Polaris GENERAL 2016 Service Manual Download

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9929375 R02 - 2016-2019

GENERAL

GENERAL 4

Service Manual

9.1

BRAKE SYSTEM

CHAPTER 9

BRAKE SYSTEM

GENERAL INFORMATION - BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

SERVICE NOTES - BRAKE SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

SPECIAL TOOLS - BRAKE SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

TORQUE SPECIFICATIONS - BRAKE SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

SERVICE SPECIFICATIONS - BRAKE SYSTEM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

SERVICE SPECIFICATIONS - BRAKE SYSTEM (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

ANTILOCK BRAKE SYSTEM (ABS) (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

ANTILOCK BRAKING SYSTEM (ABS) OVERVIEW (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

BRAKE SYSTEM ASSEMBLY VIEW (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

BRAKE LINE ROUTING AND RETENTION (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8

BRAKE LINE ROUTING AND RETENTION NON-ABS (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12

BRAKE PEDAL REMOVAL (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15

BRAKE PEDAL INSTALLATION (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15

BRAKE PRESSURE SWITCH REPLACEMENT (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16

ABS BRAKE BLEEDING / FLUID CHANGE (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16

TONE RING INSPECTION (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17

TONE RING REPLACEMENT (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17

WHEEL SPEED SENSOR REPLACE (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17

WHEEL SPEED SENSOR AIR GAP ADJUSTMENT (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.18

ABS HECU REMOVAL (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19

ABS HECU INSTALLATION (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20

ABS TROUBLESHOOTING (INTL)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21

ASSEMBLY VIEWS - BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22

BRAKE SYSTEM ASSEMBLY VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22

BRAKE SYSTEM ASSEMBLY VIEW — GENERAL 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23

LINE ROUTING AND RETENTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.24

GENERAL 4 BRAKE LINE ROUTING AND RETENTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.27

BRAKE LINE ROUTING AND RETENTION (2019) GENERAL 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.30

BRAKE CALIPER ASSEMBLY VIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.33

FRONT CALIPER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.33

REAR CALIPER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.34

BRAKE SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.35

BRAKE SYSTEM OPERATION OVERVIEW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.35

BRAKE BLEEDING / FLUID CHANGE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.35

BRAKE BURNISHING PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.36

MASTER CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.37

MASTER CYLINDER REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.37

MASTER CYLINDER INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.37

BRAKE PEDAL SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.38

BRAKE PEDAL REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.38

BRAKE PEDAL INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.38

Summary of Contents for GENERAL 2016

Page 1: ...horized 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 Polar...

Page 2: ...s injury WARNING SAFETY ALERT WARNING indicates a hazardous situation which if not avoided COULD result in death or serious injury CAUTION SAFETY ALERT CAUTION indicates a hazardous situation which if not avoided COULD result in minor to moderate injury CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage NOTICE NOTICE provides key information...

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: ...REVISION INDEX TRADEMARKLIST REV DATE CHANGES R01 07 27 2018 Initial Release R02 09 05 2018 Driven Clutch Alignment Procedure added ...

Page 5: ...er to provide Polaris with an overall satisfaction rating for this service manual provide comments on your experience or upload pictures video This feedback form is viewable on a mobile device by scanning the QR code or by clicking HERE if viewing this document electronically ...

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

Page 7: ...CATIONS 1 16 2017 POLARIS GENERAL 1 17 2017 POLARIS GENERAL SPECIFICATIONS 1 18 2017 POLARIS GENERAL 4 1 19 2017 POLARIS GENERAL 4 SPECIFICATIONS 1 20 2018 POLARIS GENERAL 1 21 2018 POLARIS GENERAL SPECIFICATIONS 1 22 2018 POLARIS GENERAL 4 1 23 2018 POLARIS GENERAL 4 SPECIFICATIONS 1 24 2018 POLARIS GENERAL OVERVIEW INTL 1 25 2018 POLARIS GENERAL SPECIFICATIONS INTL 1 26 2018 POLARIS GENERAL EU O...

Page 8: ...y or death If a torquing sequence is indicated for nuts bolts or screws of a certain component start all fasteners and hand tighten Following the method and sequence indicated tighten evenly to the specified torque value When removing nuts bolts or screws from a component with several fasteners loosen them all about 1 4 turn before removing them to prevent distortion of that component Replace all ...

Page 9: ...98 2018 GENERAL TRACTOR INTL R18RGC99CM R18RGS99CM R18RGS99CB 9928197 2019 GENERAL R19RGE99A2 R19RGE99AR R19RGE99BR R19RGK99AK R19RGK99BK R19RGU99A9 R19RGU99AF R19RGU99AL R19RGU99AM R19RGU99B9 R19RGU99BF R19RGU99BL R19RGU99BM 9928863 2019 GENERAL 4 R19RHE99AD R19RHE99BD R19RHE99LD R19RHK99AK R19RHK99BK 9928864 NOTICE When ordering service parts be sure to use the correct parts manual REPLACEMENT K...

Page 10: ... 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 by phone at 1 800 345 2233 or on line at http polaris service solutions com GENERAL INFORMATION ...

Page 11: ...Use With 2 Bore Stand PU 50625 Engine Stand Sleeve Adapter Use With 2 375 Bore Stand PW 47054 CHAPTER 3 ENGINE COOLING SYSTEM Engine Stand 2 Bore PU 50624 Clutch Center Distance Tool PU 50658 A Valve Spring Compressor Adapter PV 43513 A Valve Spring Compressor PV 1253 or PV 4019 Flywheel Puller PA 49316 Cylinder Holding Camshaft Timing Plate PU 50563 Piston Ring Compressor Pliers PV 43570 1 Water ...

Page 12: ...d Installation Tool 2870341 Piston Pin Puller 2870386 Clutch Bushing Replacement Tool Kit 2871226 Bushing Replacement Tool PA 47336 Universal Clutch Compressor PU 50518 CHAPTER 6 TRANSMISSION Drive Clutch Puller 2872085 Snorkel Tool PA 50231 Clutch Center Distance Tool PU 50658 A Crankcase Sealant 3 Bond 2871557 Rear Output Seal Driver 2871698 Rear Driveshaft Seal Guide 2871699 CHAPTER 7 FINAL DRI...

Page 13: ...939 Shock Rod Holding Tool PU 51024 Gas Shock Fill Tool PU 51039 CHAPTER 9 BRAKE SYSTEM Mityvac Pressure Test Tool 2870975 CHAPTER 10 BODY FRAME Multi Function Pliers 2876389 CHAPTER 11 ELECTRICAL Digital Wrench Diagnostic Kit PU 47063 B Digital Wrench SmartLink Module Kit PU 47471 Digital Wrench PC Interface Cable PU 47470 Digital Wrench Vehicle Interface Cable PU 47469 Digital Wrench SmartLink M...

Page 14: ...unting Bolts 7 ft lb 10 Nm Tie Rod Jam Nut 15 lb ft 20 Nm Transmission Fill Drain Plug 14 lb ft 19 Nm Valve Cover Bolts 7 lb ft 10 Nm Wheel Hub Castle Nuts 180 lb ft 244 Nm Wheel Nuts 120 lb ft 163 Nm 120 lb ft 163 Nm CHAPTER 3 ENGINE COOLING SYSTEM PART DESCRIPTION TORQUE SPECIFICATION Air Box Fasteners 3 5 lb ft 4 7 Nm Camshaft Carrier Bolts 7 ft lb 10 Nm Camshaft Sprocket Bolts 14 ft lb 19 Nm C...

Page 15: ...t lbs 10 Nm Oil Pump Pick Up Retaining Screws 7 ft lb 10 Nm Oil Sump Cover Bolts M8 26 ft lb 35 Nm CHAPTER 3 ENGINE COOLING SYSTEM PART DESCRIPTION TORQUE SPECIFICATION Oil Sump Cover Bolts M6 9 lb ft 12 Nm One Way Clutch Retaining Screws 9 ft lb 12 Nm Outer Clutch Cover Screws 50 lb in 5 Nm Oxygen Sensor 13 lb ft 18 Nm Rear Shock Mounting Bolt 20 lb ft 27 Nm 90 Spark Plug 7 lb ft 10 Nm Starter Mo...

Page 16: ... Nm Engine Transmission Mounting Bolts Step 1 2 64 lb ft 87 Nm Engine Transmission Mounting Bolts Step 3 5 lb ft 7 Nm Engine Transmission Mounting Bolts Step 4 7 44 lb ft 60 Nm Intake Plenum Hose Clamps 17 lb in 2 Nm CHAPTER 6 TRANSMISSION PART DESCRIPTION TORQUE SPECIFICATION Isolator Mount Bolts 22 lb ft 30 Nm Lower Intake Plenum Fastener 22 lb ft 30 Nm Pivot Shaft Fastener 10 lb ft 14 Nm Rear M...

Page 17: ...t Lower 30 lb ft 41 Nm Steering Shaft to Rack Pinch Bolt Lower 48 lb ft 65 Nm Steering Tilt Assembly Fasteners 40 lb ft 54 Nm Steering Wheel Nut 65 lb ft 88 Nm Tie Rod Jam Nut 15 lb ft 20 Nm CHAPTER 9 BRAKE SYSTEM PART DESCRIPTION TORQUE SPECIFICATION ABS Bracket Mount INTL 22 lb ft 30 Nm ABS Sensor Fastener INTL 8 lb ft 11 Nm ABS HECU Flare Fitting INTL 15 lb ft 20 Nm ABS HECU Mounting Fasteners ...

Page 18: ...ear Fastener M10 x 1 5 x 55 30 ft lbs 41 Nm Frame Seat Base Rear Fastener M8 x 1 25 x 55 10 ft lbs 14 Nm CHAPTER 10 BODY FRAME PART DESCRIPTION TORQUE SPECIFICATION Frame Seat Base Front Fastener M10 x 1 5 x 25 30 ft lbs 41 Nm Frame Seat Base Front Fastener M8 x 1 25 x 55 10 ft lbs 14 Nm Front Cross Fasteners 40 lb ft 54 Nm Intake Duct Hose Clamp 3 lb ft 4 Nm Lower Close off Panel Fasteners Rear 3...

Page 19: ...Retaining Screws 24 lb in 2 7 Nm Fuse Box Fasteners 35 lb in 4 Nm Ignition Coil Retaining Bolt 8 lb ft 11 Nm Instrument Cluster to Mounting Bracket Fasteners 30 lb in 3 4 Nm Instrument Cluster Mounting Bracket to Vehicle Fasteners 3 5 lb ft 4 7 Nm Intake Boot Clamp 49 lb in 5 5 Nm Oxygen Sensor 13 lb ft 18 Nm Pulse Bar Bracket Fasteners 60 in lbs 7 Nm Pulse Bar Cable Nuts 24 in lbs 3 Nm Pulse Bar ...

Page 20: ...s 1 through 8 determine Digital Wrench calibration VEHICLE IDENTIFICATION NUMBER VIN DESIGNATION Example 4XAKA09A0E3000000 WORLD MFG ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE ENGINE SIZE ENGINE MODIFIER CATEGORY CHECK DIGIT MODEL YEAR MFG LOCATION INDIVIDUAL SERIAL NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A K A 0 9 A 0 E 3 0 0 0 0 0 0 Model Year A 2010 B 2011 C 2012 D 20...

Page 21: ...m Wheel Base 81 in 206 cm Ground Clearance 12 in 30 5 cm Dry Weight 1430 lb 649 kg 1491 lb 676 kg 1544 lb 700 kg Gross Vehicle Weight 2796 lb 1268 kg Cargo Box Capacity 600 lb 272 kg Cargo Box Dimensions inside dimensions 26 x 43 x 11 in 66 x 109 x 28 cm Maximum Weight Capacity Payload 1030 lb 467 kg Includes riders cargo and accessories Hitch Towing Capacity 2000 lb 907 kg Hitch Tongue Capacity 1...

Page 22: ...0A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift H L N R P Transmission Gear Ratios High Low Reverse 10 73 1 22 79 1 20 41 1 Front Drive Ratio 3 182 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL Gearcase Lubricant 44 oz 1300 mL S...

Page 23: ...in 206 cm Ground Clearance 12 in 30 5 cm Dry Weight 1430 lb 649 kg 1491 lb 676 kg 1544 lb 700 kg Gross Vehicle Weight 2796 lb 1268 kg Cargo Box Capacity 600 lb 272 kg Cargo Box Dimensions inside dimensions 26 x 43 x 11 in 66 x 109 x 28 cm Maximum Weight Capacity Payload 1030 lb 467 kg Includes riders cargo and accessories Hitch Towing Capacity 2000 lb 907 kg Hitch Tongue Capacity 150 lb 68 kg GENE...

Page 24: ...Type Polaris Automatic PVT Shift Type In Line Shift H L N R P Transmission Gear Ratios High Low 10 73 1 22 79 1 20 41 1 DRIVETRAIN Reverse Front Drive Ratio 3 182 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL Gearcase Lubricant 44 oz 1300 mL STEERING SUSPENSION Steering Wheel Free Play 0 8 1 0 in 20 25 mm Toe Out 0 1 8 in 0 3 175 mm ...

Page 25: ...m Wheel Base 113 in 287 cm Ground Clearance 12 in 30 5 cm Dry Weight 1857 lb 842 kg Gross Vehicle Weight 2796 lb 1268 kg Cargo Box Capacity 600 lb 272 kg Cargo Box Dimensions inside dimensions 26 x 43 x 11 in 66 x 109 x 28 cm Maximum Weight Capacity Payload 1030 lb 467 kg Includes riders cargo and accessories Hitch Towing Capacity 2000 lb 907 kg Hitch Tongue Capacity 150 lb 68 kg GENERAL INFORMATI...

Page 26: ... Fan Fuses 20A EFI 10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift H L N R P Transmission Gear Ratios High Low 12 05 1 25 59 1 22 92 1 DRIVETRAIN Reverse Front Drive Ratio 3 182 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL Gea...

Page 27: ...in 206 cm Ground Clearance 12 in 30 5 cm Dry Weight 1430 lb 649 kg 1491 lb 676 kg 1544 lb 700 kg Gross Vehicle Weight 2796 lb 1268 kg Cargo Box Capacity 600 lb 272 kg Cargo Box Dimensions inside dimensions 26 x 43 x 11 in 66 x 109 x 28 cm Maximum Weight Capacity Payload 1030 lb 467 kg Includes riders cargo and accessories Hitch Towing Capacity 2000 lb 907 kg Hitch Tongue Capacity 150 lb 68 kg GENE...

Page 28: ...Type Polaris Automatic PVT Shift Type In Line Shift H L N R P Transmission Gear Ratios High Low 10 73 1 22 79 1 20 41 1 DRIVETRAIN Reverse Front Drive Ratio 3 182 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL Gearcase Lubricant 44 oz 1300 mL STEERING SUSPENSION Steering Wheel Free Play 0 8 1 0 in 20 25 mm Toe Out 0 1 8 in 0 3 175 mm ...

Page 29: ...m Wheel Base 113 in 287 cm Ground Clearance 12 in 30 5 cm Dry Weight 1857 lb 842 kg Gross Vehicle Weight 2796 lb 1268 kg Cargo Box Capacity 600 lb 272 kg Cargo Box Dimensions inside dimensions 26 x 43 x 11 in 66 x 109 x 28 cm Maximum Weight Capacity Payload 1030 lb 467 kg Includes riders cargo and accessories Hitch Towing Capacity 2000 lb 907 kg Hitch Tongue Capacity 150 lb 68 kg GENERAL INFORMATI...

Page 30: ...oling Fan Fuses 20A EFI 10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift H L N R P Transmission Gear Ratios High Low Reverse 12 05 1 25 59 1 22 92 1 Front Drive Ratio 3 182 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL Gearcase ...

Page 31: ...in 206 cm Ground Clearance 12 in 30 5 cm Weight 1616 lb 733 kg ABS 1614 lb 732 kg EPS Deluxe 1581 lb 717 kg EPS Gross Vehicle Weight 2796 lb 1268 kg Cargo Box Capacity 600 lb 272 kg Cargo Box Dimensions inside dimensions 26 x 43 x 11 in 66 x 109 x 28 cm Maximum Weight Capacity Payload 1030 lb 467 kg Includes riders cargo and accessories Hitch Towing Capacity 1500 lb 680 kg Hitch Tongue Capacity 15...

Page 32: ...20A Cooling Fan Fuses 20A EFI 10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift H L N R P Transmission Gear Ratios 10 73 1 DRIVETRAIN High Low Reverse 22 79 1 20 41 1 Front Drive Ratio 3 182 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirem...

Page 33: ... in 206 cm Ground Clearance 12 in 30 5 cm Weight 1552 lb 704 kg EPS 1585 lb 719 kg EPS Deluxe 1592 lb 722 kq ZUG Gross Vehicle Weight 2796 lb 1268 kg Cargo Box Capacity 600 lb 272 kg Cargo Box Dimensions inside dimensions 26 x 43 x 11 in 66 x 109 x 28 cm Maximum Weight Capacity Payload 1030 lb 467 kg Includes riders cargo and accessories Hitch Towing Capacity 1500 lb 680 kg Hitch Tongue Capacity 1...

Page 34: ...reaker 20A Cooling Fan Fuses 20A EFI 10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift H L N R P Transmission Gear Ratios High Low Reverse 10 73 1 22 79 1 20 41 1 Front Drive Ratio 3 182 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement ...

Page 35: ...e 81 in 206 cm Ground Clearance 12 in 30 5 cm Dry Weight 1430 lb 649 kg 1491 lb 676 kg 1544 lb 700 kg Gross Vehicle Weight 2796 lb 1268 kg Cargo Box Capacity 600 lb 272 kg Cargo Box Dimensions inside dimensions 26 x 43 x 11 in 66 x 109 x 28 cm Maximum Weight Capacity Payload 1030 lb 467 kg Includes riders cargo and accessories Hitch Towing Capacity 2000 lb 907 kg Hitch Tongue Capacity 150 lb 68 kg...

Page 36: ...Type Polaris Automatic PVT Shift Type In Line Shift H L N R P Transmission Gear Ratios High Low 11 72 1 23 74 1 25 83 1 DRIVETRAIN Reverse Front Drive Ratio 3 182 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL Gearcase Lubricant 44 oz 1300 mL STEERING SUSPENSION Steering Wheel Free Play 0 8 1 0 in 20 25 mm Toe Out 0 1 8 in 0 3 175 mm ...

Page 37: ...93 cm Wheel Base 113 in 287 cm Ground Clearance 12 in 30 5 cm Dry Weight 1857 lb 842 kg Gross Vehicle Weight 2796 lb 1268 kg Cargo Box Capacity 600 lb 272 kg Cargo Box Dimensions inside dimensions 26 x 43 x 11 in 66 x 109 x 28 cm Maximum Weight Capacity Payload 1030 lb 467 kg Includes riders cargo and accessories Hitch Towing Capacity 2000 lb 907 kg Hitch Tongue Capacity 150 lb 68 kg GENERAL INFOR...

Page 38: ...oling Fan Fuses 20A EFI 10A Fuel Pump 5A Brake Light 20A Accessory 10A Drive 10A Lights 20A EPS if appl DRIVETRAIN Transmission Type Polaris Automatic PVT Shift Type In Line Shift H L N R P Transmission Gear Ratios High Low Reverse 11 72 1 23 74 1 25 83 11 Front Drive Ratio 3 182 1 Front Gearcase Lubricant Requirement Demand Drive Fluid 8 5 oz 250 mL Transmission Lubricant Requirement AGL Gearcase...

Page 39: ...inch x 2 54 cm mile 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 ...

Page 40: ... 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 EQUIVA LENT 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 8...

Page 41: ...906 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 70...

Page 42: ...1 36 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc NOTES GENERAL INFORMATION ...

Page 43: ... 14 PRE RIDE DAILY INSPECTION 2 14 FRAME NUTS BOLTS AND FASTENERS 2 14 SHIFT CABLE INSPECTION ADJUSTMENT 2 14 HEAT SHIELD INSPECTION 2 15 ENGINE MAINTENANCE 2 16 ENGINE OIL LEVEL 2 16 ENGINE OIL AND FILTER CHANGE 2 17 ENGINE CRANKCASE BREATHER HOSE INSPECTION 2 18 ENGINE CYLINDER LEAKDOWN TEST 2 18 VALVE CLEARANCE INSPECTION 2 18 CAM CHAIN TENSIONER INSPECTION 2 20 COOLING SYSTEM MAINTENANCE 2 21 ...

Page 44: ...33 STEERING INSPECTION 2 33 STEERING WHEEL FREE PLAY 2 33 TIE ROD END WHEEL HUB INSPECTION 2 34 WHEEL TOE ALIGNMENT INSPECTION 2 34 WHEEL TOE ADJUSTMENT 2 35 SUSPENSION MAINTENANCE 2 36 SPRING ADJUSTMENT 2 36 SPRING ADJUSTMENT GENERAL 4 2 37 SHOCK COMPRESSION ADJUSTMENT 2 37 BRAKE SYSTEM MAINTENANCE 2 38 BRAKE HOSE AND FITTING INSPECTION 2 38 BRAKE FLUID INSPECTION 2 38 BRAKE PAD DISC INSPECTION 2...

Page 45: ...ine in your eyes or if you swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result in loss of consciousness or death in a short time Never drain the fuel when the engine is hot Severe bu...

Page 46: ...4 2019 Front 18 psi 124 kPa Rear 20 psi 137 kPa Steering Wheel Free Play 0 8 1 0 in 20 25 mm Wheel Toe Out 0 1 8 in 0 3 175 mm Spring Adjustment Front 6 625 in 16 828 cm Rear 1 625 in 4 128 cm Spring Adjustment GENERAL 4 Front 4 00 in 10 16 cm Rear 0 938 in 2 38 cm Brake Pad Thickness 0 040 1 mm Brake Disc Thickness 0 170 4 32 mm Spark Plug Type NGK MR7F FLUID SPECIFICATIONS ITEM FLUID TYPE CAPACI...

Page 47: ...n 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 compo...

Page 48: ...pect for tire damage nails in tire Verify there is adequate tread depth Wheels Lug Nuts Ensure rim is not cracked bent Verify proper lug nut torque Headlights Taillights Ensure all lights are operational Adjust headlight aim as required Brake System Check brake fluid level is between MIN and MAX Check brake pedal is not soft when pushed Verify brakes stop and hold the vehicle Inspect for leaks Fra...

Page 49: ...ITEM INSPECTION CHECK Engine Intake Pre Filter Screen LH side Inspect clean often PVT Intake Pre Filter Screen RH side Inspect clean often Power Steering Unit Inspect clean often Spark Arrester Clean when driving in mud and water replace a cracked or damaged arrester before operating MAINTENANCE ...

Page 50: ...nsmission Fluid AGL 25 H 1 M Initial fluid level inspection add lubricant if needed E Engine Oil Filter Change Break In 25 H 500 800 Perform break in oil filter change General Lubrication 50 H 3 M 500 800 Lubricate all fittings pivots cables etc Shift Linkage 50 H 6 M 500 800 Inspect lubricate adjust Steering 50 H 6 M 500 800 Lubricate Front Rear Stabilizer Bars 50 H 6 M 500 800 Lubricate and insp...

Page 51: ... 12 M 1000 1600 Remove and grease E Spark Plug 100 H 12 M 1000 1600 Inspect replace as needed Wiring 100 H 12 M 1000 1600 Inspect for wear routing security inspect connectors subjected to water mud etc Clutches Drive and Driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Front Wheel Bearings 100 H 12 M 1000 1600 Inspect replace as needed Shock Seals 100 H Visually inspect shock seals Sho...

Page 52: ...l Polaris PS 4 or Polaris PS 4 Extreme Duty 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 Under Front Hood Access Panel Polaris 50 50 Extended Life Coolant Maintain coolant level in coolant reservoir bottle r Check level daily change coolant every two years More often under severe use such as opera...

Page 53: ...l during pre ride inspection change fluid every two years Front Gearcase Polaris Demand Drive Add lubricant until it is visible at the fill hole threads w 8 5 oz 250 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 e More often under severe use suc...

Page 54: ... Stabilizer Bar Bushings Grease the fitting on each side of the vehicle q Premium All Season Grease Grease fittings every 500 miles 800 km Grease before long periods of storage and after thoroughly washing or submerging the vehicle Rear Stabilizer Bar Bushings Grease 2 fittings through the skid plate access holes on each side of the vehicle w Premium All Season Grease Propshaft Yokes Grease middle...

Page 55: ...Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz 24 count 2871423 Premium All Season Grease 14 oz 10 count 2871515 Premium U Joint Lubricant 3 oz 24 count 2871551 Premium U Joint Lubricant 14 oz 10 count 2871329 Dielectric Grease Nyogel Coolant 2880514 50 50 EL Anti Free Qt 12 count 2880513 50 50 EL Anti Free Gal 4 count 2880512 50 50 EL Anti Free 55 Gal Drum NOTICE Each item c...

Page 56: ...age Heat Shields ensure they are not damaged and are properly secured If any heat shields are found to be damaged or missing they must be replaced FRAME NUTS BOLTS AND FASTENERS Periodically inspect the torque of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each chapter SHIFT CABLE INSPECTION ADJUSTME...

Page 57: ...rly secured A rattling sound while the engine or when the unit is moving is running is a good indication of an unsecured heat shield If any heat shields are found to be damaged loose or missing they must be replaced prior to operation q Chassis Heat Shield r Box Heat Shield w Headpipe Heat Shield t Silencer Outer Heat Shield Elbow e Midpipe Heat Shield y Silencer Heat Shield Main MAINTENANCE ...

Page 58: ... the RH rear wheel opening Remove the dipstick and wipe it dry with a clean cloth 4 Reinstall the dipstick and push it into place Do not lock the dipstick NOTICE Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent 5 Remove the dipstick and check the oil level 6 Add the recommended oil as necessary to bring the oil level within the S...

Page 59: ... fresh engine oil Check to make sure the O ring is in good condition Install the oil filter TORQUE Oil Filter Torque Turn by hand until filter O ring contacts sealing surface then turn an additional 3 4 turn 8 Replace the sealing washer on drain plug NOTICE The sealing surface on the drain plug should be clean and free of burrs nicks or scratches 9 Reinstall the engine crankcase drain plug Torque ...

Page 60: ...n test Never use high pressure leakage testers as crankshaft seals may dislodge and leak Cylinder Leakage Service Limit 20 If leakage exceeds service limit inspect the engine for the cause VALVE CLEARANCE INSPECTION NOTICE Valve clearance inspection should be performed on a cold engine at room temperature 1 Remove the driver s seat and access panel Disconnect the negative battery cable 2 Remove ei...

Page 61: ...nd to the spark plug threads and reinstall the spark plugs Torque spark plugs to specification TORQUE Spark Plug 7 lb ft 10 Nm 12 Inspect the valve cover seal and replace if necessary 13 Install NEW isolators on the valve cover bolts Install the valve cover and the four T 40 bolts Torque bolts to specification TORQUE Valve Cover Bolts 7 lb ft 10 Nm 14 Install the spark plug wires Ensure wires are ...

Page 62: ...tensioner mounting bolts w 4 Push on the tensioner lock e and manually move the plunger in and out It should move freely If it does not move freely replace the tensioner assembly 5 Retract the plunger all the way in and install into the cylinder 6 Install the two mounting bolts Torque fasteners to specification TORQUE Tensioner Mounting Bolts 7 ft lb 10 Nm 7 Install the plunger bolt Torque fastene...

Page 63: ...ght 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 50 50 Extended Life Antifreeze COOLANT LEVEL INSPECTION The pressure cap q and recovery bottle w are located under the front hood of the vehicle The coolant level must be maintained between the minimum an...

Page 64: ...start engine and check for leaks Make sure radiator fins are clean to prevent overheating COOLING SYSTEM HOSES 1 Inspect all vehicle hoses for cracks deterioration abrasion or leaks Replace if necessary q Recovery Bottle w Engine Hoses e Radiator Hoses r To Thermostat Housing t To Water Pump y To Radiator 2 Inspect all engine hoses for cracks deterioration abrasion or leaks Replace if necessary u ...

Page 65: ...ant when the engine and radiator 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 q 5 Allow ...

Page 66: ...p to inspect the quick connect fuel line w at the fuel tank for signs of wear deterioration damage or leakage Replace line s if necessary 3 Locate the fuel supply fitting e through the right rear wheel well on the upper right side of the engine Check the line and quick connect fitting for signs of wear deterioration damage or leakage Replace if necessary 4 Be sure fuel lines are routed and retaine...

Page 67: ...uel line and the loosen the PFA nut w 3 The engine uses a high volume high pressure fuel pump that includes a preliminary pickup filter e and an internal filter r located before the pump regulator 4 Cycle the ignition key to pressurize the fuel pump in accordance with the periodic maintenance chart Inspect pump for damage or leaks NOTICE Reference Chapter 4 for fuel pump replacement and other info...

Page 68: ...ne is routed properly and secured with appropriate retention components NOTICE Ensure vent line is not kinked or pinched VENT LINE TERMINATION FITTING This fitting should be inspected and tested using a Mity Vac to ensure proper venting Connect the Mity Vac to the fitting and give it 5 pumps The gauge should return to 0 immediately or there is an obstruction NOTICE If the vent line fitting is remo...

Page 69: ...ter 5 Place the air filter into the air box and reinstall the air box cover NOTICE Be sure the lower tabs on the air box cover are properly engaged into the airbox 6 Install the cover and engage the cover latches 7 Lower the cargo box and secure in position INTAKE DUCT DRAIN INSPECTION It is recommended that the intake drain be inspected daily 1 Access the intake baffle box drain q through the LH ...

Page 70: ...ely 4 Reinstall the drain plug and O ring 5 Place the transmission in PARK apply the brake and start the engine 6 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches IMPORTANT Do not hold the throttle pedal wide open for more than 5 seconds 7 Allow the engine RPM to return to idle then shift the transmission into low gear 8 Test the PVT system for belt ...

