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Polaris Ranger 500 2x4 2007, Service Manual

The Polaris Ranger 500 2x4 2007 Service Manual is a comprehensive guide that allows users to keep their vehicle running smoothly. With easy-to-understand instructions, troubleshooting tips, and maintenance procedures, this manual is a must-have for all Ranger 500 owners. Download it for free from manualshive.com to ensure hassle-free maintenance and repair.

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10.9

ELECTRICAL

10

Headlamp Housing Installation

1. To install the headlamp housing, press the headlamp tabs

back into the brackets.

2. Secure the headlamp housing with the rubber O-rings on

each side (A).  Install the adjustment screw (B).

3. Reconnect  wire  harness  or  re-insert  bulb  if  previously

removed.

4. Adjust  headlights  using  the  “High  Beam  Headlight

Adjustment” procedure on the previous page. 

TAIL LIGHT / BRAKE LIGHT

Lamp Replacement

Before replacing the tail light, use a digital multi-meter to test
the harness to ensure the lamp is receiving 12 volts and that a
ground path is present.

If the tail light / brake light does not work the lamp assembly
may need to be replaced.

1. From the rear of the tail light remove two screws holding

lens cover in place and remove lens cover. (T-20 Torx)

2. Remove  lamp  by  turning  the  rubber  base  1/4  turn  and

pulling the bulb out. Replace it with recommended lamp.
Apply Dielectric Grease (PN 2871329).

3. Reinstall the lens cover removed in Step 1.

4. Test the tail light / brake light to see it is working.

B

A

Tail Light Screws

Tail Light

Brake Light

OG and RD

RD and BN

Replacement Bulbs
PN 4030040

Summary of Contents for Ranger 500 2x4 2007

Page 1: ......

Page 2: ...1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 CARBURETION EFI 5 BODY STEERING SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION BRAKES 9 ELECTRICAL 10 ...

Page 3: ...HICLE DIMENSIONS 1 5 GENERAL SPECIFICATIONS 1 6 MODEL RANGER 2X4 1 6 MODEL RANGER 4X4 CARB 1 6 MODEL RANGER 4X4 EFI 1 7 MODEL RANGER 2X4 1 8 MODEL RANGER 4X4 CARB 1 9 MODEL RANGER 4X4 EFI 1 10 VEHICLE INFORMATION 1 11 PUBLICATION NUMBERS 1 11 PAINT CODES 1 11 REPLACEMENT KEYS 1 11 SPECIAL TOOLS 1 12 MISC SPECIFICATIONS AND CHARTS 1 16 CONVERSION TABLE 1 16 STANDARD TORQUE SPECIFICATIONS 1 17 SAE T...

Page 4: ...l number and serial number This information can be found on the sticker applied to the flywheel housing on the right side of engine Machine Model Number Identification Model Year Designation Basic Chassis Designation Engine Designation Emissions Model Option R 0 7 R B 5 0 A A 4 X A R B 5 0 A 7 P 0 0 0 0 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg ID Engine Vehicle Description Vehicle I...

Page 5: ...ehicle identification The machine serial number A is stamped on the lower LH frame rail close to the front drive wheel The model and serial number are also located on a sticker under the hood B Transmission I D Number Location A A A B The transmission I D number is located on the right side when installed in the machine ...

Page 6: ...1 4 GENERAL INFORMATION VEHICLE DIMENSIONS 75 in 190 50 cm 10 in 25 4 cm 58 in 147 cm RANGER 2X4 4X4 RANGER 2X4 4X4 ...

Page 7: ...1 5 GENERAL INFORMATION 1 VEHICLE DIMENSIONS 113 in 287 cm 58 in 147 cm 76 in 193 cm RANGER 2X4 4X4 ...

