealed Bearing 6 Cone Washer 12 Bearing Carrier FINAL DRIVE ...

Page 309: ...AL EPS 8 10 POWER STEERING UNIT REMOVAL 8 10 LOWER STEERING SHAFT REMOVAL 8 12 LOWER STEERING SHAFT INSTALLATION 8 12 POWER STEERING UNIT INSTALLATION 8 13 UPPER STEERING SHAFT INSTALLATION 8 14 FRONT SUSPENSION 8 15 FRONT SUSPENSION ASSEMBLY VIEW 8 15 FRONT CONTROL ARM REPLACEMENT 8 16 BALL JOINT REMOVAL 8 18 BALL JOINT INSTALLATION 8 18 FRONT STABILIZER BAR REPLACEMENT 50 XC 8 19 REAR SUSPENSION...

Page 310: ...com Torque Specifications ITEM SPECIFICATION A Arm Mounting Bolts front 42 ft lb 57 Nm Ball Joint Fasteners 42 ft lb 57 Nm Bearing Carrier Bolts 42 ft lb 57 Nm EPS Unit Mount Bracket Fasteners 16 ft lb 22 Nm Pivot Tube Fasteners 40 ft lb 54 Nm Shock Mounting Bolts 42 ft lb 57 Nm Stabilizer Bar Link Fasteners 40 ft lbs 54 Nm Stabilizer Bar Mounting Fasteners 17 ft lb 23 Nm Steering Pivot Bolts 40 f...

Page 311: ...rack mounting bolts 2 and remove the steering rack out of the vehicle 5 Reverse procedure for installation Torque NEW fasteners to specification Steering Shaft to Rack Fasteners 48 ft lb 65 Nm Power Steering Unit Mounting Bolts 30 ft lb 41 Nm Steering Shaft to EPS Unit Pinch Bolt 15 ft lbs 20 Nm Power Steering Unit Mount Bracket Nuts 16 ft lb 22 Nm Pivot Tube Fasteners 40 ft lb 54 Nm Tilt Shock Fa...

Page 312: ... rod jam nut and unthread the tie rod end off the tie rod 5 Install new tie rod end and thread it back to the original location of the other tie rod end Tighten jam nut to specification Tie Rod Jam Nut 14 ft lbs 19 Nm 6 Install the tie rod end into the knuckle Tighten new fastener to specification Tie Rod End to Knuckle 30 ft lbs 41 Nm 90 7 Install the wheel and four wheel nuts Tighten lug nuts to...

Page 313: ...ners 40 ft lb 54 Nm 11 Steering Rack 2 Steering Wheel Nut 65 ft lbs 88 Nm 7 Tilt Steering Shock 12 Rack Mounting Fasteners 16 ft lbs 22 Nm 3 Steering Wheel 8 Tilt Shock Fasteners 7 ft lb 10 Nm 13 Tie Rod End Nuts 30 ft lbs 41 Nm 90 4 Bushing 9 Steering Shaft 14 Tie Rod Jam Nut 14 ft lbs 19 Nm 5 Bearing 10 Shaft to Rack Fasteners 48 ft lb 65 Nm 15 Tie Rod End STEERING SUSPENSION ...

Page 314: ... tube 4 Remove the steering shaft pivot tube and steering wheel from the vehicle as an assembly 5 Refer to steps 11 16 of the Steering Shaft Bearing Replacement page 8 6 procedure for installation Steering Shaft Bearing Replacement NOTE Replacement pivot tube assembly comes with new upper and lower bearings installed Use this procedure if replacing just the bearings only 1 Perform the Steering Sha...

Page 315: ...icle Install the lower portion of the steering shaft onto the steering gear box assembly see Figure 5 16 Torque the lower pinch bolt to specification Steering Shaft to Rack Pinch Bolt 48 ft lb 65 Nm 12 Install the two fasteners 12 that retain the pivot tube Torque fasteners to specification Pivot Tube Bolts 40 ft lb 54 Nm 13 Install the fastener 13 retaining the upper portion of the steering wheel...

Page 316: ...ng Wheel 9 Upper Steering Shaft 16 Shaft to Rack Fastener 48 ft lb 65 Nm 3 Bushing 10 Shaft to EPS Fasteners 15 ft lbs 20 Nm 17 Steering Rack 4 Bearing 11 EPS 18 Tie Rod End Nut 30 ft lbs 41 Nm 90 5 Steering Pivot 12 EPS Cover 19 Rack Mounting Fasteners 16 ft lbs 22 Nm 6 Pivot Fasteners 40 ft lb 54 Nm 13 EPS Mounting Bracket 20 Tie Rod End 7 Tilt Locking Shock 14 Bracket Fasteners 30 ft lb 41 Nm S...

Page 317: ...he vehicle 2 Remove the pinch bolt 2 retaining the upper steering shaft 3 to the power steering unit 4 3 Lift the steering wheel up and remove the four fasteners 5 that retain the pivot tube 4 Remove the steering shaft pivot tube and steering wheel from the vehicle as an assembly 5 If replacing the upper steering shaft or steering wheel see Chapter 8 Steering Wheel Removal EPS page 8 10 STEERING S...

Page 318: ...ssembly in a vise 5 Using a large bronze drift and hammer strike the steering shaft nut to pop the steering wheel off the shaft taper 6 Once the steering wheel pops loose completely remove the nut and lift the steering wheel off the shaft Power Steering Unit Removal 1 Remove the upper steering shaft pivot tube and steering wheel from the vehicle as an assembly See Chapter 8 Upper Steering Shaft Re...

Page 319: ...ket 5 Carefully remove the power steering unit and mount bracket from the vehicle as an assembly 6 If replacing the power steering unit remove the three bolts 4 that retain the power steering unit to the mount bracket IMPORTANT Electronic Power Steering EPS units are programmed to be vehicle specific and are not interchangeable between product lines STEERING SUSPENSION ...

Page 320: ...move the pinch bolt 1 retaining the lower steering shaft 2 to the steering gear box assembly 3 5 Lift up on the shaft and remove it through the floor panel Lower Steering Shaft Installation 1 Install the lower steering shaft onto the gear box and align the marks made during step 2 of the Lower Steering Shaft Removal EPS Models procedure 2 Install the pinch bolt that retains the lower steering shaf...

Page 321: ...on the power steering stub shaft with the opening in the lower steering shaft 5 3 Place the power steering mount bracket over the top of the brake pedal mount studs and finger tighten the four nuts 4 Torque the four mount bracket nuts 6 to specification Power Steering Unit Mount Bracket Nuts 16 ft lb 22 Nm 5 Position the lower steering shaft on the power steering unit stub shaft and install the pi...