Page 71: ...ed lubricant as needed Do not overfill 5 Reinstall the fill plug and torque to specification TORQUE Transmission Fill Drain Plug Torque 14 lb ft 19 Nm TRANSMISSION LUBRICANT CHANGE 1 Remove the fill plug 2 Place a drain pan under the transmission drain plug The drain plug is located on the bottom of the transmission gearcase Access the drain plug through the drain hole in the skid plate 3 Remove d...

Page 72: ...s needed Do not overfill 5 Reinstall the fill plug and torque to specification TORQUE Front Gearcase Fill Drain Plug Torque 10 lb ft 14 Nm FRONT GEARCASE FLUID CHANGE 1 Remove the fill plug 2 Place a drain pan under the front gearcase drain plug The drain plug is located on the bottom of the front gearcase Access the drain plug through the access hole in the frame underneath the front gearcase 3 R...

Page 73: ... appropriate side of the vehicle by placing a suitable stand under the frame 5 Remove the wheel nuts and remove the wheel WHEEL INSTALLATION CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear 1 Verify the transmission is still in PARK 2 Place the wheel in the correct position on the wheel hub t Be sure the valve stem w is toward the outside and rotation arrow...

Page 74: ...CTION INTL Improper tire inflation may affect vehicle maneuverability When replacing a tire always use original equipment size and type The use of non standard size or type tires may affect vehicle handling and cause an ABS failure WARNING ABS vehicles are designed to be equipped only with original tire design and size with defined pressure Failure to use specified tire and wheel specifications wi...

Page 75: ...iring to be sure the steering mechanism is not restricted or limited NOTICE Check front end alignment whenever steering components are replaced WARNING Due to the critical nature of the procedures outlined in this chapter Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician STEERING WHEEL FREE PLAY 1 Position the vehicle on leve...

Page 76: ...rmal movement is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts or loose front hub nut Refer to Final Drive chapter for service procedures WHEEL TOE ALIGNMENT INSPECTION 1 Place machine on a smooth level surface and set steering wheel in a straight ahead position Secure the steering wheel in this position 2 Place a chalk mark on the center line of the front tir...

Page 77: ... tell you which tie rod needs adjusting NOTICE Be sure steering wheel is straight ahead before determining which tie rod needs adjustment CAUTION During tie rod 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 To adjust toe alignment 1 Hold tie rod end to keep it fro...

Page 78: ...ont or rear of the vehicle off the ground to allow the suspension to fully extend 2 Using the shock spanner spreader tool PN 2877408 included in the vehicle s tool kit turn the adjustment collar q to increase or decrease ride height BASE FOX WARNING DO NOT increase the spring adjustment q by more than one inch 25 4 mm over the factory setting Always return the spring adjuster to the factory settin...

Page 79: ...ht WARNING DO NOT increase the spring adjustment q by more than one inch 25 4 mm over the factory setting Always return the spring adjuster to the factory setting after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stability when operating without a load SPRING ADJUSTMENT FACTORY SETTING FRONT REAR 4 00 in 10 16 cm 0 938 in 2 38 cm NOTICE Model...

Page 80: ... Position the vehicle on a level surface Place the transmission in PARK 2 View the brake fluid level in the reservoir q The level should be between the MAX and MIN level lines 3 If the fluid level is lower than the MIN level line add brake fluid until it reaches the MAX level line 4 Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around ...

Page 81: ...ck on parking brake lever located in the center console 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 roll while parked 3 If the vehicle moves adjustment is necessary 4 Adjust the parking brake cable where it attaches to the caliper mount shift cable bracket The m...

Page 82: ... 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 10 If additional adjustment is needed the cable can be adjust on the parking brake handle side jam nut r MAINTENANCE ...

Page 83: ... with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten 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 ...

Page 84: ...er vehicle performance Refer to Battery Charging page 11 55 procedure before installing the battery 1 Place the battery in the battery holder and secure with hold down strap Torque fastener to specification TORQUE Battery Bracket 3 5 lb ft 5 Nm 2 Coat the terminals with dielectric grease 3 Connect and tighten the red q cable first 4 Connect and tighten the black w cable last 5 Verify that cables a...

Page 85: ...t the chassis ground terminals Be sure the grounds are clean and tight SPARK PLUG SERVICE WARNING A hot engine can cause serious burns Allow engine to cool or wear protective gloves when removing the spark plugs Inspect and replace the spark plugs at the intervals outlined in the Periodic Maintenance Chart 1 Lift the cargo box 2 Remove both spark plug caps w NOTICE Note MAG and PTO reference decal...

Page 86: ...occur if the incorrect spark plug is used Recommended Spark Plug NGK MR7F 10 Apply anti seize compound to the spark plug threads 11 Install spark plugs and torque to specification TORQUE Spark Plug Torque 7 lb ft 10 Nm 12 Install the plug caps to the appropriate cylinder by referencing the MAG and PTO spark plug wire decals Ensure wires are pushed down all the way so they engage onto the spark plu...

Page 87: ...16 2018 3 16 EXHAUST SYSTEM ASSEMBLY VIEW 2019 3 17 EXHAUST SYSTEM ASSEMBLY VIEW INTL 3 18 ENGINE SERVICE 3 19 ENGINE OIL LEVEL 3 19 ENGINE OIL AND FILTER CHANGE 3 20 ENGINE CRANKCASE BREATHER HOSE INSPECTION 3 21 ENGINE CYLINDER LEAKDOWN TEST 3 21 VALVE CLEARANCE INSPECTION 3 21 TOP END SERVICE ENGINE IN CHASSIS 3 23 CRANKSHAFT PTO SEAL REPLACEMENT 3 24 ENGINE REMOVAL 3 26 ENGINE INSTALLATION 3 2...

Page 88: ...IN BEARING SELECTION 3 61 UPPER CRANKCASE PREPARATION 3 62 PISTON RING INSTALLATION 3 62 PISTON CONNECTING ROD ASSEMBLY 3 64 CYLINDER PISTON INSTALLATION 3 65 CRANKSHAFT INSTALLATION 3 66 BALANCE SHAFT INSTALLATION 3 67 LOWER CRANKCASE PREPARATION 3 68 CRANKCASE ASSEMBLY 3 68 STARTER ONE WAY CLUTCH ASSEMBLY 3 72 FLYWHEEL INSTALLATION 3 72 STATOR COVER INSTALLATION 3 73 ENGINE ASSEMBLY TOP END 3 74...

Page 89: ...OLING SYSTEM PRESSURE CAP TEST 3 91 COOLING SYSTEM HOSE REPLACEMENT 3 91 RADIATOR REPLACEMENT 3 92 THERMOSTAT REPLACEMENT 3 93 COOLING SYSTEM BLEEDING 3 94 WATER PUMP REMOVAL 3 95 WATER PUMP INSTALLATION 3 95 WATER PUMP SERVICE 3 97 TROUBLESHOOTING ENGINE COOLING SYSTEM 3 100 ENGINE 3 100 COOLING SYSTEM 3 101 ENGINE COOLING SYSTEM ...

Page 90: ...ings SPECIAL TOOLS ENGINE COOLING SYSTEM TOOL DESCRIPTION PART NUMBER Oil Filter Wrench PU 50105 Oil Pressure Gauge PV 43531 Oil Pressure Gauge Adapter 2017 PU 50565 Oil Pressure Gauge Adapter 2018 PU 52502 Engine Stand Adapter Mounts To The Engine PU 50562 Engine Stand Sleeve Adapter Use With 2 Bore Stand PU 50625 Engine Stand Sleeve Adapter Use With 2 375 Bore Stand PW 47054 Engine Stand 2 Bore ...

Page 91: ...M6 9 lb ft 12 Nm Upper Crankcase Bolts M8 26 lb ft 35 Nm Upper Crankcase Bolts M6 9 lb ft 12 Nm Oil Pump Mounting Bolts 7 lb ft 10 Nm Oil Pump Pick Up Retaining Screws 7 lb ft 10 Nm Oil Sump Cover Bolts M8 26 lb ft 35 Nm PART DESCRIPTION TORQUE SPECIFICATION Oil Sump Cover Bolts M6 9 lb ft 12 Nm Oil Cooler Retaining Bolts 7 lb ft 10 Nm One Way Clutch Retaining Screws 9 lb ft 12 Nm Flywheel Retaini...

Page 92: ...ut of Round Limit 001 0 025 mm Cylinder Taper Limit 001 0 025 mm Cylinder to Piston Clearance 0009 0019 0 025 0 050 mm Cylinder Head Cylinder Head Surface Warp Limit 0039 0 1 mm Cylinder Head Standard Height 4 717 0019 119 82 0 05 mm Valve Valve Lash Cold Intake 006 002 0 15 0 051 mm Valve Lash Cold Exhaust 010 002 0 25 0 051 mm Valve Stem Diameter Intake 2155 2161 5 475 5 490 mm Valve Stem Diamet...

Page 93: ...d Bore I D 1 7323 1 7326 44 003 44 010 mm Crankshaft B Marking Main Journal O D 1 6140 1 6143 40 996 41 004 mm 1 6129 40 970 mm G Marking Main Journal O D 1 6137 1 6140 40 988 40 995 mm 1 6129 40 970 mm Y Marking Main Journal O D 1 6134 1 6137 40 980 40 987 mm 1 6129 40 970 mm B Marking Rod Journal O D 1 6118 1 6122 40 942 40 950 mm 1 6104 40 906 mm G Marking Rod Journal O D 1 6115 1 6118 40 934 4...

Page 94: ... 8 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc ASSEMBLY VIEWS ENGINE MAIN ENGINE COMPONENTS TORQUE SPECIFICATION AND SEQUENCE Cam Carrier ENGINE COOLING SYSTEM ...

Page 95: ...3 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 3 9 Crankcase Split Line Bottom Crankcase Split Line Top ENGINE COOLING SYSTEM ...

Page 96: ...3 10 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc Cylinder Head Sump Cover ENGINE COOLING SYSTEM ...

Page 97: ...3 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 3 11 Stator Cover ENGINE COOLING SYSTEM ...

Page 98: ...3 12 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc BALANCE SHAFT CONNECTING RODS CRANKCASE CRANKSHAFT PISTONS ENGINE COOLING SYSTEM ...

Page 99: ...3 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 3 13 CYLINDER OIL COOLER OIL FILTER OIL PUMP OIL SUMP WATER PUMP ENGINE COOLING SYSTEM ...

Page 100: ...3 14 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc CAMSHAFTS CYLINDER HEAD FLYWHEEL IDLER GEARS STATOR COVER ENGINE COOLING SYSTEM ...

Page 101: ...3 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 3 15 SPARK PLUGS STARTER THERMOSTAT HOUSING THROTTLE BODY VALVE COVER ENGINE COOLING SYSTEM ...

Page 102: ...right Polaris Industries Inc EXHAUST SYSTEM ASSEMBLY VIEW 2016 2018 q Headpipe fasteners 18 lb ft 24 Nm t Double Spherical Gasket w Oxygen Sensor 13 lb ft 18 Nm y Exhaust Spring e Isolator Mount u Exhaust Stud 21 lb ft 28 Nm r Spring i Silencer ENGINE COOLING SYSTEM ...

Page 103: ...ght Polaris Industries Inc 3 17 EXHAUST SYSTEM ASSEMBLY VIEW 2019 q Headpipe fasteners 18 lb ft 24 Nm t Double Spherical Gasket w Oxygen Sensor 13 lb ft 18 Nm y Exhaust Spring e Isolator Mount u Exhaust Stud 21 lb ft 28 Nm r Spring i Silencer ENGINE COOLING SYSTEM ...

Page 104: ...pyright Polaris Industries Inc EXHAUST SYSTEM ASSEMBLY VIEW INTL q Headpipe fasteners 18 lb ft 24 Nm t Double Spherical Gasket w Oxygen Sensor 13 lb ft 18 Nm y Exhaust Spring e Isolator Mount u Exhaust Stud 21 lb ft 28 Nm r Spring i Silencer ENGINE COOLING SYSTEM ...

Page 105: ...H rear wheel opening Remove the dipstick and wipe it dry with a clean cloth 4 Reinstall the dipstick and push it into place Do not lock the dipstick NOTICE Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent 5 Remove the dipstick and check the oil level 6 Add the recommended oil as necessary to bring the oil level within the SAFE ra...

Page 106: ... engine oil Check to make sure the O ring is in good condition Install the oil filter TORQUE Oil Filter Torque Turn by hand until filter O ring contacts sealing surface then turn an additional 3 4 turn 8 Replace the sealing washer on drain plug NOTICE The sealing surface on the drain plug should be clean and free of burrs nicks or scratches 9 Reinstall the engine crankcase drain plug Torque drain ...

Page 107: ...st Never use high pressure leakage testers as crankshaft seals may dislodge and leak Cylinder Leakage Service Limit 20 If leakage exceeds service limit inspect the engine for the cause VALVE CLEARANCE INSPECTION NOTICE Valve clearance inspection should be performed on a cold engine at room temperature 1 Remove the driver s seat and access panel Disconnect the negative battery cable 2 Remove eight ...

Page 108: ...the spark plug threads and reinstall the spark plugs Torque spark plugs to specification TORQUE Spark Plug 7 lb ft 10 Nm 12 Inspect the valve cover seal and replace if necessary 13 Install NEW isolators on the valve cover bolts Install the valve cover and the four T 40 bolts Torque bolts to specification TORQUE Valve Cover Bolts 7 lb ft 10 Nm 14 Install the spark plug wires Ensure wires are instal...

Page 109: ... 3 23 TOP END SERVICE ENGINE IN CHASSIS Some top end engine components can be serviced while the engine is mounted in the chassis To service the top end of the engine refer to Valve Clearance Inspection page 3 21 which provides detailed steps to access the valve cover ENGINE COOLING SYSTEM ...

Page 110: ...2018 engines and does NOT work with 2017 and older models CRANKSHAFT PTO SEAL REMOVAL 1 Remove the Inner PVT Cover Refer to PVT disassembly to access the crankcase seal 2 Using a commercially available seal puller tool remove crankcase seal from crankcase IMPORTANT Use care not to scratch the crankcase while removing seal 3 Inspect the crankcase and crankshaft surfaces for any burrs or scratches t...

Page 111: ...he orientation of the seal is critical Install the seal with the flat side of the seal facing out as shown 2 Tighten the drive bolt e until the cylinder r bottoms out against the crankcase 3 Once the seal is properly installed loosen the drive bolt e and remove special tool PU 52493 from the crankshaft 4 Refer to Inner PVT Cover installation 5 Field test the vehicle before putting back into servic...

Page 112: ...river seat and disconnect the negative battery cable from the battery 5 Remove the cargo box Refer to Cargo Box Removal page 10 41 procedure 6 Remove the air box assembly Refer to Intake Removal page 3 85 procedure 7 Elevate the rear of the vehicle off the ground using a suitable lift WARNING Use care when supporting vehicle so that it does not tip or fall Serious injury may occur if vehicle tips ...

Page 113: ...d pipe o to the muffler Remove exhaust head pipe towards the front of the vehicle Discard exhaust gaskets a 18 Place a suitable drain pan under the vehicle and remove the thermostat housing coolant hose g and the water pump coolant hose h from the engine Dispose of engine coolant properly 19 Use an overhead or portable engine hoist and suitable engine straps to secure engine in its current positio...

Page 114: ...njury or damage to vehicle components 23 Remove the starter motor bolts 2 and starter motor from the engine 24 Remove the six transmission joint bracket bolts 2 and transmission joint bracket 2 from the engine 25 Install the engine stand adapter PU 50562 onto the engine where the starter motor was located 26 Select the proper engine stand sleeve adapter and install it onto the engine stand adapter...

Page 115: ...specification in sequence TORQUE Starter Motor Bolts 7 lb ft 10 Nm Trans Joint Bracket Bolts 44 lb ft 60 Nm 4 Use the overhead or portable engine hoist and suitable engine straps to lower the engine into the vehicle frame CAUTION Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components 5 Align both the ...

Page 116: ...T Use hole number 4 on the Drive clutch side and hold number 4 on the Driven Clutch 8 Loosen the two bolts t retaining transmission joint bracket to the transmission on the right side 9 Align the front transmission mounting holes with transmission joint bracket mounting holes on engine 10 Install the two bolts y retaining the transmission joint bracket to the engine on the right side Hand tighten ...

Page 117: ...breather hose to the crankcase 21 Install the spark plug wires to the appropriate cylinder by referencing the MAG and PTO spark plug wire decals NOTICE Ensure plug wires caps are pushed down all the way so they engage onto the spark plugs 22 Install the throttle body assembly and connect fuel lines Install throttle cable retaining clip 23 Secure wire harness in the routing clip on the rear cross m...

Page 118: ...aded fuel which has a minimum pump octane number of 87 R M 2 2 Check oil level indicated on dipstick Add oil if necessary Refer to Engine Oil Level page 3 19 procedure 3 Drive slowly at first to gradually bring engine up to operating temperature 4 Vary throttle positions Do not operate at sustained idle or sustained high speed 5 Perform regular checks on fluid levels controls and all important bol...

Page 119: ...ce Manual Copyright Polaris Industries Inc 3 33 6 Upon assembly torque the crankcase gallery plug to specification TORQUE Crankcase Oil Gallery Plug M20 22 ft lbs 30 Nm TORQUE Crankcase Oil Gallery Plug 1 2 NPT 16 ft lbs 22 Nm ENGINE COOLING SYSTEM ...

Page 120: ...3 34 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc ENGINE OIL FLOW CHART ENGINE COOLING SYSTEM ...

Page 121: ... prevent anything from falling into the combustion chamber CAMSHAFT REMOVAL NOTICE 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 lobes should face out q and the slots on the end of the camshafts should line up 2 Remove the cam chain tensioner w from th...

Page 122: ...the camshafts to allow each sprocket to be removed 8 Using a paperclip or other tool hold cam chain up to keep it from falling down into the crankcase NOTICE The crankcase has a built in lower guide to prevent the chain from falling off the crankshaft 9 Evenly loosen the four bolts retaining each rear camshaft carrier a and carefully lift the carriers off the camshafts 10 Mark the intake s and exh...

Page 123: ... if any part is worn past the service limit MEASUREMENT Camshaft Lobe Height Intake 1 5390 1 5429 39 09 39 19 mm Service Limit 1 5370 39 04 mm Exhaust 1 5142 1 5181 38 46 38 56 mm Service Limit 1 5122 38 41 mm 3 Visually inspect each camshaft journal for scoring wear or damage 4 Measure the diameter of the camshaft journals using a micrometer Compare to specification NOTICE Replace camshafts if da...

Page 124: ...39 0 1 mm CYLINDER HEAD REMOVAL NOTICE The cylinder head can be serviced with the engine installed in the chassis 1 Remove the two outer M6 bolts q that retain the cylinder head w to the cylinder 2 Loosen the six cylinder head bolts e evenly 1 8 turn at a time until all are loose 3 Remove and discard the cylinder head bolts 4 Tap cylinder head lightly with a soft faced hammer until loose 5 Tap onl...

Page 125: ...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 MEASUREMENT Cylinder Head Warp Limit 0039 0 1 mm CYLINDER HEAD DISASSEMBLY WARNING Wear eye protection during cylinder head disassembly and reassembly or when working with the valve springs NOTICE Keep mated parts together and in or...

Page 126: ...ion 6 Lift up the cylinder head and push the valve i 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 9 Check the condition of each valve spring Replace if wear or cracking is present on the spring VALVE INSPECTION 1 Remove all carbon from valves with a soft wire wheel or...

Page 127: ...Valve Guide I D 2165 2171 5 500 5 515 mm 7 Be sure to measure each guide and valve combination individually NOTICE 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 q NOTICE Carbon Clean Fuel Treatment 2871326 can be used to help remove c...

Page 128: ...e circumference 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 i...

Page 129: ...he 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 seat is too narrow widen using the 45 cutter and re check contact point on the valve face and seat width after each cut NOTICE When using an interference angle the seat contact poi...

Page 130: ...er based lapping compound to the face of the valve NOTICE 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 seat rotate 1 4 turn and rep...

Page 131: ...e 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 2 Carefully pry the stator cover off the engine using the two pry areas as shown 3 Inspect the condition of the stator windings q and output wires w If replacement is required refer...

Page 132: ...et and oil cooler Leave them all attached to the water pump housing 2 Remove the three long gold colored bolts q retaining the water pump housing to the engine 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 page 3 97 FLYWHEEL REMOVAL NOTICE The flywheel can be servic...

Page 133: ...an be serviced with the engine installed in the chassis 7 Remove the stator cover and flywheel see Chapter 3 Stator Cover Removal Inspectionpage 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 Insp...

Page 134: ...eplace the clutch and starter gear as an assembly CRANKCASE DISASSEMBLY INSPECTION 1 Remove the four screws retaining the oil cooler q to the crankcase 2 Remove the crankcase drain plug w Drain any oil remaining in the engine Reinstall the plug 3 Remove the oil filter 4 Install the Cylinder Holding Camshaft Timing Plate PU 50563 e onto the cylinder The cylinder holding tool retains the cylinder an...

Page 135: ...ove the pump drive sprocket NOTICE 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 d for wear or damage Replace oil pump drive chain and sprocket if worn or damaged If any part of the oil pump is ...

Page 136: ...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 Inspectionpage 3 48 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 w and remov...

Page 137: ...VAL INSPECTION 1 Perform Crankcase Disassembly Inspectionpage 3 48 procedure 2 Perform Balance Shaft Removal Inspectionpage 3 50 procedure 3 For ease of assembly mark each connecting rod and end cap 4 Loosen remove and discard the four connecting rod bolts q Remove the end caps from the crankshaft 5 Carefully lift the crankshaft w out of the crankcase 6 Remove the cam chain e oil pump drive chain ...

Page 138: ... main journal and connecting rod journal in two locations 90 degrees apart Replace crankshaft if any journal is worn below the service limit specification i MAG End d Journal 4 Rod Bearing o Journal 1 Main Bearing f Journal 5 Main Bearing a Journal 2 Rod Bearing g Journal 6 Main Bearing s Journal 3 Main Bearing h PTO End 12 Refer to the six letters stamped onto the PTO end of the crankshaft 13 Use...

Page 139: ...re installing the original refer to the bearing selection chart provided in the Crankshaft Main Bearing Selectionpage 3 61 and Connecting Rod Bearing Selectionpage 3 61 procedures CRANKCASE INSPECTION 1 Remove the oil drain diverter q from the upper crankcase 2 Remove all traces of crankcase sealer from the crankcase mating surfaces Inspect the surfaces closely for nicks burrs or damage 3 Be sure ...

Page 140: ...eeds the service limit replace the cylinder MEASUREMENT Cylinder Warp Limit 002 0 05 mm 2 Inspect cylinder for wear scratches or damage NOTICE DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing 3 Inspect cylinder for taper and out of round with a dial bore gauge Measure in two different directions front to back and side to side on three levels 0 59 down from top the middle...

Page 141: ...NGINE DISASSEMBLY INSPECTION BOTTOM ENDpage 3 45 and the procedures 2 Rotate the engine so the cylinder is facing up 3 Remove the Cylinder Holding Camshaft Timing Plate PU 50563 q from the cylinder 4 Carefully lift the cylinder and pistons from the upper crankcase 5 Remove the piston connecting rod assemblies from the cylinder NOTICE If the pistons are to be reused mark the pistons so they are rea...

Page 142: ...1 20 009 20 018 mm Service Limit 7893 20 05 mm 4 Measure piston pin O D in two directions 90 apart at three locations on the length Replace piston and piston pin if out of specification MEASUREMENT Piston Pin O D 7873 7875 20 000 20 005 mm Service Limit 7866 19 98 mm PISTON RING REMOVAL 1 Carefully remove top compression ring q by hand or using a ring removal pliers CAUTION DO NOTexpand the ring m...

Page 143: ...t 0047 0 12 mm PISTON RING INSTALLED GAP 1000 1 Place each piston ring q inside the cylinder w Use the piston to push the ring squarely into cylinder as shown below 2 Measure installed gap with a feeler gauge e at both the top and bottom of the cylinder NOTICE A difference between top and bottom end gap measurements is a general indication of cylinder taper wear The cylinder should be measured for...

Page 144: ...connecting rod are serial numbers used to match the rod cap w with the rod stem e 2 The number r and letter t stamped onto the exhaust side of the connecting rod represent the bore diameter and weight grading of the connecting rod 3 Inspect the small end and big end of connecting rod and matching rod cap for damage galling of surface or pitting 4 Measure small end I D in two directions as shown Re...

Page 145: ...g rod This number represents the bore diameter 9 The table below lists the big end bore diameter specifications Bearing Selection Chart Rod Bearings 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 10 Whether using new connecting rods or re installing the original ones refer to the bearing selection chart provi...

Page 146: ...CATION LETTERS AND NUMBERS q Connecting Rod Bearing Identification Number one number w Crankcase Bearing Identification Number six numbers Some engines may only have 4 digits The extra two digits will refer to the balance shaft bearings which should now all be standard e Crankshaft Bearing Identification Letters six letters ENGINE COOLING SYSTEM ...

Page 147: ...Rod 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 i and match that up with the main journal letters on the crankshaft u In this example you would use the number 2 as the crankcase codes case journals 1 2 3 4 You...

Page 148: ...ths 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 NOTICE Apply clean engine oil to all ring surfaces and ring lands upon installation Always check piston ring installed gap before rings are i...

Page 149: ... second ring with marking facing top of piston Rotate ring to position the end gap toward intake side of piston as shown below 5 Install top ring with mark facing top of piston Rotate ring to position the end gap toward exhaust side of piston as shown below 6 Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand ENGINE COOLING SYSTEM ...

Page 150: ...ting rods orientate the rods the same as when removed If new connecting rods are being installed they can be installed either way there is no piston pin offset in the rod however it is recommended they be installed with rods facing the same direction 3 Place piston q on connecting rod w Push piston pin e through rod and piston until it seats against the installed circlip NOTICE Do not tap on pin o...

Page 151: ...on see Chapter 3 Piston Ring Installationpage 3 62 3 Note the piston orientation mark arrow located on top of the piston Arrow should point toward the exhaust side NOTICE Orientation arrow is also located on the bottom side of piston as an additional reference 4 Carefully compress the piston rings with your fingers and install the piston assemblies into the cylinder from the bottom side Use piston...

Page 152: ...npage 3 61 1 Rotate the engine so the cylinder is facing down 2 Clean the bearing bore surfaces of upper crankcase main bearings connecting rods and connecting rod caps 3 Align tab of new main bearing q 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 w with the slot in the connecting rod ...

Page 153: ...crankcase 11 Clean bolt hole threads in connecting rod to remove all oil 12 Install matching rod cap on connecting rod with 3 digit serial number stampings aligned w e 13 Install new bolts s and tighten evenly until snug 14 Torque connecting rod bolts to specification TORQUE Connecting Rod Bolts Step 1 9 ft lbs 12 Nm Step 2 13 ft lb 18 Nm Step 3 Tighten add n 105 BALANCE SHAFT INSTALLATION 1 Clean...

Page 154: ...aring inserts have rotated in the case 4 Be sure alignment pins are in place where used 5 Refer to Engine Oil Flow Chartpage 3 34 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...

Page 155: ...se of any gaps 9 Install the eight M10 t two M8 u and one M6 y lower crankcase bolts Tighten all bolts lightly by hand NOTICE Install new M10 lower crankcase bolts 10 Torque lower crankcase bolts in sequence to specification Repeat sequence to verify final torque TORQUE Lower Crankcase Bolts M10 Bolts 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 156: ... pump drive chain and install the oil pump 17 Install dowel pins a into oil pump mounting holes 18 Install the three bolts f that retain oil pump d to the crankcase Torque mounting bolts to specification TORQUE Oil Pump Mounting Bolts 7 ft lbs 10 Nm 19 Reinstall oil pump pick up s Torque mounting screws to specification TORQUE Oil Pump Pick Up Retaining Screws 7 ft lb 10 Nm 20 Clean the gasket sea...

Page 157: ...e crankcase 24 Torque the oil sump cover bolts in sequence to specification Repeat the sequence to verify final torque TORQUE Oil Sump Cover Bolts M8 Bolts 26 ft lb 35 Nm M6 Bolts 106 in lb 12 Nm 25 Install the crankcase drain plug if previously removed Torque drain plug to specification TORQUE Crankcase Drain Plug 12 ft lbs 16 Nm 26 Install the oil cooler l Use new O rings 1 upon installation Tor...

Page 158: ...damage is present Clean taper of crankshaft to remove all oil or grease 3 Using an applicator apply a 360 degree bead of Loctite 641 Yellow to the internal taper surface on the flywheel Apply Loctite bead 5 6 mm from the center of the taper offset to the larger diameter of the taper on the flywheel 4 Using an applicator apply a 360 degree bead of Loctite 641 Yellow to the external taper surface on...

Page 159: ...assembly 2 Install a new stator 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 TORQUE Stator Cover ...

Page 160: ... CAUTION Valve seals should be installed AFTER the valves are in the head to avoid valve seal damage 5 Dip the valve spring e and retainer r in clean engine oil 6 Install the valve spring with widely spaced coils y on the top and tightly spaced coils u facing down toward the cylinder head IMPORTANT Valve springs to be installed with paint mark facing up i 7 Place the valve retainer on the spring 8...

Page 161: ...der Holding Camshaft Timing Plate PU 50563 q from the cylinder NOTICE Once the cylinder head is removed nothing retains the cylinder to the engine DO NOT rotate the engine without using the Cylinder Holding Camshaft Timing Plate PU 50563 3 Prepare cylinder head gasket sealing surfaces by cleaning thoroughly to remove all residue The head gasket must be installed clean and dry free from oil or grea...