Page 8: ...42 x 10 in 147 x 106 7 x 25 4 cm Vehicle Payload 1350 lbs 613 kg Includes driver and two passengers 500 lbs 227kg Hitch Towing Capacity 1500 lbs 681 kg Hitch Tongue Capacity 150 lbs 68 kg Category Dimension Capacity Length 113 in 287 cm Width 60 in 152 4 cm Height 75 in 190 5 cm Wheel Base 76 in 193 cm Ground Clearance 11 5 in 29 cm Turning Radius 132 in 335 cm Dry Weight 1185 lbs 537 kg Gross Veh...

Page 9: ...el Base 76 in 193 cm Ground Clearance 11 5 in 29 cm Turning Radius 132 in 335 cm Dry Weight 1185 lbs 537 kg Gross Vehicle Weight 2700 lbs 1226 kg Cargo Box Capacity 1000 lbs 454 kg Cargo Box Dimensions 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Vehicle Payload 1500 lbs 681 kg Includes driver and two passengers 500 lbs 227kg Hitch Towing Capacity 1500 lbs 681 kg Hitch Tongue Capacity 150 lbs 68 kg ...

Page 10: ... Yuasa YB30L B 30 Amp Hr 12 Volt Instrument Panel Type Indicator Lights Hour Meter DC Outlet Standard Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio High Low Rev 3 83 1 8 71 1 5 9 1 Final Drive Ratio 3 70 1 Shift Type In Line Shift H L N R Trans Oil Requirements Polaris AGL Gearcase Lube Belt 3211077 Drive Belt Deflection 1 125 28 57 mm Center Distance 10 254 5 mm Clutch Offset 0 5 ...

Page 11: ...YB30L B 30 Amp Hr 12 Volt Instrument Panel Type Indicator Lights Hour Meter DC Outlet Standard Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio High Low Rev 3 83 1 8 71 1 5 9 1 Final Drive Ratio 3 70 1 Drive Ratio Front 3 818 1 Shift Type In Line Shift H L N R Trans Oil Requirements Polaris AGL Gearcase Lube Belt 3211077 Drive Belt Deflection 1 125 28 57 mm Center Distance 10 254 5 mm...

Page 12: ...tery Model Amp Hr Yuasa YB30L B 30 Amp Hr 12 Volt Instrument Panel Type Indicator Lights Hour Meter DC Outlet Standard Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio High Low Rev 3 83 1 8 71 1 5 9 1 Final Drive Ratio 3 70 1 Drive Ratio Front 3 818 1 Shift Type In Line Shift H L N R Trans Oil Requirements Polaris AGL Gearcase Lube Belt 3211077 Drive Belt Deflection 1 125 28 57 mm Cen...

Page 13: ... the right for the proper part number Model Model No Owner s Manual PN Parts Manual PN 2007 RANGER 2X4 CARB R07RB50AA 9920634 9920904 2007 RANGER 4X4 CARB R07RH50AA 9920634 9920904 2007 RANGER 4X4 EFI R07RH50AF AR AT 9920635 9920905 Painted Part Color Description Polaris Number Frame Cab Medium Gloss Black P 067 RANGER 2X4 4X4 CARB EFI Plastic Hood Dash Dark Green P 195 RANGER 4x4 EFI Plastic Hood...

Page 14: ...rvicing any Polaris product STANDARD TOOLS AND ENGINE TOOLS STANDARD TOOLS AND ENGINE TOOLS PU 45432 Caliper or A Basic Caliper Basic Micrometer 2871043 Flywheel Puller 2870773 C Clip Install Tool 2870967 Slotted Nut Socket 8700229 Flywheel Holder and Adapter 2870569 Crankshaft True Kit 2870386 Piston Pin Puller 2871445 Piston Pin Puller Adapter 2870968 Counter Balance Puller PV 43527 Oil Filter W...

Page 15: ... Hone Oil 12 oz 2870459 Dial Indicator PV 35667 A Cylinder Leakdown Tester 2872105 Water Pump Seal Puller 2871283 Crank Water Pump Seal Install Kit Clutch PVT Tools 2870506 Drive Clutch Puller 2870913 Driven Clutch Puller 2870654 Clutch Align Tool 9914177 A Drive Clutch Holding Tool 2871358 Clutch Holding Fixture ...

