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TRANSMISSION

8.18

Install Cover and Bolts

Cover Bolt Torque:

6--12 ft. lbs. (12--16 Nm)

30. Install a new bellcrank onto the shift shaft. Note

the keyed spline on the bellcrank and shaft.
Install the washer and nut. Torque the bellcrank
nut to 12--18 ft. lbs. (16--24 Nm).

Bellcrank Nut Torque:

12--18 ft. lbs. (16--24 Nm)

31. Install transmission and add Polaris Premium

Synthetic Gear Case Lubricant (

PN 2871477

) in

the

recommended

amount.

Refer

to

Maintenance Chapter 2.

TROUBLESHOOTING
CHECKLIST

Check the following items when shifting difficulty is
encountered.

S

Idle speed adjustment

S

PVT alignment

S

Transmission oil type/quality

S

Transmission

torque

stop

adjustment (where applicable)

S

Engine

torque

stop

adjustment

(where applicable)

S

Drive belt deflection

S

Loose fasteners on rod ends

S

Loose fasteners on selector box

S

Worn rod ends, clevis pins, or pivot
arm bushings

S

Linkage rod adjustment and rod end
positioning

S

Shift selector rail travel

S

*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 linkage rod from
transmission bellcrank. Manually select each gear
range at the transmission bellcrank, and test ride
vehicle. If it functions properly, the problem is outside
the transmission.

If

transmission

problem

remains,

disassemble

transmission and inspect all gear dogs for wear
(rounding), damage. Inspect all bearings, circlips,
thrust washers and shafts for wear.

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Summary of Contents for 6X6

Page 1: ...cation 1 2 Serial Number Location 1 2 Models Numbers Replacement Key 1 3 Machine Dimensions 1 4 1 5 Specifications RANGER 2X4 1 6 1 7 Specifications RANGER 4X4 1 8 1 9 Specifications RANGER 6X6 1 10 1...

Page 2: ...16 17 4 X A R F 5 0 A 1 P 0 0 0 0 0 0 Vehicle Description Vehicle Identifier Powertrain Engine Emissions Model Year Plant No Individual Serial No Body Style Check Digit World Mfg ID This could be eit...

Page 3: ...The model and serial number B are also located on a sticker on the hood liner REPLACEMENT KEYS Replacement keys can be made from the original key To identify which series the key is take the first tw...

Page 4: ...GENERAL INFORMATION 1 4 MACHINE DIMENSIONS 58 in 147 cm 75 in 190 50 cm 13 in 23 cm Front of Box 7 2 in 18 cm...

Page 5: ...GENERAL INFORMATION 1 5 MACHINE DIMENSIONS 120 in 305 cm 90 in 229 cm 48 in 152 cm 113 in 76 in 193 cm 7 2 in 18 25 cm 42 in 107 cm 33 cm...

Page 6: ...nsing Automatic PVT Front Suspension MacPherson Strut Gear Reduction Low 8 66 1 MIddle Suspension MacPherson Strut Gear Reduction Rev 5 91 1 Turning Radius 186I 472 cm Gear Reduction Hi 3 81 1 Toe Out...

Page 7: ...0 6000 12000 10 RH 5630515 Blue Green 7041157 Black 7041782 41 37 5132344 ENGINE Type 4 Cycle Single Cyl Displacement 425 cc Bore 3 46I 92mm Stroke 2 76I 75mm Valve Clearance In Ex 0 006 0 006I TDC on...

Page 8: ...nt Suspension MacPherson Strut Gear Reduction Low 8 66 1 MIddle Suspension MacPherson Strut Gear Reduction Rev 5 91 1 Tow Capacity 1500 lbs 680 kg Gear Reduction Hi 3 81 1 Turning Radius 150I 381 cm F...

Page 9: ...0 6000 12000 10 WH 5630515 Blue Green 7041157 Black 7041782 40 5131446 ENGINE Type 4 Cycle Single Cyl Displacement 499 cc Bore 3 625I 92mm Stroke 2 955I 75mm Valve Clearance In Ex 0 006 0 006I TDC on...

Page 10: ...sing Automatic PVT Front Suspension MacPherson Strut Gear Reduction Low 8 66 1 MIddle Suspension MacPherson Strut Gear Reduction Rev 5 91 1 Tow Capacity 1500 lbs 680 kg Gear Reduction Hi 3 81 1 Turnin...

Page 11: ...6000 12000 F 5630515 Blue Green 7041157 Silver 7041499 41 37 5132344 ENGINE Type 4 Cycle Single Cyl Displacement 498 cc Bore 3 625I 92mm Stroke 2 955I 75mm Valve Clearance In Ex 0 006 0 006I TDC on c...

Page 12: ...OLARIS NUMBER Springs Medium Gloss Black 9440 P 067 Hood Dash Eddie Bauer Green 44931 P 195 Frame Cab Medium Gloss Black 9440 8520147 P 067 Order direct from Midwest Industrial Coatings 952 942 1840 M...

Page 13: ...2 11 Transmission Lubrication 2 11 2 12 Shift Linkage Adjustment 2 13 Throttle Pedal Inspection 2 14 Fuel System 2 14 2 17 Battery Maintenance 2 17 2 18 Spark Plug Electrical 2 18 2 19 Engine Coolant...

Page 14: ...lace if necessary Air Box Sediment Tube Daily N A Drain deposits whenever visible Engine Breather Filter 25 hrs Monthly N A Inspect and replace if necessary Oil Tank Vent Hose 100 hrs 12 months N A In...

Page 15: ...s required N A Periodic Inspection Adjust When Parts are Re placed Front Suspension 50 hrs 6 months N A Inspect Lubricate Rear Suspension 50 hrs 6 months N A Inspect Lubricate Tires Pre ride Pre ride...

Page 16: ...2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogelt Coolant 2871323 60 40 Coolant Gallon 6 Count 2871534 60 40 Coolant Quart 12 Count Additives Sealants Thread Locking Agents Misc 2870585 Loctite...

Page 17: ...lacement Tool Kit 6 2870386 Piston Pin Puller 6 8700220 Clutch Compression Tool 6 2871025 Clutch Bushing Replacement Tool Kit 6 2872608 Roller Pin Removal Tool 7 8700226 CV Boot Clamp Pliers 7 PV 4356...

Page 18: ...sed in severe conditions 3 Brake Fluid DOT 3 PN 2870990 or Dot 4 Fill reservoir between MAX and Min lines As required Change fluid every 2 years More often under severe use such as operated in water o...

Page 19: ...d grease with grease gun Semi annually 9 Front Prop Shaft Yoke Polaris Premium U Joint Lube PN 2871551 Drain completely Add lube to spe cified quantity Semi annually 10 Middle Gearcase Polaris Gear Dr...

Page 20: ...se fittings on both ends joints of driveshaft and grease with grease gun Locate grease fitting in center of driveshaft and grease with grease gun Semi Annually 13 Swing Arm Pivot Polaris All Season Gr...

Page 21: ...the vehicle securely with a jackstand and remove the front tire on the driver s side 3 Remove gearcase drain plug located on the bottom of the gearcase and drain oil The drain plug is accesible throu...

Page 22: ...ole threads or 6 75 oz View of Fill Plug Area Fill Plug Threads REAR GEARCASE LUBRICATION ALL MODELS Specified Lubricant Polaris Gear Drive Fluid PN 2871653 Capacity 10 Oz 300 ml Drain Plug Fill Plug...

Page 23: ...Torque 14 ft lbs 19 4 Nm TRANSMISSION SPECIFICATIONS The transmission lubricant level should be checked and changed in accordance with the maintenance schedule S Be sure vehicle is level before proce...

Page 24: ...Transmission 1 1 2 ILL 4 Fluid Level To change lubricant 1 Remove skid plate if necessary 2 Place a drain pan beneath the transmission oil drain plug area 3 Remove the drain plug and wipe the magneti...