Page 162: ...heel Top Dead Center TDC mark q is aligned or centered in the Crankshaft Position Sensor CPS mounting hole w This places the PTO cylinder at TDC for camshaft installation NOTICE DO NOT use the V mark located on the flywheel opposite of the I mark Only the I mark should be used as a TDC reference 2 Reference the intake and exhaust markings made during disassembly If installing new camshafts or if c...

Page 163: ...re it is engaged with the drive sprocket on the crankshaft 10 While lifting the cam chain up engage the cam sprockets 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 Chapter 3 Camshaft Timing Quick Referencepage 3 80 NOTICE Intake cam sprocket should have I marks aligned with gasket su...

Page 164: ... Cylinder Holding Camshaft Timing Plate PU 50563 from the end of the camshafts 16 Rotate the engine using the flywheel and install the remaining bolt in each camshaft sprocket Torque the sprocket bolts to specification TORQUE Camshaft Sprocket Bolts 14 ft lb 19 Nm 17 Rotate the engine using the flywheel and torque the remaining sprocket bolts to specification 18 Install the front camshaft carrier ...

Page 165: ...IONER ONLY Install the cam chain tensioner s into the cylinder and torque to specification TORQUE Hydraulic Cam Chain Tensioner 29 ft lb 40 Nm 23 MECHANICAL TENSIONER ONLY Retract the plunger all the way in and install into the cylinder Install the two mounting bolts Torque fasteners to specification TORQUE Tensioner Mounting Bolts 7 ft lb 10 Nm Install the plunger bolt Torque fastener to specific...

Page 166: ...G QUICK REFERENCE q Intake Cam r Align marks with surface w Exhaust Cam t CPS Mounting Hole e Align marks with surface y Align Flywheel Mark in Mounting Hole IMPORTANT DO NOT use the V mark located on the flywheel opposite of the I mark Only the I mark should be used as a TDC reference ENGINE COOLING SYSTEM ...

Page 167: ...afts Carrier openings should face each other when installed properly 5 Install the four bolts r that retain each rear camshaft carrier t and tighten the bolts evenly to specification TORQUE Camshaft Carrier Bolts 7 ft lb 10 Nm 6 Rotate the camshaft until the cam lobes above the valves you are inspecting are facing up y 7 Measure the valve clearance u using a thickness feeler gauge Record the measu...

Page 168: ...ave been adjusted 16 Reinstall the camshafts and camshaft carriers and tighten the bolts evenly to specification TORQUE Camshaft Carrier Bolts 7 ft lb 10 Nm 17 Measure and confirm that valve clearance is now within specification for each valve 18 If valve clearance is not within specification repeat this procedure 19 If all valve clearance measurements are now within specification remove the camsh...

Page 169: ...ion and Measured Valve lash must be calculated in millimeters mm 1 Subtract the actual valve lash on the engine from the valve lash specification i e 0 29 mm 0 20 mm 0 09 mm 2 Divide the 3 digit tappet number by 100 i e 450 100 4 5 mm 3 Add the results of step 1 and step 2 i e 0 09 mm 4 5 mm 4 59 mm 4 Multiply that answer by 100 to obtain the correct new tappet i e 4 59 mm x 100 459 5 Refer to the...

Page 170: ...0 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 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 0 475 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 53...

Page 171: ...bly to the rear upper close off panel and the frame of the vehicle 5 Remove the clamp holding the air box intake duct to the air box assembly Remove the air box and engine intake hose assembly from the vehicle 6 Elevate and support front of vehicle CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 7 Remove the main skid plate ...

Page 172: ... hood liner Torque to specification TORQUE Intake Duct Clamps 3 lb ft 4 Nm 3 Install the hood onto the vehicle Refer to Hood Installation page 10 56 procedure 4 With the skid plate removed install the floor intake duct into position and install the fasteners 2 holding the floor intake duct to the vehicle Install the clamps 1 holding the engine and clutch intake ducts to the floor intake duct Torqu...

Page 173: ...h in Electronic Throttle Control ETC inlet preventing anything from entering engine Install the clamp holding the engine intake hose to the ETC Torque to specification TORQUE Engine Intake Hose Clamp 49 lb in 5 5 Nm 10 Lower the cargo box and secure in position EXHAUST REMOVAL 1 Pull the cargo box handle and lift out of the way 2 Remove the fasteners holding the headpipe assembly to the engine 3 D...

Page 174: ... the engine Torque fasteners to specification TORQUE Exhaust Headpipe Fasteners 18 lb ft 24 Nm 3 Connect the oxygen sensor to the wiring harness 4 If necessary install the fasteners holding the headpipe to silencer Torque fasteners to specification TORQUE Exhaust Headpipe to Silencer Fasteners 21 lb lb 28 Nm 5 Install the spring holding the silencer to the vehicle 6 Lower the cargo box and secure ...

Page 175: ...SERVICE COOLING SYSTEM ASSEMBLY VIEW q Thermostat housing y Filler Neck s Oil Cooler Inlet Hose w Water Pump u Radiator d Oil Cooler Outlet Hose e Engine Hoses i Pressure Cap f Bypass Hose r Lower Radiator Hose o Upper Radiator Hose g Water Pump Outlet Hose t Fan Assembly a Recovery Bottle ENGINE COOLING SYSTEM ...

Page 176: ...ratio depending on freeze protection required in your area CAUTION Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation resulting in possible engine damage Polaris Premium 60 40 Antifreeze Coolant is recommended for use in all cooling systems and comes pre mixed ready to use COOLING SYSTEM PRESSURE TEST 1 Remove the ho...

Page 177: ... pressure cap tester commercially available 3 The pressure cap relief pressure is 13 psi Replace cap if it does not meet this specification COOLING SYSTEM HOSE REPLACEMENT 1 Inspect cooling system hoses for cracks deterioration abrasion or leaks Refer to Cooling System Hosespage 2 22 topic 2 Replace coolant hose and torque hose clamps to specification TORQUE Coolant Hose Clamp 35 lb in 4 Nm 3 If r...

Page 178: ...ngine to cool before servicing 4 Disconnect cooling fan electrical connector 5 Remove the upper radiator hose from the radiator 6 Remove the four upper radiator support fasteners w and disconnect the small radiator bypass hose e 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 f...

Page 179: ...r bolt w retaining the thermostat cover 6 Remove the cargo box access panel 7 Using an 8 mm swivel socket and long extension remove the front bolt e retaining the thermostat cover 8 Lift the cover from the housing and remove the thermostat NOTICE Thermostat has a pop off relief to allow the bypass system to operate until thermostat opens 9 Install a new thermostat with the bleed hole r positioned ...

Page 180: ...ount of Polaris Premium Antifreeze to the radiator filler neck 5 Remove the seats engine service panel and divider panel heat shield to access the coolant bleed screw 6 Open the bleed screw e to allow any trapped air to escape Close the bleed screw once a steady stream of coolant begins to drain out 7 Tighten the bleed screw to specification top off coolant and properly install the pressure cap TO...

Page 181: ...hoses that are attached to the water pump Note location and routing for installation Be sure to catch and dispose of coolant properly 11 Remove the three bolts q w retaining water pump to engine block Note different bolt lengths for installation 12 Remove water pump from engine by gently twisting and rocking the water pump housing while pulling outward 13 Maneuver water pump downward and remove it...

Page 182: ...drive tab and slot are properly engaged 10 Install the three water pump mounting bolts t y and torque to specification NOTICE Install different bolt lengths as shown TORQUE Water Pump Mounting Bolts 7 lb ft 10 Nm Apply Loctite 204 to bolt threads 11 Install the four coolant hoses u a that attach to the water pump Be sure orientation and routing are correct 12 Install the right rear lower shock bol...

Page 183: ...ter pump shaft 6 Using an appropriate arbor press properly support the water pump housing and press out the water pump shaft from the impeller side 7 Extract the mechanical seal and the oil seal from the water pump housing CAUTION A 5 32 4 mm diameter punch y will fit in the lubrication slot to aid in the removal of the oil seal Be sure not to damage the water pump shaft bearing surface 8 Inspect ...

Page 184: ...te 204 to the threads of the impeller bolt Install washer and impeller bolt and torque to specification TORQUE Water Pump Impeller Bolt 7 lb ft 10 Nm Apply Loctite 204 to bolt threads 18 Clean cover q and housing gasket surfaces w 19 Install a new water pump cover gasket e 20 Install the water pump cover and three retaining bolts i Torque bolts in sequence to specification TORQUE Water Pump Cover ...

Page 185: ... Service Manual Copyright Polaris Industries Inc 3 99 Water Pump Assembly View o Bolt f Washers k Oil Seal a Loctite 204 g Drive Tab l Impeller s Mechanical Seal h Water Pump Shaft 1 Washer d O Rings j Water Pump Housing ENGINE COOLING SYSTEM ...

Page 186: ...estricted fuel supply Low compression Crankcase breather restricted Engine Idles But Will Not Accelerate Spark plug fouled weak spark Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Incorrect ignition timing Restricted exhaust system Cam worn excessively Engine Has Low Power Spark plug fouled Cylinder piston ring or valve wear or damage check compres...

Page 187: ...LING SYSTEM Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiator lines pump or water jacket accident damage Lean mixture vents fuel pump or fuel valve Fuel pump output weak Electrical malfunction Water pump failure Loose impeller...

Page 188: ...3 102 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc NOTES ENGINE COOLING SYSTEM ...

Page 189: ...URGE VALVE REPLACEMENT 4 10 PURGE VALVE OHM TEST 4 10 FUEL LINES 4 11 FUEL LINE ROUTING 4 11 FUEL LINE ROUTING GENERAL 4 4 13 FUEL LINE ROUTING EVAP MODELS 4 15 FUEL LINE ROUTING GENERAL 4 EVAP MODELS 4 19 VENT LINE TERMINATION FITTING 4 23 FUEL LINE QUICK CONNECT REMOVAL 4 23 FUEL INJECTOR 4 25 FUEL INJECTOR OPERATION OVERVIEW 4 25 FUEL INJECTOR OVERVIEW 4 25 FUEL INJECTOR O RINGS 4 25 FUEL INJEC...

Page 190: ... issues a known good ECU from another POLARIS of the same model and year may be used without damaging system or engine components Never attempt to service any fuel system component while engine is running or ignition switch is on Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system Dirt even in small quantities can cause significant problems Do n...

Page 191: ...d pressure relief valve that can be used to bleed off pressure once you have completed the fuel pressure test TORQUE SPECIFICATIONS FUEL SYSTEM PART DESCRIPTION TORQUE SPECIFICATION Seat Base Frame Front Fasteners 10 lb ft 14 Nm Seat Base Frame Rear Fasteners 30 lb ft 41 Nm Close Off Panel Fasteners 3 5 lb ft 5 Nm Console Fasteners 3 5 lb ft 5 Nm Fuel Pump Nut 70 lb ft 95 Nm Fuel Rail Mounting Bol...

Page 192: ...ies Inc ASSEMBLY VIEWS FUEL SYSTEM FUEL SYSTEM ASSEMBLY VIEW q Vent Termination Fitting i Fuel Cap w Routing Clip Hinged o Fuel Tank Assembly e Fuel Vent Line a PFA Nut r Fuel Feed Line s Fuel Pump Cap t Harness Clip d Fuel Sender y Routing Clip f Fuel Vent u Fuel Fill Neck FUEL SYSTEM ...

Page 193: ... Mount 2 Hinged Routing Clip r Fuel Pump Assembly f Carbon Canister 2 Vent Line Termination Fitting t PFA Nut 70 lb ft 95 Nm g Carbon Canister to Canister Filter Line 2 Purge Valve Fasteners y Routing Clip h Carbon Canister Filter 2 Purge Valve Bracket u Fuel Feed Line j Carbon Canister Filter Mount 2 Purge Valve i Vent Rollover Valve k Carbon Canister Filter Fastener 2 Purge Valve to Throttle Bod...

Page 194: ...19 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc FUEL PUMP ASSEMBLY VIEW q Fuel Pump r Fuel Level Sensor w Fuel Pressure Regulator t Float Arm Assembly e Wire Harness Connector y Pickup Filter FUEL SYSTEM ...

Page 195: ...osest to the charcoal canister and the ATM side is the end where air enters first If the air filter becomes plugged or restricted fuel vapors will not properly flow through the air filter to the charcoal canister and purge valve The EVAP lines are multi layer formed lines that have low permeability If a line needs replacement be sure to replace the line with its direct replacement It is critical t...

Page 196: ... will NOT trigger a trouble code but may cause a fuel odor Excessive hydrocarbon emissions may be caused by any of the following An ignition misfire Improper ignition timing Excessively lean or rich air fuel mixture Low Compression Worn valves or guides Worn cylinder or piston rings Vacuum leaks Dirty fuel injector Defective sensor or damaged sensor wiring Excessive carbon monoxide emissions may b...

Page 197: ...rbon canister filter 6 Installation is performed by reversing the removal procedure TORQUE Carbon Canister Filter Fasteners 72 in lbs 8 Nm 7 Reinstall rear lower close off panel and center council Reference page 10 43 8 Reinstall seats See page 10 56 CARBON CANISTER REPLACEMENT NOTICE 2019 models only 1 Remove seats See page 10 25 2 Remove center council and rear lower close off panel by referenci...

Page 198: ...ng page 10 35 3 Remove lines connected to purge valve q 4 Disconnect purge valve electrical connector w 5 Remove purge valve from the bracket 6 Install new purge valve onto its bracket 7 Installation is performed by reversing the removal procedure 8 Reinstall rear lower close off panel and center council Reference page 10 43 9 Reinstall seats See page 10 56 PURGE VALVE OHM TEST Use a multimeter to...

Page 199: ...016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 4 11 FUEL LINES FUEL LINE ROUTING Fuel Feed Line Routing q Fuel Pump Assembly e Harness Clip Interlock w Routing Clip r Fuel Rail FUEL SYSTEM ...

Page 200: ... 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc Fuel Vent Line Routing q Fuel Vent r Routing Clip Hinged w Routing Clip t Vent Line Termination Fitting e Harness Clip Interlock FUEL SYSTEM ...

Page 201: ...929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 4 13 FUEL LINE ROUTING GENERAL 4 Fuel Feed Line Routing q Routing Clip w Harness Clip e Fuel Rail Fitting FUEL SYSTEM ...

Page 202: ...14 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc Fuel Vent Line Routing q Routing Clip w Harness Clip e Routing Clip Hinged r Vent Termination Fitting FUEL SYSTEM ...

Page 203: ...2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 4 15 FUEL LINE ROUTING EVAP MODELS Fuel Feed Line Routing q Fuel Pump Assembly e Panduit Strap w Routing Clip Hinged r Fuel Rail FUEL SYSTEM ...

Page 204: ...4 16 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc Purge Line Routing FUEL SYSTEM ...

Page 205: ...R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 4 17 q Fuel Vent t Purge Valve w Routing Clip Hinged y Panduit Strap e Carbon Canister u Throttle Body r Panduit Strap i FUEL SYSTEM ...

Page 206: ...ual Copyright Polaris Industries Inc Fuel Vent Line Routing q Fuel Vent t Canister Filter w Routing Clip Hinged y Panduit Strap e Carbon Canister u Routing Clip Hinged r Carbon Canister to Canister Filter 5 16 Hose i Vent Line Termination Fitting FUEL SYSTEM ...

Page 207: ...2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 4 19 FUEL LINE ROUTING GENERAL 4 EVAP MODELS Fuel Feed Line Routing q Fuel Pump Assembly e Panduit Strap w Routing Clip Hinged r Fuel Rail FUEL SYSTEM ...

Page 208: ...4 20 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc Purge Line Routing FUEL SYSTEM ...

Page 209: ... R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 4 21 q Fuel Vent t Purge Valve w Routing Clip Hinged y Panduit Strap e Carbon Canister u Throttle Body r Panduit Strap FUEL SYSTEM ...

Page 210: ...ual Copyright Polaris Industries Inc Fuel Vent Line Routing q Fuel Vent t Canister Filter w Routing Clip Hinged y Panduit Strap e Carbon Canister u Routing Clip Hinged r Carbon Canister to Canister Filter 5 16 Hose i Vent Line Termination Fitting FUEL SYSTEM ...

Page 211: ...roperly used fuel line quick connects can be disconnected and reconnected multiple times for vehicle service needs If the quick connect is damaged it is not designed to be serviceable and the fuel line assembly will require replacement There are two methods of disconnecting Fuel line quick connects the preferred method is by using a small straight blade screwdriver Screwdriver Method 1 Insert a 1 ...

Page 212: ...eeds Indicators that the quick connect is damaged and assembly replacement is needed 1 The retaining clip can be closed without the insertion of a hard line end The retaining clip is designed to lock only when a hard line end has been fully inserted 2 Retaining tabs are deformed and no longer lock into the body of the quick connect 3 Broken retaining tabs or any sign of cracks in the retaining cli...

Page 213: ...uel injection FUEL INJECTOR OVERVIEW The fuel injector q is mounted into the cylinder head with the fuel rail w retaining it from the top end O rings on both ends of the injector prevent external fuel leaks and also insulate the injectors from heat and vibration When the key switch is on the fuel rail is pressurized and the EFI relay provides voltage to the injectors During engine operation the EC...

Page 214: ...h the ignition on lnjector s will open turn on if relay is energized If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows Injector leakage is very unlikely but in rare instances it can be internal past the tip of the valve needle or external weeping around the injector body The loss of system pressure from the leakage can ...

Page 215: ...tance Specification 11 4 12 6 Ω NOTICE 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 1 Lift the cargo box assembly 2 Be sure the engine has cooled enough to work on 3 Loosen the hose clamps q retaining the intake plenum w to the throttle body 4 Remove the two screws e retaining th...

Page 216: ... the two screws y that mount the fuel rail to the throttle body using a 5 mm Allen wrench 9 Carefully pull up on the fuel rail u and injectors and remove them from the throttle body as an assembly Take care not to damage the fuel injector ends during removal 10 Pull out on the fuel injector retaining clip and pull the injector out of the fuel rail Repeat on the other injector if removal is necessa...

Page 217: ... lead to the MAG injector to ensure proper engine operation 18 Use a tie strap to retain the harness leads to the fuel rail 19 Reconnect the negative battery cable and reinstall the driver s seat 20 Turn key on to allow the fuel system to prime and inspect the fuel rail and injectors for fuel leaks 21 Reinstall the intake plenum assembly and fasten the lower mount to the transmission mount bracket...

Page 218: ...ce the fuel line back over the fitting and slide the green connector locking mechanism back into place Verify the connector tabs snap back into place 7 Be sure fuel line is routed and retained properly 8 Ensure PFA cap is fully seated over PFA nut FUEL TANK REMOVAL NOTICE Syphon as much fuel from the tank as possible before attempting to remove it from the vehicle WARNING Always wear safety goggle...

Page 219: ...uel may come out of the fuel lines or pump fitting Properly drain fuel into a suitable container 5 Disconnect the fuel pump electrical harness w 6 Remove the fuel cap 7 Remove the interior body components down to the rear lower close off panel Refer to Interior Body Component Removal page 10 35 procedure 8 Remove the fasteners holding the seat base assembly to the vehicle 9 Lift the rear of the fu...

Page 220: ... Close off Panel Fasteners 3 5 lb ft 5 Nm 5 Reinstall center console Connect the shift linkage to the shifter 6 Install RH and LH center console sides Torque fasteners to specification TORQUE Console Fasteners 3 5 lb ft 5 Nm 7 Reconnect the fuel line and fuel pump electrical harness Verify connections are secure NOTICE If equipped re install the rubber fuel pump cover 8 Reinstall the battery and b...

Page 221: ...er float to sit in the EMPTY position and compare to specification 4 Slowly move the sender float to the FULL position and compare to specification 5 If the readings are out of specification or if the reading is erratic or LCD display sticks check the following before replacing the fuel pump assembly Loose float Float contact with tank Bent float rod 6 If none of the conditions exist the fuel send...

Page 222: ...ntinuity between the pump terminals replace the fuel pump assembly 8 If voltage at the plug was within the specified range and there was continuity across the pump terminals reconnect the plug to the fuel pump making sure you have a clean connection Turn on the key switch and listen for the pump to activate NOTICE If the pump starts repeat steps 3 4 and 5 to verify correct pressure 9 If the pump s...

Page 223: ... 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 of one hour after shutting off the engine before servicing the fuel pump This allows the exhaust to cool and fuel pressure to drop NOTICE A small amount of fuel may come out of the fuel lines or pump fitting Properly drain fuel into a suitable container 7 D...

Page 224: ...unt of clean fuel Do not use water or any other chemicals to remove debris 12 Remove new fuel pump assembly t gasket y and nut u from packaging Use care not to bend float arm i during un packaging Do not lift or carry fuel pump assembly by the float arm 13 Use cleaning wipes provided to clean fuel tank surface and threads o Remove all debris grease and oil Allow surfaces to dry completely 14 Insta...

Page 225: ... Pump Nut 70 lb ft 95 Nm 20 Verify alignment of fuel pump orientation marks 21 Connect the fuel supply line to the pump Refer to Fuel Line Replacement page procedure NOTICE Be sure to engage the retainers on each fuel line until each snaps into place Pull on fuel lines lightly to confirm connection 22 If equipped reinstall the rubber fuel pump cover 23 Install the fuel tank vent line onto the tank...

Page 226: ... misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug 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 war...

Page 227: ...0 PVT SYSTEM MAINTENANCE INSPECTION 5 10 PVT SYSTEM OVERHEATING DIAGNOSIS 5 11 PVT SYSTEM SERVICE 5 12 PVT DISASSEMBLY 5 12 PVT ASSEMBLY 5 13 DRIVE BELT SERVICE 5 15 DRIVE BELT REMOVAL 5 15 DRIVE BELT INSPECTION 5 15 DRIVE BELT INSTALLATION 5 16 DRIVE CLUTCH SERVICE 5 17 DRIVE CLUTCH DISASSEMBLY INSPECTION 5 17 NEEDLE BEARING INSPECTION 5 18 SHIFT WEIGHT INSPECTION 5 19 BUTTON TO TOWER CLEARANCE I...

Page 228: ...R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc DRIVEN CLUTCH DISASSEMBLY 5 31 DRIVEN CLUTCH ASSEMBLY 5 33 TROUBLESHOOTING PVT SYSTEM 5 35 PVT SYSTEM TROUBLESHOOTING 5 35 PVT SYSTEM ...

Page 229: ...backshift During the development of the Polaris vehicle the PVTsystem is matched first 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 SPECIAL ...

Page 230: ...mL Loctite 620 Drive Clutch Cover Bolts 9 lb ft 12 Nm Driven Clutch Spring Retaining Ring Bolts 12 lb ft 16 Nm SERVICE SPECIFICATIONS PVT SYSTEM PART DESCRIPTION SERVICE SPECIFICATION SERVICE LIMIT Drive Clutch Spring Part Number 7044263 Drive Clutch Spring Color Black Red Drive Clutch Spring Free Length 3 219 in 8 18 cm Drive Clutch Spring Part Number CREW 7044465 Drive Clutch Spring Color CREW B...

Page 231: ...SYSTEM PVT COVERS AND DUCT COMPONENTS q Band Clamp o Outlet Duct w Intake Hose a Outlet Duct Screen e Intake Hose Bracket s Inner Clutch Cover r Outer Clutch Cover d Inner Cover Seal t Outer Cover Screws f Intake Duct y Outer Cover Seal g Inlet Hose u Guard Plate h Clutch Cover Drain Screw i Outlet Hose PVT SYSTEM ...

Page 232: ...LUTCH ASSEMBLY VIEW q Washer Clutch a Pin Roller w Bearing Needle s Asm Roller and Bushing washer e Bearing d Nut Jam r Spacer Clutch Short f Spring Clutch t Bolt Shoulder g Cover Bearing y Weight Shift h Screw u Nut Flex Lock j Washer i Button Clutch k Screw o Washer Clutch Spider Roller PVT SYSTEM ...

Page 233: ...ht Polaris Industries Inc 5 7 DRIVEN CLUTCH ASSEMBLY VIEW q Shoulder Sleeve o Flanged Bearing w Ball Bearing a Spring r Roller Pin s Retaining Ring t Puck d Thrust Washer y Stationary Sheave f Clutch Roller u Spring Pin g Spider i Moveable Sheave h Screw PVT SYSTEM ...

Page 234: ... Copyright Polaris Industries Inc DRIVEN CLUTCH ASSEMBLY VIEW q Shoulder Sleeve i Spring w Bearing o Spider e Spring Pin a Roller r Slider s Washer t Slider Pin d E clip y Stationary Sheave f Helix Cam u Moveable Sheave g Helix Screws 48 in lb 5 Nm PVT SYSTEM ...

Page 235: ...ves inward and contacts the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive belt rotates low in the drive clutch sheaves As engine RPM increases centrifugal force causes the drive belt to be forced upward on drive clutch sheaves DRIVEN CLUTCH OPERATION Driven clutches primarily sense t...

Page 236: ...ystem 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 be inspected and maintained to ensure maximum performance and service life of PVT components Refer to the troubleshooting checklist at the end of this chapter for more information 1 Belt Inspection 2 Drive and Driven ...

Page 237: ...ge 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 PVT system Remove the PVT drain plug Shift the transmission to neutral Using the throttle vary the engine rpm from idle to full throttl...

Page 238: ... Remove the driven clutch retaining bolt and driven clutch 8 Install the Drive Clutch Holding Tool 9314177 A on the drive clutch 9 Remove the drive clutch retaining bolt and remove the drive clutch using Drive Clutch Puller 2872085 CAUTION Be sure to use the correct Drive Clutch Puller PN 2872085 to prevent damage to crankshaft 10 Remove the fasteners that secure the upper guard plate w to the top...

Page 239: ...6 Install the protective cover and the fasteners that secure the cover to the top of the inner PVTcover 7 Install the four inner clutch cover bolts and washers that retain the cover to the transmission Torque bolts to specification 8 Install the three inner clutch cover bolts and washers that retain the cover to the engine Torque bolts to specification TORQUE Inner Clutch Cover Bolts 10 lb ft 14 N...

Page 240: ...tation refer to Drive Belt Installation page 5 16 procedure If a new belt is installed install so numbers can be easily read 16 Install a new outer clutch cover seal with the colored stripe facing the inner clutch cover 17 Reinstall outer clutch cover and secure with screws Torque screws to specification TORQUE Outer Clutch Cover Screws 4 5 lb ft 6 Nm 18 Install inlet and outlet ducts and tighten ...

Page 241: ... clutch as shown tool included with vehicle s tool kit NOTICE Make sure the tool is square with the moveable sheave surface of the driven clutch 5 Rotate tool towards the clutch to open the sheaves 6 Walk the belt out of the driven clutch and drive clutch Remove the belt from the vehicle DRIVE BELT INSPECTION 1 Inspect belt for hour glassing extreme circular wear in at least one spot and on both s...

Page 242: ...2878925 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 to specification TORQUE Outer Clutch Co...

Page 243: ...ring clutch assembly IMPORTANT Upon reassembly if the reference marks created in step 2 are not in alignment 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 q The outer cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushi...

Page 244: ...tical components of the PVT system It is also one of the easiest to service Due to the severe relaxation the spring is subject to during operation it should always be inspected for tolerance limits during any clutch operation diagnosis or repair Check to see that spring coils are parallel to one another using a straight edge Distortion of the spring indicates stress fatigue requiring replacement N...

Page 245: ... with new bolts and nuts WARNING The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clutch assembly NOTICE 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 INSPECTION 1 Inspect the button to tower clearance as shown Replace the drive cl...

Page 246: ...Fixture PN 2871358 B 2 Loosen and remove the spider e counterclockwise using Clutch Spider Removal Installation Tool r Spider Removal Installation Tool 2870341 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 spots replace the drive cl...

Page 247: ...ust washers w 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 MEASUREMENT Shaft Diameter Standard 1 3725 1 3712 34 8615 34 8488 mm Service Limit 1 3704 34 808...

Page 248: ...EBS 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 IT...

Page 249: ...n Pin Puller 2870386 3 Remove nut from puller rod and set aside 4 Install puller adapter a from kit PN 2871226 5 Install main adapter Item D onto puller 6 With towers pointing toward the vise slide sheave onto puller rod 7 Install removal tool Item A B into center of sheave with A side toward sheave NOTICE Use Bushing Tool PA 47336 8 Install nut C onto end of puller rod and hand tighten Turn pulle...

Page 250: ...increase tension as needed 27 Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free 28 Remove nut from puller rod and set aside 29 Remove bushing and bushing removal tool from puller Discard bushing Cover Bushing Installation 30 Apply Loctite 648 evenly to bushing bore in the cover 31 Working from inside of cover insert new bushing and bushing installation ...

Page 251: ...sembly onto the shaft threads Be sure all of the alignment marks i are in alignment t Moveable Sheave Asm y Jam Nut u Spider 6 Install clutch onto holding fixture and secure in a bench vice Tighten the spider o using Clutch Spider Tool a Torque spider to specification Clutch Holding Fixture 2871358 A Clutch Spider Tool 2870341 TORQUE Spider Assembly 290 ft lb 393 Nm Apply 0 4 mL Loctite 7088 Prime...

Page 252: ... the clutch assembly from the holding fixture and inspect the alignment marks made during disassembly NOTICE If the marks illustrated below are 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 f and the clutch spring g CAUTION DO NOT reassemble the drive clutch without the limiter spacer Belt life will be ...

Page 253: ... 4 Remove the screwdriver from the driven clutch Insert the driven clutch retaining bolt to keep the washers aligned during clutch installation 5 Reinstall the driven clutch and drive belt 6 Test the vehicle to ensure proper operation DRIVEN CLUTCH DISASSEMBLY DISASSEMBLY 1 Remove driven clutch from the transmission input shaft 2 It is important to mark the position of the helix cover sheaves and ...

Page 254: ...t using a proper compressor may result in personal injury or damage to the clutch 5 Remove the universal clutch compressor 6 Note the alignment of the X s w on the spider and moveable sheave Remove the spider assembly e and spring NOTICE Spring is compression only and has no torsional wind 7 Remove the E clips r washers t and the clutch rollers y Inspect the rollers for wear replace if worn 8 Pres...