Page 322: ...teners to specification Pivot Tube Fasteners 40 ft lb 54 Nm 3 Install the tilt shock and torque fastener to specification Tilt Shock Fastener 7 ft lb 10 Nm 4 Be sure the front wheels are pointing straight ahead and install the steering wheel and retaining nut Torque the nut to specification and reinstall the plastic wheel cover Steering Wheel Nut 65 ft lbs 88 Nm 5 Install a new upper steering shaf...

Page 323: ...Polaris Industries Inc FRONT SUSPENSION Front Suspension Assembly View 1 Upper A arm 5 Shock Assembly 2 Lower A arm 6 Shock Fasteners 42 ft lb 57 Nm 3 Bushings 7 Ball Joint Fasteners 42 ft lb 57 Nm 4 Ball Joint 8 Control Arm Bolt 42 ft lb 57 Nm STEERING SUSPENSION ...

Page 324: ...d rear though bolt fastener 4 Remove the upper control arm from the vehicle 7 Examine A arm bushings and pivot tube Replace if worn Discard hardware WARNING The locking agent on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation 8 If not replacing the control arm thoroughly clean the control arm an...

Page 325: ...ol arm from the vehicle 17 Examine A arm bushings and pivot tube Replace if worn Discard hardware 18 If not replacing the control arm thoroughly clean the control arm and pivot tube 19 Install new ball joint into control arm Refer to Ball Joint Replacement section 20 Insert new control arm bushings and pivot tube into new control arm A light press force may be needed 21 Install new lower control a...

Page 326: ... the ball joint 2 10 Place a proper sized driver on the ball joint and place the A arm in a press 11 Carefully press the ball joint out of the A arm and discard the ball joint Ball Joint Installation 1 By hand install the NEW ball joint into the A arm 2 Using a press carefully drive in the new ball joint into the A arm 3 After the new ball joint 3 is fully installed into the A arm 1 install a new ...

Page 327: ...arm 3 on both sides 2 Remove the Fasteners retaining the stabilizer bar mount to the frame 3 Remove the stabilizer bar out the side of the vehicle 4 Remove the fasteners 4 retaining the stabilizer bar link to the stabilizer bar 5 To install reverse procedure and torque fasteners to specification Stabilizer Bar Link Fasteners 40 ft lb 54 Nm Stabilizer Bar Mount Fasteners 17 ft lb 23 Nm STEERING SUS...

Page 328: ...pivot tubes Replace if worn Discard hardware 6 If not replacing the A arm thoroughly clean the a arm and pivot tubes WARNING The locking agent on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation 7 Insert new bushings and pivot tubes into new A arm Lower A arm Removal 1 RZR 60 ONLY While holding t...

Page 329: ...5 Install upper A arm assembly onto vehicle frame Torque new fastener to specification 6 Install the lower portion of the shock to the lower control arm Torque shock fastener to specification 7 RZR 50 and XC ONLY Mount stabilizer bar to upper control arm Torque fasteners to specification 8 Attach upper A arm to bearing carrier Torque new fastener to specification 9 Install wheel and torque wheel n...

Page 330: ...zer bar brackets 4 to the vehicle frame and remove the brackets bushings 4 Remove the stabilizer bar from the vehicle 5 To Install carefully install the stabilizer bar in the vehicle 6 Fully install the stabilizer bar bushings bracket and fasteners Center stabilizer bar in the frame Torque mounting fasteners to specification Stabilizer Bar Mounting Bolts 16 ft lb 22 Nm 7 Install the stabilizer bar...

Page 331: ...3 9925723 R01 2015 RZR 900 Service Manual Copyright 2014 Polaris Industries Inc SHOCKS SPRINGS Front Shock Assembly View 50 Model XC 60 Model Rear Shock Assembly View 50 Model XC 60 Model STEERING SUSPENSION ...

Page 332: ... Replacement 1 Remove the shock and note where the spring adjustment setting is set at 2 Loosen jam nut if applicable and adjustment ring until the spring is loose If needed use a spring compressor to compress the spring far enough to remove the spring retainer 3 Remove the spring and spring retainer from the existing shock and install components onto the new shock 4 Install the spring s and sprin...

Page 333: ...ON REBOUND 1 600 x 008 DB 1 425 x 008 1 600 x 008 1 425 x 008 1 600 x 008 1 425 x 008 1 600 x 008 0 800 x 006 0 750 x 008 1 425 x 010 1 600 x 012 1 350 x 010 1 425 x 012 1 250 x 010 1 350 x 012 1 100 x 010 1 250 x 012 0 950 x 010 1 100 x 012 1 230 x 082 Top Out 0 950 x 012 0 750 x 100 Back Up 1 570 x 128 Top Out XC Rear Shock Valving COMPRESSION REBOUND 1 600 x 008 DB 1 425 x 008 1 600 x 008 1 425...

Page 334: ... 425 x 008 1 600 x 008 1 425 x 008 1 600 x 008 1 425 x 008 1 600 x 008 0 800 x 006 0 750 x 008 1 425 x 012 1 600 x 012 1 350 x 012 1 600 x 012 1 250 x 012 1 600 x 012 1 100 x 012 1 600 x 012 0 950 x 012 1 600 x 012 1 230 x 082 Top Out 1 600 x 012 0 750 x 100 Back Up 1 100 x 006 1 570 x 128 Top Out 60 S Rear Shock Valving COMPRESSION REBOUND 1 600 x 006 DB 1 425 x 010 1 600 x 010 1 425 x 010 1 600 ...

Page 335: ...ean towel can be used in the vice jaws to protect the body cap 2 Discharge nitrogen pressure from reservoir chamber 3 Once nitrogen pressure has been released depress reservoir cap and remove retaining ring Typically a valve shim can be used 4 Remove the end cap using the appropriate extractor tool 5 Place the bearing cap removal tool around the body and install retaining ring 6 Tap bearing cap re...

Page 336: ...ly down with your fingers At the same time push the IFP tool upwards with your thumbs 9 Remove retaining ring with a valve shim 10 Remove shock shaft assembly by pushing down on the IFP removal tool while pulling up on shock shaft assembly 11 Dump out used oil 12 Using a 9 16 open end wrench and a 1 8 Hex Tee handle wrench remove the bleed screw STEERING SUSPENSION ...

Page 337: ...e cap to be removed with a torx bit driver 15 Remove the LSC using a 5 8 wrench 16 Remove the DSC using a DSC removal socket 17 Remove the reservoir with a rubber belted strap wrench 18 Before putting the body into the clamp blocks partially insert an old or used bearing assembly in the body This will prevent over tightening and deforming the body STEERING SUSPENSION ...