Page 25: ...ar selector in neutral Make sure the transmission bell crank is engaged in the neutral position detents 4 With two wrenches loosen the outside jam nut counterclockwise Turn the outside jam nut 1 1 2 t...

Page 26: ...o 1 8 freeplay is achieved pedal NOTE While adjusting freeplay it is important you flip the throttle lever back and forth 3 Tighten locknut and slide boots over cable adjuster until they touch at the...

Page 27: ...n the friction nut until the choke will maintain a set position Re install boot PILOT SCREW ADJUSTMENT 1 Start engine and warm it up to operating temperature about 10 minutes Pilot Screw FRONT Engine...

Page 28: ...and change clothing S Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time S Never drain the float...

Page 29: ...erious burns can result from contact with skin eyes or clothing Anti dote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetabl...

Page 30: ...black cable 9 Reattach vent hose making sure it is properly routed and not kinked or pinched 10 Coat terminals and bolt threads with Dielectric Grease PN 2871329 11 Reinstall battery cover and holder...

Page 31: ...d Overheating of engine could occur if air is not fully purged from system PolarisPremium60 40isalreadypremixedandready to use Do not dilute with water COOLANT STRENGTH TYPE Test the strength of the c...

Page 32: ...stem has been drained for maintenance and or repair However if the recovery bottle has run dry or if overheating is evident the level in the radiator should be inspected and coolant added if necessary...

Page 33: ...at secure the wheel well panel to the frame Remove two bolts that secure the top bumper to the frame Bolts Bolts Wheel Well 2 Remove two mounting screws that secure the top of the radiator to the fram...

Page 34: ...o the cover and seal all the way around 3 Remove air filter assembly Do not clean the main filter the filter should be replaced 4 Inspect main element and replace if necessary If the filter has been s...

Page 35: ...ough gently in direction of arrow on filter to check for clogging Replace as needed A In line breather filters should be installed with the arrow pointing toward the engine away from the air box NOTE...

Page 36: ...affle boxes FLYWHEEL HOUSING S Drain the housing periodically to remove moisture S Drain the flywheel housing after operating the vehicle in very wet conditions This should also be done before storing...

Page 37: ...oil level is over the full mark change the oil OIL AND FILTER CHANGE WARNING Personal injury can occur when handling used oil Hot oil can cause burns or skin damage NOTICE Care must be taken to ensur...

Page 38: ...ve dipstick and fill tank with 2 quarts 1 9 l of Polaris Premium 4 Synthetic Oil PN 2871281 22 Place gear selector in neutral and set parking brake 23 Prime oil pump using procedure below Stop the eng...

Page 39: ...te engine slowly with recoil rope watching the intake valve s open and close NOTE At this point watch the camshaft sprocket locating pin and slowly rotate engine until locating pin is facing upward di...

Page 40: ...through entire range of travel without binding Check routing of all cables hoses and wiring to be sure the steering mechanism is not restricted or limited NOTE Whenever steering components are replac...

Page 41: ...d adjustment it is very important that the following precautions be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and may break Incorrectly Tigh...

Page 42: ...the clean out plugs while revving the engine several more times 4 If particles are still suspected to be in the muffler back the machine onto an incline so the rear of the machine is one foot higher t...

Page 43: ...e engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the...

Page 44: ...orn tires will increase the possibility of the vehicle skidding easily with possible loss of con trol Worn tires can cause an accident Always replace tires when the tread depth measures 1 8 3 cm or le...

Page 45: ...olt Washer Bolt Coil Over Rear Axle U Bolt Frame Shock Rear Suspension Pivot Bolt Lock S Compress and release rear suspension Damping should be smooth throughout the range of travel S Check all rear s...

Page 46: ...GENERAL INFORMATION 2 34 NOTES...

Page 47: ...Priming Procedure 3 10 Lubrication Oil Flow 3 11 3 12 Engine Exploded View 3 13 Engine Top End Disassembly 3 14 3 23 Valve Seat Service 3 23 3 26 Cylinder Head Assembly 3 26 3 31 Engine Bottom End Dis...

Page 48: ...12mm 11 15 15 21 Nm Oil Drain Bolt Crankcase 14mm 14 17 19 23 Nm Oil Filter Pipe Fit ting 20mm 36 43 49 59 Nm Oil Hose Fitting 1 8 Pipe Thread 6 5 11 9 15 Nm Oil Pump 6mm 5 6 5 7 9 Nm Oil Pump Case Sc...

Page 49: ...il clearance Std 0022 0035 055 090 mm 0022 0035 055 090 mm Limit 0039 10 mm 0039 10 mm Cylinder Head Surface warpage limit 0020 05 mm 0020 05 mm y Standard height 3 870 98 3 mm 3 870 98 3 mm Valve Sea...

Page 50: ...hand fit at 68 F 20 C Piston Ring Piston ring installed gap Top ring Std 0079 0138 20 36 mm 0079 0138 20 36 mm g g g p p g Limit 039 1 0 mm 039 1 0 mm Second i Std 0079 0138 20 36 mm 0079 0138 20 36...

Page 51: ...entification mark the direction for placement of the piston does not matter Note the directional and identification marks when viewing the pistons from the top The letter F or must always be toward th...

Page 52: ...2 Remove recovery bottle hose from coolant filler 3 Connect a Mity Vact PN 2870975 to radiator and pressurize system to 10 PSI The system must retain 10 lbs of pressure for five minutes or longer If...

Page 53: ...kcase It may be necessary to loosen engine mounts and move engine slightly to access water pump Use the Water Pump Mechanical Seal Puller PN 2872105 to replace mechanical seal with engine in frame ENG...

Page 54: ...eeze coolant lines to force air out of system 4 Again remove radiator cap and slowly add coolant to top of fill neck 5 Start engine and observe coolant level in the radiator Allow air to purge and top...

Page 55: ...t the end of each stroke S Release the hone at regular intervals and inspect the bore to determine if it has been cleared and to check piston fit NOTE Do not allow cylinder to heat up during honing Th...

Page 56: ...RPM Polaris 0W 40 Synthetic Engine Hot OIL PRESSURE TEST EH42PL EH50PL 1 Remove blind plug on front left cylinder head 2 Insert a 1 8 NPT oil pressure gauge adaptor into the cylinder head and attach...

Page 57: ...Here it passes through the slotted friction bearing located in the stator plate into the crankshaft An oil seal on the stator plate prevents oil from entering the stator flywheel area Oil travels thr...

Page 58: ...ry Crankcase Small End Bearing Cylinder Sleeve Main Bearing PTO Large End Bearing Crank Pin Crankshaft Screen Fitting Bottom of Tank Oil Flow Chart Top of Oil Tank Union Fitting Lower Oil Jet Union Fi...

Page 59: ...ENGINE 3 13 EH42PL EH50PL ENGINE EXPLODED VIEW Crankcase Cylinder Cylinder Head Crankshaft and Piston Valve Train A...

Page 60: ...engine slowly watching camshaft sprocket marks and the mark in the timing inspection hole 4 Align single TDC mark on flywheel with projection in inspection hole and the cam sprocket pin facing upward...

Page 61: ...Spring Free Length 2 320I 5 9 cm 4 Measure free length of tensioner spring Replace spring if excessively worn Compare to specifications 5 Replace entire tensioner assembly if any part is worn or dama...

Page 62: ...rts and visually inspect surface Compare to specifications 6 Subtract rocker shaft O D from rocker arm shaft support I D This is the oil clearance Compare to specifications 7 Inspect rocker adjuster s...

Page 63: ...e to prevent it from falling into the crankcase Inspect for Areas of Tooth Wear or Damage Sprocket Teeth 9 Inspect cam sprocket teeth for wear or damage Replace if necessary Decompressor Ball Retainer...

Page 64: ...he camshaft until the actuator ball is in the lowest position and install the release lever shaft If Camshaft Is Installed In The Engine 4 Use a small magnet to draw the actuator ball outward or rotat...