Page 255: ...y and fixed sheaves for reassembly 11 Inspect the clutch bushings for wear If there is heavy wear on the bushings replace the clutch assembly 12 Inspect the sheaves for excessive wear or damage DRIVEN CLUTCH ASSEMBLY 1 Align the X s q on the moveable and stationary sheaves 2 Install the square sliders w and slider pins e 3 Install the spring pins r to retain the slider pins PVT SYSTEM ...

Page 256: ...n the clutch and compress the helix cover CAUTION The helix cover is loaded by the spring Not using a proper compressor may result in personal injury or damage to the clutch 8 Align the marks previously made on the helix cover and moveable sheave Install the helix cover and the four fasteners a Torque fasteners to specification TORQUE Helix Retaining Screws 48 in lb 5 Nm 9 Once back together verif...

Page 257: ...f the slider block w Replace the sliders if they are smaller than the service limit MEASUREMENT Slider to Sheave Clearance q Service Limit 0 175 4 5 mm Slider Width w Service Limit 0 975 24 8 mm DRIVEN CLUTCH DISASSEMBLY 1 Remove driven clutch from the transmission input shaft 2 It is important to mark the position of the helix cover sheaves and spider with a tape or grease marker as shown before ...

Page 258: ...t using a proper compressor may result in personal injury or damage to the clutch 5 Remove the universal clutch compressor 6 Note the alignment of the X s w on the spider and moveable sheave Remove the spider assembly e and spring NOTICE Spring is compression only and has no torsional wind 7 Remove the E clips r washers t and the clutch rollers y Inspect the rollers for wear replace if worn 8 Pres...

Page 259: ...Inspect the clutch bushings for wear If there is heavy wear on the bushings replace the clutch assembly 12 Inspect the sheaves for excessive wear or damage DRIVEN CLUTCH ASSEMBLY 1 Align the X s q on the moveable and stationary sheaves 2 Install the square sliders w and slider pins e 3 Install the spring pins r to retain the slider pins 4 If removed install the rollers t washers y and E clips u on...

Page 260: ...ver CAUTION The helix cover is loaded by the spring Not using a proper compressor may result in personal injury or damage to the clutch 8 Align the marks previously made on the helix cover and moveable sheave Install the helix cover and the four fasteners a Torque fasteners to specification TORQUE Helix Retaining Screws 48 in lb 5 Nm 9 Once back together verify the grease tape marks made during di...

Page 261: ... above specified 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 prob...

Page 262: ...ned 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 nois...

Page 263: ... REMOVAL INSTALLATION 6 8 SHIFT CABLE INSPECTION 6 8 SHIFT CABLE ADJUSTMENT 6 9 TRANSMISSION SERVICE 6 10 TRANSMISSION REMOVAL 6 10 TRANSMISSION INSTALLATION 6 12 TRANSMISSION MOUNTING TORQUE VALUES 6 16 DIFFERENTIAL OPERATION 6 17 TRANSMISSION DISASSEMBLY 6 19 GEAR CLUSTER DISASSEMBLY 6 21 SNORKEL SHAFT REMOVAL DISASSEMBLY 6 22 PLANETARY DIFFERENTIAL DISASSEMBLY 6 24 PLANETARY DIFFERENTIAL BUSHIN...

Page 264: ...ferential is beneficial in low traction and rough terrain conditions Unlocking the rear differential makes maneuvering easier and minimizes damage to terrain SPECIAL TOOLS TRANSMISSION TOOL DESCRIPTION PART NUMBER Drive Clutch Puller 2872085 Clutch Center Distance Tool PU 50658 A Snorkel Tool PA 50231 Rear Output Seal Driver 2871698 Part of 2871702 Kit Rear Driveshaft Seal Guide 2871699 Part of 28...

Page 265: ...6 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 6 3 ASSEMBLY VIEWS TRANSMISSION TRANSMISSION ASSEMBLY VIEW 2016 2018 TRANSMISSION ...

Page 266: ...her 48 Case RH 82 Chain Silent 16 Pin Dowel 49 Drum Shift 83 Solenoid 17 Pin Spring 50 Gear Sector 16T 84 Switch Rotary 2 Pin 18 Retaining Ring External 51 Gear Sector 31T 85 O Ring 19 Snap Ring 52 Pawl Detent 86 O Ring 20 Retaining Ring External 53 Star Detent 87 O Ring 21 Retaining Ring External 54 Bearing Plain 88 Seal Triple Lip 22 Retaining Ring Internal 55 Shaft Idler 29T 89 Seal Dual Lip 23...

Page 267: ... Fork Retainer Fastener 9 ft lbs 12 Nm t Transmission Case Fastener QTY 14 20 ft lbs 27 Nm y Speed Sensor Fastener 10 ft lbs 14 Nm u Rear Mount Bracket Fastener QTY 2 20 ft lbs 27 Nm i Bearing Cover Fastener 9 ft lbs 12 Nm o Bearing Cover Fastener QTY 3 9 ft lbs 12 Nm a Ring Gear Fastener QTY 8 28 ft lbs 38 Nm s Bellcrank Nut 14 ft lbs 19 Nm d Sector Cover Fastener QTY 5 10 ft lbs 14 Nm f Park Pla...

Page 268: ...yright Polaris Industries Inc TRANSMISSION VENT LINE 2017 2018 The transmission vent line runs up towards the passenger frame rail and through an open section of the frame to a vent line termination fitting q Hose Clamp w Vent Line Termination Fitting TRANSMISSION ...

Page 269: ...ISSION VENT LINE ROUTING RETENTION 2019 The transmission vent line starts from the right hand side of the transmission where it is hose clamped q to a barb fitting The vent line then routes upward toward the rear of the unit where it enters an open section of the frame where it terminates TRANSMISSION ...

Page 270: ... Disconnect cable end from the lever 5 Remove the retaining ring J and slide the shift lever D off the mounting bracket and out from the frame 6 Remove both bushings K from the shift lever and service as needed 7 Perform the previous steps in reverse order to reinstall the shift lever lever cable dash panel shift knob SHIFT CABLE INSPECTION Shift cable adjustment may be necessary if symptoms inclu...

Page 271: ...e the upper jam nut F 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 NOTICE This procedure may require a few attempts to obtain the proper adjustment 6 Once the proper adjustment is obtained place the shift cable and upper jam nut into the mount Tig...

Page 272: ...ion Refer to Rear Drive Shaft Removal page procedure 6 Remove the outer clutch cover drive and driven clutch and inner clutch cover Refer to PVT Disassemblypage procedure CAUTION Be sure to use the correct Drive Clutch Puller 2872085 to prevent damage to crankshaft 7 Disconnect the harness from the T MAP sensor A ETC B fuel injectors C rear differential relay and solenoid D Remove the five plastic...

Page 273: ...3mm socket and wrench remove the fastener R securing the bottom of the intake plenum to the rear transmission mount 14 Using a long screwdriver loosen both hose clamps S that retain the intake plenum runners to the cylinder head intake adapters Remove the intake plenum and electronic throttle control as an assembly 15 Use an overhead or portable hoist to support the transmission by securing a stra...

Page 274: ...e straps to lower the transmission into the vehicle frame CAUTION Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components 2 Use the overhead or portable hoist to support the transmission by securing a strap A through the rear mount NOTICE Place a spacer or support between the vehicle frame and engine t...

Page 275: ...ight side IMPORTANT DO NOT torque fasteners at this time 7 Install the two bolts E and transmission joint retainer plate F on the right side Hand tighten the bolts so they remain loose at this time 8 Install the two longer bolts into left side mounting holes Torque left side mounting bolts to specification using the numbered sequence shown 9 Torque right side mounting bolts to specification using ...

Page 276: ...ters before tightening the hose clamps 15 Tighten the hose clamps to specification TORQUE Intake Plenum Hose Clamps 17 lb in 2 Nm 16 Install the fastener securing the bottom of the intake plenum to the rear transmission mount Torque fastener to specification TORQUE Lower Intake Plenum Fastener 22 lb ft 30 Nm 17 Wipe any dirt off the fuel line connector and the fuel rail Reconnect the fuel line to ...

Page 277: ...r clutch cover drive clutch driven clutch drive belt and outer clutch cover Refer to PVT Assemblypage procedure 26 Install both rear drive shafts Refer to Rear Drive Shaft Installation page procedure 27 Install the front propshaft Refer to Front Propshaft Removal Installation page procedure 28 Safely lower the vehicle 29 Install the rear cargo box assembly Refer to Cargo Box Installation page proc...

Page 278: ...6 16 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc TRANSMISSION MOUNTING TORQUE VALUES TRANSMISSION ...

Page 279: ...cal solenoid mounted in the rear portion of the gearcase actuates the shift fork The solenoid plunger extends out to move the fork and slides the engagement dog away from the side gear that is part of the planetary differential assembly This unlocks the rear differential The rear drive shafts are now dependent on the differential allowing for tighter turns When Differential Lock is selected power ...

Page 280: ...N q Ring Gear Assembly w Male Side Gear Assembly e Planet Gear Assembly r Female Gear Assembly t Differential Cover Assembly y Planetary Differential Assembly Fasteners u Engagement Dog i Bearing o Shift Fork Retainer Fastener a Torsion Spring s Retainer d Shift Fork f Solenoid Spring g Solenoid TRANSMISSION ...

Page 281: ...d by using your thumbs to press in on the shafts while pulling out the cover with your fingers 6 Remove the compression spring H 7 Remove the detent star I Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly 8 Remove the spacer J 9 Remove the shift shaft K detent pawl L and the shift sector gears M and N IMPORTANT Note the timing marks on the shi...

Page 282: ... 14 Remove the rear output shaft assembly S by lifting underneath the gear or by tapping the shaft from the opposite side If use of a pry bar is necessary take care not to pry on sealing surfaces of case 15 Remove the idler gear shaft assembly T and gear cluster assembly U from the transmission housing by pulling both assemblies straight up 16 Place the idler gear shaft assembly T and gear cluster...

Page 283: ... the snorkel tube 20 Remove all seals from the gearcase halves and clean the cases in preparation for assembly GEAR CLUSTER DISASSEMBLY 1 Remove the bearing from the reverse shaft using a bearing puller Remove the retaining ring and slide the washers 49T gear and needle bearing off the reverse shaft see Figure 8 1 2 Remove the retaining ring and engagement dog from the reverse shaft see Figure 8 1...

Page 284: ...X 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 the snorkel shaft 1 Extract the seal from ...

Page 285: ...ing Y and shim Z from the snorkel shaft 5 Use an arbor press to remove the snorkel tube from the snorkel shaft 6 Remove the snap ring A and shim B retaining the bearing in the snorkel tube 7 Lightly tap on the bearing from the opposite side to remove it from the snorkel tube 8 Remove the retaining ring to remove the remaining washer bearing and gear from the snorkel shaft TRANSMISSION ...

Page 286: ...d ring gear prior 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 r...

Page 287: ...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 and check for any unwanted burs 7 Press the new bushing into the planet...

Page 288: ...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 side gear 13 Thoroughly clean the bore of the side gear and check for any unwanted burs 14 P...

Page 289: ...ously 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 NOTICE The are two possible grades for the differential cover screws The grade can be located on the head of the fastener The two possible fasteners are grade 8 8 and grade 10 9 Torque the screws according to their corresponding grade TORQUE Different...

Page 290: ...g gear q prior to disassembly 2 Remove eight fasteners w retaining the ring gear 3 Remove ring gear e thrust washer r and output gear t 4 Remove dowel pin from the differential pin 5 Slide the differential pin y out of the carrier and remove the pinion gears u 6 Remove output gear i and Thrust washer o BEVEL DIFFERENTIAL ASSEMBLY 2019 1 Thoroughly clean the differential components TRANSMISSION ...

Page 291: ...into the carrier and slide the differential pin r into the carrier NOTICE Align the hole of the differential pin with the dowel pin hole in the carrier 4 Insert the dowel pin through the carrier into the differential pin 5 Install the output gear t thrust washer y and ring gear u NOTICE When installing the ring gear align with the mark made of the carrier during disassembly TRANSMISSION ...

Page 292: ...6 30 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 6 Install eight fasteners i securing ring gear TORQUE Ring Gear Fasteners 28 ft lbs 38 Nm TRANSMISSION ...

Page 293: ...6 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 6 31 GEAR SHAFT BEARING INSPECTION TRANSMISSION ...

Page 294: ...e 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 CAUTION 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 white lithium grease or Anti Seize on the threads of t...

Page 295: ...NT DO NOT install the longer screw A Installing the longer screw will lock the snorkel tube and not allow for backlash setting adjustment 10 Torque the bearing cover retaining screws to specification TORQUE Bearing Cover Retaining Screws 8 10 lb ft 11 14 Nm 11 Rotate the snorkel tube counterclockwise using the snorkel tool PA 50231 until the snorkel gear and pinion gear have zero backlash IMPORTAN...

Page 296: ...he 3rd notch from the zero backlash position obtained in step 11 14 Check the pinion shaft gear backlash again by feel If the pinion shaft gear lash appears to be too tight rotate the snorkel shaft clockwise to the next notch 4th notch 15 Once the backlash is set apply Loctite 242 to the threads and install the locking screw to secure the snorkel tube 16 Torque the locking screw to specification T...

Page 297: ... halves thoroughly Inspect case half mating surfaces for damage 2 Install shift fork S and torsion spring into transmission housing as an assembly Load spring as shown in image below 3 Apply Loctite 242 to two screws T and install with retaining plates over shift fork Torque to specification TORQUE Shift Fork Screws 17 lb ft 23 Nm 4 Slide engagement dog U onto retaining pins of shift fork 5 Assemb...

Page 298: ...s with engagement dog Ensure bearing is fully seated upon assembly 8 Assemble shift shaft rail if previously disassembled NOTICE Both shift forks need to be orientated the same way so that the shift fork pins are both offset to the same side of the rail 9 Install the shift shaft rail D and shift forks into the transmission housing as an assembly Be sure the shift forks are engaged into the engagem...

Page 299: ... Sealant PN 2871557 to the left hand transmission mating surface 13 Install the transmission case cover and retaining bolts Torque bolts to specification TORQUE Transmission Case Bolts 15 20 lb ft 20 27 Nm 14 Install new seals into the transmission case halves The snorkel shaft seal F should be pressed in until it seats against the housing counter bore The input shaft seal G should be pressed in u...

Page 300: ...ift drum shaft Install the shift shaft assembly and sector gear 11T into the bushing pocket on the left side Align the timing marks on the gears as shown 17 Install the spacer onto the shift drum shaft 18 Install the detent star onto the shift drum shaft Be sure to install the detent star with the raised edge facing outward and skip tooth aligned 19 Install the detent pawl onto the shift shaft and...

Page 301: ... onto the cover and transmission case mating surface 23 Install the sector cover and align the transmission case dowel with the alignment hole Install and torque the bolts to specification TORQUE Sector Cover Bolts 9 12 lb ft 12 16 Nm Fill Drain Plug 10 14 lb ft 14 19 Nm Bellcrank Nut 12 18 lb ft 16 24 Nm 24 Install the transmission drain plug and torque to specification 25 Install the bellcrank o...

Page 302: ...ft selector rail travel Worn broken or damaged internal transmission components NOTICE 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 303: ...7 7 13 PROPSHAFT REMOVAL GENERAL 4 2017 7 14 PROPSHAFT REMOVAL 2018 7 16 PROPSHAFT REMOVAL GENERAL 4 2018 7 17 U JOINT DISASSEMBLY 7 19 U JOINT ASSEMBLY 7 20 PROPSHAFT INSTALLATION 2016 2017 7 21 PROPSHAFT INSTALLATION GENERAL 4 2017 7 23 PROPSHAFT INSTALLATION 7 25 PROPSHAFT INSTALLATION GENERAL 4 2018 7 26 DRIVE SHAFT SERVICE 7 29 FRONT DRIVE SHAFT REMOVAL 7 29 FRONT DRIVE SHAFT INSTALLATION 7 3...

Page 304: ...STALLATION 7 45 REAR BEARING CARRIER INSTALLATION 7 45 FRONT GEARCASE SERVICE 7 47 ALL WHEEL DRIVE OPERATION 7 47 FRONT GEARCASE REMOVAL 7 47 FRONT GEARCASE DISASSEMBLY INSPECTION 7 49 FRONT GEARCASE ASSEMBLY 7 52 FRONT GEARCASE INSTALLATION 7 55 TROUBLESHOOTING FINAL DRIVE 7 57 FINAL DRIVE TROUBLESHOOTING 7 57 FINAL DRIVE ...

Page 305: ...rs 8700226 Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com TORQUE SPECIFICATIONS FINAL DRIVE PART DESCRIPTION TORQUE SPECIFICATION Propshaft Support Bearing Fasteners 33 lb ft 45 Nm Ball Joint Pinch Bolts 42 lb ft 57 Nm Wheel Hub Castle Nuts 180 lb ft 244 Nm Front Caliper Mounting Bolts 30 lb ft 41 Nm Rear Bearing Carrier Mounting Fasteners 42 lb ft 57 Nm Re...

Page 306: ...ual Copyright Polaris Industries Inc ASSEMBLY VIEWS FINAL DRIVE PROPSHAFT ASSEMBLY VIEW 2016 2017 q Asm Propshaft Front u Asm Bearing Flex w Yoke Pin i Yoke Slip e U Joint o Bolt r Yoke Slip a Pin Spring t Fitting s U Joint y Asm Propshaft Rear FINAL DRIVE ...

Page 307: ...L 4 Service Manual Copyright Polaris Industries Inc 7 5 PROPSHAFT ASSEMBLY VIEW GENERAL 4 2016 2017 q Asm Propshaft Front t Yoke Slip w Asm Propshaft Center y Yoke Pin e Asm Propshaft Rear u Fitting r U Joint i Asm Bearing Flex FINAL DRIVE ...

Page 308: ...16 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc PROPSHAFT ASSEMBLY VIEW 2018 2019 q Grease Fitting r Fastener w Asm Prop Shaft Rear t Asm Prop Shaft Front e Asm Bearing y Pin Spring FINAL DRIVE ...

Page 309: ...e Manual Copyright Polaris Industries Inc 7 7 PROPSHAFT ASSEMBLY VIEW GENERAL 4 2018 2019 q Grease Fitting y U Joint w Asm Propshaft Rear u Asm Propshaft Center e Asm Bearing Flex i Asm Propshaft Front r Fastener o Pin Spring t Yoke Slip FINAL DRIVE ...

Page 310: ...E SHAFT ASSEMBLY VIEW FRONT DRIVE SHAFT q Asm Front Drive Shaft t Boot w Circlip y Clamp Small e Kit Boot Plunging Joint u Circlip r Clamp Large i Circlip REAR DRIVE SHAFT q Asm Rear Drive Shaft y Boot w Circlip u Clamp Small e Kit Boot i Joint Plunging r Clamp Large o Circlip t Grease FINAL DRIVE ...

Page 311: ...NERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 7 9 DRIVE SHAFT ASSEMBLY VIEW INTL FRONT DRIVE SHAFT INTL q Outer Race y Cage w Clamp Large u Ball e Kit Boot i ABS Ring r Clamp Small o Circlip t Shaft FINAL DRIVE ...

Page 312: ...75 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc REAR DRIVE SHAFT INTL q Outer Race y Cage w Clamp Large u Ball e Kit Boot i ABS Ring r Clamp Small o Circlip t Shaft FINAL DRIVE ...

Page 313: ...EARCASE ASSEMBLY VIEW q Asm Front Gearcase i Cage Rollers w Asm Cover Output o Asm Roller Cage e Asm Output Hub a Asm Gearcase r Kit Cover Fasteners s Plug Drain t Complete Seal Repair d Plug Fill y Plate 4WD Armature f Asm Gear Housing and Pinion Gear u Bearing g Spring Torsion and Retainer FINAL DRIVE ...

Page 314: ...RAL GENERAL 4 Service Manual Copyright Polaris Industries Inc GEARCASE VENT LINE The front gearcase vent line routs vertically and into an open section of the frame REF Description q Hose Clamp w Vent Hose Retention Point FINAL DRIVE ...

Page 315: ...rd roll pin Push the front prop shaft rearward to remove it from the front gearcase input shaft 4 Slide the front propshaft q off the rear propshaft w and remove it from the vehicle CAUTION Use care not to damage brake lines when removing propshafts 5 Remove the fasteners retaining the support bearing cover to the frame 6 Slide the rear prop shaft forward to remove it from the transmission output ...

Page 316: ... roll pin Discard roll pin Push the front prop shaft rearward to remove it from the front gearcase input shaft 4 Slide the front propshaft q off the center propshaft w and remove it from the vehicle CAUTION Use care not to damage brake lines when removing propshafts 5 Remove the fasteners retaining the support bearing for the center propshaft to the frame 6 Slide the center propshaft off the rear ...

Page 317: ...nt NOTICE The rear of the propshaft must be angled and guided backwards to aid in clearing the mount 10 Angle the front of the propshaft and support bearing downward and move toward the front of the vehicle to remove CAUTION Use care not to damage brake lines when removing propshafts 11 With the propshafts removed from the vehicle inspect the shaft for cracks damage from debris and straightness FI...

Page 318: ...emove the roll pin Discard roll pin Push the front prop shaft rearward to remove it from the front gearcase input shaft 4 Slide the front propshaft q off the rear propshaft w and remove it from the vehicle 5 Remove the fasteners retaining the support bearing to the frame 6 Slide the rear propshaft forward to remove it from the transmission output shaft 7 Angle the front of the propshaft and suppor...

Page 319: ...he Roll Pin Removal Tool 2872608 to remove the roll pin Discard roll pin Push the front propshaft rearward to remove it from the front gearcase input shaft 4 Slide the front propshaft q off the center propshaft w and remove it from the vehicle CAUTION Use care not to damage brake lines when removing propshafts 5 Remove the fasteners retaining center propshaft support bearing to the frame 6 Slide t...

Page 320: ...s mount NOTICE If necessary separate the support bearing to gain clearance NOTICE The rear of the propshaft must be angled and guided backwards to aid in clearing the mount 10 Angle the front of the propshaft and support bearing downward and move toward the front of the vehicle to remove CAUTION Use care not to damage brake lines when removing propshafts 11 With the propshafts removed from the veh...

Page 321: ...the retaining rings q from both sides of the yoke 2 Using a commercially available Ball Joint U Joint Press Set place a receiving cup adapter w with a larger ID than the U joint cap OD on one end 3 Place a remover adapter e on other end of U joint with a smaller OD than the U joint cap 4 Position clamp r over receiving cup adapter and remover adapter 5 Tighten clamp with hand tools to force U join...

Page 322: ...l off during installation 2 Ensure yoke bores and ring grooves are clean before installing new U joint 3 Place U joint ends w without caps into yoke bores 4 Place caps e into yoke bores and align with U joint ends by hand 5 Place clamp and installer adapters r with smaller OD than caps over each cap 6 Tighten clamp to install caps simultaneously into yoke bores 7 Push U joint side to side during c...

Page 323: ...oves freely and does not bind PROPSHAFT INSTALLATION 2016 2017 1 Lubricate front gearcase shaft splines with Anti Seize 2 Lubricate the transmission output shaft splines with Polaris All Purpose Grease 3 Lubricate the front and rear prop shaft mid joint with Polaris All Purpose Grease 4 Slide the rear prop shaft forward from the left rear of the machine just below the PVT cover Install the rear pr...

Page 324: ...ntation of the support bearing assembly The shallow ridge of the bearing should be facing upwards 8 Align the front prop shaft paint mark with the front gearcase input shaft mark so the pin holes align Install a new roll pin IMPORTANT Always use a new roll pin when installing the front propshaft onto the gearcase Do not reuse roll pins 9 Torque the support bearing fasteners to specification TORQUE...

Page 325: ...transmission output shaft NOTICE If necessary separate the support bearing to gain clearance WARNING Use care not to damage brake lines when installing propshafts 5 Lubricate the support bushing with light oil to ease installation and install the bushing on the rear prop shaft bearing 6 Install the center propshaft and align with alignment marks on rear propshaft NOTICE Paint marks are applied to ...

Page 326: ...p shaft paint mark with the front gearcase input shaft mark so the pin holes align Install a new roll pin IMPORTANT Always use a new roll pin when installing the front propshaft onto the front gearcase Do not reuse roll pins 10 Torque the center and rear prop shaft support bearing fasteners to specification TORQUE Support Bearing Fasteners 33 lb ft 45 Nm 11 Install the skid plates on the vehicle R...

Page 327: ... rear of the machine just below the PVT cover Install the rear prop shaft on the transmission output shaft 5 Lubricate the support bushing with light oil to ease installation and install the bushing on the rear prop shaft bearing 6 Install the front propshaft and align with the alignment mark on the rear propshaft NOTICE Paint marks are applied to the front and rear prop shafts to aid shaft alignm...

Page 328: ... vehicle Refer to Skid Plate Replacement page 10 73 procedure PROPSHAFT INSTALLATION GENERAL 4 2018 1 Lubricate front gearcase shaft splines with Anti Seize 2 Lubricate the transmission output shaft splines with Polaris All Purpose Grease 3 Lubricate the front center and rear propshaft mid joint with Polaris All Purpose Grease 4 Slide the rear propshaft forward from the left rear of the machine ju...

Page 329: ... alignment mark if necessary as shown above Install the front propshaft in the vehicle and align with the alignment mark on the center propshaft 8 Ensure proper orientation of support bearing assemblies for rear and center propshafts The shallow ridge of the bearings should be facing upwards 9 Align the front propshaft paint mark with the front gearcase input shaft mark so the pin holes align Inst...

Page 330: ...r and rear propshaft support bearing fasteners to specification IMPORTANT Ensure the coolant line clip is reinstalled and torqued down with the support bearing TORQUE Support Bearing Fasteners 33 lb ft 45 Nm 11 Install the skid plates on the vehicle Refer to Skid Plate Replacement page 10 73 procedure FINAL DRIVE ...

Page 331: ...he nut and cone washer e from the front wheel hub assembly NOTICE 2016 2017 models have two cone washers 4 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc Refer to Brake Caliper Removal Front page 9 42 procedure 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 w...

Page 332: ... 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 and nuts Torque to specification TORQUE Ball Joint Pinch Bolts 42 lb ft 57 Nm 6 Apply Anti Seize to drive shaft axle splines 7 Install front wheel hub assembly r cone washer t and hand ti...

Page 333: ...Nuts Alum 120 lb ft 163 Nm NOTICE Do not lubricate the stud or the lug nut 11 Rotate wheel and check for smooth operation REAR DRIVE SHAFT REMOVAL 1 Raise and support the vehicle CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this procedure Always wear eye protection 2 Remove the wheel nuts and rear wheel 3 Remove the cotter pin q and loosen t...

Page 334: ...transmission splines REAR DRIVE SHAFT INSTALLATION 1 Install NEW spring ring on drive shaft Apply an anti seize compound to the splines IMPORTANT 2019 General Models have an O ring A on the drive shaft Ensure the O ring is present and not damaged before installation 2 Align splines of drive shaft with transmission splines and reinstall the drive shaft Use a rubber mallet to tap on the outboard end...

Page 335: ...EW mounting bolts Torque to specification TORQUE Rear Caliper Mounting Bolts 46 lb ft 62 Nm CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 7 Torque wheel hub nut r to specification and install a NEW cotter pin t Tighten nut slightly if necessary to align cotter pin holes Bend both ends of cotter pin aroun...

Page 336: ...amage Make sure surface ground areas and splines of shaft are protected during handling to avoid damage Do not allow boots to come into contact with sharp edges or hot engine and exhaust components The drive shaft is not to be used as a lever arm to position other suspension components Never use a hammer or sharp tools to remove or to install boot clamps Be sure joints are thoroughly clean and tha...

Page 337: ...one side to expose each ball Severe pitting galling play between the ball and its cage window any cracking or damage to the cage pitting or galling or chips in raceways call for joint replacement NOTICE Shiny areas in ball tracks and on the cage spheres are normal Do not replace CV joints because parts have polished surfaces Replace CV joint only if components are cracked broken worn or otherwise ...

Page 338: ...t housing and shaft Make sure the boot is not dimpled or collapsed 18 Install and tighten the large clamp e using the appropriate clamp tool Axle Boot Clamp Tool PU 48951 or CV Boot Clamp Pliers 8700226 19 While pulling out on the CV shaft fully extend the CV joint and slide a straight O ring pick or a small slotted screw driver between the small end of the boot and the shaft This will allow the a...

Page 339: ...rom the plunging joint and slide the boot down the shaft 3 Clean the grease from the face of the joint and place the drive shaft in a soft jawed vise 4 Using a soft faced hammer or brass drift strike the inner race of the joint to drive the joint off the shaft Be sure to tap evenly around the joint to avoid binding IMPORTANT Tap on inner race only 5 Make sure the circlip w is on the shaft and not ...

Page 340: ... provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s inner race Pack the ball tracks and outer face flush with grease Place any remaining grease into the boot CAUTION The grease provided in the replacement kit is specially formulated for wear resistance and durability DO NOT use substitutes or mix with other lubricants NOTICE The amount of grea...

Page 341: ...sing Slide a straight O ring pick or a small slotted screw driver between the large end of the boot and the joint housing and lift up to equalize the air pressure in the boot 21 Position the boot lip in its groove Install and tighten the large clamp r using the appropriate clamp tool Axle Boot Clamp Tool PU 48951 or CV Boot Clamp Pliers 8700226 FINAL DRIVE ...

Page 342: ...e front wheel 4 Remove the cotter pin q and loosen the front wheel hub castle nut w Remove the nut and cone washer e from the front wheel hub assembly NOTICE 2016 2017 models have two cone washers 5 Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc Refer to Brake Caliper Removal Front page 9 42 procedure CAUTION Do not hang the caliper by the ...