Page 338: ...ve apply heat to the body cap 20 Use torque cap socket or adjustable wrench to remove body cap CAUTION Body Cap will be hot 21 Discard all O rings and clean Loctite residue completely out of threads of the body 22 Clean body cap using a wire brush and pick 23 Remove both retaining rings in the body cap using a sharp pick STEERING SUSPENSION ...

Page 339: ...25 Prep the threads on the body cap with Loctite primer 7649 and set aside 26 Place shock shaft assembly in clamp blocks and remove nut from non BOC equipped shaft assembly 27 For Bottom Out Cup equipped shocks remove the retaining ring from the Bottom Out Post 28 Remove retaining ring on BOC post assembly with valve Valving laid out in order removed from post STEERING SUSPENSION ...

Page 340: ...he shims together this will keep valve shim stack in their assembled order 31 Note the side of the piston as it comes off the shock shaft Compression side down 32 Remove the piston bearing if it shows any signs of damage or wear 33 Remove piston O ring 34 Take note if you have a bleed shim when removing compression valve stack 35 Remove bearing assembly and bearing cap STEERING SUSPENSION ...

Page 341: ...37 Apply heat with a propane torch to the bottom of shock eyelet 38 Remove eyelet using an adjustable wrench or Body Cap socket 398 00 626 CAUTION Eyelet will be Hot 39 Clean Loctite residue out from threads of the eyelet 40 Remove Loctite residue from shock shaft 41 Remove Jet Check Valve with Hex T handle wrench STEERING SUSPENSION ...

Page 342: ...ng a metering rod and Hex T handle wrench 43 Remove O ring from needle 44 Back out rebound adjuster with flat head screw driver 45 Keep a magnet close to catch ball and spring when the round adjuster is almost out 46 Remove dust boot 47 Remove both retaining rings from the eyelet and press out bearing STEERING SUSPENSION ...

Page 343: ...935 NOTE DX Bushing style eyelets have larger bore diameters than conventional eyelets 3 Remove dust seal from bearing cap NOTE On some models the seal may be in the bearing assembly 4 Remove low friction seal pack from bearing assembly 5 Remove U Cup seal from bearing assembly Note the direction seal was installed 6 Remove external O ring from bearing assembly NOTE If internal bearing is damaged ...

Page 344: ...sembly 1 Install one retaining ring in the eyelet 2 Press bearing into the eyelet using Bearing Press 803 00 569 3 Install second retaining ring 4 Install Dust Plug 5 Apply shock oil to rebound adjuster 6 Insert spring 7 Put the steel ball on the spring with a dab of shock oil STEERING SUSPENSION ...

Page 345: ... knob to allow metering rod to obtain maximum travel in eyelet 10 Install new O ring on needle and apply thin layer of Slick Honey 11 Place shock shaft in clamp blocks and insert needle into shock shaft 12 Thread in the damping jet and torque to specification 13 Reverse shock shaft in clamp blocks and apply a thin layer of Slick Honey to metering rod 14 Apply specified Loctite two threads down and...

Page 346: ...s 16 Reverse shock shaft in clamp blocks and install air side shaft spacers if equipped and jounce bumper 17 Install wiper seal in body cap if equipped 18 Apply thin layer of shock oil to seal 19 Install body cap There are two different sides on the U Cup seal When seal is installed energizing side should be facing internal bearing 20 Install U Cup seal 21 Install back up washer STEERING SUSPENSIO...

Page 347: ...Install bearing assembly using the appropriate bullet tool 24 Install piston O ring if applicable 25 Install piston bearing on installation tool 803 00 187 26 Place installation tool assembly on top of the piston and push down to install bearing NOTE Bearing will be fully seated around piston when done correctly STEERING SUSPENSION ...

Page 348: ...d up with compression port 28 Install rebound valve stack with required top out washer 29 Apply a thin layer of float fluid to the threads nut or BOC post and torque to 22 ft lbs 30 Nm 30 Install BOC post valving NOTE Ensure retaining ring is fully installed and secure 31 Install BOC piston and retaining ring 32 Apply Loctite primer to the body cap threads STEERING SUSPENSION ...

Page 349: ...r to installing body if equipped 35 Apply Loctite 638 to body two threads down and two threads wide 360 around body 36 Place body in clamp blocks and torque body cap to 100 ft lbs 136 Nm using body cap socket 37 Place body in block clamps parallel to the ground 38 Replace both O rings on DSC or LSC 39 Torque DSC to 35 ft lbs 47 Nm or LSC to 12 ft lbs 16 Nm 40 Apply Loctite to LSC screw if equipped...

Page 350: ...e LSC or DSC high and low speed adjusters are fully open before filling reservoir with oil 46 Install IFP bearing and O ring on the IFP and apply a thin layer of shock oil to bearing and O ring 47 Install IFP assembly without bleed screw using the IFP installation tool NOTE Push IFP into reservoir about 1 500 with hand on top of tool If you do not place hand on top of tool you will be wearing oil ...

Page 351: ...he shock shaft assembly so the piston assembly is just below the retaining ring groove in the body 52 Slowly compress the bearing assembly to release any air that may be trapped below the bearing assembly 53 Apply a thin layer of shock oil to the bearing assembly s external O ring 54 Push bearing assembly in with your finger tips 55 Install retaining ring 56 Use IFP tool to push down on IFP and fu...

Page 352: ...ir cap O ring on cap and apply a thin layer of shock oil to side and O ring 60 Install reservoir cap and retaining ring 61 With shock shaft fully extended charge reservoir to the appropriate nitrogen pressure 100 PSI 690 kPa 62 Ensure rebound and compression adjuster are fully functioning by hand actuating the shock absorber NOTE Check for any leaks or faults in the shock absorber s functionality ...

Page 353: ...BLY VIEW 9 10 PARKING BRAKE INSPECTION 9 11 PARKING BRAKE CABLE ADJUSTMENT 9 11 PARKING BRAKE CALIPER 9 12 PARKING BRAKE DISC 9 15 FRONT BRAKE PADS 9 16 FRONT CALIPER PAD REMOVAL 9 16 FRONT PAD INSPECTION 9 17 FRONT CALIPER PAD INSTALLATION 9 17 BRAKE BURNISHING PROCEDURE 9 18 FRONT CALIPER SERVICE 9 19 FRONT CALIPER ASSEMBLY VIEW 9 19 FRONT CALIPER DISASSEMBLY 9 20 FRONT CALIPER INSPECTION 9 21 F...