Page 65: ...are to specifications Camshaft Oil Clearance Std 0022 0035I 055 090 mm Limit 0039I 10 mm NOTE Replace camshaft if damaged or if any part is worn past the service limit NOTE Replace cylinder head if ca...

Page 66: ...ENGINE 3 20 CYLINDER HEAD EXPLODED VIEW EH42PL EH50PL A EH42PL EH50PL...

Page 67: ...ervice limit replace the cylinder head CYLINDER HEAD DISASSEMBLY WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly NOTE Keep all parts in order with respect...

Page 68: ...ve face for runout pitting and burnt spots To check for bent valve stems mount valve in a drill or use V blocks and a dial indicator A B 3 Check end of valve stem for flaring pitting wear or damage A...

Page 69: ...ng the valve guides and valve seats requires special tools and a thorough knowledge of reconditioning techniques Follow the instructions provided in the cylinder head service tool kit CAUTION Wear eye...

Page 70: ...lled Height Valve Guide Height 689 709I 17 5 18 0 mm 4 Place a new guide in the valve guide installation tool and press guide in to proper depth Check height of each guide above the cylinder head A NO...

Page 71: ...5 cutter to raise the seat When contact area is centered on the valve face measure seat width S If the seat is too wide or uneven use both top and bottom cutters to narrow the seat S If the seat is to...

Page 72: ...carefully with a rotating motion to avoid damaging valve seal 5 Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head 6 Place retaine...

Page 73: ...500 engines valves NOTE Both feeler gauges should remain inserted during adjustment of each valve 006 15 mm EXHAUST VALVE CLEARANCE 3 When clearance is correct hold adjuster screw and tighten locknut...

Page 74: ...upport Block PN 2870390 8 Remove dowel pins from crankcase PISTON REMOVAL 1 Remove circlip Note piston directional arrow pointing toward the right Mag side of engine 2 Remove piston circlip and push p...

Page 75: ...of the cylinder for warpage using a straight edge and feeler gauge Cylinder Warpage 002 05 mm 3 Inspect cylinder for wear scratches or damage 1 2 Down From Top of Cylinder 1 2 Up From Bottom X X Y Y X...

Page 76: ...surement obtained in Step 5 above Piston to Cylinder Clearance Std 0006 0018I 015 045 mm Piston O D Std 3 6204 3 6215I 91 970 91 985 mm PISTON ROD INSPECTION Piston Pin Bore Piston Pin Bore 9055 9057I...

Page 77: ...A difference in end gap indicates cylinder taper The cylinder should be measured for excessive taper and out of round 3 If the bottom installed gap measurement exceeds the service limit replace the ri...

Page 78: ...gear teeth on starter drive Replace starter drive if gear teeth are cracked worn or broken FLYWHEEL STATOR REMOVAL INSPECTION 1 Remove flywheel nut and washer 2 Install Flywheel Puller PN 2871043 and...

Page 79: ...h for wear or damage 7 Inspect Woodruff key for wear 8 Replace any worn or damaged parts ONE WAY VALVE The one way valve prevents oil from drainingout of the oil tank and into the crankcase when the e...

Page 80: ...o not strike the oil pump shaft at an angle or the shaft may bend causing irreparable damage Tap only lightly on the pump shaft if necessary 4 Remove the Mag RH crankcase from the PTO case OIL PUMP RE...

Page 81: ...nner and outer scavenge rotor and inspect pump shaft for wear OIL PUMP ASSEMBLY 1 Clean and dry all parts thoroughly Apply clean engine oil to all parts Do not use gasket sealer on the pump body matin...

Page 82: ...s of discoloration scoring or galling Turn the inner race of each bearing The bearings should turn smoothly and quietly The outer race of each bearing should fit tightly in the crankcase The inner rac...

Page 83: ...bearings and pump shaft bearing use a blind hole bearing puller NOTE Bearings are stressed during the removal process and should not be re used PUMP SHAFT OIL SEAL WATER PUMP MECHANICAL SEAL REMOVAL E...

Page 84: ...INSPECTION ADJUSTMENT Before reassembling the crankcase the following steps should be performed to determine the amount of crankshaft counter balancer shaft and pump shaft end play Excessive end play...

Page 85: ...record below Total Case Width 7 Measure the width of the crankshaft at the bearing seats with a micrometer or dial caliper and record Crankshaft Width 8 Subtract the Crankshaft Width measured in Step...

Page 86: ...red in Step 2 from the figure obtained in Step 5 7 Subtract the thickness of the existing shim from the result of Step 6 to determine if a different shim is needed The result must be within the specif...

Page 87: ...crankshaft and balancer gears Install the proper shim washer on the shaft 5 Inspect the oil pump sealing surface on the crankcase Apply a light film of engine oil to the surface and install the oil p...

Page 88: ...e can result in a bent water pump shaft Pump shaft replacement requires engine removal and crankcase separation Use caution while performing this procedure Make sure that the puller is parallel to the...

Page 89: ...ntil the remaining portion of mechanical seal has been removed from the cases Ill 6 Pump shaft oil seal can also be replaced at this time if necessary 7 The Water Pump Install Kit PN 5131135 is requir...

Page 90: ...on The tab must be positioned in the notch on the side of the piston as shown A A 3 Install the bottom rail with the gap at least 30 from the end of the expander on the side opposite the top rail gap...

Page 91: ...linder base gasket A 2 Position the Piston Support Block PN 2870390 A beneath the piston skirt to support the piston during cylinder installation 3 Apply clean engine oil to the ring compressor Snap O...

Page 92: ...reads and washers and hand tighten the bolts The following procedure must be used to torque the cylinder head properly Torque all bolts evenly in a criss cross pattern Torque bolts to 22 ft lbs 30 Nm...

Page 93: ...utward and the alignment pin notch facing directly upward A B 5 Before positioning the sprocket on the camshaft check the position of the cam sprocket alignment pin When the cam is positioned properly...

Page 94: ...ENGINE 3 48 CAMSHAFT TIMING Single TDC Mark Aligned Crankshaft to Camshaft Centerline Sprocket Alignment Pin Do Not Use Advance Marks Rotation TDC Mark Dots...

Page 95: ...e crankshaft seal Apply molybdenum disulfide grease or assembly lubricant to the crankshaft bushing 2 Install a new O Ring in the oil passage recess in the crankcase 3 Apply Crankcase Sealant PN 28715...

Page 96: ...faces 4 Rotate the engine until the cam lobes are pointing downward 5 Be sure the dowel pins are in place and install the rocker shaft assembly 6 Apply a light film of engine oil to the threads of the...

Page 97: ...r the recoil housing through the rope NOTE The handle must seal tightly on the recoil housing to prevent water from entering 11 Remove center bolt from recoil friction plate A 12 Inspect plate for wea...

Page 98: ...3 To complete recoil assembly 1 Route rope through guide bushing in recoil housing and into reel Tie a secure knot in end of the rope 2 Wind rope counterclockwise onto the reel as viewed from ratchet...

Page 99: ...Low compression high cylinder leakage S No spark Spark plug fouled Engine Does Not Turn Over S Dead battery S Starter motor does not turn S Engine seized rusted or mechanical failure Engine Runs But W...

Page 100: ...sticking S Air leaks in intake S Lean condition COOLING SYSTEM TROUBLESHOOTING Overheating S Low coolant level S Air in cooling system S Wrong type of coolant S Faulty pressure cap or system leaks S R...

Page 101: ...umbers 4 4 CV Carburetor System Function 4 Cycle 4 5 CV Carburetor Vent System 4 Cycle 4 5 CV Carburetor Operation 4 5 4 7 Removal CV Carburetor 4 8 Disassembly Notes CV Carburetor 4 8 4 9 Cleaning CV...

Page 102: ...E Ring 20 Cap 21 Screw 22 Drain Screw 23 O Ring 24 Washer 25 Adjuster 26 Spring 27 Pilot Jet 28 Main Jet 29 Washer 30 Jet Needle 31 Float Assembly 32 Float Body Assembly 33 Float Pin 34 Needle Valve 3...