Page 343: ...rier tap on the outer bearing race with a drift punch in the reliefs as shown 3 Drive bearing out evenly by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 4 Inspect the bearing carrier housing for scratches wear or damage Replace front bearing carrier if damaged BEARING INSTALLATION 1 Thoroughly clean the front bearing carri...

Page 344: ...end onto the front bearing carrier Torque the tie rod end fastener to specification TORQUE Tie Rod End Fastener 15 lb ft 20 Nm 5 Apply Anti Seize to drive shaft axle splines 6 Install front wheel hub assembly w and cone washer e Install washer with domed side out Hand tighten the castle nut NOTICE 2016 2017 models have two cone washers 7 Install NEW brake caliper mounting bolts and torque to speci...

Page 345: ...on when removing bearings and seals 2 Check bearings for side play by grasping the top and bottom of the tire firmly and checking for movement The tire should rotate smoothly without binding or rough spots 3 Remove the four wheel nuts and rear wheel 4 Remove the cotter pin q and loosen the rear wheel hub castle nut w Remove the nut and cone washer e from the rear wheel hub assembly NOTICE 2016 201...

Page 346: ... quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 9 Replace bearing if moisture dirt corrosion or roughness is evident REAR BEARING REPLACEMENT BEARING REMOVAL 1 Remove the outer snap ring q 2 From the back side of the bearing carrier tap on the outer bearing race with a drift punch in the reliefs as shown 3 Drive bearing out evenly by tapp...

Page 347: ... and carefully press the new bearing into the bearing carrier housing e NOTICE Use care to not allow any of the Loctite compound to get in the bearing 4 Wipe the housing clean of any excess compound and install the snap ring r REAR BEARING CARRIER INSTALLATION 1 Install drive shaft through the backside of the bearing carrier 2 Install rear bearing carrier onto control arms and mounting fasteners T...

Page 348: ...nt which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 6 Torque wheel hub nut t to specification and install a NEW cotter pin y Tighten nut slightly if necessary to align cotter pin holes Bend both ends of cotter pin around end of spindle in different directions TORQUE Wheel Hub Castle Nut 180 lb ft 244 Nm 7 Install wheel and wheel nuts Refer to Wheel Installa...

Page 349: ...ture plate q that is keyed to the roll cage w When the ring gear e and roll cage are spinning vehicle is moving the energized coil and armature plate will apply drag to the roll cage that indexes the rollers inside the ring gear to an engagement position While in the engagement position the front drive will be in an over running condition not engaged until the rear wheels lose traction Once the re...

Page 350: ...se Refer to Front Drive Shaft Removal page procedure 11 Remove Skid plate 12 Remove two 15mm fasteners e securing support bearing 13 Without removing the front propshaft from the support bearing slide the assembly rearward to disengage the front propshaft from the gearcase input shaft 14 Disconnect the wire harness for the front gearcase and remove the harness from the retaining dart 15 Remove the...

Page 351: ... slide it out of the vehicle above the upper A arm FRONT GEARCASE DISASSEMBLY INSPECTION 1 Drain and properly dispose of gearcase fluid Remove any metal particles from the drain plug magnet 2 Remove the seven cover screws and remove the cover plate assembly 3 Remove the LH output hub assembly from the clutch housing or outer cover plate assembly IMPORTANT Nylon spacer is non serviceable and should...

Page 352: ...late Refer to Final Drive Troubleshooting page 7 57 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 7 Remove the RH output hub assembly from the gearcase housing FINAL DRIVE ...

Page 353: ...e Troubleshooting page 7 57 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 order to retain all the rollers IMPORTANT Rollers are spring loaded Take care not to allow them to fall out or lose them upon removal of the roll cage 12 Thoroughly clean all parts and inspe...

Page 354: ...place if needed 16 Clean and inspect all remaining front gearcase components Check each for excessive wear or damage FRONT GEARCASE ASSEMBLY 1 As mentioned during gearcase disassembly section replace all O rings seals and worn components 2 Install pinion shaft assembly and install internal snap ring NOTICE If bearing replacement was required press new bearing onto the pinion shaft and install a ne...

Page 355: ...ar grooves line up with the roll cage windows see below Be sure role cage top groove is facing upward 6 Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear 7 Align spring retainer dowel pin with ring gear dowel pin and install the retainer on top of the torsion spring 8 Check the action of the torsion spring by rotating in both directions to ensure t...

Page 356: ...arefully install the ring gear and roll cage assembly into the gearcase housing 11 Install a new O ring on the cover plate assembly IMPORTANT Be sure the square O ring is placed flat on the cover surface If the O ring is twisted fluid leakage may occur 12 Carefully install the LH output hub assembly into the cover plate Take care not to damage the new cover plate seal while installing the output h...

Page 357: ...th Anti Seize 3 Install the fasteners that secure the front gearcase q to the frame and torque to specification TORQUE Front Gearcase Mounting Bolts 33 lb ft 45 Nm 4 Install the vent line 5 Connect the AWD wire harness 6 Slide the propshaft assembly forward to engage the front propshaft into the gearcase input shaft Use a NEW spring pin 7 Install two 15mm fasteners w securing support bearing assem...

Page 358: ...nt Gearcase Lubrication page 2 30 procedure NOTICE Reinstall winch if equipped 11 Install winch mounting plate and secure with four 15mm nuts e TORQUE Winch Mounting Plate 30 lb ft 41 Nm 12 Install winch from passenger side 13 Install four fasteners r securing winch to mounting plate TORQUE Winch Fasteners 16 lb ft 22 Nm 14 Reinstall lower fastener on passenger front shock TORQUE Shock Fastener 20...

Page 359: ... 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 t is seated in the U shaped y insert that is pressed into the gearcase cover u The top of the coil should be seated below the U shaped insert The U shaped...

Page 360: ...7 58 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc NOTES FINAL DRIVE ...

Page 361: ...ER 8 10 STEERING SHAFT BEARING REPLACEMENT 8 11 STEERING SHAFT INSTALLATION LOWER 8 11 POWER STEERING UNIT INSTALLATION 8 12 STEERING SHAFT INSTALLATION UPPER 8 13 TIE ROD END WHEEL HUB INSPECTION 8 15 STEERING RACK REMOVAL 8 15 STEERING RACK INSTALLATION 8 16 WHEEL TOE ALIGNMENT INSPECTION 8 16 WHEEL TOE ADJUSTMENT 8 17 STEERING WHEEL FREE PLAY 8 18 EPAS OPERATION OVERVIEW 8 18 SHOCK SERVICE 8 20...

Page 362: ... 50 STABILIZER BAR REMOVAL FRONT 8 53 STABILIZER BAR INSTALLATION FRONT 8 53 STABILIZER BAR REMOVAL REAR 8 54 STABILIZER BAR INSTALLATION REAR 8 55 BALL JOINT SERVICE 8 56 BALL JOINT PREPARATION 8 56 BALL JOINT REMOVAL 8 56 BALL JOINT INSTALLATION 8 56 TROUBLESHOOTING STEERING SERVICE 8 57 EPAS TROUBLESHOOTING 8 57 POWER STEERING NON FUNCTIONAL WITH MIL ON 8 57 POWER STEERING NON FUNCTIONAL WITH M...

Page 363: ...U 51024 Gas Shock Fill Tool PU 51039 Shock Bearing Cap Removal Tool Commercially Available Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com TORQUE SPECIFICATIONS STEERING SUSPENSION PART DESCRIPTION TORQUE SPECIFICATION Lower Steering Shaft to Rack Pinch Bolt 48 lb ft 65 Nm Power Steering Unit Fasteners 30 lb ft 41 Nm Lower Steering Shaft to Power Steering Pi...

Page 364: ...Polaris Industries Inc SERVICE SPECIFICATIONS STEERING SUSPENSIONS PART DESCRIPTION SERVICE SPECIFICATION Steering Wheel Free play 0 8 1 0 in 20 25 mm Wheel Toe Out 0 1 8 in 0 3 175 mm Spring Adjustment Front 6 625 in 16 828 cm Rear 1 625 in 4 128 cm STEERING SUSPENSION ...

Page 365: ... Polaris Industries Inc 8 5 ASSEMBLY VIEWS STEERING SUSPENSION STEERING ASSEMBLY VIEW q Steering Wheel y EPS Unit w Steering Wheel Nut u Steering Shaft Lower e Shock Steering i Steering Rack r Asm Tilt Steering o Tie Rod End t Steering Shaft Upper STEERING SUSPENSION ...

Page 366: ...pyright Polaris Industries Inc FRONT SUSPENSION ASSEMBLY VIEW q Bearing Carrier Front RH y Bushing Stabilizer Bar w Shield Front u Link Stabilizer Bar e Shock Front RH i Control Arm Lower LH r Control Arm Upper RH o Joint Ball t Stabilizer Bar STEERING SUSPENSION ...

Page 367: ...ht Polaris Industries Inc 8 7 REAR SUSPENSION ASSEMBLY VIEW q Bearing Carrier Rear LH t Bracket Stabilizer Bar w Link Stabilizer Bar y Stabilizer Bar e Shock Rear LH u Bushing Stabilizer Bar r Control Arm Upper Rear RH i Control Arm Lower Rear RH STEERING SUSPENSION ...

Page 368: ... it is readily available before proceeding Failure to replace fastener can result in injury or death 1 Remove the fasteners retaining the black plastic cover and remove the cover from the vehicle 2 Remove and discard the pinch bolt retaining the upper steering shaft to the power steering unit 3 Remove the fasteners that retain the tilt assembly to the mounting bracket 4 Remove the steering shaft p...

Page 369: ... 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 as an assembly before attempting to remove the steering wheel Refer to Steering...

Page 370: ...sted Steering EPAS units are programmed to be vehicle specific and are not interchangeable between product lines STEERING SHAFT REMOVAL LOWER 1 Use the steering wheel to position the front wheels so they point straight ahead 2 Locate the lower steering shaft through the left front wheel well Mark the lower steering shaft gear box stub shaft and gear box to aid installation 3 Remove the power steer...

Page 371: ...Steering Fault 2 Rotate the steering wheel to inspect bearing operation The wheel should spin smoothly and consistently 3 If the steering wheel has trouble turning the steering shaft bearings may need replacing However the steering shaft bearings are not serviceable If found faulty replace the entire steering tilt assembly STEERING SHAFT INSTALLATION LOWER 1 Install the lower steering shaft onto t...

Page 372: ...o the vehicle and align the skip tooth spline on the power steering stub shaft with the opening in the lower steering shaft 3 Place the power steering mount bracket over the top of the brake pedal mount studs and finger tighten the four nuts 4 Position the lower steering shaft on the power steering unit stub shaft and install the pinch bolt Torque to specification TORQUE Lower Steering Shaft to Po...

Page 373: ...tub shaft CAUTION Striking the steering wheel or steering shaft can permanently damage the EPS unit and cause a Power Steering Fault 1 Install the upper steering shaft and align the skip tooth spline on the power steering stub shaft with the opening in the upper steering shaft 2 Install the fasteners that retain the tilt assembly to the mounting bracket Torque the fasteners to specification TORQUE...

Page 374: ...n TORQUE Silver 10 9 Upper Steering Shaft Pinch Bolt 30 lb ft 41 Nm NOTICE The upper steering shaft pinch bolt must be replaced with PN 7520943 which has a silver finish and is 10 9 grade Reference Figure 1 5 Install the fasteners retaining the black plastic cover and torque to specification TORQUE Power Steering Unit Cover Fasteners 7 lb ft 10 Nm 6 Turn the key switch on and test EPAS operation S...

Page 375: ...at front and rear Try to move the wheel and hub by pushing inward and pulling outward 4 If abnormal movement is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts or loose front hub nut Refer to Final Drive chapter for service procedures STEERING RACK REMOVAL 1 Remove the wheel nuts and wheels from the vehicle 2 Remove the fasteners securing the tie rods end to the...

Page 376: ...e rods end to the front bearing carriers Torque fasteners to specification TORQUE Tie Rod Jam Nut 15 lb ft 20 Nm 5 Verify front wheel alignment Refer to Wheel Toe Alignment Inspection page 2 34 procedure 6 Install the wheel nuts and wheels from the vehicle Refer to Wheel Installation page procedure WHEEL TOE ALIGNMENT INSPECTION 1 Place machine on a smooth level surface and set steering wheel in a...

Page 377: ...Inspection page 8 16 but instead measure the distance between each wheel and the vehicle center This will tell you which tie rod needs adjusting NOTICE Be sure steering wheel is straight ahead before determining which tie rod needs adjustment CAUTION During tie rod adjustment it is very important that the following precautions be taken when tightening tie rod end jam nuts If the rod end is positio...

Page 378: ... the system will illuminate a fault indicator and transition to a normal mechanically coupled steering system The system is Polaris Digital Wrench compatible for simplified diagnostics and system troubleshooting through the vehicle s diagnostic port With the engine off and the key on the power steering unit will operate for up to five minutes After the five minutes you will need to cycle the key s...

Page 379: ...al Copyright Polaris Industries Inc 8 19 2 PIN CONNECTOR WIRE COLOR FUNCTION ORANGE Main Power 25A 30A Protected BROWN Ground 8 PIN CONNECTOR WIRE COLOR FUNCTION ORANGE Key On Battery Voltage YELLOW CAN High Signal GREEN CAN Low Signal STEERING SUSPENSION ...

Page 380: ...HOCK VALVING COMPRESSION REBOUND 1 600 x 006 DB 1 425 x 008 1 600 x 006 1 425 x 008 1 600 x 006 1 425 x 008 1 600 x 006 0 800 x 006 0 750 x 012 1 425 x 012 1 600 x 012 1 350 x 012 1 425 x 012 1 250 x 012 1 350 x 012 1 100 x 012 1 570 x 128 Top Out 0 950 x 012 1 230 x 0 082 Top Out 0 750 x 0 100 Back Up REAR SHOCK VALVING COMPRESSION REBOUND 1 600 x 012 SB 1 425 x 010 1 600 x 008 1 425 x 010 1 600 ...

Page 381: ... 600 x 008 1 425 x 006 1 600 x 008 1 425 x 006 0 750 x 015 1 425 x 006 1 600 x 012 1 425 x 006 1 600 x 012 0 850 x 010 1 600 x 012 0 850 x 008 1 600 x 012 1 425 x 015 1 600 x 012 1 350 x 015 1 600 x 012 1 250 x 015 1 250 x 006 1 230 x 082 Top Out 1 570 x 128 Top Out 875 x 100 Back UP REAR SHOCK VALVING COMPRESSION REBOUND 1 600 x 006 DB 1 425 x 008 1 600 x 010 1 425 x 015 R 1 600 x 008 1 250 x 006...

Page 382: ...nd lower fasteners retaining the shock and remove the shock from the vehicle Discard nuts and replace with new upon installation SPRING REPLACEMENT 1 Remove the shock and note the spring preload distance Refer to Shock Removal page 8 22 and Spring Adjustment page 2 36 procedures 2 Loosen the jam nut if applicable and adjustment ring until the spring is loose If needed use a spring compressor to co...

Page 383: ...the vehicle off the ground to allow the suspension to fully extend 2 Using the shock spanner spreader tool PN 2877408 included in the vehicle s tool kit turn the adjustment collar q to increase or decrease ride height BASE FOX WARNING DO NOT increase the spring adjustment q by more than one inch 25 4 mm over the factory setting Always return the spring adjuster to the factory setting after the loa...

Page 384: ...the vehicle s tool kit turn the adjustment collar q to increase or decrease ride height WARNING DO NOT increase the spring adjustment q by more than one inch 25 4 mm over the factory setting Always return the spring adjuster to the factory setting after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stability when operating without a load SPRING...

Page 385: ...y a clean 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 reservoir end cap using a commercially available extractor tool 5 Place a commercially available bearing cap removal tool around the shock ...

Page 386: ...ing Piston IFP into the shock reservoir 9 Press the bearing assembly down with your fingers At the same time push the IFP tool upwards with your thumbs 10 Remove the bearing cap retaining ring with a valve shim 11 Remove shock shaft assembly by pushing down on the IFP removal tool while pulling up on shock shaft assembly 12 Dump out used oil 13 Using a 9 16 inch open end wrench and a 1 8 inch Hex ...

Page 387: ...river 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 19 To assist in breaking the bond with the Loctite adhesive apply heat to the body cap STE...

Page 388: ... Clean body cap using a wire brush and pick 23 Remove both retaining rings in the body cap using a sharp pick 24 Press the bearing out of the body cap using a bearing press set or assorted sockets 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...

Page 389: ...components for assembly 30 Remove BOC post 31 Remove rebound valve stack Note order of valve stack for assembly NOTICE If you are not changing valve shims you can zip tie the shims together this will keep valve shim stack in their assembled order 32 Remove the piston Note the orientation of the piston as it comes off the shock shaft compression side down STEERING SUSPENSION ...

Page 390: ...ation of the notches in the bleed shim align with the compression ports of the piston 34 Remove the piston bearing if it shows any signs of damage or wear 35 Remove piston O ring 36 Remove compression valve stack 37 Remove bearing assembly and bearing cap 38 Place shock shaft in clamp blocks STEERING SUSPENSION ...

Page 391: ...CAUTION Eyelet will be Hot 41 Remove Loctite residue out from threads of the eyelet and shock shaft EYELET MOUNTED REBOUND ADJUSTER 1 For shocks with remove Jet Check Valve with Hex T handle wrench 2 Push needle out of shock shaft using a metering rod and Hex T handle wrench 3 Remove O ring from needle 4 Back out rebound adjuster with flat head screw driver but do NOT fully remove rebound adjuster...

Page 392: ...oot 7 Remove both retaining rings from the eyelet and press out bearing DX BUSHING AND SEAL STYLE EYELET NOTICE DX Bushing style eyelets have larger bore diameters than conventional eyelets 1 Remove both dust seals from the eyelet 2 Press out DX bushing using DX Bushing Press Kit 3 Remove dust seal from bearing cap NOTICE On some models the seal may be in the bearing assembly STEERING SUSPENSION ...

Page 393: ...aring assembly Note the direction seal was installed for assembly 6 Remove external O ring from bearing assembly NOTICE If internal bearing is damaged replace with complete bearing assembly SHOCK ASSEMBLY FOX 1 Install one retaining ring in the eyelet 2 Press bearing into the eyelet using Bearing Press or proper sized socket 3 Install second retaining ring STEERING SUSPENSION ...

Page 394: ...ing 4 Put the steel ball on the spring with a dab of shock oil 5 Install rebound knob into eyelet holding steel ball in place with fingers Ensure rebound knob threads into eyelet correctly and you can feel the detents click NOTICE Adjust rebound knob to allow metering rod to obtain maximum travel in eyelet 6 7 Install a NEW O ring on needle and apply thin layer of Slick Honey STEERING SUSPENSION ...

Page 395: ...shock shaft in clamp blocks and apply a thin layer of Slick Honey to metering rod ASSEMBLY CONTINUED 1 Apply specified Loctite two threads down and two threads wide completely around shock shaft threads 2 Place shaft back in clamp blocks apply Loctite primer to eyelet and Torque eyelet to shock shaft to specification TORQUE Eyelet 30 lb ft 41 Nm 3 Reverse shock shaft in clamp blocks and install ai...

Page 396: ...in layer of Slick Honey to seal 5 Install body cap NOTICE There are two different sides on the U Cup seal When seal is installed energizing side should be facing internal bearing 6 Install U Cup seal 7 Install back up washer 8 Apply thin layer of shock oil to washer 9 Install bearing assembly using the appropriate bullet tool STEERING SUSPENSION ...

Page 397: ...llation tool assembly on top of the piston and push down to install bearing NOTICE Bearing will be fully seated around piston when done correctly 13 Install compression side valve stack NOTICE When installing bleed shim ensure the tab is lined up with compression port 14 Install piston onto shock shaft 15 Install rebound valve stack with required top out washer STEERING SUSPENSION ...

Page 398: ...ble and torque to specification TORQUE Piston Nut 22 lb ft 30 Nm 17 If applicable install BOC post valving NOTICE Ensure retaining ring is fully installed and secure 18 If applicable install BOC piston and retaining ring 19 Apply Loctite primer to the body cap threads 20 Install appropriate O ring and apply a thin layer of shock oil to the O ring ONLY STEERING SUSPENSION ...

Page 399: ...body 23 Place body in clamp blocks and install body cap Torque body cap to specification using body cap socket TORQUE Body Cap 100 lb ft 136 Nm 24 Place body in block clamps parallel to the ground 25 Replace both O rings on DSC or LSC Torque DSC or LSC to specification TORQUE DSC 35 lb ft 47 Nm LSC 12 lb ft 16 Nm 26 Apply Loctite to LSC screw if equipped 27 Install LSC knob and torque screw to spe...

Page 400: ...bearing and O ring on the IFP and apply a thin layer of shock oil to bearing and O ring 32 Install IFP assembly without bleed screw using the IFP installation tool IMPORTANT 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 33 Ensure oil is 0 250 above IFP and install bleed screw with O ring 34 Fill shock body with oil abou...

Page 401: ...ring Push bearing assembly in with your finger tips 38 Install retaining ring 39 Use IFP tool to push down on IFP and fully extend the shock shaft assembly 40 Remove bleed screw and set IFP to the appropriate height While holding the IFP install bleed screw with O ring using a 9 16 open end wrench 41 Install reservoir cap O ring on cap and apply a thin layer of shock oil to side and O ring 42 Inst...

Page 402: ...SEMBLY WALKER EVANS 1 Insert needle into charge port to release the nitrogen charge 2 Remove the wiper cap 3 With needle still in bleeder valve press seal case down as far as possible 4 Remove needle from charge port 5 Remove the wire ring 6 Remove bleed screw from the seal head 7 Remove the shaft assembly 8 Dump all oil from the shock and let drain 9 Remove the piston lock nut from shaft 10 Remov...

Page 403: ...parate into three separate pieces NOTICE Use a heat gun to aid in disassembly 14 Remove the base valve 15 Remove the IFP from reservoir eyelet cap 16 Replace all o rings SHOCK ASSEMBLY WALKER EVANS 1 With the needle in the charge port push IFP until it bottoms out Then remove the needle 2 Replace o ring in the coupler thread on body side Thread onto the main body with threadlocker 3 Install the ba...

Page 404: ...ew out push the seal case down until it is 1 500 from top of the main body 8 Making sure oil is on top of the seal case pull up on the shaft until the piston stops against the seal case Ensure the seal case is still 1 500 from the top of the main body 9 Install the bleed screw in the seal case and wire ring Make sure the wire ring is in its groove 10 Slowly add nitrogen Once the seal case seats ag...

Page 405: ...loosen the upper control arm ball joint end while lifting upward on the upper control arm Completely remove the ball joint end from the bearing carrier 7 Loosen and remove the upper control arm through bolt fasteners r Remove the upper control arm from the vehicle 8 Remove ball joint from control arm Refer to Ball Joint Removal page 8 56 procedure 9 Examine control arm bushings and pivot tube Repl...

Page 406: ...e 2016 2018 models have M12 hardware 4 Remove ball joint from control arm Refer to Ball Joint Removal page 8 56 procedure 5 Examine control arm bushings and pivot tube Replace if worn Discard hardware 6 If not replacing the control arm thoroughly clean the control arm and pivot tube CONTROL ARM INSTALLATION FRONT UPPER CONTROL ARM 1 Install NEW ball joint into control arm Refer to Ball Joint Insta...

Page 407: ...ORQUE Ball Joint Pinch Bolts 42 lb ft 57 Nm 5 Install brake line mounting brackets y 6 Attach shock to control arm with fastener Torque lower shock bolt to specification TORQUE Shock Mount Fasteners 20 lb ft 27 Nm 90 7 Attach stabilizer link to control arm with fastener Torque to specification TORQUE Stabilizer Bar Link Fastener 42 lb ft 57 Nm 8 Install NEW ball joint into control arm Refer to Bal...

Page 408: ...ecification NOTICE 2019 models have M12 hardware 2016 2018 models have M10 hardware TORQUE Front Control Arm Fasteners 42 lb ft 57 Nm 3 Insert lower control arm ball joint end into the bearing carrier Install lower ball joint pinch bolt into the bearing carrier and torque bolt to specification TORQUE Ball Joint Pinch Bolts 42 lb ft 57 Nm 4 Install front wheels Refer to Wheel Installation page proc...

Page 409: ...s 4 Examine control 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 5 If not replacing the control arm thoroughly clean the control arm and pivot tube LOWER CONTROL ARM 1 Remove lower shock fastener q from ...

Page 410: ...ivot tube Replace if worn Discard hardware 7 If not replacing the control arm thoroughly clean the control arm and pivot tube CONTROL ARM INSTALLATION REAR UPPER CONTROL ARM 1 Insert NEW pivot caps q control arm bushings w and pivot tube e into new control arm 2 Install upper control arm assembly onto vehicle frame Install NEW fasteners r holding control arm to vehicle Torque fasteners to specific...

Page 411: ...uter Upper Control Arm Fasteners 42 lb ft 57 Nm LOWER CONTROL ARM 1 Insert NEW pivot caps q control arm bushings w and pivot tube e into new control arm A light press force may be needed 2 Install lower control arm assembly onto vehicle frame Install NEW fasteners r holding control arm to vehicle Torque fasteners to specification TORQUE Rear Inner Control Arm Fasteners 40 lb ft 54 Nm 90 STEERING S...

Page 412: ...stall NEW fasteners y holding control arm to bearing carrier Torque fasteners to specification TORQUE Rear Outer Lower Control Arm Fasteners 40 lb ft 54 Nm 180 6 Attach stabilizer link to control arm with fastener u Torque to specification TORQUE Stabilizer Bar Link Fastener 42 lb ft 57 Nm 7 Install front wheels Refer to Wheel Installation page procedure WARNING Upon control arm installation test ...

Page 413: ...t the stabilizer bar for straightness Inspect the pivot bushings and replace if needed STABILIZER BAR INSTALLATION FRONT 1 Carefully install stabilizer Align mounting brackets with marks from removal 2 Install bushings and mounting brackets onto stabilizer bar Align mounting brackets with marks from removal 3 Install the fasteners q retaining the stabilizer bar mounts bushings to the vehicle frame...

Page 414: ...stabilizer bar to reference during installation 4 Remove the fasteners q retaining the stabilizer bar to the linkage Repeat step for opposite side 5 Mark the location and remove the two stabilizer bar mounts if replacing stabilizer bar 6 Remove the fasteners w retaining the stabilizer bar mounts bushings to the vehicle frame 7 Carefully remove the stabilizer bar from the vehicle 8 Inspect the stab...

Page 415: ... bar Align mounting brackets with marks from removal 3 Install the fasteners q retaining the stabilizer bar mounts bushings to the vehicle frame Torque fasteners to specification TORQUE Stabilizer Bar Mount Fasteners 42 lb ft 57 Nm 4 Install the fasteners w retaining the stabilizer bar to the linkage on each side of the vehicle Torque fasteners to specification TORQUE Stabilizer Bar Link Fasteners...

Page 416: ...rm to frame mounting bolts and remove the A arm from the chassis BALL JOINT REMOVAL 1 Remove the retaining ring q from the ball joint w 2 Place a proper sized driver on the ball joint and place the A arm in a press 3 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 control arm 2 Using a press carefully ...

Page 417: ...SERVICE EPAS TROUBLESHOOTING NOTICE Verify the EPAS unit has the latest software version and calibration loaded before replacing the EPAS unit If not update to the latest version for each and follow the guided diagnostic procedure s available in Digital Wrench POWER STEERING NON FUNCTIONAL WITH MIL ON STEERING SUSPENSION ...

Page 418: ...8 58 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc POWER STEERING NON FUNCTIONAL WITH MIL OFF STEERING SUSPENSION ...

Page 419: ...8 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 8 59 EPAS TROUBLESHOOTING USING DIGITAL WRENCH STEERING SUSPENSION ...

Page 420: ...8 60 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc NOTES STEERING SUSPENSION ...

Page 421: ...KE BLEEDING FLUID CHANGE INTL 9 16 TONE RING INSPECTION INTL 9 17 TONE RING REPLACEMENT INTL 9 17 WHEEL SPEED SENSOR REPLACE INTL 9 17 WHEEL SPEED SENSOR AIR GAP ADJUSTMENT INTL 9 18 ABS HECU REMOVAL INTL 9 19 ABS HECU INSTALLATION INTL 9 20 ABS TROUBLESHOOTING INTL 9 21 ASSEMBLY VIEWS BRAKE SYSTEM 9 22 BRAKE SYSTEM ASSEMBLY VIEW 9 22 BRAKE SYSTEM ASSEMBLY VIEW GENERAL 4 9 23 LINE ROUTING AND RETE...

Page 422: ...MENT 9 46 REAR PAD SERVICE 9 48 BRAKE PAD REMOVAL REAR 9 48 BRAKE PAD INSPECTION 9 49 BRAKE PAD INSTALLATION REAR 9 49 REAR CALIPER SERVICE 9 50 BRAKE CALIPER REMOVAL REAR 9 50 BREAK CALIPER DISASSEMBLY REAR 9 50 BRAKE CALIPER INSPECTION REAR 9 51 BRAKE CALIPER ASSEMBLY REAR 9 51 BRAKE CALIPER INSTALLATION REAR 9 52 PARKING BRAKE INT L 9 53 PARKING BRAKE ASSEMBLY VIEW 9 53 PARKING BRAKE INSPECTION...

Page 423: ...pheric vent on reservoir is unobstructed Test for brake drag after any brake system service and investigate cause if brake drag is evident Make sure caliper moves freely on guide pins where applicable Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely Perform a brake burnishing procedure after installing new pads to maximize service life DO N...