Page 354: ...LY 9 29 REAR CALIPER INSPECTION 9 29 REAR CALIPER ASSEMBLY 9 30 REAR BRAKE DISC 9 31 REAR DISC INSPECTION 9 31 REAR DISC REPLACEMENT 9 31 TROUBLESHOOTING 9 33 BRAKE NOISE TROUBLESHOOTING 9 33 POOR BRAKE PERFORMANCE 9 34 PEDAL VIBRATION 9 34 CALIPER OVERHEATS BRAKES DRAG 9 34 BRAKES LOCK 9 34 BRAKE SYSTEM ...

Page 355: ...rake Disc Mounting Bolt 14 ft lb 20 Nm Park Brake Lever Mount Bolts 16 ft lb 22 Nm Park Brake Caliper Assembly Bolts 37 ft lb 50 Nm Wheel Hub Castle Nuts 110 ft lbs 149 Nm Wheel Lug Nuts Aluminum 120 ft lbs 163 Nm Steel 60 ft lb 81 Nm GENERAL SPECIFICATIONS FRONT BRAKE SYSTEM Item Standard Service Limit Front Brake Pad Thickness 0 297 007 7 54 178 mm 180 4 6 mm Front Brake Disc Thickness 0 188 4 7...

Page 356: ...nd starts to build pressure within the brake system As the pressure within the system is increased the pistons located in the brake calipers move outward and apply pressure to the moveable brake pads These pads contact the brake discs and move the calipers in their floating bracket pulling the stationary side pads into the brake discs The resulting friction reduces brake disc and vehicle speed The...

Page 357: ... 30 ft lb 42 Nm 10 Brake Fittings 15 ft lb 20 Nm 3 Caliper Mount CV Shield 11 Junction Block 4 Brake Disc Scraper 12 Junction Block Bolts 35 in lb 4 Nm 5 Scraper Bolts 7 ft lb 11 Nm 13 Rear Caliper 6 Brake Switch 15 ft lb 20 Nm 14 Brake Line Retainers 35 in lb 4 Nm 7 Master Cylinder Mounting Fasteners 23 ft lbs 31 Nm 15 Rear Caliper Bolts 46 ft lb 62 Nm 8 Master Cylinder BRAKE SYSTEM ...

Page 358: ...ge finished surfaces Do not allow brake fluid to come in contact with finished surfaces NOTE Make note of front and rear brake line locations to master cylinder 4 Loosen the brake line banjo bolts and allow fluid to drain NOTE Dispose of fluid properly Do not re use 5 Remove the two mounting fasteners 5 that secure the master cylinder to the frame Master Cylinder Installation 1 Reverse Steps 1 5 f...

Page 359: ...teps to install brake pedal lever Excessive free play may be caused by loose brake pedal bushings worn master cylinder or low brake fluid level in the master cylinder To measure the brake pedal free play measure the distance from the back of the brake pedal to the floor behind the brake pedal Then push on the brake pedal until the free play is gone and measure the distance from the back of the ped...

Page 360: ...r Install a box end wrench on caliper bleeder screw Attach a clean clear hose to fitting and place the other end in a clean container Be sure the hose fits tightly on fitting 5 Have an assistant slowly pump foot pedal until pressure builds and holds 6 Hold brake pedal down to maintain pedal pressure and open bleeder screw 3 Close bleeder screw and release pedal NOTE Do not release foot pedal befor...

Page 361: ... Polaris Industries Inc 12 Field test machine at low speed before putting into service Check for proper braking action and pedal reserve With pedal firmly applied pedal reserve should be no less than 1 2 1 3 cm 13 Check brake system for fluid leaks BRAKE SYSTEM ...

Page 363: ...ily disconnect the parking brake switch electrical connector Reconnect the connector as soon as practicable and adjust the parking brake cable to proper tension 1 Pull back on parking brake lever located in the dash 2 After 3 to 4 clicks BRAKE should display on the instrument cluster and the wheels should not rotate when turning by hand After 8 full clicks of lever travel the vehicle should not ro...

Page 365: ...remove it from the vehicle Caliper Disassembly Inspection NOTE Refer to the Electronic Parts Catalog for parking brake caliper replacement parts information 1 Remove the two caliper assembly bolts C 2 Slide the brake pads and springs from the assembly NOTE Retain the lever and ball bearings for reassembly 3 Inspect brake pads for excessive wear Replace as needed 4 Check the three steel balls for a...

Page 366: ...Lubricant to the thrust washer and shims 4 Torque the caliper assembly bolts to specification Parking Brake Caliper Assembly Bolts 37 ft lb 50 Nm 5 Ensure the parking brake assembly functions properly by actuating the lever Install the mounting sleeves D before installation Brake Caliper Installation 1 Install the parking brake caliper over the brake disc Align the caliper mounting sleeves with th...

Page 367: ...ke disc see Chapter 9 Disc Replacement page Disc Replacement 1 Remove the parking brake caliper from the disc see Chapter 9 2 Using a 1 2 socket and ratchet remove the brake disc retaining bolt and flat washer 3 Remove the disc from the transmission shaft 4 Install the new brake disc Install the mounting bolt and flat washer Torque the mounting bolt to specification Parking Brake Disc Mounting Bol...

Page 368: ... bolts and remove the caliper from the front hub NOTE When removing caliper use care not to damage brake line Support caliper to avoid kinking or bending brake line 5 Push caliper piston into 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...

Page 369: ...ad Installation 1 Lubricate mounting bracket pins 1 with a light film of silicone grease and install rubber dust boots 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other CAUTION If brake pads are contaminated with grease oil or liquid soaked do not use the pads Use only new clean pads 3 Install caliper onto front hub and torq...

Page 370: ...d install reservoir cap Master Cylinder Fluid Up to MAX line inside reservoir 7 Install wheel and torque wheel nuts to specification Wheel Nuts Aluminum 120 ft lbs 163 Nm Steel 60 ft lb 81 Nm Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mp...

Page 371: ...right 2014 Polaris Industries Inc FRONT CALIPER SERVICE Front Caliper Assembly View 1 Socket Set Screw 6 Pistons 2 Bleeder Screw 48 in lb 5 Nm 7 Caliper Mount 3 Caliper Assembly 8 Brake Pads 4 Boots 9 Brake Scraper 5 Square O Rings 10 Bolts BRAKE SYSTEM ...

Page 372: ...sassembly 4 Use a commercially available caliper piston pliers to extract the pistons from the caliper NOTE Do not remove the caliper pistons with a standard pliers The piston sealing surfaces will become damaged if a standard pliers is used 5 Once the pistons are removed use a pick to carefully remove the square O rings from the caliper O rings should be replaced during caliper service 6 Clean th...