Page 16: ...l Tool 2870910 Roll Pin Tool 2871226 Clutch Bushing Replacement Kit 8700220 Clutch Compression Tool 2870338 Spider Nut Socket 2870871 Ball Joint Tool Kit 2871071 Shock Body Holding Tool 2870623 Shock Spring Compressor 2871573 2871574 Strut Spring Compressor 8700225 8700226 CV Boot Clamp Pliers ...

Page 17: ...l Sensor probe Harness PV 39617 Current Clamp 2870836 Battery Hydrometer 8712500 Tachometer PV 39951 A Tachometer 2870630 Timing Light 2871745 Static Timing Light Harness PV 39991 Peak Reading Adapter PV 37453 Christie Se Sulfating Multi Battery Charger PV 63070 Christie Multi Battery Charger Fuel Brake Systems 2870975 Mity VacTM Fuel Injection System See Chapter 4 EFI for Special Tool Listing ...

Page 18: ...1 16 GENERAL INFORMATION MISC SPECIFICATIONS AND CHARTS Conversion Table C to F 9 C 40 5 40 F F to C F 40 9 40 C ...

Page 19: ...The following torque specifications are to be used only as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views or each manual section for torque values of fasteners before using standard torque ...

Page 20: ...1 18 GENERAL INFORMATION SAE Tap Drill Sizes Metric Tap Drill Sizes Decimal Equivalents ...

Page 21: ...he end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In lb 12 in lbs 1 ft lb kg cm Kilograms per square centimeter kg m Kilogram meters Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a rotational direction l or ltr Liter lbs in Pounds per...

Page 22: ...FUEL SYSTEM AND AIR INTAKE 2 14 FUEL SYSTEM 2 14 FUEL LINES 2 14 FUEL FILTER CARB MODELS 2 14 VENT LINES 2 14 THROTTLE PEDAL INSPECTION 2 14 THROTTLE FREEPLAY ADJUSTMENT 2 15 THROTTLE CABLE ADJUSTMENT CARB MODELS 2 15 CHOKE ADJUSTMENT CARB MODELS 2 15 PILOT SCREW CARB MODELS 2 16 PILOT SCREW ADJUSTMENT CARB MODELS 2 16 IDLE SPEED ADJUSTMENT CARB MODELS 2 17 CARBURETOR DRAINING CARB MODELS 2 17 AIR...

Page 23: ... 32 ELECTRICAL AND IGNITION SYSTEM 2 32 BATTERY MAINTENANCE 2 32 BATTERY FLUID LEVEL CONVENTIONAL BATTERY 2 33 BATTERY REMOVAL 2 33 BATTERY INSTALLATION 2 33 BATTERY STORAGE 2 33 BATTERY CHARGING 2 33 SPARK PLUG SERVICE 2 34 ENGINE TO FRAME GROUND 2 34 STEERING AND SUSPENSION 2 34 STEERING 2 34 TIE ROD END STEERING INSPECTION 2 35 CAMBER AND CASTER 2 35 WHEEL TOE ALIGNMENT INSPECTION 2 35 TOE ADJU...

Page 24: ...ately 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 Maintenance Chart Key The following symbols denote potential items to be aware of during maintenance CAUTION Due to the nature of these adjustments it is recommended this service be performed by an authorized Polaris dealer SEVERE USE ITEM If vehicle is...

Page 25: ...nspect clean often E Air Box Sediment Tube Daily Drain deposits when visible Coolant Level Daily Check level daily change coolant every 2 years Head Lamp Tail Lamp Daily Check operation apply dielectric grease if replacing E Air Filter Main Element Weekly Inspect replace as needed Brake Pad Wear Inspect Parking Brake Pads 10 H Monthly Inspect periodically Battery 20 H Monthly Check terminals clean...