Page 424: ...4 in 34 900 mm Front Caliper Piston O D 1 370 in 34 798 mm 1 368 in 34 760 mm REAR BRAKE SYSTEM ITEM STANDARD SERVICE LIMIT Rear Brake Pad Thickness 0 270 005 in 6 858 127 mm 0 150 in 3 810 mm Rear Brake Disc Thickness 0 188 in 4 775 mm 0 181 in 4 597 mm Rear Brake Disc Thickness Variance 0 002 0 051 mm Rear Brake Disc Runout 0 010 0 254 mm Rear Caliper Piston Bore I D 1 191 in 30 251 mm 1 192 in ...

Page 425: ...374 in 34 900 mm Front Caliper Piston O D 1 370 in 34 798 mm 1 368 34 760 mm REAR BRAKE SYSTEM ITEM STANDARD SERVICE LIMIT Rear Brake Pad Thickness 0 300 0 005 in 7 62 mm 0 127 mm 0 180 in 4 572 mm Rear Brake Disc Thickness 0 188 in 4 775 mm 0 181 in 4 597 mm Rear Brake Disc Thickness Variance 0 002 in 0 051 mm Rear Brake Disc Runout 0 010 in 0 254 mm Rear Caliper Piston Bore I D 1 191 in 30 251 m...

Page 426: ...onitors the vehicle wheel speed at via a tone ring that is fixed to the half shafts on both the front and rear gearcase The sensor outputs an analog signal while the tone ring spins with the wheel to generate a speed signal for each wheel When the brakes are applied the ABS HECU is able to control the brake pressure going to each wheel to aid in deceleration The ABS feature can be enabled and disa...

Page 427: ...ront Brake Caliper Fasteners 30 lb ft 41 Nm e Banjo Bolt 15 lb ft 20 Nm o ABS Module Step 1 Pre torque all three fasteners to 1 8 lb ft 2 Nm Step 2 Torque all three fasteners to 3 lb ft 4 Nm Step 3 Torque all three fasteners to 4 lb ft 5 4 Nm r Rear Brake Caliper Fasteners46 lb ft 62 Nm a Junction Block Fasteners 35 in lbs 4 Nm t Brake Pressure Switch s Junction Block y Master Cylinder Fasteners 2...

Page 428: ...75 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc BRAKE LINE ROUTING AND RETENTION INTL MASTER CYLINDER TO ABS MODULE q Master Cylinder w Routing Clips e ABS Module BRAKE SYSTEM ...

Page 429: ...9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 9 9 ABS MODULE TO FRONT BRAKE CALIPERS q ABS Module e Brake Clip w Routing Clip r Front Brake Calipers BRAKE SYSTEM ...

Page 430: ...9 10 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc ABS MODULE TO JUNCTION BLOCK q ABS Module w Routing Clip e Junction Block BRAKE SYSTEM ...

Page 431: ...5 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 9 11 JUNCTION BLOCK TO REAR BRAKE CALIPERS q Junction Block r Hose Clamp w Routing Clip t Rear Brake Caliper e Clip BRAKE SYSTEM ...

Page 432: ...ERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc BRAKE LINE ROUTING AND RETENTION NON ABS INTL FRONT BRAKE CALIPERS TO MASTER CYLINDER q Front Brake Calipers w Brake Line Retention Points e Master Cylinder BRAKE SYSTEM ...

Page 433: ...929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 9 13 MASTER CYLINDER TO JUNCTION BLOCK q Master Cylinder w Brake Line Retention Points e Master Cylinder BRAKE SYSTEM ...

Page 434: ...9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc JUNCTION BLOCK TO REAR BRAKE CALIPERS q Junction Block w Brake Line Retention Points e Rear Brake Caliper BRAKE SYSTEM ...

Page 435: ...om the pedal mount and remove the brake pedal lever from the vehicle with its bushings t BRAKE PEDAL INSTALLATION INTL 1 Install the brake pedal onto pedal pivot shaft 2 Insert E Clip q into end of pivot shaft 3 Install the shoulder bolt washer and nut w connecting the master cylinder to the brake pedal Torque to specification TORQUE Brake Pedal Shoulder Bolt 13 lb ft 18 Nm 4 Ensure brake pedal fr...

Page 436: ...e brake pedal 7 Open the reservoir cap 8 Pump the brake pedal several times until no air bubbles appear and the brake pedal feels firm 9 Add DOT 4 brake fluid to the reservoir to the max line 10 Reinstall reservoir cap 11 Clean any brake fluid spills with isopropyl alcohol based cleaner ABS BRAKE BLEEDING FLUID CHANGE INTL The Digital Wrench ABS Brake Bleed Procedure must be performed if the ABS H...

Page 437: ...e new halfshaft will come with the tone ring installed 1 Remove drive shaft Refer to Front Drive Shaft Removalpage 7 29 or Rear Drive Shaft Removalpage 7 31 2 Replace the faulty tone ring halfshaft with the new halfshaft Refer to Inner Plunging Joint Boot Replacementpage 7 37 3 Reinstall drive shaft onto vehicle Take care when installing to prevent damage to tone ring Refer to Front Drive Shaft In...

Page 438: ...en the tone ring and sensor must be set to a specific value Adjusting wheel speed must be done for all four sensors Two sensors are located on the right and left hand side of the transmission Two sensor are located on right and left hand side of the front gearcase Air Gap Specification 0 8 1 0 mm 1 Loosen the Allen head fasteners q securing the wheel speed sensor bracket to the gearcase NOTICE The...

Page 439: ...al amount of force 4 With the proper air gap attained torque the fasteners to specification TORQUE ABS Sensor Mount INTL 5 lb ft 7 Nm 5 Repeat the procedure on the adjacent side of the gearcase ABS HECU REMOVAL INTL The ABS HECU can be accessed through the right front wheel well 1 Disconnect the ABS HECU electrical connector q 2 Disconnect the brake lines w and allow the brake fluid to drain NOTIC...

Page 440: ... HECU for the vehicle ABS HECU INSTALLATION INTL 1 Install the HECU onto its bracket 2 Install three HECU fasteners q and torque to specification in sequence TORQUE ABS HECU Mounting Fasteners INTL Step 1 Pre torque all three fasteners to 1 8 lb ft 2 Nm Step 2 Torque all three fasteners to 3 lb ft 4 Nm Step 3 Torque all three fasteners to 4 lb ft 5 4 Nm BRAKE SYSTEM ...

Page 441: ...0 Nm 5 Connect ABS HECU electrical connector r 6 Bleed Brake System See ABS Brake Bleeding Fluid Change INTL page 9 16 ABS TROUBLESHOOTING INTL Bent Wheel speed sensor bracket Damaged tone ring broken missing teeth Incorrect wheel speed sensor air gap Tone ring slid off from its original position Faulty HECU Faulty brake pressure switch Wheels Speed Sensor wire short Brake line leak Undersized or ...

Page 442: ...M ASSEMBLY VIEW q Brake Caliper Bleeder Screw4 lb ft 5 4 Nm y Master Cylinder Fasteners22 lb ft 30 Nm w Banjo Bolt15 lb ft 20 Nm u Brake Switch e Rear Caliper Fasteners46 lb ft 62 Nm i Junction Block r Front Caliper Fasteners30 lb ft 41 Nm o Junction Block Fasteners35 in lbs 4 Nm t Brake Line Clamp a Retention Fasteners BRAKE SYSTEM ...

Page 443: ...E SYSTEM ASSEMBLY VIEW q Brake Caliper Bleeder Screw 4 lb ft 5 4 Nm y Master Cylinder Fasteners 22 lb ft 30 Nm w Banjo Bolt 15 lb ft 20 Nm u Brake Switch e Rear Caliper Fasteners 46 lb ft 62 Nm i Junction Block r Front Caliper Fasteners 30 lb ft 41 Nm o Junction Block Fasteners 35 in lbs 4 Nm t Brake Line Clamp a Retention Fasteners BRAKE SYSTEM ...

Page 444: ... 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc LINE ROUTING AND RETENTION FRONT BRAKE CALIPERS TO MASTER CYLINDER q Front Brake Calipers w Brake Line Retention Points e Master Cylinder BRAKE SYSTEM ...

Page 445: ...9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 9 25 MASTER CYLINDER TO JUNCTION BLOCK q Master Cylinder w Brake Line Retention Points e Junction Block BRAKE SYSTEM ...

Page 446: ...9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc JUNCTION BLOCK TO REAR BRAKE CLIPERS q Junction Block w Brake Line Retention Points e Rear Brake Calipers BRAKE SYSTEM ...

Page 447: ...L GENERAL 4 Service Manual Copyright Polaris Industries Inc 9 27 GENERAL 4 BRAKE LINE ROUTING AND RETENTION FRONT BRAKE CALIPERS TO MASTER CYLINDER q Front Brake Calipers w Brake Line Retention Points e Master Cylinder BRAKE SYSTEM ...

Page 448: ... 28 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc MASTER CYLINDER TO JUNCTION BLOCK q Master Cylinder w Brake Line Retention Points e Junction Block BRAKE SYSTEM ...

Page 449: ...375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 9 29 JUNCTION BLOCK TO REAR BRAKE CALIPERS q Junction Block w Brake Line Retention Points e Rear Brake Calipers BRAKE SYSTEM ...

Page 450: ...RAL GENERAL 4 Service Manual Copyright Polaris Industries Inc BRAKE LINE ROUTING AND RETENTION 2019 GENERAL 4 FRONT BRAKE CALIPERS TO MASTER CYLINDER q Front Brake Calipers w Brake Line Retention Points e Master Cylinder BRAKE SYSTEM ...

Page 451: ...9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 9 31 MASTER CYLINDER TO JUNCTION BLOCK q Master Cylinder w Brake Line Retention Points e Junction Block BRAKE SYSTEM ...

Page 452: ...9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc JUNCTION BLOCK TO REAR BRAKE CALIPERS q Junction Block w Brake Line Retention Points e Rear Brake Calipers BRAKE SYSTEM ...

Page 453: ... Manual Copyright Polaris Industries Inc 9 33 BRAKE CALIPER ASSEMBLY VIEW FRONT CALIPER q Asm Brake Pad y Square Ring w Asm Caliper Mount u Caliper Brake e Boot Pin Seal i Bolt r Boot Pin Bushing o Bleeder Screw t Piston Brake a Cap Plug BRAKE SYSTEM ...

Page 454: ...L GENERAL 4 Service Manual Copyright Polaris Industries Inc REAR CALIPER q Asm Brake Pad y Square Ring w Asm Caliper Mount u Caliper Brake e Boot Pin Seal i Bolt r Boot Pin Bushing o Bleeder Screw t Piston Brake a Cap Plug BRAKE SYSTEM ...

Page 455: ...stem changes this port compensates for fluid expansion or contraction Due to the high temperatures created within the system during heavy braking it is very important that the master cylinder reservoir have adequate space to allow for fluid expansion Never overfill the reservoir Do not fill the reservoir beyond the MAX LEVEL line When servicing Polaris brake systems use only Polaris DOT 4 Brake Fl...

Page 456: ... lb ft 5 4 Nm 9 Repeat steps 5 8 for the remaining calipers 10 Add brake fluid to MAX level inside reservoir Master Cylinder Fluid Level Up to MAX line inside reservoir 11 Install master cylinder reservoir cover 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 1...

Page 457: ...Loosen the brake line banjo bolts and allow fluid to drain 5 Remove the two mounting fasteners that secure the master cylinder to the frame MASTER CYLINDER INSTALLATION 1 Install the master cylinder into the mounting bracket on the vehicle Install mounting fasteners and torque to specification TORQUE Master Cylinder Mounting Fasteners 22 lb ft 30 Nm 2 Install the brake line banjo bolts in correct ...

Page 458: ...e brake pedal lever 2 Remove the E clip from the pedal mount and remove the brake pedal lever from the vehicle BRAKE PEDAL INSTALLATION 1 Install the brake pedal onto pedal pivot shaft 2 Insert E Clip into end of pivot shaft 3 Install the clevis pin and clip holding the master cylinder to the brake pedal 4 Ensure brake pedal freeplay is within specification Brake Pedal Free play 0 090 in 2 28 mm B...

Page 459: ...s and remove the caliper from the front hub WARNING 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 NOTICE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper...

Page 460: ...mm BRAKE PAD INSTALLATION FRONT 1 Lubricate mounting bracket pins q 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 WARNING 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 fr...

Page 461: ...y pad contacts disc then back off 1 2 turn counterclockwise 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap Master Cylinder Fluid Up to MAX line inside reservoir 7 Install front wheels Refer to Wheel Installation page procedure NOTICE If new pads are installed refer to Brake Burnishing Procedure page 9 36 BRAKE SYSTEM ...

Page 462: ...ne q Remove brake line from caliper CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 5 Loosen brake pad adjustment set screw 2 3 turns to allow brake pad removal after the caliper is removed 6 Remove the two caliper mounting bolts and remove the caliper assembly from the front hub BRAKE CALIPER DISASSEMBLY FRONT 1 Remove both brak...

Page 463: ...ved use a pick to carefully remove the square O rings e from the caliper O rings should be replaced during caliper service 6 Clean the caliper body pistons and retaining bracket r with brake cleaner or alcohol NOTICE Be sure to clean seal grooves in caliper body BRAKE CALIPER INSPECTION FRONT 1 Inspect caliper body for nicks scratches pitting or wear Measure bore size and compare to specifications...

Page 464: ...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 e 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 cleaner or denatured alcohol to remove ...

Page 465: ... 2 turn counterclockwise 5 Bleed the brake system Refer to Brake Bleeding Fluid Change page 9 35 procedure 6 Install front wheels Refer to Wheel Installation page procedure 7 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when pedal is released If the brake drags re check assembly and installation NO...

Page 466: ...scoring scratches or gouges Replace disc if deep scratches are evident 2 Use a 0 1 micrometer and measure disc thickness at eight different points around the pad contact surface Replace disc if worn beyond service limit Brake Disc Thickness Std 0 188 in 4 775 mm Service Limit 0 181 in 4 597 mm Brake Disc Thickness Variance Service Limit 0 002 0 051 mm BRAKE DISC REPLACEMENT 1 Remove the appropriat...

Page 467: ...ocking agent which is destroyed upon removal 6 Install wheel hub assembly washers and castle nut Refer to Front Bearing Carrier Installation page or Rear Bearing Carrier Installation page procedure 7 Install the brake caliper Refer to Brake Caliper Installation Front page 9 44 or Brake Caliper Installation Rear page 9 52 procedure 8 Bleed the brake system Refer to Brake Bleeding Fluid Change page ...

Page 468: ...ng bolts and lift caliper off the brake disc WARNING When removing caliper be careful not to damage brake line Support caliper to avoid kinking or bending brake line 5 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers with pads installed NOTICE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into ...

Page 469: ...se oil or liquid soaked do not use the pads Use only new clean pads 3 Install the caliper and torque the new mounting bolts to specification TORQUE Rear Caliper Mounting Bolts 46 lb ft 62 Nm 4 Slowly pump the brake pedal until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the brake system 5 Install the adjustment set screw and...

Page 470: ... not allow brake fluid to come in contact with finished surfaces 5 Loosen brake pad adjustment set screw 2 3 turns to allow brake pad removal after the caliper is removed 6 Remove the caliper mounting bolts and remove the caliper assembly from the rear hub BREAK CALIPER DISASSEMBLY REAR 1 Thoroughly clean the caliper before disassembly and prepare a clean work area for disassembly 2 Remove brake p...

Page 471: ...m Service Limit 1 192 in 30 277 mm 2 Inspect piston for nicks scratches pitting or wear Measure piston diameter and replace if damaged or worn beyond service limit MEASUREMENT Rear Caliper Piston O D Std 1 187 in 30 162 mm Service Limit 1 186 in 30 124 mm 3 Inspect the brake disc and pads as outlined in this chapter BRAKE CALIPER ASSEMBLY REAR 1 Install new caliper seals q in the caliper body w Be...

Page 472: ...e NEW mounting bolts to specification TORQUE Rear Caliper Mounting Bolts 46 lb ft 62 Nm 3 Torque the banjo bolt w to specification TORQUE Brake Line Banjo Bolts 15 lb ft 20 Nm 4 Install the adjustment set screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise 5 Bleed the brake system Refer to Brake Bleeding Fluid Change page 9 35 procedure 6 Install rea...

Page 473: ... L PARKING BRAKE ASSEMBLY VIEW q Parking Brake Lever u Edge Clip w Pin Clip i Parking Brake Bracket e Pin Clevis o Parking Brake Caliper Fastener 37 lb ft 50 Nm r Parking Brake Lever Fastener 22 lb ft 30 Nm a Parking Brake Spacer 2 in 51 mm t Parking Brake Cable s Parking Brake Caliper y Battery Pad BRAKE SYSTEM ...

Page 474: ...k on parking brake lever located in the center console 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 roll while parked 3 If the vehicle moves adjustment is necessary 4 Adjust the parking brake cable where it attaches to the caliper mount shift cable bracket The mo...

Page 475: ...brake caliper off the brake disc and remove it from the vehicle CALIPER INSTALLATION 1 Install the parking brake caliper over the brake disc Align the caliper mounting sleeves with the holes in the mount bracket 2 Install and tighten the two caliper mount shift cable bracket fasteners w to specification TORQUE Parking Brake Caliper Mount Bracket Bolts 37 lb ft 50 Nm 3 Install the cable pin and cli...

Page 476: ...ERAL 4 Service Manual Copyright Polaris Industries Inc 4 Install the new brake disc Install the flat washer q and mounting bolt w Torque the mounting bolt to specification TORQUE Parking Brake Disc Mounting Bolt 20 lb ft 28 Nm BRAKE SYSTEM ...

Page 477: ...s Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Damaged break pad noise insulator Brake pads dragging Brake caliper dragging PEDAL VIBRATION Disc damaged Disc worn runout or thickness variance exceeds service limit CALIPER OVERHEATS BRAKES DRAG Compensating port plugged Pad clearance set incorrectly Brake pedal binding or unable to return fully Residue build up ...

Page 478: ...9 58 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc NOTES BRAKE SYSTEM ...

Page 479: ...RAL 4 10 15 ROPS ASSEMBLY VIEW 10 17 ROPS ASSEMBLY VIEW GENERAL 4 10 18 FRAME ASSEMBLY VIEW 10 19 FRAME ASSEMBLY VIEW GENERAL 4 10 20 FRAME ASSEMBLY VIEW GENERAL 4 2019 10 21 BODY COMPONENT REMOVAL 10 23 ROOF REMOVAL 10 23 AUDIO SYSTEM REMOVAL 10 23 REAR VIEW MIRROR REMOVAL 10 24 DOOR REMOVAL 10 24 DOOR REMOVAL GENERAL 4 10 25 SEAT REMOVAL 10 25 HOOD REMOVAL 10 25 FRONT BUMPER REMOVAL 10 26 EXTERI...

Page 480: ...LATION 10 56 SEAT INSTALLATION 10 56 DOOR INSTALLATION 10 57 DOOR INSTALLATION GENERAL 4 10 58 DOOR CABLE ADJUSTMENT 10 61 AUDIO SYSTEM INSTALLATION 10 65 REAR VIEW MIRROR INSTALLATION 10 67 ROOF INSTALLATION 10 68 FRAME COMPONENT INSTALLATION 10 69 ROPS REMOVAL 10 69 ROPS REMOVAL GENERAL 4 10 69 ROPS INSTALLATION 10 70 ROPS INSTALLATION GENERAL 4 10 71 SKID PLATE REPLACEMENT 10 73 SKID PLATE REPL...

Page 481: ...Nm Front Close off Panel Fasteners 3 5 lb ft 4 7 Nm Rear Lower Close off Panel Fasteners 3 5 lb ft 4 7 Nm Seat Belt Fasteners 40 lb ft 54 Nm Rear Upper Close off Panel Fasteners 3 5 lb ft 4 7 Nm Center Console Panel Fasteners 3 5 lb ft 4 7 Nm Passenger Grab Handle Fasteners 6 lb ft 8 Nm Main Dash Fasteners 3 5 lb ft 4 7 Nm Terminal Block Fasteners 3 lb ft 4 Nm Intake Duct Hose Clamp 3 lb ft 4 Nm C...

Page 482: ...tries Inc ASSEMBLY VIEWS BODY FRAME EXTERIOR BODY COMPONENT ASSEMBLY VIEW q Liner Hood u Asm Fender Flare LH Rear w Hood Outer i Panel Rocker LH e Hood o Asm Fender Flare LH Front r 1 4 turn latch a Fascia Front Upper t Fender Front LH s Fascia Front Lower y Fender Rear LH BODY FRAME ...

Page 483: ...RIOR BODY COMPONENT ASSEMBLY VIEW GENERAL 4 q Hood i Fender Rear LH w 1 4 Turn Latch o Asm Fender Flare Rear LH e Hood Outer a Asm Rocker LH r Liner Hood s Asm Fender Flare Front LH t Fender Front LH d Fascia Front Upper y Fender Center Lower LH f Fascia Front Lower u Fender Center Upper LH BODY FRAME ...

Page 484: ... Inc EXTERIOR BODY COMPONENT ASSEMBLY VIEW INT L q Inner Hood u Mud Fender LH w 1 4 Turn Latch i Front Render Flare LH e Outer Hood o Rocker Assembly LH r Front Upper Floor Panel a Rear Fender LH t Front Upper Fascia s Rear Fender Flare LH y Front Lower Fascia d Front Fender LH BODY FRAME ...

Page 485: ...el Close off Rear Upper a Holder Cup w Panel Service s Panel Console Service e Panel Close off Rear Lower d Panel Console Controls r Panel Service f Storage Dash Center t Floor Main LH g Door Glovebox y Console Center LH h Dash Main u Console Center Cover j Panel Dash Upper i Console Center top k Panel Floor Upper o Handle Grab BODY FRAME ...

Page 486: ...l Close off Rear Lower j Panel Console Service r Panel Service k Console Center Top t Panel Floor Upper l Console Center Cover y Floor Main LH 1 Handle Grab u Floor Main RH 2 Holder Cup i Plug Floor Drain 2 Storage Underseat o Panel Dash Upper 2 Panel Close off Front a Dash Main 2 Floor Rear LH s Door Glovebox 2 Floor Rear RH d Storage Dash Center 2 Console Center Rear Top f Panel Console Controls...

Page 487: ...10 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 10 9 SEAT ASSEMBLY VIEW q Back Seat r Frame Seat w Bottom Seat t Asm Seat Base e Asm Seat Slider BODY FRAME ...

Page 488: ...10 10 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc CARGO BOX ASSEMBLY VIEW q Asm Cargo Box e Asm Box Support w Asm Tailgate r Latch Cargo Box BODY FRAME ...

Page 489: ...02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 10 11 DOOR ASSEMBLY VIEW q Panel Door Outer r Panel Door Inner w Frame Door t Trim Door Inner e Door Seal y Cover Door Hinge BODY FRAME ...

Page 490: ...10 12 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc q Door Latch w Door Cable e Door Handle Assembly BODY FRAME ...

Page 491: ...2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 10 13 DOOR ASSEMBLY VIEW 2019 q Panel Door Outer r Panel Door Inner w Frame Door t Trim Door Inner e Door Seal y Cover Door Hinge BODY FRAME ...

Page 492: ...10 14 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc q Door Latch w Door Cable e Door Handle Assembly BODY FRAME ...

Page 493: ...NERAL 4 Service Manual Copyright Polaris Industries Inc 10 15 DOOR ASSEMBLY VIEW GENERAL 4 q Cover Bolster Rear t Door Seal w Panel Door Outer y Panel Door Inner e Bolster Rear u Trim Door Inner r Frame Door i Cover Door Hinge BODY FRAME ...

Page 494: ...10 16 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc q Door Cable w Door Handle Assembly e Door Latch BODY FRAME ...

Page 495: ...10 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 10 17 ROPS ASSEMBLY VIEW q ROPS Rear r ROPS RH w ROPS LH t Panel Visor e Front Cross BODY FRAME ...

Page 496: ... GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc ROPS ASSEMBLY VIEW GENERAL 4 q Panel Visor t ROPS Center w ROPS Front Support y ROPS Rear LH e ROPS Front LH u ROPS Rear RH r ROPS Front RH i ROPS Rear BODY FRAME ...

Page 497: ...19 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 10 19 FRAME ASSEMBLY VIEW q Plate Skid Rear t Frame Dash w Plate Skid Main y Frame Seat Base e Bracket Suspension Mount u Frame Top r Frame Main BODY FRAME ...

Page 498: ...pyright Polaris Industries Inc FRAME ASSEMBLY VIEW GENERAL 4 q Frame Main Front y Frame Top w Frame Main Rear u Frame Seat Base Front e Plate Skid Front i Frame Seat Base Rear r Plate Skid Center o Frame Dash t Plate Skid Rear a Bracket Suspension Mount BODY FRAME ...

Page 499: ...pyright Polaris Industries Inc 10 21 FRAME ASSEMBLY VIEW GENERAL 4 2019 q Frame Main Front y Frame Top w Frame Main Rear u Frame Seat Base Rear e Plate Skid Front i Frame Seat Base Front r Plate Skid Center o Bracket Suspension Mount t Plate Skid Rear BODY FRAME ...

Page 500: ... Seat Base Rear Fastener M10 x 1 5 x 55 30ft lbs 41 Nm u Main Frame Outside Fastener M10 x 1 25 x 70 40 ft lbs 54 Nm e Frame Seat Base Rear Fastener M8 x 1 25 x 55 10 ft lbs 14 Nm i Main Frame Inside M10 x 1 25 x 55 40 ft lbs 54 Nm r Frame Seat Base Front Fastener M10 x1 5 x25 30 ft lbs 14 Nm o Main Frame Outside M10 x 1 25 x 40 40 ft lbs 54 Nm t Frame Seat Base Front Fastener M8 x 1 25 x 55 10 ft...

Page 501: ...to remove it from the ROPS Trim Panel AUDIO SYSTEM REMOVAL 1 Remove fasteners from audio system to visor panel upper mounting points 2 Remove fasteners from audio system to visor panel lower mounting points 3 Remove fasteners from visor panel and remove visor panel 4 Remove Rear View Mirror Refer to Rear View Mirror Removalpage 10 24 procedure 5 Disconnect ROPS audio harness from audio system harn...

Page 502: ...d remove audio system 7 Remove the ROPS audio harness from the RH ROPS REAR VIEW MIRROR REMOVAL 1 Remove the top mounting fastener from the rear view mirror 2 Remove the rear view mirror from the front support ROPS taking car not to lose the mounting bracket DOOR REMOVAL 1 Open door to expose door hinge 2 Remove door hinge fasteners 3 Remove door from vehicle BODY FRAME ...

Page 503: ... 1 Open door to expose door hinge 2 Remove door hinge fasteners 3 Remove door from vehicle SEAT REMOVAL 1 To remove any of the seats lift upward on the latch lever located behind the seat bottom 2 Lift upward and forward on the seat while lifting up on the latch lever to remove the seat from the vehicle HOOD REMOVAL 1 Rotate the latches 90 to release the hood from the vehicle 2 Pull the hood forwa...

Page 504: ...ators in the bumper before removing front bumper 4 Remove the front bumper lower mounting fasteners and remove bumper from the vehicle EXTERIOR BODY COMPONENT REMOVAL 1 Remove the hood from the vehicle Refer to Hood Removal page 10 25 procedure 2 Remove the front bumper from the vehicle Refer to Front Bumper Removal page 10 26 procedure 3 Remove the fastener holding the front fender flair to the f...

Page 505: ...e cargo box out of the way 6 Remove the fasteners holding the rear fender flair to the rear fender Pull the rear fender flair from the tabs holding it to the vehicle 7 Remove the fasteners holding the rear fender to the vehicle and rocker panel Pull the rear fender from the tabs holding it to the vehicle NOTICE Remove the clutch intake hose from the LH rear fender 8 Remove the remaining fasteners ...

Page 506: ...ve the remaining fasteners holding the upper front fascia to the vehicle and the hood liner Disconnect the headlights from the electrical harness and remove the front fascia from the vehicle 11 To remove the hood liner remove the fasteners and clamps securing the terminal block intake vent and coolant expansion bottle 12 Remove the fasteners holding the hood liner to the vehicle and remove the hoo...

Page 507: ...ding it to the vehicle 4 Remove the fasteners holding the front fender to the vehicle Pull the front fender off the vehicle NOTICE Remove the front grill mesh to access the fasteners on the front of the fender 5 Pull the cargo box handle and lift the cargo box out of the way 6 Remove the fasteners holding the rear fender flair to the rear fender Pull the rear fender flair from the tabs holding it ...

Page 508: ...o the vehicle Remove the lower front fascia from the vehicle 10 Remove the remaining fasteners holding the upper front fascia to the vehicle and the hood liner Disconnect the headlights from the electrical harness and remove the front fascia from the vehicle 11 To remove the hood liner remove the fasteners and clamps securing the pulse bar mounting bracket intake vent and coolant expansion bottle ...

Page 509: ... to the vehicle 4 Remove the fasteners holding the front fender to the vehicle Pull the front fender off the vehicle NOTICE Remove the front grill mesh to access the fasteners on the front of the fender 5 Remove the fasteners holding the center upper fender to the vehicle Pull the fender off the vehicle 6 Remove the fasteners holding the center lower fender to the vehicle Pull the fender tabs up o...

Page 510: ... and remove the panel from the vehicle NOTICE Remove the gas cap to remove the RH rocker panel 11 Remove the fasteners holding the lower front fascia to the vehicle Remove the lower front fascia from the vehicle 12 Remove the remaining fasteners holding the upper front fascia to the vehicle and the hood liner Disconnect the headlights from the electrical harness and remove the front fascia from th...

Page 511: ...the fastener holding the front fender flair to the front fender Pull the front fender flair from the tabs holding it to the vehicle 4 Remove the fasteners holding the front fender to the vehicle Pull the front fender off the vehicle NOTICE Remove the front grill mesh to access the fasteners on the front of the fender 5 Remove the fasteners holding the center upper fender to the vehicle Pull the fe...