Page 373: ...cations Replace if damaged or worn beyond service limit Front Caliper Piston Bore I D Std 1 373 34 87 mm Service Limit 1 375 34 93 mm 2 Inspect piston for nicks scratches pitting or wear Measure piston diameter and replace if damaged or worn beyond service limit Front Caliper Piston O D Std 1 370 34 80 mm Service Limit 1 368 34 75 mm 3 Inspect the brake disc and pads as outlined in this chapter BR...

Page 374: ... DOT 4 Brake Fluid Install pistons with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounting bracket pins 3 with silicone grease and install the rubber dust seal boots 4 Compress the mounting bracket and make sure the dust seal boots are fully seated Install the brake pads Clean the disc and pads with brake parts clea...

Page 375: ...erent points around the pad contact surface Replace disc if worn beyond service limit Brake Disc Thickness New 0188 4 78 mm Service Limit 0 170 4 32 mm Brake Disc Thickness Variance Service Limit 0 002 051 mm difference between measurements Front Brake Disc Runout Mount dial indicator as shown to measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the dis...

Page 376: ...on Brake Disc Mounting Bolts 18 ft lb 24 Nm CAUTION Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal 6 Install wheel hub assembly washers and castle nut Torque castle nut to specification and install a new cotter pin Castle Nut 110 ft lbs 149 Nm 7 Install the front brake caliper see Chapter 9 FRONT CALIPER SERVICE page 8 Follow ble...

Page 377: ...nd lift caliper off the brake disc CAUTION When removing caliper be careful not to damage brake line Support caliper to avoid kinking or bending brake line 5 If brake caliper will not come off 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 pist...

Page 378: ... 0 180 4 6 mm Rear Caliper Pad Installation 1 Lubricate mounting bracket pins 1 with a light film of silicone grease and install rubber dust boots 2 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other CAUTION If brake pads are contaminated with grease oil or liquid soaked do not use the pads Use only new clean pads 3 Install t...

Page 379: ...install reservoir cap Master Cylinder Fluid Up to MAX line inside reservoir 7 Install wheel and torque wheel nuts to specification Wheel Nuts Aluminum 120 ft lbs 163 Nm Steel 60 ft lb 81 Nm 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 ...

Page 380: ...e Manual Copyright 2014 Polaris Industries Inc REAR CALIPER SERVICE Rear Caliper Assembly View 1 Socket Set Screw 5 Pistons 2 Bleeder Screw 48 in lb 5 Nm 6 Boots 3 Caliper Assembly 7 Caliper Mount 4 Square O Rings 8 Brake Pad BRAKE SYSTEM ...

Page 381: ...caliper body 8 5 Clean the caliper body piston and retaining bracket 10 with brake cleaner or alcohol NOTE Be sure to clean caliper body seal grooves Rear 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 Rear Caliper Piston Bore I D Standard 1 505 38 23 mm Service Limit...

Page 382: ...piston with clean Polaris DOT 4 Brake Fluid PN 2872189 Install piston 3 with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounting bracket pins 4 with silicone grease and install the rubber dust seal boots 5 4 Compress the mounting bracket and make sure the dust seals are fully seated Install the brake pads Clean the d...

Page 383: ...nce Service Limit 0 002 0 051 mm Difference Between Measurements 3 Mount a dial indicator and measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 0 010 0 254 mm Rear Disc Replacement 1 Remove the rear brake caliper see Chapter 9 REAR CALIPER SERVICE page 2 Remove wheel hub cotter pi...

Page 384: ...d castle nut Torque castle nut to specification and install a new cotter pin Rear Wheel Hub Castle Nut 110 ft lbs 149 Nm 7 Install rear caliper see Chapter 9 REAR CALIPER SERVICE page Bleed the brake system See Chapter 9 BRAKE BLEEDING FLUID CHANGE page 9 8 8 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure brakes do not drag w...

Page 385: ... equivalent non flammable aerosol brake cleaner Remove pads and or disc hub to clean imbedded material from disc or pads Pad s dragging on disc due to Improper adjustment Master cylinder reservoir overfilled Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston s not returning Operator error riding the brake Adjust pad stop front calipers Set t...

Page 386: ...maged 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 Parking brake lever incorrectly adjusted INT L Model Brake pedal binding or unable to return fully Parking brake left on INT L Model Residue build up...

Page 387: ...NT BODY 10 6 CHASSIS MAIN FRAME 10 7 SEATS 10 8 FLOOR ROCKER PANELS 10 9 REAR CARGO BOX FENDERS 10 10 REAR BUMPER 10 11 BODY COMPONENT REMOVAL 10 12 SEAT REMOVAL 10 12 ENGINE SERVICE PANEL 10 12 FRONT BUMPER REMOVAL 10 12 REAR BUMPER REMOVAL 10 13 HOOD REMOVAL 10 13 UPPER DASH REMOVAL 10 13 LOWER DASH REMOVAL 10 13 FRONT FENDER BODY REMOVAL 10 14 REAR FENDER FENDER FLAIR REMOVAL 10 14 CARGO BOX RE...

Page 388: ...iers assists in removing the plastic push rivets used to fasten body components Torque Specifications ITEM TORQUE Cab Frame Bolts 40 ft lb 54 Nm Door Fasteners 8 ft lb 11 Nm Frame Support Bar Fasteners above engine 22 ft lb 30 Nm Front Fascia Fender Fasteners 8 ft ln 11 Nm Hip Bolster Fasteners 16 ft lb 22 Nm Seat Frame Fasteners front 14 ft lb 19 Nm Seat Frame Fasteners rear 30 ft lb 41 Nm Seat B...

Page 389: ... M8x1 25x55 fasteners Torque fasteners to 17 ft lb 23 Nm 4 Install front ROPS to the frame with M10x1 5x45 fasteners Install front ROPS to rear ROPS and front ROPS cross brace to the left and right front ROPS with M10x1 5x20 screws Torque fasteners to 40 ft lb 54 Nm 5 Install visor on front ROPS with M6x1 0x25 screws Torque fasteners to 8 ft lb 11 Nm 1 Rear ROPS 8 M8 x 1 25 Nut 2 Visor 9 M8 x 1 25...

Page 390: ... 4 9925723 R01 2015 RZR 900 Service Manual Copyright 2014 Polaris Industries Inc Doors 1 Door Panel 4 Hinge Pin 8 ft lb 11 Nm 2 Door Frame 5 Latch Release 3 Latch Striker 8 ft lb 11 Nm 6 Latch BODY FRAME ...