Page 26: ...loat Bowl if applicable 50 H 6 M Drain bowl periodically and prior to storage E Throttle Cable Throttle Pedal 50 H 6 M Inspect adjust lubricate replace if necessary E Choke Cable if applicable 50 H 6 M Inspect adjust lubricate replace if necessary E Carburetor Throttle Body Air Intake Ducts Flange 50 H 6 M Inspect ducts for proper sealing air leaks Drive Belt 50 H 6 M Inspect adjust replace as nee...

Page 27: ...ng Hoses 100 H 12M Inspect for leaks Engine Mounts 100 H 12M Inspect Exhaust Muffler Pipe 100 H 12M Inspect E Spark Plug 100 H 12M Inspect replace as needed E Ignition Timing 100 H 12M Inspect Wiring 100 H 12M Inspect for wear routing security apply dielectricgreasetoconnectorssubjectedto water mud etc Clutches Drive and Driven 100 H 12M Inspect clean replace worn parts Front Wheel Bearings 100 H ...

Page 28: ...r Distribution Module PDM Front Gearcase Behind Radiator Engine under seat Rear Gearcase Gas Tank Dash Components 1 2 3 4 5 6 7 8 9 1 Indicator Lights 2 Gear Shifter 3 Ignition Key 4 Choke 5 12V accessory 6 Hourmeter 7 AWD Differential Switch 8 Light Switch 9 Glove Box 4X4 ...

Page 29: ...2 8 MAINTENANCE LH Side and Rear View Battery Front Prop Shaft 4x4 PVT Cover Transmission Rear Prop Shaft Tail Gate Latch Air Cleaner Muffler 2 Hitch Drive Shafts 2x4 4x4 ...

Page 30: ...ized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 24 Count 2871423 Premium All Season Grease 14 oz cartridge 10 Count 2871460 Starter Drive Grease 12 Count 2871515 Premium U Joint Lube 3 oz 24 Count 2871551 Premium U Joint Lube 14 oz 10 Count 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogel Coolant 2871323 60 40 Coolant Gallon 6 Count 2871534 60 40 Coolant Quart 12 Count Part...

Page 31: ...aris 0W 40 Synthetic PN 2871281 Add oil to proper level Change after 1st month 25 hrs 6 months or 100 hours thereafter Change more often in extremely dirty conditions or short trip cold weather operation Polaris Brake Fluid Polaris Synthetic Gearcase Lube Polaris Synthetic OW 40 Oil Polaris Demand Drive Hub Fluid Polaris ATV Angle drive Fluid Polaris U Joint Lube Polaris All Season Grease RANGER 5...

Page 32: ...oir between MAX and Min lines As required Change fluid every 2 years 3 Transmission Polaris AGL Gearcase Lubricant PN 2873602 Add lube to bottom of fill plug threads Change annually Change more often if used in severe conditions 4 Front Gearcase Polaris Demand Drive Hub Fluid PN 2871654 Drain completely Add lube to specified quantity Change annually 5 Rear Gearcase ATV Angle Drive Fluid PN 2871653...

Page 33: ...mium All Season Grease Conoco Superlube M or Mobilegrease Special Item Lube Rec Method Frequency 6 Hubsrut Assembly Both Sides Polaris All Season Grease PN 2871423 Locategreasefittingontheundersideofthe hubstrut assembly and grease with grease gun Semi annually 7 Front Prop Shaft Yoke 4x4 Polaris Premium U Joint Lube PN 2871551 Locate fittings and grease with grease gun Semi annually Front Hub Str...

Page 34: ...nspect 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 Linkage Inspection Adjustment Linkage rod adjustment is necessary when symptoms include No All Wheel Drive light Noise on deceleration Inability to engage a gear Excessive gear clash noise Shift selectors moving out o...