Page 103: ...mponents B Fuel Cap Gauge C Fuel Tank D Tank Support E Fuel Pump F Fuel Filter Line G Tank Secure Strap H Tank Venting I Tank Foil Fuel Tank Fuel Valve Engine Filter Fuel Pump Carburetor Fuel Tank Ven...

Page 104: ...for an altitude of 0 6000 ft 0 1800 meters and ambient temperatures between 40 and 80 F 5 to 26 C Carburetors must be re calibrated if operated outside this temperature and or altitude range The jett...

Page 105: ...id range and high throttle settings 1 4 to full throttle VENT SYSTEMS CV CARBURETOR The carburetor float bowl vent lines supply atmospheric pressure to the float bowl The lines must be free of kinks r...

Page 106: ...ikuni BST carburetor PILOT IDLE AND SLOW SYSTEM This system supplies fuel during engine operation with throttle valve closed 1 or slightly opened The fuel from float chamber 2 is metered by pilot jet...

Page 107: ...r the needle valve admits and shuts off fuel alternately to maintain a practically constant fuel level inside the float chamber Inlet Pipe 1 4 2 3 MAIN SYSTEM As throttle valve 1 is opened engine spee...

Page 108: ...ews on Diaphragm Cover per 2003 CARB standards for LSI large spark ignition engines All RANGER s are classified within LSI The existence of these tamper resistant screws will require customers to purc...

Page 109: ...ing can loosen the adhesive sealer on the passage drill way plugs Do not soak rubber or plastic components such as the vacuum slide diaphragm needle seat screen or O Rings in caustic cleaning solution...

Page 110: ...er of turns NOTE The final pilot idle mixture must be adjusted with the engine running Refer to Page 2 15 Pilot Mixture Screw Base Setting Set at Factory Refer to Specifications in Chapter 1 FLOAT HEI...

Page 111: ...de Bend to adjust float Float arms even NEEDLE AND SEAT LEAKAGE TEST 1 Install the float bowl Invert the carburetor and install a Mity Vact PN 2870975 to the fuel inlet fitting Apply 5 PSI pressure to...

Page 112: ...r 3 to 5 seconds to allow fuel level to stabilize in the line If level is out of specification remove carburetor and inspect inlet needle and seat float height passages etc NOTE If a line was removed...

Page 113: ...iaphragm Vacuum slide stuck closed or sticky GImproper spring GJet needle position incorrect GIncorrect pilot screw adjustment RICH MIXTURE Symptoms Fouls spark plugs black sooty exhaust smoke rough i...

Page 114: ...ottle cable incorrectly adjusted GAir leaks dirty carburetor passages pilot circuit GPilot mixture screw damaged or adjusted incorrectly GTight valves GIgnition timing incorrect GBelt dragging GDirty...

Page 115: ...Exploded View 5 7 Cargo Box Exploded View 5 8 Dash Instruments Controls 5 9 Steering Assembly Exploded View 5 1 A Arm Strut Exploded View 5 11 A Arm Replacement 5 12 Middle A Arm Replacement 6x6 5 13...

Page 116: ...r Control Arm Mounting Bolt 30 ft lbs 41 Nm Upper Wheel Bearing Carrier Bolt 35 ft lbs 48 Nm Lower Wheel Bearing Carrier Bolt 30 ft lbs 41 Nm Strut Rod Retaining Nut Top 15 ft lbs 21 Nm Strut Casting...

Page 117: ...sses Remove air baffling boxes Front Bumper Remove Hood 3 front Torx screws from LH and RH wheel well panels 2 top bumper mounting bolts 3 lower bumper mounting bolts Cargo Box Place box in the down p...

Page 118: ...BODY STEERING SUSPENSION 5 4 CAB FRAME SEAT EXPLODED VIEW Cab Frame and Seat Assembly Cab Frame Seat Belts Seat Assembly...

Page 119: ...SUSPENSION 5 5 FRAME BODY ASSEMBLY EXPLODED VIEW Chassis Body Assembly Bumper Seat Frame Panel LH Floor Support Front Cab Support Main Frame Seat Base RH Floor Support Oil Tank Bracket Grills Frame E...

Page 120: ...ION 5 6 BODY MOLDING EXPLODED VIEW Body Molding Drive Shaft Wheel Well Panel LH Front Fender Foil Cover RH Front Fender Main Frame Dog House Cover Main Floor Skid Plate RH Rear Fender Floor Foil Floor...

Page 121: ...BODY STEERING SUSPENSION 5 7 HOOD EXPLODED VIEW Glove Box Assembly Cup Holder Hood Liner Hood Latch Strap Hood Hinge Headlight Dash...

Page 122: ...GO BOX EXPLODED VIEW Cargo Box Tail Brake Light Box Paddle Latch Spring Screw Screws Box Latch Box Base Bushings Dump Box Shock Reflector Hinge Pin Tailgate Cable Tailgate Cover Latches Shafts Latch B...

Page 123: ...le 1 2 3 4 5 6 7 8 9 10 11 12 13 2 1 Storage Box 2 Cup Holder 3 Indicator Lights 4 Light Switch 5 AWD Switch 6 Hour Meter 7 Glove Box 8 12V Acc Plug 9 Storage Tray 10 Choke Knob 11 Ignition Switch 12...

Page 124: ...SSEMBLY EXPLODED VIEW Boots Steering Box Cap Steering Wheel Bushing Tie Rod Lower Steering Shaft Tie Rod Rod End Jam Nut Bolt End Bolt Upper Steering Shaft Wave Washers Nut 242 Apply Loctitet 242 242...

Page 125: ...t lbs 34 41Nm 30 ft lbs 41 4 Nm 1 12 14 ft lbs 16 19 Nm 15 22 ft lbs 20 30 Nm 40 ft lbs 54 Nm NOTE Refer to Page 5 10 for Steering Component Identification NOTE To avoid damage to the tie rod ends and...

Page 126: ...cle frame Torque new bolts to 30 ft lbs 41 4 Nm WARNING The locking features on the existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fastener...

Page 127: ...que new bolts to 30 ft lbs 41 4 Nm WARNING The locking features on the existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose...

Page 128: ...vot Bolt U Bolt Nut Washer Axle Tube 60 ft lbs 81 Nm Axle Tube Retaining Ring 150 ft lbs 203 Nm Pivot Bushing Swing Arm Bushing Jam Nut Washer Grease Fitting U Bolt Screw Washer 40 ft lbs 54 Nm Apply...

Page 129: ...to help remove the the swing arm assembly Swing Arm Installation 6 Raise swing arm assembly and align the drive shaft to the rear gearcase splined shaft Lube splines 7 Insert new bushings check pivot...

Page 130: ...2 location Check lubrication guide for recommended service intervals Nut 15 ft lbs 21 Nm 18 ft lbs 25 Nm Bearing Washer Top Pivot Ball Bottom Pivot Ball Washer Spacer Rubber Spring Retainer Spring Bo...

Page 131: ...otrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure 3 Remove wheel nuts and wheels 4 Remove cotter pin A from...

Page 132: ...N 2871949 to threads of retaining plate screws or install new screws with pre applied locking agent Torque screws to 8 ft lbs 11 Nm 10 Install A arm on ball joint and torque castle nut to 25 ft lbs 35...

Page 133: ...removal process The box is not as stable with the hinge pins removed Hinge PIn 6 With both hinge pins removed remove the box from the frame Two people maybe needed to remove the bed from the frame CA...

Page 134: ...ocedure in a well ventilated area away from gasoline or other flammable materials Be sure the area to be flame treated is clean and free of gasoline or flammable residue To flame treat the decal area...

Page 135: ...rive Clutch Spring Specifications 6 8 Shift Weights 6 9 Drive Clutch Inspection 6 10 Drive Clutch Disassembly Inspection 6 10 6 12 Drive Clutch Assembly 6 12 6 13 Drive Belt Tension 6 13 Drive Belt Re...