Page 512: ...r fender from the tabs holding it to the vehicle NOTICE Remove the clutch intake hose from the LH rear fender 10 Remove the remaining fasteners on the rocker panel and remove the panel from the vehicle NOTICE Remove the gas cap to remove the RH rocker panel 11 Remove the fasteners holding the lower front fascia to the vehicle Remove the lower front fascia from the vehicle 12 To remove the hood lin...

Page 513: ...and remove the hood liner INTERIOR BODY COMPONENT REMOVAL NOTICE ROPS shown removed for illustration purposes only It is not necessary to remove the ROPS to remove the interior body components 1 Remove the hood front and rear fenders and rocker panels Refer to Exterior Body Component Removal page 10 26 procedure 2 Remove the fasteners holding the upper dash panel to the vehiclė and remove the pane...

Page 514: ...e panel and behind the speedometer display holding the main dash to the vehicle Disconnect the rest of the interior controls from the wire harness and remove the main dash from the vehicle NOTICE Remove the gauge cluster if necessary to aid in removal 6 Remove the fasteners holding the passenger grab handle to the vehicle 7 Remove the fasteners holding the center tunnel access cover to the center ...

Page 515: ...and remove the rear upper close off panel from the vehicle NOTICE If necessary loosen remove the fasteners holding the door latch mounts to the vehicle to aid in panel removal 11 Remove the fasteners holding the rear lower close off panel to the vehicle Remove the seat belt buckles seat belt shoulder strap mounts and brackets and fuse box from the panel Remove the lower close off panel from the ve...

Page 516: ...holding the upper dash panel to the vehiclė and remove the panel 3 Remove the fasteners holding the upper floor panel to the main floor panels 4 Pull the controls console panel from the main dash tabs Remove the wiring harness connectors components in the controls console panel 5 Remove the remaining fasteners in the glovebox behind the controls console panel and behind the speedometer display hol...

Page 517: ...ter console panels to the vehicle 9 Remove the shift boot from the center console top and remove the remaining fasteners holding center console top to the vehicle Disconnect the 12 V power connectors and remove the center console top from the vehicle 10 Remove the fasteners holding the rear center console cover to the vehicle 11 Remove the fasteners holding the rear center console to the vehicle 1...

Page 518: ...ve the fasteners holding the rear lower close off panel to the vehicle Remove the seat belt buckles seat belt shoulder strap mounts and brackets and fuse box from the panel Remove the lower close off panel from the vehicle 15 Remove the fasteners holding the front close of panel to the vehicle 16 Remove the fasteners holding the front seat base frame to the vehicle 17 Remove the remaining fastener...

Page 519: ... floors to the vehicle CARGO BOX REMOVAL 1 Pull the cargo box handle and lift the cargo box up 2 Remove the pin holding the shock to the cargo box 3 Disconnect the cargo box wire harness from the main wire harness 4 Remove the fasteners holding the cargo box to the vehicle frame With the help of an assistant remove the cargo box from the vehicle BODY FRAME ...

Page 520: ...f the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged CAUTION Do not flame treat painted plastic components Painted plastic surfaces should only be wiped clean prior to decal adhesion To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the are...

Page 521: ...ock to the cargo box 4 Lower the cargo box and secure in position INTERIOR BODY COMPONENT INSTALLATION NOTICE ROPS shown removed for illustration purposes only It is not necessary to remove the ROPS to remove the interior body components 1 Install the RH and LH main floors in the vehicle and install the fasteners holding the main floors to the vehicle 2 Install the brake pedal accelerator pedal an...

Page 522: ...QUE Rear Upper Close off Panel Fasteners 3 5 lb ft 4 7 Nm 7 Install the ECU Refer to ECU Replacementpage 11 43 procedure 8 Install the center console top into the vehicle and over the shift lever Install the shift boot into the center console top Connect the 12 V power receptacles to the wiring harness 9 Install the fasteners holding the RH and LH center console panels to the vehicle Torque fasten...

Page 523: ...or panel to the main floor panels 13 Connect the interior controls to the wiring harness and install the main dash into the vehicle Install the fasteners in the glovebox behind the controls console panel and behind the speedometer display holding the main dash to the vehicle Torque fasteners to specification TORQUE Main Dash Fasteners 3 5 lb ft 4 7 Nm 14 Install the wiring harness connectors to th...

Page 524: ... It is not necessary to remove the ROPS to remove the interior body components 1 Install the RH and LH main floors in the vehicle and install the fasteners holding the main floors to the vehicle Torque the fasteners to specification TORQUE Floor Fasteners 3 5 lb ft 4 7 Nm 2 Install the brake pedal accelerator pedal and mounting bracket Refer to Brake Pedal Installation page 9 38 procedure 3 Instal...

Page 525: ...ff Panel Fasteners 3 5 lb ft 4 7 Nm 6 Install the fasteners holding the rear lower close off panel to the vehicle Torque fasteners to specification TORQUE Rear Lower Close off Panel Fasteners 3 5 lb ft 4 7 Nm 7 Install the seat belt buckles and seat belt shoulder strap mounts TORQUE Seat Belt Fasteners 40 lb ft 54 Nm 8 Install the fuse box Refer to Fuse Box Replacementpage 11 61 procedure 9 Instal...

Page 526: ...et 13 Install the center console top into the vehicle and over the shift lever Install the shift boot into the center console top Connect the 12 V power receptacles to the wiring harness 14 Install the fasteners holding the RH and LH center console panels to the vehicle Torque fasteners to specification TORQUE Center Console Panel Fasteners 3 5 lb ft 4 7 Nm 15 Install the center tunnel access cove...

Page 527: ...or panel to the main floor panels 18 Connect the interior controls to the wiring harness and install the main dash into the vehicle Install the fasteners in the glovebox behind the controls console panel and behind the speedometer display holding the main dash to the vehicle Torque fasteners to specification TORQUE Main Dash Fasteners 3 5 lb ft 4 7 Nm 19 Install the wiring harness connectors to th...

Page 528: ... to Exterior Body Component Installation page 10 50 procedure EXTERIOR BODY COMPONENT INSTALLATION 1 If removed install fasteners holding the hood liner to the vehicle 2 Install the fasteners and clamps securing the terminal block intake duct and coolant surge Torque fasteners to specification TORQUE Terminal Block Fasteners 3 lb ft 4 Nm Intake Duct Hose Clamp 3 lb ft 4 Nm Coolant Surge Tank Faste...

Page 529: ...Fasteners 3 5 lb ft 4 7 Nm 4 Install the fasteners holding the lower front fascia to the vehicle 5 Install the fasteners holding the rocker panel to the vehicle TORQUE Rocker Panel Fasteners 3 5 lb ft 4 7 Nm 6 Install the rear fender on the vehicle Connect the clutch intake hose to the LH rear fender and tighten hose clamp until taught do NOT overtighten hose clamp Install the fasteners holding th...

Page 530: ...on 9 Install the fasteners holding the front fender to the vehicle Torque the fasteners to specification TORQUE Front Fender Fasteners 3 5 lb ft 4 7 Nm 10 Install the fastener holding the front fender flair to the front fender Torque the fastener to specification TORQUE Front Fender Flair Fastener 3 5 lb ft 4 7 Nm 11 Install the hood onto the vehicle Refer to Hood Installation page 10 56 procedure...

Page 531: ...Torque fasteners to specification TORQUE Terminal Block Fasteners 3 lb ft 4 Nm Intake Duct Hose Clamp 3 lb ft 4 Nm Coolant Surge Tank Fasteners 2 lb ft 2 7 Nm 3 Install the front fascia on the vehicle and connect the headlights to the wiring harness Install the fasteners holding the upper front fascia to the vehicle and the hood liner Torque the fasteners to specification TORQUE Upper Front Fascia...

Page 532: ...the fasteners holding the rear fender to the vehicle and rocker panel Torque the fasteners to specification TORQUE Rear Fender Fasteners 3 5 lb ft 4 7 Nm 7 Install the fasteners holding the rear fender flair to the rear fender 8 Close the cargo box and secure in position 9 Install the center lower fender tabs into of the rocker panel Install the fasteners holding the center lower fender to the veh...

Page 533: ...orque the fastener to specification TORQUE Front Fender Flair Fastener 3 5 lb ft 4 7 Nm 13 Install the hood onto the vehicle Refer to Hood Installation page 10 56 procedure FRONT BUMPER INSTALLATION 1 Install the front bumper on the vehicle and align mounting points Install the front bumper lower mounting fasteners and torque to specification TORQUE Front Bumper Fasteners 30 lb ft 41 Nm 2 Install ...

Page 534: ...ching the winch hook HOOD INSTALLATION 1 Install the hood on the vehicle and align the latches 2 Rotate the latches 90 to secure the hood SEAT INSTALLATION 1 To install the seats install the front tabs of the seat base assembly into the mounting bracket 2 Press down on the back of the seat to latch the seat onto the frame Lift up on the seat to ensure it is fully installed BODY FRAME ...

Page 535: ...e plastic covers off of door panel 2 Loosen 13mm door hinge fasteners q 3 With the help of an assistant align the Driver door hinges with door hinge mounting brackets 4 Place door pivot bushings in door hinge mounting brackets 5 Install the door hinge pivot bolts and nuts into the door hinges using a 13mm socket and wrench Torque the nuts to specification TORQUE Door Hinge Pivot Nut 8 lb ft 11 Nm ...

Page 536: ...eners 27 lb ft 37 Nm 9 Check the front door gap on its leading edge NOTICE If door gap adjustment is needed make a small adjustment to the striker pin vertical position and redo steps 2 7 and 8 10 Verify the door properly open closes and locks 11 Install plastic door panel covers DOOR INSTALLATION GENERAL 4 CAUTION Be careful not to damage body panels during door adjustment Leave the packaging on ...

Page 537: ...e front door hinges with door hinge mounting brackets 5 Install the door hinge pivot bolts and nuts into the door hinges using a 13 mm socket and wrench Torque the nuts to specification TORQUE Door Hinge Pivot Nut 8 lb ft 11 Nm 6 Verify the striker is in a nominal position both vertically and laterally and adjust if needed w 7 Close the door slowly and guide the latch to the striker NOTICE The lat...

Page 538: ...door gap on its leading edge NOTICE If door gap adjustment is needed make a small adjustment to the striker pin vertical position and redo steps 2 7 and 8 10 Verify the door properly opens closes and locks 11 Install plastic door panel covers Rear Door Alignment 1 Loosen 13mm hinge fasteners q 2 Remove hinge fasteners and remove plastic packaging clip 3 Close door and guide door latch into striker...

Page 539: ...rs 27 lb ft 37 Nm 6 Check the door gap on its leading edge NOTICE If door gap adjustment is needed make a small adjustment to the striker pin vertical position and redo steps 1 4 7 Verify that the door properly opens closes and locks DOOR CABLE ADJUSTMENT To watch a video on this procedure Scan the provided QR code or click here 1 Remove inner door trim by removing it s fastener q 2 Remove door hi...

Page 540: ... Inc 3 Remove inner door panel by removing it s fasteners e 4 Push door latch into double lock position 5 Locate exterior handle cable adjuster 6 Loosen the door cable lock collar and adjuster until no threads are showing 7 Hold the exterior door handle in the full open position BODY FRAME ...

Page 541: ...on to the paint mark 11 Push door latch into double lock position 12 Open exterior door handle slowly NOTICE The exterior door handle should be about 3 4 of the way through its throw when it releases the latch Adjust cable if necessary 13 When cable is adjusted properly tighten lock collar 14 Locate interior door cable adjuster 15 Push door latch into double lock position 16 Loosen M10 nuts on eit...

Page 542: ...n the door handle side M10 nut 22 Push door latch into double lock position 23 Open interior door handle slowly NOTICE The interior door handle should be about 3 4 of the way through its throw when it releases the latch Adjust cable if necessary General 4 Models 1 Remove seven door panel fasteners 2 Locate door cable adjuster 3 Loosen door cable adjuster 4 Push door latch into double lock position...

Page 543: ... 8 Reinstall the door panel and fasteners AUDIO SYSTEM INSTALLATION SERVICE VIDEO A service video has been created to help highlight this procedure To view the video either Scan the QR Code with a mobile device From a computer right click HERE and open link in a new window 1 Route the ROPS audio harness down the RH ROPS from behind front support ROPS down to frame mounting point Connect ROPS audio...

Page 544: ... System Fasteners 3 5 lb ft 4 7 Nm 5 Connect ROPS audio harness to audio system harness connectors matching wire colors NOTICE EARLY MODELS Connect brown ROPS audio harness wire to black audio system wire 6 Install Rear View Mirror Refer to Rear View Mirror Installationpage 10 67 procedure 7 Install the U type nuts onto front support ROPS to visor panel top mounting points 8 Install U type nuts on...

Page 545: ...b ft 4 7 Nm 11 Install fasteners into audio system to visor panel lower mounting points Torque fasteners to specification TORQUE Audio System Fasteners 3 5 lb ft 4 7 Nm 12 Install fasteners into audio system to visor panel upper mounting points Torque fasteners to specification TORQUE Audio System Fasteners 3 5 lb ft 4 7 Nm REAR VIEW MIRROR INSTALLATION 1 Install the foam pads on the inside surfac...

Page 546: ...r depending on torque ROOF INSTALLATION SERVICE VIDEO A service video has been created to help highlight this procedure To view the video either Scan the QR Code with a mobile device From a computer right click HERE and open link in a new window 1 Ensure the ROPS Visor Trim Panel installed 2 With the help of an assistant place the roof onto the top of the ROPS 3 Engage the front hooks into the ROP...

Page 547: ...d the front cross to the RH and LH ROPS 3 Remove the fasteners that hold the RH and LH ROPS to the vehicle frame and rear ROPS 4 Pull the cargo box handle and lift the cargo box out of the way 5 Remove the fasteners that hold the rear ROPS to the vehicle frame ROPS REMOVAL GENERAL 4 1 Remove the fasteners that hold the visor panel to the front cross 2 Remove the fasteners that hold the front cross...

Page 548: ...move the fasteners holding the seat belt shoulder strap assemblies to the center and rear ROPS 7 Remove the fasteners that hold the rear ROPS to the vehicle frame 8 Remove the fasteners that hold the center ROPS to the vehicle frame ROPS INSTALLATION NOTICE Loosely install ROPS onto vehicle with all fasteners before beginning to torque fasteners 1 Pull the cargo box handle and lift the cargo box o...

Page 549: ...RQUE Rear ROPS Fasteners 40 lb ft 54 Nm Side ROPS Fasteners 40 lb ft 54 Nm Front Cross Fasteners 40 lb ft 54 Nm 6 Install the fasteners that hold the visor panel to the front cross Torque the fasteners to specification TORQUE Visor Panel Fasteners 3 5 lb ft 4 7 Nm ROPS INSTALLATION GENERAL 4 NOTICE Loosely install ROPS onto vehicle with all fasteners before beginning to torque fasteners 1 Loosely ...

Page 550: ...vehicle frame and rear ROPS 6 Loosely install the fasteners that hold the front cross to the front RH and LH ROPS Torque the ROPS fasteners to specification in order of installation TORQUE Center ROPS Fasteners 40 lb ft 54 Nm Rear ROPS Fasteners 40 lb ft 54 Nm Side ROPS Fasteners 40 lb ft 54 Nm Front Cross Fasteners 40 lb ft 54 Nm 7 Install the fasteners that hold the visor panel to the front cros...

Page 551: ...lation Torque fasteners to specification TORQUE Skid Plate Fasteners 3 5 lb ft 4 7 Nm SKID PLATE REPLACEMENT GENERAL 4 1 Remove the fasteners that hold the front skid plate to the frame and remove the front skid plate 2 Remove the fasteners that hold the center skid plate to the frame and remove the center skid plate 3 Remove the remaining fasteners that hold the rear skid plate to the frame and r...

Page 552: ...10 74 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc NOTES BODY FRAME ...

Page 553: ...S ELECTRICAL SYSTEM 11 22 ELECTRICAL DIAGNOSTICS 11 23 ELECTRICAL SERVICE NOTES 11 23 DIGITAL MULTI METER DMM NOTES 11 23 STATIC AND DYNAMIC TESTING 11 23 STATIC TESTING 11 23 DYNAMIC TESTING 11 23 CONNECTOR PROBING GUIDELINES 11 24 FRONT PROBING 11 24 BACK PROBING 11 24 BREAK OUT 11 24 TESTING CONTINUITY RESISTANCE 11 25 TESTING FOR A SHORT TO GROUND 11 25 TESTING FOR A SHORT TO VOLTAGE 11 26 TES...

Page 554: ... 52 BATTERY SERVICE 11 53 BATTERY SPECIFICATIONS 11 53 BATTERY REMOVAL 11 53 BATTERY REMOVAL INTL 11 53 BATTERY INSTALLATION 11 54 BATTERY INSTALLATION INTL 11 54 BATTERY OFF SEASON STORAGE 11 54 BATTERY TESTING 11 55 OPEN CIRCUIT VOLTAGE OCV TEST 11 55 LOAD TEST 11 55 CURRENT DRAW KEY OFF 11 55 BATTERY CHARGING PROCEDURE 11 55 FUSE RELAY SERVICE 11 57 FUSE RELAY OPERATION OVERVIEW 11 57 FUSE RELA...

Page 555: ...N COIL TESTS 11 74 SPARK PLUG SERVICE 11 75 ELECTRONIC POWER ASSISTED STEERING 11 76 EPAS OPERATION OVERVIEW 11 76 EPAS SYSTEM DIAGNOSTICS 11 76 LIGHTING SYSTEM SERVICE 11 77 HEADLIGHT ADJUSTMENT 11 77 HEADLIGHT BULB REPLACEMENT 11 77 HEADLIGHT REMOVAL 11 78 HEADLIGHT INSTALLATION 11 78 TAIL LIGHT REPLACEMENT 11 79 DASH LED LIGHT 11 79 WINCH SERVICE 11 80 WINCH REPLACEMENT 11 80 SWITCH SERVICE 11 ...

Page 556: ...RICAL SERVICE 11 98 12V RECEPTACLE 11 98 AWD COIL 11 98 OPERATION OVERVIEW 11 98 TESTING 11 98 TERMINAL BLOCK 11 98 PULSE BAR 11 99 CHASSIS GROUND 11 99 DIAGNOSTIC PLUG 11 99 DIGITAL WRENCH 11 100 DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW 11 100 SPECIAL TOOLS 11 100 GUIDED DIAGNOSTIC AVAILABLE 11 100 DIGITAL WRENCH VERSION AND UPDATE ID 11 101 DIGITAL WRENCH UPDATES 11 101 DIGITAL WRENCH COMMUNI...

Page 557: ...375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 5 VEHICLE SPEED SENSOR BREAKOUT 11 114 LIGHTS BREAKOUT 11 115 EPAS BREAKOUT 11 116 RIDE COMMAND BREAKOUT 11 117 ELECTRICAL ...

Page 558: ...Polaris Industries Inc ASSEMBLY VIEWS HARNESS ROUTING RETENTION 2017 2018 NOTICE If replacing the harness Noting routing during removal will aid in proper installation FRONT q Zip Tie Retention Location The white tape on the harness signifies a retention point ELECTRICAL ...

Page 559: ...2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 7 REAR HARNESS ROUTING RETENTION GENERAL 4 NOTICE If replacing the harness Noting routing during removal will aid in proper installation ELECTRICAL ...

Page 560: ...11 8 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc FRONT q Zip Tie Retention Location The white tape on the harness signifies a retention point ELECTRICAL ...

Page 561: ...11 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 9 REAR q Zip Tie Retention Location The white tape on the harness signifies a retention point ELECTRICAL ...

Page 562: ...right Polaris Industries Inc HARNESS ROUTING RETENTION ABS 2018 INTL NOTICE If replacing the harness Noting routing during removal will aid in proper installation FRONT q Zip Tie Retention Location The white tape on the harness signifies a retention point ELECTRICAL ...

Page 563: ...11 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 11 REAR q Zip Tie Retention Location The white tape on the harness signifies a retention point ELECTRICAL ...

Page 564: ...ght Polaris Industries Inc HARNESS ROUTING RETENTION NON ABS 2018 INTL NOTICE If replacing the harness Noting routing during removal will aid in proper installation FRONT q Zip Tie Retention Location The white tape on the harness signifies a retention point ELECTRICAL ...

Page 565: ...11 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 13 REAR 1 Zip Tie Retention Location The white tape on the harness signifies a retention point ELECTRICAL ...

Page 566: ... Copyright Polaris Industries Inc HARNESS ROUTING RETENTION 2019 NOTICE If replacing the harness Noting routing during removal will aid in proper installation FRONT q Zip Tie Retention Location The white tape on the harness signifies a retention point ELECTRICAL ...

Page 567: ...11 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 15 REAR ELECTRICAL ...

Page 568: ...right Polaris Industries Inc HARNESS ROUTING RETENTION 2019 GENERAL 4 NOTICE If replacing the harness Noting routing during removal will aid in proper installation FRONT q Zip Tie Retention Location The white tape on the harness signifies a retention point ELECTRICAL ...

Page 569: ...375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 17 REAR q Zip Tie Retention Location The white tape on the harness signifies a retention point w Panduit Strap ELECTRICAL ...

Page 570: ...pyright Polaris Industries Inc HARNESS ROUTING RETENTION 2019 EVAP NOTICE If replacing the harness Noting routing during removal will aid in proper installation FRONT q Zip Tie Retention Location The white tape on the harness signifies a retention point ELECTRICAL ...

Page 571: ...29375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 19 REAR q Zip Tie Retention Location The white tape on the harness signifies a retention point w Edge Clip ELECTRICAL ...

Page 572: ...istance of a component that has a resistance value under 10 Ohms remember to subtract meter lead resistance from the reading Connect the leads together and record the resistance The resistance of the component 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...

Page 573: ...nductance Analyzer MDX 610P PU 50296 Connector Test Kit PV 43526 Timing Light 2870630 Relay Bypass PU 49466 Bosch Automotive Service Solutions 1 800 345 2233 or http polaris service solutions com TORQUE SPECIFICATIONS ELECTRICAL SYSTEM PART DESCRIPTION TORQUE SPECIFICATION Instrument Cluster to Mounting Bracket Fasteners 30 lb in 3 4 Nm Instrument Cluster Mounting Bracket to Vehicle Fasteners 3 5 ...

Page 574: ...nce 0 07 0 13 Ω Stator Leg to Ground Resistance Open Line OL Stator Leg Voltage 1300 RPM 21 VAC 25 Stator Leg Voltage 3000 RPM 47 VAC 25 Stator Leg Voltage 5000 RPM 79 VAC 25 Starter Solenoid Terminal Resistance 77 F 0 0 5 Ω CPS Resistance 1000 Ω 10 ECT Resistance 77 F 25 C 29 9 kΩ 6 ECT Resistance 248 F 120 C 1 22 kΩ 2 AWD Hub Coil Resistance 24 Ω 5 Current Draw Key Off Max 01 DCA 10 mA ELECTRICA...

Page 575: ...ters beside a DMM will only work in one scenario and slight variables can provide you with misleading results The testing practices described in this chapter are more certain and rely only on the DMM and your knowledge STATIC AND DYNAMIC TESTING There are many methods for testing a DC circuit These methods fall into one of two categories either static or dynamic STATIC TESTING The two most common ...

Page 576: ...ector is held upside down this is an indication that the female connector in the harness has insufficient tension and will cause connection issues You can either replace that harness or service it by replacing the terminal or attempting to adjust tighten the tang in the female terminal For a video demonstration scan the QR code below or right click it and select open in new tab BACK PROBING Back p...

Page 577: ...om B finds an easier way to return to ground B so much more of it can flow than the circuit is designed for This causes the circuit s protection device either a fuse or circuit breaker to open protecting the circuit from damage There are many possible causes of a short to ground here are some The harness rubbing against a component that is grounded such as the frame chassis component or engine A c...

Page 578: ... of the circuit Testing Continuity Resistancepage 11 25 4 Ensure you have checked for a short to ground Testing For A Short To Groundpage 11 25 5 Ensure that neither end of the circuit is connected 6 Set your DMM to DC volts 7 Connect one meter lead securely to the battery negative post 8 Connect the other lead to either end of the disconnected circuit Ensure you are using the correct adapter Conn...

Page 579: ...ime when changing the temp of an area Failure to do so can lead to Serious injury and or damage to the machine TESTING CURRENT FLOW AMPERAGE Performing a current flow test requires the meter leads be inserted into the correct cavities in the meter and be placed in series in the circuit to be tested Refer to your Digital Multi Meter s owner s manual for potential model specific instructions Ensure ...

Page 580: ...k such as move a solenoid or light a bulb Voltage coming into the load should be near battery voltage with current flowing There will be some loss from moving through electrical contacts in connectors and relays but it will be minimal NOTICE You will need to backprobe to perform this test For information about doing this safely refer to Connector Probing Guidelinespage 11 24 Voltage should be near...

Page 581: ...descriptions CAUTION Some features are not applicable to all models The use of a high pressure washer may damage the instrument cluster Wash the vehicle by hand or with 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 Imme...

Page 582: ... CAUTION Some features are not applicable to all models The use of a high pressure washer may damage the instrument cluster Wash the vehicle by hand or with 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 clea...

Page 583: ...uminates when the ECU has detected a Diagnostic Trouble Code in the engine management system 10 AWD Indicator Illuminates when the AWD TURF switch is in the AWD position 11 Neutral Gear Indicator Illuminates when gear selector is in the neutral N position 12 Gear Position Indicator Displays gear selector position H High L Low N Neutral R Reverse P Park Gear Signal Error shifter stuck between gears...

Page 584: ...en gears 13 Power Steering System MIL Illuminates when a fault has occurred with the power steering system This indicator illuminates when the key is turned to the ON position and goes off when the engine is started 14 Turn Signal Hazard Lamp Indicator Illuminates whenever the LH RH or hazard lamps are activated INT L Models Only 15 Helmet Seat Belt Indicator Illuminates for several seconds when t...

Page 585: ...coolant Vehicle Speed Speed of vehicle Tachometer Engine speed RPM AREA 2 MODES MODE DESCRIPTION Odometer The odometer records and displays the total distance traveled by the vehicle The odometer can not be reset Trip Meters T1 T2 The trip meter records the miles traveled by the vehicle on each trip if reset before each trip Trip Time Time length of vehicle operation since mode was last reset Engi...

Page 586: ...be set to either blue or red 1 Press and hold the MODE button to enter the settings menu 2 Press either toggle button to cycle to the BL COLOR option Press MODE to select 3 Press either toggle button to cycle to the desired setting 4 Press MODE to save and exit to the settings menu CLOCK The clock must be reset any time the battery has been disconnected or discharged 1 Press and hold the MODE butt...

Page 587: ...on to cycle to the trip time option TT 2 Press and hold either toggle button until the meter resets to zero PROGRAMMED SERVICE INTERVAL The service interval counter is programmed to 25 hours at the factory As hours of engine operation increase the counter decreases The wrench icon will flash for about 10 seconds when the counter reaches zero 0 and each time the key is turned on thereafter until th...

Page 588: ...t Turn Signal Input 7 High Beam Input 8 Trailer Turn Sign Input 10 Fuel Level Sensor 11 Blackout Mode Input 12 Accy Air Temp Input 15 INSTRUMENT CLUSTER PINOUTS INTL FUNCTION PIN CAN HIGH 1 CAN LOW 2 SWITCHED POWER 3 CONSTANT POWER 4 GROUND 5 LEFT TURN SIGNAL INPUT 6 RIGHT TURN SIGNAL INPUT 7 HIGH BEAM SWITCH INPUT 8 9 TRAILER TURN SIGNAL 10 ANALOG FUEL LEVEL INPUT 11 BLACKOUT MODE INPUT 12 13 14 ...

Page 589: ...ness connector from the back side of the instrument cluster 3 Remove the fasteners holding the instrument cluster mounting bracket to the vehicle 4 Remove the fasteners holding the instrument cluster mounting bracket to the instrument cluster 5 Push the instrument cluster bezel off the instrument cluster 6 For installation reverse removal procedure Torque fasteners to specification TORQUE Instrume...

Page 590: ...stable Speed Limiting Device ASLD function allows the rider to limit the maximum speed that the vehicle can achieve When a vehicle is operated past the set speed the ECU will limit the fuel supply to the engine The setting can be adjusted at any time by the rider in the options menu on the instrument cluster Refer to the owners manual to access the ALSD ELECTRICAL ...

Page 591: ...l for software display setting and user information See page 1 3 RIDE COMMAND DISPLAY REMOVAL INSTALLATION 1 Remove Hood by turning 1 4 turn fasteners 2 Remove seven push pins q retaining upper dash panel 3 Disconnect Ride Command Display electrical connectors w 4 Remove four fasteners e securing Ride Command Display Mount 5 Remove three fasteners r securing Ride Command Display to its mount ELECT...

Page 592: ...019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 6 Installation is performed by reversing the removal procedure TORQUE Ride Command Display Mount Fasteners TORQUE Ride Command Display Fasteners ELECTRICAL ...

Page 593: ...p 8 Go to Step 5 5 Refer to the wiring schematic and check circuits without voltage for continuity and proper operation Did you find any problems in the circuit Go to Step 7 Go to Step 1 and repeat diagnosis 6 Replace display with known good display Did you find and repair the condition Go to Step 8 Go to Step 1 and repeat diagnosis 7 Repair replace and check all affected power ground circuits Che...

Page 594: ... display Did you find and repair the condition Go to Step 2 Repeat Diagnosis GPS Antenna Troubleshooting 1 Unplug connector from GPS antenna and verify all contacts are securely seated in the connector 2 Turn ignition on and make the following measurements on the antenna connector WIRING CONNECTION TO MEASURE VOLTAGE SPECIFICATION Power Between Pins 4 and 3 12Vdc Battery Voltage 3 If antenna conne...

Page 595: ... 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 8800 ECU SERVICE Never attempt to disassemble the EC...