Page 35: ...d with cable ties CAUTION Make sure lines are not kinked or pinched Throttle Pedal Inspection If the throttle pedal has excessive play due to cable stretch or cable misadjustment it will cause a delay in throttle speed Also the throttle may not open fully If the throttle pedal has no play the throttle may be hard to control and the idle speed may be erratic WARNING Gasoline is extremely flammable ...

Page 36: ...just the cable at the carburetor using the following procedure 1 Remove seat 2 Slide boot off throttle cable adjuster and jam nut 3 Loosen lock nut and turn adjuster until proper throttle lever freeplay is obtained 4 Tighten locknut and slide boot back over adjuster 5 Reinstall seat 6 Check for proper throttle operation and correct freeplay in all handlebar positions Choke Adjustment Carb Models W...

Page 37: ... slightly opened The fuel air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet Pilot Screw Adjustment Carb Models 1 Start engine and warm it up to operating temperature about 10 minutes CAUTION The pilot screw is calibrated at the factory to meet EPA CARB regulations for air quality standards and is sealed with a brass plug to prevent tampering Removal o...

Page 38: ...ut counterclockwise to decrease RPM NOTE Adjusting the idle speed affects throttle cable freeplay Always check throttle cable freeplay after adjusting idle speed and adjust if necessary Carburetor Draining Carb Models The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl or before extended periods of storage NOTE The bowl drain screw is located on th...

Page 39: ...ervice It is recommended that the air filter be replaced annually When riding in extremely dusty conditions replacement will be required more often The filter should be inspected periodically before each ride using the following procedure 1 Lift the box to access the filter box cover 2 Remove clips 2 from air box cover and remove cover Inspect the gasket It should adhere tightly to the cover and s...

Page 40: ... the EFI fuel system refer to Chapter 4 ENGINE Compression and Leakdown Test NOTE 4 Stroke 500 engines are equipped with an automatic decompressor Compression readings will vary in proportion to cranking speed during the test Average compression measured is about 60 90 psi during a compression test Smooth idle generally indicates good compression Low engine compression is rarely a factor in runnin...

Page 41: ... to remove moisture Drain the flywheel housing after operating the vehicle in very wet conditions This should also be done before storing the vehicle The drain screw is located at the bottom of the flywheel housing Remove the plug Reinstall the plug once housing has been drained After travelling in wet areas the engine housing and starter should always be drained completely by removing the housing...

Page 42: ... plug NOTE The sealing surfaces on drain plug and oil tank should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to 14 ft lbs 19 Nm 8 Loosen clamp D 9 Remove oil hose from screen fitting C on bottom of oil tank 10 Remove screen fitting C 11 Clean screen thoroughly 12 Apply Loctite 565 Thread Sealant PN 2871956 to the clean and oil free threads of the fitting 13 Ins...

Page 43: ...of Polaris Premium 4 Synthetic Oil PN 2871281 22 Place gear selector in neutral and set parking brake 23 Prime oil pump using the Oil Pump Priming Procedure Stop the engine and inspect for leaks 24 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 25 Dispose of used filter and oil properly Oil Pump Priming Procedure NOTE This primi...

Page 44: ...n lead A and remove the spark plug B CAUTION Place a clean shop towel into the spark plug cavity to prevent dirt from entering 3 Remove rocker cover bolts cover C and gasket NOTE It may be necessary to tap cover lightly with a soft faced hammer to loosen it from the cylinder head 4 Remove the flywheel cover D and rotate flywheel so the piston is at TDC 5 Rotate engine slowly by turning the flywhee...

Page 45: ...knut s and turn adjuster screw s until there is a slight drag on feeler gauge s The Valve Clutch Adjuster Tool PA 44689 can be used to adjust the engines valves NOTE The exhaust valves share a common rocker arm and must be adjusted using two feeler gauges 3 When clearance is correct hold adjuster screw and tighten locknut securely 4 Re check the valve clearance Exhaust Pipe The exhaust pipe must b...