Page 136: ...The Drive Belt The internal components of the drive clutch and driven clutch control engagement initial vehicle movement clutch upshift and backshift During the development of a Polaris ATV the PVT sy...

Page 137: ...peration the PVT system will provide years of trouble free operation Periodic inspection and maintenance is required to keep the system operating at peak performance The following list of items should...

Page 138: ...r snow Shift the transmission to Low carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large o...

Page 139: ...or drive belt removal A B 6 Install the Drive Clutch Holder PN 9314177 A 7 Remove drive clutch retaining bolt and remove drive clutch using the Drive Clutch Holder PN 9314177 B Drive Clutch Puller PN...

Page 140: ...orque 45 50 in lbs 5 5 6 Nm Driven Clutch Retaining Bolt Torque 17 ft lbs 23 5 Nm Drive Clutch Retaining Bolt Torque 40 ft lbs 55 Nm Offset Spacer Offset Spacer 7 Install clutch offset spacers on tran...

Page 141: ...VE CLUTCH EXPLODED VIEW Drive Clutch Mark with permanent marker before disassembly Teflont coated brass bushing Teflont coated brass bushing PVT Outer Cover Cover Bolts Inner Cover Inner Cover Seal Re...

Page 142: ...subject to during operation it should always be inspected for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from th...

Page 143: ...ement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave cleara...

Page 144: ...uld be smooth and free of dents or gall marks Inspect the weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or broken replace in sets of three with new bolts NOTE A da...

Page 145: ...e clutch assembly if worn or damaged 5 Remove and inspect spring See Page 6 8 SPIDER REMOVAL Clutch Holding Fixture PN 2871358 Spider Removal Tool PN 2870341 1 Install clutch in holding fixture and lo...

Page 146: ...oller pin DRIVE CLUTCH ASSEMBLY NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly The Teflont bushings are self lubricating Do not a...

Page 147: ...T TENSION 1 1 8 28 5 mm Straight Edge Belt Deflection Tension 1 1 8 2 9 cm 1 1 4 3 2 cm NOTE Pinch the sheaves lightly together with clamp to prevent the belt from being pushed into the driven sheave...

Page 148: ...side of the drive belt G Place another straight edge on top of belt G Measure the distance where the side straight edges intersect the top as shown in the illustration below 5 Inspect belt for loose...

Page 149: ...the driven clutch 1 Remove belt and install the Clutch Offset Alignment Tool PN 2870654 as shown 2 With tool touching rear of driven clutch inner sheave the distance at point A should be 1 8 If the d...

Page 150: ...BUSHING SERVICE Clutch Bushing Replacement Tool Kit PN 2871226 Stamp Qty Part Desciption Part 2 1 P 90 Drive Driven Cluth Bushing Install Tool 5020628 3 1 Drive Clutch Cover Bushing Removal Installat...

Page 151: ...LUTCH MOVEABLE SHEAVE BUSHING INSTALLATION 1 Place the Main Puller Adapter 8 PN 5020632 onto the puller 2 Apply Loctitet 680 PN 2870584 to the back side of new bushing Push bushing into center of shea...

Page 152: ...ack side of new bushing Working from inside of cover insert bushing and bushing installation tool into center of clutch cover Bushing PN 3576510 Loctitet 680 PN 2870584 2 With the Main Puller Adapter...

Page 153: ...sheaveand replace if worn NOTE The ramp buttons are secured by Torxt screws T20 Belt deflection adjustment washers 7 Remove moveable sheave and note the number of spacer washers One spacer must remain...

Page 154: ...uicker backshift or downshift when pulling or negotiating a hill for example The least amount of tension will create a slower downshift and a harder upshift Align boss spline to install helix 4 Line u...

Page 155: ...ller diameter toward bushing to be removed See illustration 6 Install sheave onto puller 7 Install nut onto puller rod and tighten by hand Turn puller barrel for further tension if needed 8 Turn clutc...

Page 156: ...g upward as shown Install the Number Two Puller Adapter 10 PN 5020633 4 Install nut onto puller rod and hand tighten against installation tool 5 Turn clutch sheave counterclockwise until bushing is se...

Page 157: ...s Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassemble clean and inspec...

Page 158: ...ch engagement Caution operator to operate machine within guidelines Vehicle operated with park brake on Inspect brake system Fast effective use of throttle for efficient engagement PVT noise Belt worn...

Page 159: ...2 6x6 Mid Drive Hub Removal Install 7 23 7 25 6x6 Mid Drive Hub Disassembly Assembly 7 25 7 26 6x6 Mid Drive Hub Exploded View 7 27 6x6 Mid Drive Shaft Removal Installation 7 27 7 29 6x6 Mid Drive Sha...

Page 160: ...or destroyed during removal 2X4 FRONT HUB REMOVAL INSPECTION 1 Elevate front end and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure...

Page 161: ...nto the spindle 4 Apply grease to washer and install with domed side out Out Cone Washer 5 Install spindle nut and tighten to specification 2 x 4 Spindle Nut Torque 40 ft lbs 55 0 Nm 6 Install a new c...

Page 162: ...val Always use new brake caliper mounting bolts upon assembly 11 Install wheel and wheel nuts and tighten evenly in a cross pattern to 35 ft lbs 47 Nm Flange Nuts Flat side against wheel 35 ft lbs 47...

Page 163: ...emove wheel nuts and wheel 4 Remove the two brake caliper attaching bolts CAUTION Do not hang the caliper by the brake line Use wire to hang the caliper to prevent possible damage to the brake line 5...

Page 164: ...Tighten bolts to specified torque Brake Caliper Bolt Torque 18 ft lbs 24 Nm CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bol...

Page 165: ...ration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 5 Inspect bearing housing for scrat...

Page 166: ...uld rotate smoothly without binding or rough spots 3 Remove wheel nuts and wheel 4 Remove the two brake caliper attaching bolts CAUTION Do not hang the caliper by the brake line Use wire to hang the c...

Page 167: ...to ensure proper shaft function and a normal service life S The complete driveshaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage t...

Page 168: ...from driveshaft If the ATV has been operated with a damaged boot the CV joint grease may be contaminated Inspect the grease carefully for contamination and clean the joint thoroughly if necessary Fro...

Page 169: ...1 Elevate front end and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure We...

Page 170: ...wear eye protection 1 Remove internal or external snap ring from all bearing caps NOTE If yoke or bearing is removed cross bearing must be replaced Note orientation of grease fitting and mark inner a...

Page 171: ...e side Continually check for free movement of bearing cross as bearing caps are assembled 3 Install snap ring to contain bearing cap just installed Repeat procedure for other side 4 Install outer yoke...

Page 172: ...are spinning severe drive shaft and clutch damage could result Roller Cage Bearings Output Hub Armature Plate Disengagement As soon as the front and rear wheels gain traction and are rotating at very...

Page 173: ...NSPECTION 4X4 6X6 1 Drain and properly dispose of used oil Remove any metal particles from the drain plug magnet 2 Remove bolts and output shaft cover Gearcase Coil Resistance NOTE To test the gearcas...

Page 174: ...hes A B C 8 Inspect roll cage B sliding surface This surface must be clean and free of nicks burrs or scratches Remove and inspect the H springs B H spring 9 Remove the ring gear C the output hub D th...

Page 175: ...d worn components 2 Press the pinion shaft seal into the pinion cover until the seal is flush with the sealing surface 3 Inspect bearings on output and pinion shafts To replace press new bearing on to...

Page 176: ...de the roll cage into the ring gear Insert the rollers as the roll cage is installed 8 Install the shim onto the ring gear 9 Install the armature plate onto the ring gear NOTE Be sure armature plate t...

Page 177: ...and gearcase housing cover 13 Install the drain plug and torque the drain plug to 14 ft lbs 19 Nm 14 Set the gearcase on a level surface Remove the fill plug and fill the gearcase with 5 oz 150 ml of...

Page 178: ...inside the other 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 4 A band with an interrupted wear mark may indicate a warped p...