Page 391: ...10 5 9925723 R01 2015 RZR 900 Service Manual Copyright 2014 Polaris Industries Inc Dash Instruments 1 Instrument Cluster 4 Headlight Switch 2 Key Switch 5 AWD Switch 3 12V Accessory Port 6 Bezel BODY FRAME ...

Page 392: ...y 1 Front Bumper 7 Grill 2 Fright Front Fender 8 Front Bumper Cover 3 Right Front Fender Flair 50 model has smaller flair 9 Radiator Shroud 4 Left Front Fender 10 Screw 8 ft lb 11 Nm 5 Left Front Fender Flair 50 model has smaller flair 11 Bolt 7 ft lb 10 Nm 6 Hood 12 Screw 8 ft lb 11 Nm BODY FRAME ...

Page 393: ...a Bracket 2 Skid Plate 9 Dash Mounting Bracket 3 Rear Fascia Mount Tiedown 10 Front Fascia Lower Mount Plate 4 Seat Base Frame 11 Frame Fasteners 14 ft lb 19 Nm 5 Dash Frame 12 Skid Plate Screws 8 ft lbs 11 Nm 6 Upper Frame Support 13 Seat Frame Bolt rear 30 ft lb 41 Nm 7 Front Tiedown 14 Frame Support Bracket 22 ft lb 30 Nm BODY FRAME ...

Page 394: ...r 2 Seat Mounting Screw 4 ft lb 5 Nm 12 Flange Nut Nylok 3 Seat Base Assembly Slider 13 Slider Adjustment Plate 4 Seat Latch Lever 14 Carriage Bolt 5 Spring Seat Latch 15 Shoulder Bolt 6 Plate Seat Latch 16 Seat Slider Mounting Plate 7 Seat Latch Screw 4 ft lb 5 Nm 17 Spring 8 Shoulder Belt 18 Seat Slider Lever 9 Spring Lock Washer 19 Seat Bottom 10 Flat Washer 20 Seat Back BODY FRAME ...

Page 395: ...ice Manual Copyright 2014 Polaris Industries Inc Floor Rocker Panels 1 Upper Floor 7 RH Rocker 2 T27 Screw 8 Push Rivots 3 LH Rocker 9 Console Cover 4 U Type Nuts 10 Seat Belt Boot 5 Block Off Flap 11 Shifter Boot 6 Lower Floor BODY FRAME ...

Page 396: ...c Rear Cargo Box Fenders 1 RH Fender 7 Air Intake Cover 2 RH Fender Flair 50 model has smaller flair 8 Engine Access Panel 3 LH Fender 9 Bumper Bracket 4 LH Fender Flair 50 model has smaller flair 10 T27 Torx Screws 8 ft lb 11 Nm 5 Rear Bumper 11 Plastic Rivets 6 Cargo Box BODY FRAME ...

Page 398: ...vehicle Engine Service Panel Lift the panel upward and towards the front of the vehicle to remove the panel 1 Front Bumper Removal 1 Remove the ten T 40 Torx screws retaining the front bumper 2 Disconnect the front headlight connectors 3 Remove the ten Torx screws retaining the upper middle and lower portion of the bumper 4 Pull out on the front bumper to remove the bumper headlights and radiator ...

Page 399: ...isengage the front tabs and remove the hood from the vehicle Upper Dash Removal 1 Remove the hood as previously described 2 Remove the two T 40 Torx screws retaining the Upper Dash cover between the front fenders 2 3 Disconnect the instrument cluster AWD switch headlight switch and ignition switch Note their location and wire routing Remove the upper dash Lower Dash Removal 1 Remove the Upper Dash...

Page 400: ...cifications 5 Remove the front fender Rear Fender Fender Flair Removal 1 Remove the four T27 Torx screws 1 Remove the three plastic rivets on the lower side of the rear fender flare 2 Remove the fender flare 2 from the vehicle 3 Remove the four plastic rivets one of them hidden on the inside retaining the rear fender 4 Remove the one T 40 Torx screw on the top rear of the fender 5 Remove it from t...

Page 401: ...rews in the bed of the cargo box 8 Remove the seven T 40 Torx screws on the cab side of cargo box 9 Remove the cargo box half from the vehicle Rocker Panel Console Floor 1 Remove the push rivets and Torx screws retaining the rocker panel and remove panel from the vehicle NOTE If replacing the floor remove rocker panels from both sides 2 Remove the T27 screws 1 retaining the console 5 to the floor ...

Page 402: ... treated prior to installing a decal to ensure good adhesion The flame treating procedure can also be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly gl...

Page 403: ...3 TRANSMISSION GEAR POSITION SWITCH 11 13 SEAT BELT SWITCH 11 14 CHARGING SYSTEM 11 15 STATOR 11 15 VOLTAGE REGULATOR 11 15 CHARGING SYSTEM BREAK EVEN TEST 11 16 CHARGING SYSTEM STATOR ALTERNATOR TESTS 11 16 CHARGING SYSTEM TESTING FLOW CHART 11 18 BATTERY 11 19 BATTERY SPECIFICATIONS 11 19 BATTERY REMOVAL 11 19 BATTERY INSTALLATION 11 19 CURRENT DRAW KEY OFF 11 20 OCV OPEN CIRCUIT VOLTAGE TEST 11...

Page 404: ...OLENOID DRIVER TURF MODE MODELS ONLY 11 31 MISC ELECTRICAL 11 32 12V RECEPTACLE 11 32 AWD COIL 11 32 SPEED SENSOR 11 32 TERMINAL BLOCK 11 32 IGNITION COIL 11 33 CHASSIS GROUND POINT 11 33 DIAGNOSTIC PLUG 11 33 BREAK OUT DIAGRAMS 11 34 AWD BREAK OUT DIAGRAM 11 34 COOLING SYSTEM BREAK OUT DIAGRAM 11 35 EPS BREAK OUT DIAGRAM 11 36 LIGHTING BREAK OUT DIAGRAM 11 37 STARTING SYSTEM BREAK OUT DIAGRAM 11 ...

Page 405: ...ent is equal to tested value minus the lead resistance Become familiar with the operation of your meter Be sure leads are in the proper jack for the test being performed i e 10A jack for current readings Refer to the Owner s Manual included with your meter for more information Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 Th...

Page 406: ...a garden hose using mild soap Certain products including insect repellents and chemicals will damage the instrument cluster lens Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster The rider information display is located in the instrument cluster All segments will light up for ...

Page 407: ...e preset service interval has been reached and maintenance should be performed The wrench icon will flash for 10 seconds upon start up once it reaches 0 9 Check Engine MIL Illuminated when the ECM has detected a Diagnostic Trouble Code in the engine management system 10 AWD Indicator Illuminated when the AWD 2WD switch is in the AWD position 11 Differential Unlocked Indicator If equipped with Turf...