Page 46: ...is in Park and repeat Steps 2 and 3 SEE WARNING 6 Repeat steps 2 through 5 until no more particles are expelled when the engine is revved 7 Stop the engine and allow the arrestor to cool 8 Reinstall the clean out plugs TRANSMISSION AND GEARCASES Transmission Lubrication NOTE It is very important to follow a regular transmission fluid check change schedule The service manual of the RANGER recommend...

Page 47: ...ccordance with the maintenance schedule Be sure vehicle is level with parking brake on before proceeding Check vent hose to be sure it is routed properly and unobstructed The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid To check the lubricant level The front gearcase lubricant level cannot be checked with a dipstick The gearcase must be drained and re filled with the...

Page 48: ...el in the left wheel well 4 Remove fill plug 8 mm hex and check the O ring 5 Fill with the recommended fluid amount 5 oz or to the bottom of the fill plug hole threads 6 Install fill plug and check for leaks Rear Gearcase Lubrication To check the level 1 With machine on level ground and with the parking brake on remove fill plug from rear gearcase 10 ft lbs 14 Nm A B Top View of Hood Area LH Side ...

Page 49: ...w The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the ...

Page 50: ...nd or repair However if the recovery bottle has run dry or if overheating is evident the level in the radiator should be inspected and coolant added if necessary NOTE Use of a non standard pressure cap will not allow the recovery system to function properly To access the radiator pressure cap raise the front hood The radiator cap is located on the drivers side Coolant Strength Type Test the streng...

Page 51: ...o bolts that secure the top bumper to the frame Remove the darts that attach the plastic to the bumper 2 Remove two mounting screws that secure the top of the radiator to the frame Remove the radiator cap Pull the radiator out of the frame at an angle NOTE If you have trouble reaching the top radiator bolts remove four screws from the top front of the hood liner Prop the front of the hood up 1 5 i...

Page 52: ...otrest frame 4 Remove the wheel nuts and washers and remove the wheel Wheel Installation 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the washers if applicable and wheel nuts and finger tighten them 3 Lower the ...

Page 53: ...it could affect vehicle handling and tire wear On vehicles with tapered rear wheel nuts make sure tapered end of nut goes into taper on wheel WARNING Operating a RANGER with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the tread depth measures 1 8 3 cm or less Tread Depth 1 8 3 mm CA...

Page 54: ...ust be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte 4 Coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables are properly routed Battery Storage Whenever the vehicle is not used for a...

Page 55: ...lug and torque to specification Engine To Frame Ground Inspect engine ground cable connection Be sure it is clean and tight The ground cable runs from the engine to the terminal block located under the front hood next to the battery STEERING AND SUSPENSION Steering The steering components should be checked periodically for loose fasteners worn tie rod ends and damage Also check to make sure all co...

Page 56: ...traight ahead position and secure the steering wheel in this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible NOTE It is important that the height of both marks be equally positioned in order to get an accurate measurement 4 Measure the distance between the marks and record the measuremen...

Page 57: ... held parallel to prevent rod end damage and premature wear Damage may not be immediately apparent if done incorrectly After alignment is complete torque jam nuts to 12 14 ft lbs 16 19 Nm Front Suspension Compress and release front suspension Damping should be smooth throughout the range of travel Check all front suspension components and fasteners for wear or damage Inspect front strut cartridges...

Page 58: ... 2 Reposition the shocks to the outside mounting holes 3 Reinstall the shock mounting bolts Torque to 30 ft lbs 40 Nm Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjustment cam either clockwise or counterclockwise to increase or decrease spring tension To adjust the suspension use the adjustment cam located near the bottom of the rear shock This will allow y...

Page 59: ...he disc Brake Pad Inspection Pads should be changed when the friction material is worn to 180 4 6 mm When the pad are new the thickness is 298 007 7 56 178 mm Parking Brake Pad Inspection Measure the thickness of the rear caliper parking brake pads Replace assembly as needed See illustration below for proper readings Brake Hose and Fitting Inspection Check brake system hoses and fittings for crack...