Page 179: ...d insert Coil Gearcase Cover Side Cutaway View of Centralized Hilliard Cover 5 Inspect the rollers for nics and scratches The rollers must slide up and down and in and out freely within the roll cage...

Page 180: ...e Output Male 27 1 Gearcase LH 8 1 Pin Dowel 28 2 Seal Oil 9 1 Bearing Roller Ball 29 1 Plug Oil Fill 10 1 Clutch Housing Ring Gear 30 4 Washer Spring Lock 11 1 Spring 31 4 Screw 12 14 Kit Roll 32 1 P...

Page 181: ...afely raise the center of the machine with a floor jack Raise the machine just enough to remove the middle wheel 2 Remove the four wheel nuts and wheel 3 Remove the hub cap and cotter pin 4 Remove the...

Page 182: ...e shaft 2 Align bottom of carrier housing and lower control arm Grease and slide lower control arm bushings into place securing corner housing 3 Install and torque both lower control arm bolts Lower C...

Page 183: ...heel nuts to 20 ft lbs 27 Nm Rear Hub Nut Torque 110 ft lbs 149 Nm Rear Wheel Nut Torque 35 ft lbs 47 Nm 9 Install a new cotter pin Tighten nut slightly to align holes if required 10 Install hub cap M...

Page 184: ...movement and minimal movement sideways between inner and outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged MID DRIVE BEARING CARRIER HUB ASSEMBLY 6X6 1 Suppo...

Page 185: ...Remove the roll pin from the middle axle C using the Roll Pin Removal Tool PN 2872608 The spring pin secures the yolk of the middle axle to the middle gearcase D output shaft NOTE To ease the removal...

Page 186: ...d onto the middle gearcase output shaft splines Reinstall the middle driveshaft A onto the middle gearcase output shaft Be sure to align the roll pin holes of the middle driveshaft A and middle gearca...

Page 187: ...er pin and hub cap Rear Hub Nut Torque 110 ft lbs 149 Nm 6 Install rear wheel and torque wheel nuts to specification Out Cone Washer Cone wash er dome to outside 110 ft lbs 149 Nm Flat Washer Wheel Nu...

Page 188: ...o position the grease fittings correctly 1 Assemble the axle U joints as described in the U JOINT ASSEMBLY section Page 7 14 Inspect the yoke bore alignment on all of the yokes If a yoke is twisted wa...

Page 189: ...ive gearcase remove the coupler Step 3 4 Use the Roll Pin Removal Tool PN 2872608 to remove the roll pin that secures the coupler to the middle drive gearcase 5 Remove the four bolts and washers that...

Page 190: ...tput cover NOTE The two shims are different of thickness Be sure to note the placement of the shims as they are removed from the output cover for later installation C D 4 Remove the output shaft and r...

Page 191: ...se the following steps to aid in removal S Hold the pinion gear assembly S Use a rubber mallet to lightly tap around the bearing cup of the front cover S Tap the front cover in an X pattern follow the...

Page 192: ...the retaining ring O shim P and input gear R from the output thru shaft Q Inspect the input gear for abnormal wear broken or chipped teeth Q R P O 14 Inspect the two flange bearings S inside the gear...

Page 193: ...Gearcase C 2 Install the 26T input gear D shim E and a new retaining ring F onto the output thru shaft D E F 3 Assemble the pinion shaft assembly if previously disassembled Install the 26T gear G and...

Page 194: ...bly S Use a rubber mallet to lightly tap on the front of the input cover around the bearing cup S Tap the front cover in an X pattern follow the pattern in the photo on the right until the pinion gear...

Page 195: ...ut pinion gear and the output pinion gear mesh smoothly Output Shaft PInion Gear 9 Install the shims M into the output cover N Install the shims in the order that they were removed during the disassem...

Page 196: ...ll plug P and fill the mid gearcase with 6 75 oz 200 ml of Polaris Gearcase Lube PN 2871653 Torque the fill plug to 14 ft lbs 19 Nm P Middle Gearcase Specifications Capacity 6 75 oz 200 ml Specified L...

Page 197: ...output shafts 6 Install the vent tube and clamp 7 Lift bearing carrier into place and install bolt to upper control arm Torque bolt to 35 ft lbs 48 Nm Refer to the MID DRIVE SHAFT INSTALLATION section...

Page 198: ...hing 4 1 Tube Vent 18 1 Gearcase R11 5 1 Cover Output 19 1 Bushing 6 1 Shim 20 1 Pinion 10T 7 1 Bearing Ball 21 1 Gear 26T Output 8 1 Gear Ring 37T 22 1 Bearing Ball 9 1 Shaft Output 23 1 Shaft Output...

Page 199: ...could occur if machine tips or falls Brake Caliper 4 Remove the hub cover cotter pin spindle nut and washer both sides 5 Pull the hub off of the axle NOTE ONLY 2x4 and 4x4 models have an actuator on...

Page 200: ...ns of the the four U bolts that secure the axle to the frame This will aid with proper U bolt and axle placement during reassembly Mark U bolt Positions 12 Loosen the four U bolts Loosen each U bolt n...

Page 201: ...xle Tube Removal 14 Place the rear axle assembly on a clean surface 15 Remove the bolts that secure the rear gearcase to the axles 16 Remove the rear gearcase skid plate Skid Plate 17 Remove the axle...

Page 202: ...installation 23 Reinstall the retaining ring REAR AXLE HOUSING INSTALLATION 1 Lube the splines of the rear gearcase with anti seize 2 Reinstall the axle spacer seals Reinstall the axle onto the rear g...

Page 203: ...TE Use caution when removing the rear axle assembly Extra jacks maybe needed to raise the rear axle assembly safely 6 Install the four U bolts Align the U bolts with the white marks previously made on...

Page 204: ...ft lbs 54 Nm 25 ft lbs 35 Nm Rear Coil Over Shock Bolt Torque 11 Reinstall the vent hose and clamp to the rear gearcase housing 12 Apply anti seize to the splines of the axle Reinstall the hub onto t...

Page 205: ...R AXLE BEARING REMOVAL INSTALLATION 1 For rear axle bearing removal see Page 7 44 Axle Retaining Ring Bearing Axle Tube REAR DIFFERENTIAL REMOVAL 1 Refer to Steps 1 17 in the REAR DIFFERENTIAL REMOVAL...

Page 206: ...differential housing cover Inspect the ring gear for abnormal wear broken or chipped teeth 6 Remove retaining ring and the shim from the ring gear 7 Remove the pinion gear cover and the pinion shaft...

Page 207: ...he differential cover Actuator Arm 9 Inspect the actuator assembly and replace parts as needed Refer to you parts manual for new parts NOTE The actuator assembly can be taken apart refer to the explod...

Page 208: ...r New O ring 4 Bolts Pinion Shaft Cover Bolt Torque 20 ft lbs 27 Nm 4 Install a NEW seal O ring and retaining ring onto the actuator if the actuator was removed Install the actuator into the different...

Page 209: ...ase lip New O ring 8 Install the shift dog into the differential housing cover The shift lever arm fits into the groove of the shift dog 9 Lubricate the shim with grease and place the shim in the diff...

Page 210: ...1 Refer to the REAR AXLE HOUSING INSTALLATION section on Pages 7 44 7 45 for the installation of the rear gearcase and axle 2 Add Polaris Premium Gearcase Lubricant PN 2871477 to rear gearcase Refer t...

Page 211: ...t 9 1 Pipe Knock 31 1 Tube Vent 10 1 O Ring 32 3 Clip 11 1 Bearing Ball 33 AR Line Vent 13 2 Ring Retaining 34 1 Clamp Hose 14 1 Housing Differential Lock 35 2 Plug Drain 15 1 Gear 14T RH 36 12 Screw...

Page 212: ...the locked position Actuator in Locked Position Ill 2 NOTE The pictures below show a cutaway view of the rear differential for display purposes only When the rear differential is in the locked positio...