Page 596: ...following procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to illuminate Error codes are not stored When the key is turned OFF the code and message is lost but will reappear if the fault reoccurs after restarting the engine If the CHECK ENGINE lamp or the EPAS lamp illuminates retrieve the active error codes from the display 1 Press an...

Page 597: ...age Too Low 4 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...

Page 598: ... Correlation Correlation Fault 65613 2 P1135 Throttle Position Sensor 2 Voltage Too High 520198 3 P0223 Voltage Too Low 4 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...

Page 599: ... P152A Throttle Body Control Repeated Adaptation Failed Condition Exists 520282 31 P152B Throttle Body Control Maximum 520283 3 P152C Minimum 4 P152D Outside of Pedal Range Level 1 2 P152F Throttle Body Control Position Deviation Fault Condition Exists 520284 31 P152E Brake Switch 1 or 2 Indeterminable Brake Switch Correlation Fault 520285 2 P153E ECU Monitoring Error Condition Exists 520286 31 P1...

Page 600: ...019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc COMPONENT CONDITION SPN FMI P CODE ECU Fault ICO Condition Exists 520309 31 P1534 ECU Fault Hardware Disruption Condition Exists 520311 31 P1537 ELECTRICAL ...

Page 601: ...r Grounded Circuit C1B31 7 Mechanical System Not Responding Or Out Of Adjustment C1731 10 Abnormal Rate Of Change C1831 20 Data Drifted High C1931 21 Data Drifted Low C1A31 31 Condition Exists C0032 906 Wheel Speed Sensor Front Right 2 Data Erratic Intermittent Or Incorrect C1034 5 Current Below Normal Or Open Circuit C1634 6 Current Above Normal Or Grounded Circuit C1B34 7 Mechanical System Not R...

Page 602: ...47 5 Current Below Normal Or Open Circuit C1647 6 Current Above Normal Or Grounded Circuit C1B47 7 Mechanical System Not Responding Or Out Of Adjustment C1747 10 Abnormal Rate Of Change C1847 20 Data Drifted High C1947 21 Data Drifted Low C1A47 31 Condition Exists C1C47 1808 Multiaxis Sensor Cluster YAW 20 Data Drifted High C1163 1809 Lateral Acceleration Sensor 13 Out of Calibration C1261 20 Data...

Page 603: ...Exists C1325 520252 31 Condition Exists C1330 520253 31 Condition Exists C1332 520254 ABS Solenoid Front Or Front Left In 31 Condition Exists C1326 520255 ABS Solenoid Front or Front Left Out 31 Condition Exists C1327 520256 ABS Solenoid Front Right In 31 Condition Exists C1328 520257 ABS Solenoid Front Right Out 31 Condition Exists C1329 520260 ABS Motor 4 Voltage Below Normal Or Shorted To Low S...

Page 604: ...misfire cannot be detected code P0314 the ECU will limit available power by limiting how far the throttle plate opens One the key is cycled the trouble code s will show current but there will be no fuel injector deactivation or throttle limitation unless the misfiring continues to occur The check engine light will remain illuminated until there are 4000 engine revolutions i e 4000 RPM for one minu...

Page 605: ...ccess the battery q 2 Disconnect the black negative battery cable CAUTION To reduce the chance of sparks Whenever removing the battery disconnect the black negative cable first When reinstalling the battery install the black negative cable last 3 Disconnect the red positive battery cable 4 Remove the battery hold down bracket w Lift the battery out of the vehicle BATTERY REMOVAL INTL 1 Remove the ...

Page 606: ...battery and result in a shorter life It can also hinder vehicle performance Refer to Battery Charging page 11 55 procedure before installing the battery 1 Place the battery in the battery holder and secure with hold down strap Torque fastener to specification TORQUE Battery Bracket 3 5 lb ft 5 Nm 2 Coat the terminals with dielectric grease 3 Connect and tighten the red q cable first 4 Connect and ...

Page 607: ...ance is encountered To perform this test use a load testing device that has an adjustable load Apply a load of three times the ampere hour rating At 14 seconds into the test check battery voltage A good 12V battery will have at least 10 5 volts If the reading is low charge the battery and retest CURRENT DRAW KEY OFF CAUTION Do not connect or disconnect the battery cable or ammeter with the engine ...

Page 608: ...AL GENERAL 4 Service Manual Copyright Polaris Industries Inc NOTICE Follow the charger instructions supplied by the manufacture regarding the order or connections switch positions and when to connect the charger to an outlet ELECTRICAL ...

Page 609: ...the fuses provide overload protection for wiring and components such as the instrument cluster ECU EFI system main harness lights accessories and power steering A 25 amp circuit breaker protects the fan motor circuit Relay Operation Located in the fuse box under the driver s seat the relays assist with component operation like the cooling fan fuel pump EFI system and electronic power assisted stee...

Page 610: ...11 58 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 2018 ELECTRICAL ...

Page 611: ...11 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 59 2019 NOTICE GENERAL 4 models have a 30 amp circuit breaker protects the fan motor circuit ELECTRICAL ...

Page 612: ...de overload protection for wiring and components such as the instrument cluster ECU EFI system main harness lights flasher accessories and power steering A 25 amp circuit breaker protects the fan motor circuit Relay Operation Located in the fuse box under the driver s seat the relays assist with component operation like the cooling fan fuel pump EFI system and electronic power assisted steering EL...

Page 613: ...ptacles Accessory Options WIRE COLOR 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 PIN FUNCTION Red Dark Blue 25 Coil power from EFI B 2 Splice Orange 26 High side power from R S B ...

Page 614: ...ed 4 High side power from EPS fuse Orange 7 High side output to EPS unit Brown 8 Chassis ground RELAY CIRCUITS 2019 Fan Relay Provides power to the following system Fan Motor Wire Color Pin Function Red Dark Brown 9 EFI B Fan Coil HI Orange Black 10 FAN B Fused Relay In Orange Black 13 FAN B Relay Out Orange Black 14 Cooling Fan Relay EFI Relay Provides power to the following systems Fuel Injector...

Page 615: ...ed Dark Green 37 Chassis Relay Out Gray 38 Chassis Relay Coil LO EPS Relay Optional Provides power to the following system Electronic Power Steering Unit Wire Color Pin Function Orange 3 Key Switch B EPS Relay Coil Power Red 4 Unswitched Fused B EPS Fuse Out Orange 7 EPS Relay Power Out Brown 8 Ground EPS Relay Coil FUSE CIRCUIT BREAKER CIRCUITS 2017 2018 Fan 25A Circuit Breaker 2017 Fan 30A Circu...

Page 616: ...ellow Power to Lights B Splice EPAS 20A Fuse WIRE COLOR FUNCTION Red Power from Solenoid B Red Power to EPS Relay high side FUSE CIRCUIT BREAKER CIRCUITS 2019 EPS 25A WIRE COLOR FUNCTION RD EPS B Fuse In RD Unswitched Fused B EPS Fuse Out EFI 10A WIRE COLOR FUNCTION RD EFI B Fuse In RD Unswitched fused B EFI Relay In Lights 15A WIRE COLOR FUNCTION RD DG Chassis Relay Out Lights Input RD YE Lights ...

Page 617: ...General 4 WIRE COLOR FUNCTION RD Fan B Fuse In OG BK Fan B Fused Relay In FUSE CIRCUIT BREAKER CIRCUITS INTL Fan 25A Circuit Breaker WIRE COLOR FUNCTION Red Power in from solenoid B Orange Black Power to Fan Relay EFI 10A Fuse WIRE COLOR FUNCTION Red 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 Spl...

Page 618: ...wer from Chassis Splice Red Dark Green Power to AWD Coil Lights 15A Fuse WIRE COLOR FUNCTION Red Dark Green Power from Chassis Splice Red Yellow Power to Lights B Splice EPAS 20A Fuse WIRE COLOR FUNCTION Red Power from Solenoid B Red Power to EPS Relay high side ABS Valves 20A Fuse WIRE COLOR FUNCTION Red Power from ABS splice Red Yellow Power to ABS Controller ABS Sensor 5A Fuse WIRE COLOR FUNCTI...

Page 619: ...n ammeter connected in series Damage to the meter or meter fuse will result Do not run test for extended period of time Do not run test with high amperage accessories 1 Using an inductive amperage metering device set to DC amps connect to the negative battery cable 2 With engine off key switch and lights in the on position the ammeter should read negative amps battery discharge 3 Shift transmissio...

Page 620: ... approximate AC Voltage readings according to RPM Test each leg at the specified RPM in the table 5 Example The alternator current output reading should be approximately 21 VAC 25 at 1300 RPM between each leg 6 If one or more of the stator leg output AC voltage varies significantly from the specified value the stator may need to be replaced RPM READING AC VOLTAGE VAC READING 1300 21 VAC 25 3000 47...

Page 621: ...d that adequate airflow is present BATTERY CONDUCTANCE ANALYZER Conductance describes the ability of a battery to conduct current A conductance tester functions 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 ...

Page 622: ...e Manual Copyright Polaris Industries Inc CHARGING SYSTEM TESTING 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 623: ... voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 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 sh...

Page 624: ...nut to specification TORQUE Starter Mounting Bolts and Nut 7 lb ft 10 Nm STARTER SOLENOID SERVICE Starter Solenoid Bench Test Test the start solenoid by powering the solenoid using battery voltage for a maximum of 5 seconds With the solenoid energized at room temperature 77 F resistance should read within specification between terminals If resistance measurement is out of specification replace the...

Page 625: ...otor or starter solenoid Refer to page 11 71 Faulty key switch Faulty starter solenoid or starter motor Engine problem seized or binding can engine be rotated easily Starter Motor Turns Over Slowly Battery discharged Excessive circuit resistance poor connections Refer to page 11 71 Engine problem seized or binding can engine be rotated easily Faulty or worn brushes in starter motor Starter Motor T...

Page 626: ...rcuit primary coil windings When the ECU commands the IC circuit OFF this will interrupt current flow through the primary coil windings The magnetic field created by the primary coil windings will collapse across the secondary coil windings which induces a high voltage across the spark plug electrodes IGNITION COIL HT LEAD REPLACEMENT NOTE The engine will misfire if the spark plug wires are instal...

Page 627: ...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 necessa...

Page 628: ...ain power steering operation NOTICE To conserve battery power the EPAS unit will shut down 5 minutes after the engine has stopped if the key remains in the ON position At this point the EPAS Malfunction Indicator Light will illuminate to indicate the EPAS has shut down and will set a fault code in Digital Wrench The Power Steering 25A 30A Fuse If the fuse fails the Power Steering Malfunction Indic...

Page 629: ...by loosening or tightening the three adjustment screws q 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 where they are operated headlight lenses become dirty Frequent washing is necessary to maintain lighting quality Riding with poor lighting can resul...

Page 630: ...l the headlight adjustment springsw onto the front bumper mounting bosses 2 Insert the three headlight mounting screws q into the headlight assembly mounting holes 3 Maneuver the headlight assembly into position Be sure all three headlight springs and mounting screws are properly aligned with mounting bosses e on the front bumper 4 Fully tighten all three headlight screws until the headlight assem...

Page 631: ...ath is present 1 Lift the cargo box 2 Remove the fastener holding the cargo box trim panel to the cargo box and remove the panel 3 Reaching through the access hole on the outside of the cargo box remove the fasteners holding the tail light to the cargo box 4 Remove the tail light from the cargo box and disconnect the wire harness 5 To install reverse removal procedure Torque tail light fasteners t...

Page 632: ... Disconnect contactor connector 5 Remove the lower fastener on the passenger front shock 6 Remove winch from passenger side NOTICE If required Remove winch mounting plate 7 Remove four 15mm nuts w retaining mounting plate 8 Remove winch mounting plate from vehicle Installation 1 Reinstall winch bracket and fastenersq if previously removed If not skip to step 2 TORQUE Winch Mounting Plate 30 lb ft ...

Page 633: ...1 3 Install four fasteners w securing winch to mounting plate TORQUE Winch Fasteners 16 lb ft 22 Nm 4 Reinstall lower fastener on passenger front shock TORQUE Shock Fastener 20 lb ft 27 Nm 90 5 Reconnect contactor connector 6 Reconnect electrical wires from bus bar 7 Reconnect battery ELECTRICAL ...

Page 634: ...brake and check for continuity If there is no continuity or if resistance is greater than 0 5 ohms clean the switch terminals Re test and replace switch if necessary REPLACEMENT NOTICE Brake fluid will leak out of the master cylinder when the brake switch is replaced Place a suitable catch container rags below the master cylinder prior to brake switch removal 1 Disconnect the harness going to the ...

Page 635: ...iring 2 Test between the 3 sets of outputs OFF LOW HIGH If any of the tests fail replace headlight switch assembly Move the switch to HIGH There should be continuity between switch pins 2 and 3 5 and 6 7 and 8 Move the switch to LOW There should be continuity between switch pins 2 and 3 4 and 5 7 and 8 Move the switch to OFF There should be continuity between switch pins 1 and 2 4 and 5 7 and 8 NO...

Page 636: ...ash by depressing the connector lock and pulling on the connector Do not pull on the wiring 2 Test between the 3 sets of outputs OFF ON START If any of the tests fail replace ignition switch assembly Turn the ignition key to ON There should 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 ELECTRICAL ...

Page 637: ...ash 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 assembly Move the switch to AWD ON There should be continuity between switch pins 2 and 3 as well as 3 and 7 Move the switch to 2WD NONE OFF There should ONLY be continuity between pins 3 and 7 ELECTRICAL ...

Page 638: ... fail replace the switch assembly Move the switch to AWD There should be continuity between switch pins 2 and 3 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 NOTICE Pins 7 and 2 provide power and ground to light the switch lamp TRANSMISSION GEAR POSITION SWITCH TESTING 1 The transmission gear pos...

Page 639: ...specification table below GEAR POSITION RESISTANCE VALUE WHEN MEASURED AT SWITCH TERMINALS A AND B HIGH 620 Ω LOW 300 Ω NEU 160 Ω REV 75 Ω PARK 24 Ω SEAT BELT SWITCH NOTICE If the circuit is open buckle undone vehicle speed will be limited to 15 mph If the circuit is closed buckle inserted the vehicle will function normally TESTING 1 Disconnect the harness q running to the driver s seat belt latch...

Page 640: ...n the connector Do not pull on the wiring 2 Test between the 3 sets of outputs ON OFF ON If any of the tests fail replace winch switch assembly Move the switch to Position 1 ON There should be continuity 1 Ω between switch pins 2 and 3 Move the switch to Position 2 OFF There should be NO continuity OL between switch pins 2 and 3 1 and 2 Move the switch to Position 3 ON There should be continuity 1...

Page 641: ... the control of ignition timing by the ECU Synchronization of the CPS and crankshaft position takes place during the first two revolutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will stop running CPS TEST The CPS is a sealed non serviceable assembly If fault code diagnosis indicates a...

Page 642: ...ar side of the vehicle 2 Disconnect the CPS harness connector 3 Remove CPS retaining bolt q and remove the sensor w from the stator cover 4 Remove CPS wire lead from wire clip e 5 Install new sensor using a light coating of oil on the O ring to aid installation 6 Torque CPS retaining bolt to specification TORQUE CPS Retaining Bolt 9 lb ft 12 Nm 7 Route CPS wire lead through wire clip and reconnect...

Page 643: ...s opened 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...

Page 644: ...EDURE IMPORTANT This procedure MUST be performed on the vehicle whenever the ECU is replaced or reflashed or the throttle body is replaced 1 After the reflash ECU replacement throttle body change leave the key on engine not running for 60 seconds Do NOTcrank the engine during this time 2 Turn the key off and wait 3 minutes During this time the ECU will write values into memory and then completely ...

Page 645: ...ed 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 10 seconds and pedal released 10 8 Pedal fully depressed 99 6 The TPS is calibrated to the thro...

Page 646: ...ital Wrench First verify if there are any stored codes for the oxygen sensor NOTICE The ECU must first run though the O2 sensor time delay before a trouble code will be set This may take several minutes at idle to occur Short drive cycles and cold temperatures will both affect the delay time of the O2 sensor increases the delay The delay time ensures the oxygen sensor heater has run long enough to...

Page 647: ...the ECU and compared to its programming for determining the fuel and ignition requirements during engine operation The T MAP provides the ECU with engine load data T MAP TEST 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 NOTICE This sensor should only be tested using Digital Wrench Diagnostic Software dealer only T MAP R...

Page 648: ...uld turn on and the Check Engine indicator should display on the instrument cluster This indicates all other components are working properly 2 If not test resistance across sensor terminals ECT Resistance 77 F 25 C 29 9 kΩ 6 ECT Resistance 248 F 120 C 1 22 kΩ 2 3 Polaris dealers can test the sensor by using Digital Wrench Diagnostic Software dealer only ECT REPLACEMENT 1 Be sure the engine has coo...

Page 649: ...oses provides input to the ECU The ECU then interprets this switching into the speed the output gear is rotating VSS TEST 1 Disconnect the three wire harness from the speed sensor and remove the sensor from the transmission 2 Connect the wires from the Static Timing Light Harness PN 2871745 to the sensor 3 pin connector using the Hall Sensor Probe Harness PN 2460761 3 Pass a screwdriver back and f...

Page 650: ...d that a minimum of 11 volts is present at the hub coil Verify the AWD hub coil is functional Test the AWD hub coil using an ohmmeter See specifications below AWD Hub Coil Resistance 24 Ω 5 Verify the wiring harness wiring connectors connector pins and grounds are undamaged clean and connect properly Verify continuity of wire connections with a known good volt ohm meter NOTICE Verify all wires and...

Page 651: ...bracket 6 Reinstall the new pulse bar to the pulse bar bracket and secure with fasteners TORQUE Pulse Bar Fasteners Torque Until Fastener Is Fully Seated 7 Reinstall positive and negative cables and secure with nuts TORQUE Pulse Bar Cable Nuts 24 in lbs 3 Nm 8 Reconnect pulse bar electrical connector 9 Reconnect batter negative cable 10 Reinstall hood CHASSIS GROUND The chassis ground point is loc...

Page 652: ...ench 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 USB Serial Adapter Cable PU 50621 Fluke 73 Digital Multi Meter or Fluke 77 DMM PV 43546 Fluke 77 PV 43568 Wireless Vehicle Link WVL PU 51435 Laptop or Desktop Computer Commercially Available refer to diagnostic software user manual or HELP...

Page 653: ...ing Digital Wrench NOTICE Always operate with the latest update DIGITAL WRENCH UPDATES Updates 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 NOTICE Only authorized Polaris dealers and distributors can access the dealer website 1 Log on to www polarisdealers com 2 Loca...

Page 654: ...ure 7 Click on the link shown above save the file to your hard disk and then double click the icon to start the update process NOTICE Do not run or open the file from where they are Select save and download them to your PC before running the install 8 When the update is complete the version shown on the right side of the Digital Wrench start up screen should match the update you just downloaded NO...

Page 655: ...r console must be removed Follow these steps to connect the diagnostic interface cable to the vehicle to allow Digital Wrench use 1 Assemble the SmartLink Module and attach the PC Interface Cable to your laptop Refer to Special Tools Electrical System page 11 21 2 Remove the protective cap from the Digital Wrench connector 3 Connect the Vehicle Interface Cable to the Digital Wrench diagnostic conn...

Page 656: ...11 104 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc DIGITAL WRENCH FEATURE MAP ELECTRICAL ...

Page 657: ...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 Refer to Digital Wrench Updates page 11 101 procedure CLOSE NON ESSENTIAL PROGRAMS Polaris recommends that you DO NOT install non essential programs on a Service Department laptop Camera de...

Page 658: ...elect the Special Tests icon 6 Select Engine Controller Reprogramming 7 Select the file you want to load into the ECU then click the Continue icon to proceed to the Integrity Check 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...

Page 659: ...pleted click the Authorize button once to proceed 12 An Authorization Key will appear in the upper left corner of the screen Copy CTRL C this key exactly as it appears 13 Enter or paste CTRL V 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...

Page 660: ... to download 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 techno...

Page 661: ...11 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 109 BREAKOUT DIAGRAMS COOLING SYSTEM BREAKOUT ELECTRICAL ...

Page 662: ...11 110 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc STARTING SYSTEM BREAKOUT Click Here to view Starting system breakout for 2019 models ELECTRICAL ...

Page 663: ...29375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 111 UNSWITCHED CHASSIS POWER BREAKOUT Click Here to view Unswitched chassis power breakout for 2019 models ELECTRICAL ...

Page 664: ...11 112 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc KEY ON BATTERY POWER BREAKOUT Click Here to view Key on battery breakout for 2019 models ELECTRICAL ...

Page 665: ...11 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 113 AWD BREAKOUT Click Here to view AWD breakout for 2019 models ELECTRICAL ...

Page 666: ...11 114 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc VEHICLE SPEED SENSOR BREAKOUT Click Here to view VSS breakout for 2019 models ELECTRICAL ...

Page 667: ...11 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 115 LIGHTS BREAKOUT Click Here to view Lights breakout for 2019 models ELECTRICAL ...

Page 668: ...11 116 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc EPAS BREAKOUT Click Here to view EPAS breakout for 2019 models ELECTRICAL ...

Page 669: ...11 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc 11 117 RIDE COMMAND BREAKOUT Click Here to view Ride Command breakout for 2019 Models ELECTRICAL ...

Page 670: ...11 118 9929375 R02 2016 2019 GENERAL GENERAL 4 Service Manual Copyright Polaris Industries Inc NOTES ELECTRICAL ...

Page 671: ...13412 2017 2018 2017 2018 GENERAL Base 2413619 2017 2018 GENERAL with Winch 2413620 2017 2018 GENERAL 4 with Winch 2413691 2018 GENERAL with Ride Command 2413527 2019 2019 GENERAL with Winch 2414379 2019 GENERAL Premium Deluxe 2414380 2019 GENERAL Ride Command 2414381 2019 GENERAL 4 Ride Command 2414382 2019 GENERAL 4 with Winch 2414383 A 2 Wiring Diagrams INTL 2018 Click HERE for INTERNATIONAL GE...

Page 672: ...dy Component Installation 10 50 Exterior Body Component Installation GENERAL 4 10 53 Exterior Body Component Removal 10 26 Exterior Body Component Removal GENERAL 4 10 31 Front Bumper Installation 10 55 Front Bumper Removal 10 26 Hood Installation 10 56 Hood Removal 10 25 Interior Body Component Installation 10 43 Interior Body Component Installation GENERAL 4 10 46 Interior Body Component Removal...

Page 673: ...3 90 Thermostat Replacement 3 93 Crankcase Assembly 3 68 Disassembly Inspection 3 48 Crankshaft Connecting Rod Bearing Selection 3 61 Connecting Rod Inspection 3 58 Installation 3 66 Main Bearing Selection 3 61 Removal Inspection 3 51 Crankshaft Position Sensor CPS Operation Overview 11 89 Replacement 11 90 Test 11 89 Crankshaft PTO Seal Installation 3 24 Removal 3 24 Replacement 3 24 Current 11 2...

Page 674: ...m Troubleshooting 3 101 Crankcase Assembly 3 68 Crankcase Disassembly Inspection 3 48 Crankshaft Installation 3 66 Crankshaft Main Bearing Selection 3 61 Crankshaft Removal Inspection 3 51 Cylinder Piston Installation 3 65 Cylinder Piston Removal 3 55 Cylinder Head Assembly 3 74 Cylinder Head Disassmebly 3 39 Cylinder Head Installation 3 75 Cylinder Head Removal 3 38 Cylinder Head Warp 3 39 Cylind...

Page 675: ...ting General 4 Retention General 4 4 13 Routing General 4 EVAP Models Retention General 4 EVAP Models 4 19 Fuel Pump Assembly View 4 6 Fuel Sender Test 4 33 Operation Overview 4 33 Replacement 4 34 Test 4 33 Fuel Sender Test 4 33 Fuel System Assembly View Fuel System Assembly View 4 4 Fuel Line Replacement 4 30 Fuel Lines 2 24 Fuel Tank Vent Line 2 26 Pump Filters Maintenance 2 25 Service Notes 4 ...

Page 676: ...3 57 Ring Installation 3 62 Ring Installed Gap 1000 3 57 Ring Removal Inspection 3 56 Piston to Cylinder Clearance 3 58 Polaris Mobile Digital Wrench PMDW 11 108 Pre Ride Inspection 2 6 Probe 11 24 Probing 11 24 Prop Shaft U Joint Assembly 7 20 U Joint Disassembly 7 19 PropShaf 7 26 Propshaft 7 16 7 17 7 25 Assembly View 7 4 7 6 Assembly View GENERAL 4 7 5 Assembly View General 4 2018 2019 7 7 Ins...

Page 677: ...ration Overview 11 71 Starter Motor Installation 11 72 Starter Motor Removal 11 71 Starter Solenoid Service 11 72 Troubleshooting 11 73 Voltage Drop Test 11 71 Static 11 23 Stator Cover Installation 3 73 Stator Cover 3 45 Steering system 8 5 Steering System 8 5 Inspection 2 33 Power Steering Unit Installation 8 12 Power Steering Unit Removal 8 9 Service Notes 8 3 Service Specifications 8 4 Special...

Page 678: ...itch 11 86 Transmission Vent Line 6 6 Retention 6 7 Routing 6 7 Troubleshooting Brake System 9 57 Cooling System 3 101 Engine 3 100 EVAP System 4 8 Final Drive 7 57 Fuel System 4 38 Misfire Detection 11 52 PVT System 5 35 Transmission 6 40 U U Joint Assembly 7 20 Disassembly 7 19 V Valve Clearance Adjustment 3 81 Inspection 3 40 Sealing Test 3 42 Seat Reconditioning 1000 3 42 Valve Clearance Exhau...

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Page 685: ...SISTANCE AT 25 127C 29 9k p2 AT 120 127C 1 22k p2 1 GROUND SENSOR PRESSURE T MAP P N 2411528 SIGNAL OUTPUT 3 5V 2 NTC 4 P N 4010425 IGNITION COIL SPEED SENSOR P N 2411719 1 2 3 SENSOR CRANK POSITION N S LAST 2 DIGITS OF 100 SERIES NUMBER CORESPOND TO CONNECTOR CAVITY NUMBER IE 110 CAVITY 10 LAST 2 DIGITS OF 100 SERIES NUMBER CORESPOND TO CONNECTOR CAVITY NUMBER IE 110 CAVITY 10 12V RECEPTACLE RH H...

Page 686: ...SENSOR NOMINAL RESISTANCE AT 25 127C 29 9k p2 AT 120 127C 1 22k p2 1 GROUND SENSOR PRESSURE T MAP P N 2411528 SIGNAL OUTPUT 3 5V 2 NTC 4 P N 4010425 IGNITION COIL SPEED SENSOR P N 2411719 1 2 3 SENSOR CRANK POSITION N S LAST 2 DIGITS OF 100 SERIES NUMBER CORESPOND TO CONNECTOR CAVITY NUMBER IE 110 CAVITY 10 LAST 2 DIGITS OF 100 SERIES NUMBER CORESPOND TO CONNECTOR CAVITY NUMBER IE 110 CAVITY 10 12...

Page 687: ...3C BN GR13C BN V01B DB RD V01B DB RD GR13F2 BN GR13F2 BN C06_2 YE BK C06_2 YE BK RT3G OG WH RT3G OG WH GR13A BN GR13A BN GR13E BN GR13E BN LED 3 CATHODE BK LED 2 CATHODE BK LED 1 CATHODE BK LED 3 ANODE RD LED 2 ANODE RD LED 1 ANODE RD E245 BK WH E245 BK WH REE RD DB REE RD DB RT1A OG WH RT1A OG WH GR25 BN GR25 BN RT1B OG WH RT1B OG WH E235 BG E235 BG REK RD DB REK RD DB GR1 BN GR1 BN GR2 BN GR2 BN...

Page 688: ... OG WH GR13A BN GR13A BN GR13E BN GR13E BN LED 3 CATHODE BK LED 2 CATHODE BK LED 1 CATHODE BK LED 3 ANODE RD LED 2 ANODE RD LED 1 ANODE RD E245 BK WH E245 BK WH REE RD DB REE RD DB RT1A OG WH RT1A OG WH GR25B BN GR25B BN RT1B OG WH RT1B OG WH RA1C RD RA1C RD RT2 OG WH RT2 OG WH RT1C OG WH RT1C OG WH GR25 BN GR25 BN E235 BG E235 BG REK RD DB REK RD DB GR3 BN GR3 BN GR2 BN GR2 BN GR1 BN GR1 BN GR13F...

Page 689: ...4B DB N04B DB N04 DB N04 DB C11_1 GY BK C11_1 GY BK C11_2 GY RD C11_2 GY RD GD1 BN GD1 BN C10_1 WH RD C10_1 WH RD C10_2 WH BK C10_2 WH BK GR13A2 BN GR13A2 BN GR13A BN GR13A BN V01B DB RD V01B DB RD RT3G OG WH RT3G OG WH B4C34 RD WH B4C34 RD WH RT3B OG WH RT3B OG WH C6L DG C6L DG C6H YE C6H YE C06_2 YE BK C06_2 YE BK GR13F2 BN GR13F2 BN GR13B BN GR13B BN GR13E BN GR13E BN GR13C BN GR13C BN N03 VT N...

Page 690: ...NOMINAL RESISTANCE AT 25 127C 29 9k p2 AT 120 127C 1 22k p2 1 GROUND SENSOR PRESSURE T MAP P N 2411528 SIGNAL OUTPUT 3 5V 2 NTC 4 P N 4010425 IGNITION COIL SPEED SENSOR P N 2411719 1 2 3 SENSOR CRANK POSITION N S LAST 2 DIGITS OF 100 SERIES NUMBER CORESPOND TO CONNECTOR CAVITY NUMBER IE 110 CAVITY 10 LAST 2 DIGITS OF 100 SERIES NUMBER CORESPOND TO CONNECTOR CAVITY NUMBER IE 110 CAVITY 10 P N 40140...

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Polaris GENERAL 2016, Service Manual

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