Page 60: ...SEMBLY 3 18 ENGINE REMOVAL 3 18 CAM CHAIN TENSIONER ROCKER ARM CAMSHAFT REMOVAL 3 18 CAM CHAIN TENSIONER INSPECTION 3 18 ROCKER ARM SHAFT INSPECTION 3 19 CAMSHAFT REMOVAL 3 20 AUTOMATIC COMPRESSION RELEASE REMOVAL INSPECTION 3 21 AUTOMATIC COMPRESSION RELEASE INSTALLATION 3 21 CAMSHAFT INSPECTION 3 22 CYLINDER HEAD REMOVAL 3 22 CYLINDER HEAD EXPLODED VIEW EH50PL EFI SHOWN 3 23 CYLINDER HEAD INSPEC...

Page 61: ...LLATION 3 41 CRANKSHAFT COUNTER BALANCE OIL PUMP INSTALLATION 3 41 CRANKCASE ASSEMBLY 3 41 WATER PUMP MECHANICAL SEAL INSTALLATION 3 41 WATER PUMP MECHANICAL SEAL REMOVAL ENGINE INSTALLED 3 42 ONE WAY VALVE INSTALLATION 3 43 CAM CHAIN DRIVE SPROCKET INSTALLATION 3 43 TENSIONER BLADE INSTALLATION 3 43 PISTON RING INSTALLATION 3 43 PISTON INSTALLATION 3 44 CYLINDER INSTALLATION 3 44 CYLINDER HEAD IN...

Page 62: ...aft Slotted Nut Cam Chain Drive Sprocket 28mm 35 51 47 69 Nm Cylinder Base Bolts 10mm 6mm 45 49 61 67 Nm 6 8 9 11 Nm Cylinder Head Bolts 11mm 6mm Refer to Engine Assembly for torque procedure Drive Clutch Bolt 7 16 20 40 55 Nm Flywheel 16mm 58 72 78 98 Nm Oil Delivery Pipe 12mm 11 15 15 21 Nm Oil Drain Bolt Crankcase 14mm 14 17 19 23 Nm Oil Filter Pipe Fitting 20mm 36 43 49 59 Nm Hard Metal Oil Li...

Page 63: ...8 005 38 025 mm Camshaft Oil clearance Std 0022 0035 055 090 mm Limit 0039 10 mm Cylinder Head Surface warpage limit 0020 05 mm Standard height 3 870 98 3 mm Valve Seat Contacting width In Std 028 7 mm Limit 055 1 4 mm Ex Std 039 1 0 mm Limit 071 1 8 mm Valve Guide Inner Diameter 2362 2367 6 0 6 012 mm Protrusion above head 689 709 17 5 18 0 mm Valve Margin thickness In Std 039 1 0 mm Limit 031 8 ...

Page 64: ...iameter 9053 9055 22 994 23 0 mm Standard clearance piston pin to pin bore 0002 0003 004 008 mm Degree of fit Piston Pin must be a push by hand fit at 68o F 20o C Piston Ring Piston Ring Installed gap Top ring Std 0079 0138 20 36 mm Limit 039 1 0 mm Second ring Std 0079 0138 20 36 mm Limit 039 1 0 mm Oil ring Std 0079 0276 20 70 mm Limit 059 1 5 mm Piston Ring Standard clearance piston ring to rin...

Page 65: ...tter Note the directional and identification marks when viewing the pistons from the top The letter F g 4 or must always be toward the flywheel side of the engine The other numbers are used for identification as to diameter length and design Four stroke engine rings have a rectangular profile See text for oil control ring upper rail installation Use the information below to identify pistons and ri...