Page 213: ...the rear differential is in the unlocked position the actuator slides the engagement dog into place so the output shafts are unlocked to form a open differential rear axle assembly An example of how t...

Page 214: ...er in a neutral position centered between the Lock and Unlocked positions Ill 1 Neutral Position Ill 1 N 3 With two wrenches loosen the jam nuts and back both of the jam nuts off Ill 2 Back Off Both J...

Page 215: ...nt DIFFERENTIAL LOCK LEVER REMOVAL INSTALLATION 2X4 4X4 1 Disconnect linkage cable from lock differential 2 Remove the cotter key washers and bushings that attach lock differential to the cable and fr...

Page 216: ...shim and O ring from the differential cover O Ring Shim 4 Remove the output shaft and ring gear from the differential Inspect the ring gear for abnormal wear broken or chipped teeth Inspect the beari...

Page 217: ...Remove the pinion gear cover and O ring Pinion Gear Cover O ring 4 Bolts 7 Remove the pinion shaft from the differential Inspect for abnormal wear broken or chipped teeth 8 Inspect the pinion shaft b...

Page 218: ...stall the four pinion shaft cover bolts and torque the bolts to 20 ft lbs 27 Nm Pinion Gear Cover New O ring 20 ft lbs 27 Nm Pinion Shaft Cover Bolt Torque 20 ft lbs 27 Nm 4 Install the wave spring in...

Page 219: ...e O ring is not damaged during output cover installation This also helps to prevent any gearcase leaks after assembly Cover Bolts 9 Torque the output cover bolts to 20 ft lbs 27 Nm Output Cover Bolt T...

Page 220: ...over Input 14 1 Gear Ring 37T 3 1 O Ring 15 1 Bearing Ball 4 1 Bearing Ball 16 1 Plug Expansion 5 1 Pinion 10T 17 3 Clip 6 1 Bushing 18 AR Line Vent 7 2 Seal 19 1 Tube Vent 8 1 Case Front 20 2 Plug Dr...

Page 221: ...hift Selector Removal Installation 8 2 Shift Linkage Adjustment 8 2 8 3 Transmission Removal 8 3 8 5 Transmission Installation 8 6 Transmission Disassembly 8 7 8 13 Transmission Assembly 8 13 8 18 Tro...

Page 222: ...ifter knob 4 Lift gear selector out of mounting bracket and away from frame 5 Repeat the steps in reverse order to install the gear selector Cover Screw Shifter Knob Grommet Shifter Cable Bolt Bearing...

Page 223: ...e jam nut clockwise until it is tight against the bracket 6 Repeat Step 4 and Step 5 until the proper adjustment is made for the transmission cable 7 Use this procedure to loosen or tighten the shift...

Page 224: ...5 Remove the cotter pin from the shift linkage rod Remove the shift linkage rod and a washer from the bellcrank 6 Loosen the jam nuts for the transmission cable Remove the cable from the mounting bra...

Page 225: ...e the four bottom transmission to frame bolts 9 Remove the rear transmission to frame bolt 10 Remove front transmission to engine mount bolt Front General Transmission Mounting 11 Remove transmission...

Page 226: ...Bolts Torque 25 ft lbs 34 5 Nm NOTE Be sure to tighten the lower transmission bolts first this ensures that the transmission is tight against the lower frame and helps to properly align the transmissi...

Page 227: ...ve the nut and washer that secure the bell crank Remove the bellcrank 3 Remove the five bolts that secure the cover Remove the detent spring Spring Bellcrank Cover Shift Shaft Detent Pawl Case Spring...

Page 228: ...move the shift gears from the case NOTE It may be helpful to accent the timing marks using a white marking pen 8 Remove the bolts on the LH transmission case Tap the cover off with a soft face hammer...

Page 229: ...uster and shift forks You may need to move the assembly back and forth to aid in removal 12 Set the upper gear cluster on a flat surface and inspect the components 13 Remove the shift forks from the a...

Page 230: ...the reverse shaft with a puller 15 Remove the park lock engagement dog Remove the wave spring and reverse engagement dog Engagement Dogs 16 Remove the bearing from the input shaft with a puller 17 Re...

Page 231: ...Use a press to remove the gear from the shaft 22 Make note of the direction of the gear and hub location 23 Remove the gear split bearing and washer from the reverse shaft 24 Slide off the shift dogs...

Page 232: ...26 Remove bearing and the helical gear 27 Remove the pinion shaft retainer plate and the pinion shaft 28 Remove the front housing cover screws 29 Remove the front housing cover shim thrust button and...

Page 233: ...on of Hubs 35 Remove seals from transmission case IMPORTANT New seals should be installed after the transmission is completely assembled 36 Inspect bearings for smooth operation Check for excessive pl...

Page 234: ...nstall pinion shaft with bearing 7 Install retainer plate with flat side toward bearing 8 Apply Loctitet 262 Red PN 2871951 to screw threads and torque screws to 6 12 ft lbs 8 16 Nm Pinion Retainer Pl...

Page 235: ...e spring groove Keep the spring in place while the fork is being installed on the shaft and while placing the shafts into the case NOTE Use caution when installing the fork the spring can easily fall...

Page 236: ...ase 21 Install the helical gear and bearing onto the pinion shaft 22 Clean the mating surfaces of the case and cover Apply Crankcase Sealant PN 2871557 to the mating surfaces Be sure the locating pins...

Page 237: ...stall the lockout disc Use the white marks that were previously applied for reference Sector Gear Lockout Disc 27 Install the shift shaft and the detent star Note the keyed spline on the end of the sh...

Page 238: ...t where applicable S Engine torque stop adjustment where applicable S Drive belt deflection S Loose fasteners on rod ends S Loose fasteners on selector box S Worn rod ends clevis pins or pivot arm bus...

Page 239: ...EW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 27 27 24 25 13...

Page 240: ...l 48 AR Shim 14 1 Chain Silent 49 1 Gearcase Cover Front 15 1 Gear 15T 50 1 Plug 16 1 Sprocket 16T 51 1 Washer 17 1 Gear 31T 52 AR Shim 18 1 Shaft Input 53 1 Shaft Output Rear 19 3 Bearing Ball 54 1 G...

Page 241: ...7 28 29 30 31 67 33 34 35 36 37 38B 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 55 56 57 58 59 60 61 62 63 64 15 19 20 11 22 24 22 23 22 27 32 11 11 7 54 14 14 15 15 65 66 68A 69A NOTE Callouts 68A a...

Page 242: ...aft Input 48 AR Shim 14 1 Bearing 49 1 Cover Output Front 15 1 Pipe Knock 50 1 Screw Tapping 16 1 Cover LH 51 1 Plug 17 1 Seal 52 AR Washer 18 1 Drum Shift 53 1 Shaft Output Main Front 19 3 Fork Shift...

Page 243: ...ont Pad Removal 9 10 Front Pad Assembly 9 11 Front Pad Adjustment 9 11 9 12 Front Disc Inspection 9 12 9 13 Front Disc Removal Replacement 9 13 Front Caliper Removal 9 13 Front Caliper Disassembly 9 1...

Page 244: ...ke Pad Thickness 298 0073 7 56 185 mm 165 4 19 mm Brake Disc Thickness 150 165 3 81 4 19mm 140 4 24mm Brake Disc Runout 005 127mm TORQUE SPECIFICATIONS Item Torque Torque Nm Front Rear Caliper Mountin...

Page 245: ...ation If cleaning does not reduce the occurrence of brake noise Permatext Disc Brake Quiet PN 2872113 can be applied to the back of the pads Follow directions on the package This will keep pads in con...

Page 246: ...cause the brakes to feel spongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating port C which is opened and closed by the master...

Page 247: ...everse Steps 1 3 for foot brake installation After installing the foot brake check pedal freeplay Pedal freeplay should not exceed 090 2 286 mm Brake Pedal Freeplay 090 2 286 mm Master Cylinder Bushin...

Page 248: ...inder 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 6 Slowly pump foot pe...