Page 408: ...nd displays the total distance traveled by the vehicle The odometer can not be reset Trip Meter The trip meter records the miles traveled by the vehicle on each trip To reset the trip meter 1 Toggle the MODE button to TRIP 1 2 To reset to 0 push and hold the MODE button until the distance display changes to 0 Tachometer RPM Engine RPM can be displayed digitally Engine Temperature Engine temperatur...

Page 409: ...is displayed Clock The clock displays the time in a 12 hour or 24 hour format Refer to Units of Measurement to change the format Standard 12 hour Metric 24 hour To set the clock follow these steps 7 Toggle the MODE button until the odometer is displayed 8 Press and hold the MODE button until the hour segment flashes Release the button 9 With the segment flashing tap the MODE button to advance to t...

Page 410: ...tes 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 a high electrical load is applied lights cooling fan or other accessories If battery voltage drops below 11 volts a warning screen will display Lo and provide the present battery voltage If voltage drops below 8 5 volts LCD backlighting and icons will turn off If battery...

Page 411: ...oggle until CK ENG displays on the information display area 2 Press and hold the MODE button to enter the diagnostics code menu 3 A set of three numbers will appear in the information area The first number located far left can range from 0 to 9 This number represents the total number of trouble codes present example 2 means there are 3 codes present The second number located top right can be 2 to ...

Page 412: ...dustries Inc Instrument Cluster Pinouts FUNCTION PIN CAN High 1 CAN Low 2 Switched Power Vdc 3 Constant Power Vdc 4 Ground 5 High Beam Input 8 Fuel Level Sensor 11 Ambient Air Temperature 15 International Models Only Turn Signal Input LH 6 Turn Signal Input RH 7 ELECTRICAL ...

Page 413: ...tainer rags below the master cylinder prior to brake switch removal 1 Disconnect the harness going to the brake switch 2 Loosen and remove the brake switch 3 Install new brake switch Torque brake switch to specifications Brake Switch 15 ft lb 20 Nm 4 Bleed the brake system See Chapter 9 BRAKE BLEEDING FLUID CHANGE page 9 8 Headlamp Switch 1 Disconnect the headlamp switch harness by depressing the ...

Page 414: ...ould be continuity between switch pins C and D Turn the ignition key to START There should be continuity between switch pins A and B C and D AWD 2WD Switch models without Turf 1 Disconnect the AWD 2WD switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 2 sets of outputs AWD 2WD If any of the tests fail replace the switch assemb...

Page 415: ... Move the switch to AWD There should be continuity between switch pins 2 and 3 5 and 6 Move the switch to 2WD There should be no continuity between any pins Move the switch to TURF There should be continuity between switch pins 1 and 2 4 and 5 Transmission Gear Position Switch 1 The transmission gear position switch 1 is located on the RH side of the transmission and can be accessed through the RH...

Page 416: ...4 Ω LOW 75 Ω NEU 160 Ω REV 300 Ω PARK 620 Ω Seat Belt Switch Location Found on the driver s seat belt latch Functionality If the circuit is open buckle undone vehicle speed will be limited to 15mph If the circuit is closed buckle inserted the vehicle will function normally Testing 1 Disconnect the harness 1 running to the seat belt 2 Using a multi meter measure between both pins on switch SEAT BEL...

Page 417: ...y clean the area around the stator cover prior to removal Voltage Regulator The regulator rectifier 1 is located in front of the left rear wheel It is mounted behind the left panel divider NOTE If the regulator rectifier case temperature exceeds 230 F or 110 C the unit will turn itself off to cool down The unit will turn on again after it has cooled down to at least 212 F or 100 C If it turns off ...

Page 418: ... amps battery discharge 3 Shift transmission into park and start the engine With the engine running at idle observe meter readings 4 Increase engine RPM while observing ammeter and tachometer Note the RPM at which the battery starts to charge ammeter indication is positive 5 With lights and other electrical loads off the break even point should occur at approximately 1500 RPM or lower Charging Sys...

Page 419: ... 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 7 Refer to the following table for approximate AC Voltage readings according to RPM Test each leg at the specified RPM in the table 8 Example The alternator current output reading should be approx...

Page 420: ...ht 2014 Polaris Industries Inc Charging System Testing Flow Chart Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in good condition connected and not exposed or pinched ELECTRICAL ...

Page 421: ...allation NOTE Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Refer to Battery Charging page 2 29 before installing the battery 1 Ensure the battery is fully charged 2 Place the battery in the battery holder and secure with hold down bracket Torque bracket fastener to specification Battery Hold Down Brac...

Page 422: ...ing storage If the battery is stored or used at a low state of charge hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery Use a volt ohm meter to test battery voltage OPEN CIRCUIT VOLTAGE STATE OF CHARGE VOLTAGE 100 12 8 V and up 75 Charged 12 6 V 50 Charged 12 3 V 25 Charged 12 0 V 0 Charged 11 8 V or less Load Test CAUTION To prevent shock or co...

Page 423: ... by sending a low frequency AC signal through the battery and a portion of the current response is captured from this output a conductance measurement is calculated Conductance testing is more accurate than voltage specific gravity or load testing Authorized Polaris dealers distributors are required to use the conductance analyzer when testing 12V Polaris batteries Polaris MDX 610P Bosch PN PU 502...

Page 424: ... the wall in Step 2 NOTE Rider weight must be included in the seat while performing this procedure 5 Adjust the beam to the desired position by loosening or tightening the three T 25 adjustment screws 1 and moving the lamp to the appropriate height 6 Adjust the beam to the desired position Repeat the procedure to adjust the other headlight WARNING Due to the nature of light utility vehicles and wh...

Page 425: ...mp mounting screws off 1 8 to 1 4 2 3 turns 5 Install the front bumper as shown in Chapter 5 if previously removed 6 Connect headlamp electrical connector to the headlamp assembly 7 Perform the Headlamp Adjustment procedure as shown in this chapter Taillights Taillight Replacement Before replacing the taillight s use a digital multi meter to test the harness to ensure the lamp is receiving 12 volt...

Page 426: ...onnect the harness from the ECT sensor and start the engine After a few seconds the fan should turn on and the Check Engine indicator should display on the instrument cluster This indicates all other components are working properly Refer to Chapter 3 and 10 for additional ECT sensor information Polaris dealers can test the sensor by using Digital Wrench Diagnostic Software dealer only ECT Sensor R...

Page 427: ...11 11 25 9925723 R01 2015 RZR 900 Service Manual Copyright 2014 Polaris Industries Inc Radiator Fan The radiator fan 1 is located on the radiator accessible through the hood access panel ELECTRICAL ...