Page 249: ...the equalizer assembly and at the brake lever on the brake caliper 3 Inspect the brake lines and brake line connections forossible leaks or loose lines NOTE Inspect the connections at the master cyli...

Page 250: ...Tighten the adjustment bolt C until the rear tire will not rotate 5 Back the adjustment bolt C out 1 4 turn 6 Tighten the jam nut B while holding the adjustment nut C in place 7 Repeat this procedure...

Page 251: ...rake Cable Nylok Nut Brake Lever Nut Park Brake Cable Equalizer and Pin Assembly Handle Parking Brake Rod U bolt Catch Spring Catch Washer Cotter Pin Catch Plate Bushing Washer Cotter Pin Foot Lever S...

Page 252: ...unting bracket 4 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...

Page 253: ...acing each other Be sure pads and disc are free of dirt or grease 3 Install caliper on hub strut and torque mounting bolts Front Caliper Mounting Bolts Torque 18 ft lbs 25 Nm 4 Slowly pump the brake p...

Page 254: ...pect the brake disc for nicks scratches or damage 2 Measure the disc thickness at 8 different points around the pad contact surface using a 0 1 micrometer Replace disc if worn beyond service limit Bra...

Page 255: ...ng vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 1 Remove brake pads See Page 9 10 9 11 2 Using a line wrench loosen and remove brake line to caliper Place a...

Page 256: ...or nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit Front Caliper Piston O D Std 1 4985 1 5000 38 062 38 10 mm Service Limit 1 4980 38 049 mm 3 Inspe...

Page 257: ...seated Install the pads as shown on Page 9 11 9 12 Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease FRONT BRAKE CALIPER EXPLODED VIEW Pads Caliper...

Page 258: ...ake pads are installed it is recommended that a burnishing procedure be performed to extend pad service life and reduce noise Start machine and slowly increase speed to 15 mph Gradually apply brakes t...

Page 259: ...ed back into caliper Remove excess fluid from reservoir as required 6 Remove the brake pads 7 Clean pad retainer pins with a wire brush 8 Clean the caliper with brake cleaner or alcohol 9 Measure the...

Page 260: ...rake pads to extend service life and reduce noise Start machine and slowly increase speed to 15 mph Gradually apply brakes to stop machine Repeat procedure 10 times REAR CALIPER REMOVAL CAUTION Use ca...

Page 261: ...he parking brake cable assembly from the caliper Parking Brake Cable Assembly 3 Lift the plunger washer and compression spring from the caliper body Inspect components and replace if needed 4 Remove t...

Page 262: ...g motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Install two new O rings in the plunger hole of the caliper assembly Be sure grooves are clean and...

Page 263: ...sket onto the caliper body Align the gasket with the three holes in the caliper body Gasket 8 Install the emergency brake actuator onto the caliper body Be sure the gasket holes line up with the calip...

Page 264: ...and torque mounting bolts Install brake lines and tighten with a flare nut wrench Caliper Mounting Bolt Torque 18 ft lbs 24 9 Nm 13 Follow bleeding procedure outlined on Pages 9 6 9 7 of this section...

Page 265: ...HOUSING 35 60 IN LBS 4 6 5 NM Finger Tight ADJ SCREW DURING ASSEMBLY APPLY POLARIS ALL PURPOSE GREASE APPLY POLARIS DOT 3 BRAKE FLUID TO COMPONENT 3 3 3 REAR BRAKE DISC INSPECTION 1 Visually inspect d...

Page 266: ...embly and installation 7 Dirty contaminated friction pads 8 Improper alignment 9 Worn disc 10 Worn disc splines TROUBLESHOOTING Brakes Squeal Poor Brake Performance S Air in system S Water in system b...

Page 267: ...Output Tests 10 8 Charging System Testing 10 8 10 10 Battery Activation Service 10 11 10 14 Head Light Brake Light Lamp Service 10 14 10 15 Brake Light Switch 10 15 Gear Indicator Light Circuit Operat...

Page 268: ...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 informati...

Page 269: ...If the ignition timing is not within the specified range adjust the stator plate position as described below Flywheel Rotation 32 Timing Pointer 30 28 EH50PL 30 BTDC 5000 RPM Timing Inspec tion Hole...

Page 270: ...ion FAN CONTROL SWITCH BYPASS TEST 1 Disconnect harness from fan switch on radiator 2 Place a jumper wire between the Red Blk and Org Blk wires in the connector 3 With the parking brake on turn the ig...

Page 271: ...On No Continuity Off 4010161 180 F 82 C 3 F 149 F 65 C 8 F FLYWHEEL IDENTIFICATION The flywheel can be identified by the stamp mark in location A or B Refer to I D location in chart below Do not use...

Page 272: ...may look the same but have different internal circuitry Be sure to always use the correct CDI box part number Battery Charging Coils Ignition Kill Wire Black Coil Lead 3 W 6300 W Pulse Coil Trigger A...

Page 273: ...nt using an ohmmeter The coil mount should have good continuity to ground on the engine 0 2 W Replace Spark Plug Disconnect and check the secondary coil Resis tance values should be Primary Side Prima...

Page 274: ...H PEAK READING VOLTMETER The following peak voltage tests will measure the amount of output directly from each component A peak reading voltmeter must be used to perform the tests A variety of peak re...

Page 275: ...d start the engine With the engine running at idle disconnect the negative cable from the battery post without disturbing the meter leads Observe meter readings 5 Increase engine RPM while observing a...

Page 276: ...egulator connector Is it Check regulator rectifier connections and ground battery connections cir cuit breaker and connecting wires Repair or replace faulty wiring or components If all of the previous...

Page 277: ...NOTE New Battery Battery must be fully charged before use or battery life will be significantly reduced 10 30 of the battery s full potential To activate a new battery 1 Remove vent plug from vent fi...

Page 278: ...er the starting or charging systems the battery should be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Lo...

Page 279: ...ash the case and battery tray with a mild solution of baking soda and water Rinse with lots of fresh water after cleaning NOTE Do not get any of the baking soda into the battery or the acid will be ne...

Page 280: ...light switch to high beam 4 Observe headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in Step 2 NOTE Rider weight must be included in...

Page 281: ...nd look behind the front left tire for the brake junction block The brake pressure switch is installed into this block Brake Switch 2 Disconnect wire harness from switch 3 Connect an ohmmeter across s...

Page 282: ...ltage Drop Test below GEngine problem seized or binding Can engine be rotated easily GFaulty or worn brushes in starter motor GAutomatic compression release inoperative Starter Motor Turns Engine Does...

Page 283: ...rush housing Make sure the brush is not touching the case The reading should be infinite 2 Remove nut flat washer large phenolic washer two small phenolic washers and O Ring from brush terminal Inspec...

Page 284: ...Inspect surface of commutator Replace if excessively worn or damaged 3 Using a digital multitester measure the resistance between each of the commutator segments The reading should be 3 ohms or less...

Page 285: ...ack brushes while installing shaft in bushing 6 Reinstall starter motor housing bolts Make sure O Rings are in good condition and seated in groove 7 Inspect permanent magnets in starter housing Make s...

Page 286: ...reaker and ignition switch The voltage on both sides should be the same NOTE The ignition switch actuated Replace the defective component Replace the diode assembly Apply dielectric grease to the term...

Page 287: ...olenoid to starter cable Reading should be less than 1 V D C Replace the starter solenoid Connect the black tester lead to the solenoid end of the solenoid to starter cable Connect the red tester lead...

Page 288: ...ELECTRICAL 10 22 NOTES...

Page 289: ...ELECTRICAL 10 23 WIRING DIAGRAM SERIES 11 RANGER 2X4...

Page 290: ...ELECTRICAL 10 24 WIRING DIAGRAM SERIES 11 RANGER 2X4...

Page 291: ...ELECTRICAL 10 25 WIRING DIAGRAM SERIES 11 RANGER 4X4 6X6...

Page 292: ...ELECTRICAL 10 26 WIRING DIAGRAM SERIES 11 RANGER 4X4 6X6...

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