Page 428: ... reading Voltage shown on the meter when testing connections should not exceed 0 1 VDC per connection or component To perform the test place the meter on DC volts and place the meter leads across the connection to be tested Refer to the voltage drop tests on the starter system in this chapter Voltage should not exceed 0 1 volts per connection Starter Removal 1 Remove driver side seat and disconnec...

Page 429: ...uld read about 0 0 5 ohms 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 provide a ground path via the orange wire The key switch must be turned to the start position to provide 12V power via the Green White wire Once the pull i...

Page 430: ...unit will shut down 5 minutes after the engine has stopped if the key remains in the ON position At this point the EPS Malfunction Indicator Light will illuminate to indicate the EPS has shut down and will set a fault code in Digital Wrench The Power Steering 20A Fuse If the fuse fails the Power Steering Malfunction Indicator Light MIL on the instrument cluster will illuminate During this time the...

Page 431: ...ssory 12V Receptacles Accessory Options WIRE COLOR FUSE BOX PIN FUNCTION Red Dark Blue 33 Coil power from EFI B 2 Splice Red 34 High side power from Start Solenoid B Red Dark Green 37 High side output to Chassis Splice Grey 38 ECU controlled ground Fuel Pump Relay provides power to the following system Fuel Pump WIRE COLOR FUSE BOX PIN FUNCTION Red Dark Blue 25 Coil power from EFI B 2 Splice Orang...

Page 432: ...Power from EFI Splice Red Power to EFI Relay high side Key 10A Fuse WIRE COLOR FUNCTION Red Power from EFI Splice Red White Power to B Unswitched Splice 1 Term Terminal Block 10A Fuse WIRE COLOR FUNCTION Red Dark Green Power from Chassis Splice Orange White Power to Key Acc Splice Accessory 10A Fuse WIRE COLOR FUNCTION Red Power from Solenoid B Orange White Power to 12V Receptacle Drive 10A Fuse W...

Page 433: ...IAL CIRCUIT TURF MODELS ONLY Turf Solenoid Turf Mode models only The Turf Solenoid 1 is located on the driver s side of the transmission above the half shaft Turf Solenoid Driver Turf Mode models only The Turf Solenoid Driver 1 is located between the clutch cover and the exhaust muffler ELECTRICAL ...

Page 434: ... pins and grounds are undamaged clean and connect properly Verify continuity of wire connections with a known good volt ohm meter NOTE 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 Speed Sensor Speed Sensor Location The speed sensor...

Page 435: ...he engine will misfire if the spark plug wires are installed incorrectly The spark plug wires are marked with PTO and MAG from the factory and should be installed to the corresponding cylinder and ignition coil post 1 Remove the seats and engine service panel to access the ignition coil 2 Disconnect the ignition coil harness and remove the high tension leads from the coil 3 Remove the fastener ret...

Page 445: ...Fluid Inspection 2 37 Brake Hose and Fitting Inspection 2 37 Brake Pad Disc Inspection 2 37 Brake Pedal Installation 9 7 Brake Pedal Removal 9 7 Brakes Lock 9 34 Caliper Assembly Front 9 22 Caliper Assembly Rear 9 30 Caliper Assembly View Front 9 19 Caliper Assembly View Rear 9 28 Caliper Disassembly Front 9 20 Caliper Disassembly Rear 9 29 Caliper Inspection Front 9 21 Caliper Inspection Rear 9 2...

Page 446: ...ition Sensor CPS 4 26 Crankshaft Removal Inspection 3 51 CV Joint Boot Replacement Outer 7 15 Cylinder Piston Installation 3 65 Cylinder Head Assembly 3 74 Cylinder Head Disassembly 3 38 Cylinder Head Inspection 3 38 Cylinder Head Installation 3 76 Cylinder Head Removal 3 37 Cylinder Head Warp 3 38 Cylinder Removal 3 55 D Dash Removal lower 10 13 Removal upper 10 13 Data Display Definitions Values...

Page 447: ...3 Piston Ring Installed Gap 3 58 Piston Ring Removal Inspection 3 57 Piston to Cylinder Clearance 3 59 Removal 3 24 Service Panel Removal 10 12 Special Tools 3 3 Starter Drive Installation 3 72 Stator Cover Installation 3 73 Top End Service 3 24 Troubleshooting 3 87 Upper Crankcase Preparation 3 63 Valve Clearance Adjustment 3 82 Valve Cover Installation 3 86 Valve Inspection 3 39 Valve Sealing Te...

Page 448: ...our 2 5 Battery 2 28 Brake System 2 37 Drive Shaft Boot Inspection 2 26 Pre Ride 50 Hour 2 4 PVT Drying 2 25 Quick Reference Chart 2 6 Shift Cable Inspection and Adjustment 2 9 Steering 2 32 Valve Clearance Inspection 2 16 Metric Bolt Torque Specification 1 20 Model Number Designation 1 2 O Oil Pressure Test 3 20 Open Circuit Voltage Test 11 20 P Parking Brake Adjustment INT L 9 11 Assembly View I...

Page 449: ... Engine 3 3 Final Drive 7 2 Fuel System 4 3 PVT 5 2 Steering Suspension 8 2 Transmission 6 2 Specification Crankshaft Bearing Journal 3 51 Cylinder Head Warp 3 38 3 55 Cylinder Taper Limit 3 55 Valve Seat Contact Width 3 41 Valve Spring Free Length 3 38 Valve Stem 3 39 Valve Stem Diameter 3 39 Wheel Toe Out 2 33 Specifications Brakes 9 3 Cooling System 3 12 Crankcase Fastener Torque 3 68 Transmiss...

Page 450: ... Body 10 2 Brakes 9 3 Final Drive 7 2 Fuel System 4 3 PVT 5 2 Steering Suspension 8 2 Transmission 6 2 Transmission Assembly 6 25 Assembly View 6 32 Disassembly 6 14 Gear Shaft Bearing Inspection 6 24 Installation 6 11 Lubrication 2 19 Lubrication Specifications 6 2 Mounting and Torque Values 6 3 Output Shaft Backlash Procedure 6 25 Removal 6 6 Shift Cable Adjustment 6 5 Shift Cable Inspection 6 5...

Page 451: ...925723 R01 2015 RZR 900 Service Manual Copyright 2014 Polaris Industries Inc Wheel and Hub Torque Table 2 26 Wheel Installation 2 26 Wheel Removal 2 26 Wheel Hub Assembly View front 7 33 Assembly View rear 7 34 ...

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Summary of Contents for 2015 RZR 900 XC Edition

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