Page 66: ...ne slightly to access water pump Use the Water Pump Mechanical Seal Puller PN 2872105 to replace mechanical seal with engine in frame Engine Removal 1 Clean work area 2 Thoroughly clean the engine and chassis 3 Disconnect negative battery cable 4 Remove the seat 5 Perform the following Remove spark plug high tension lead Remove engine to chassis ground cable Disconnect engine wiring harness near t...

Page 67: ...Relieve fuel pressure and disconnect fuel line from fuel rail Disconnect fuel injector harness TPS harness MAP harness and IAC harness Remove throttle body Insert a shop towel into the intake manifold to prevent dirt from entering the intake port 6 Remove top motor mount bracket and dampener bracket Remove any heat shields 7 Remove air box hose rear clutch hose and the starter positive cable 8 To ...

Page 68: ...ngine mount plates Carb Model shown below 13 Carefully remove engine through top of seat frame Lift the engine from bottom mounts and then lift the engine from rear mounts NOTE Use caution when lifting the engine out of frame Use an engine lift or other means if the engine appears too heavy to be lifted manually Top Rear Engine Mount Carb Top Motor Mounts Rear Motor Bottom Mount Mount ...

Page 69: ... reservoir tank after engine is cool and add coolant if necessary Engine Break In Period 4 Cycle Engine Break In Period is defined as the first 10 hours of engine operation or 2 full tanks of fuel 1 Use only Polaris Premium 4 All Season synthetic oil Never substitute or mix oil brands Serious engine damage can result 2 Use fuel with a minimum octane of 87 R M 2 method 3 Change break in oil and fil...

Page 70: ... the corners of the intake and exhaust ports Cleaning the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylinder in a solvent then in hot soapy water Pay close attention to areas where the cylinder sleeve meets the aluminum casting transfer port area Use electrical contact cleaner if necessary to clean these are...

Page 71: ... gauge adaptor into the cylinder head and attach the gauge 3 Start engine and allow it to reach operating temperature monitoring gauge indicator NOTE Use Polaris Premium 4 Synthetic Engine Lubricant PN 2871281 Oil Pump Priming Procedure NOTE This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off vent ...

Page 72: ... it passes through the slotted friction bearing located in the stator plate into the crankshaft An oil seal on the stator plate prevents oil from entering the stator flywheel area Oil travels through the crankshaft to the crank pin lubricating the connecting rod large end bearing directly Oil also passes through an oil jet drilled orifice in the end of the crank pin to the PTO end main bearings an...

Page 73: ...Delivery Pipe Oil Filter Bypass Delivery Pipe Crankcase Oil Gallery Prevents oil from draining into crankcase with engine off Union Fitting Upper Oil Hose Crankcase Oil Gallery Oil Pump Scavenging Oil Strainer Crankshaft Crank Pin Large End Bearing Indirect Lubrication Cylinder Sleeve Small End Bearing Crankcase Metal Sprocket Chain Cam Shaft Journal Cam Lobe Cam Shaft Journal Rocker Arm Rocker Sh...

Page 74: ...3 15 ENGINE 3 EH50PL Engine Exploded View Crankshaft and Piston Cylinder Cylinder Head EFI Shown Crankcase Valve Train ...

Page 75: ...essure Test 1 Remove radiator cap and test using a cap tester commercially available 2 The radiator cap relief pressure is 13 lbs Condition Approx Reading Ohms Temperature Hot Light On 185Ω 3 215 F 102 C Fan On Temp 245Ω 3 195 F 91 C Fan Off Temp 307Ω 3 180 F 82 C Room Temperature 2000Ω 3 77 F 25 C Thermostat Starts opening 176 F 80 C Open 8mm 205 F 96 C System Capacity 2 25 Quarts 2 13L Radiator ...

Page 76: ...ORTANT 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 and ready to use COOLANT FLOW Overflow Bottle To Top Radiator Fan Engine To Bottom of Radiator Radiator ...

Page 77: ...h the camshaft to crankshaft center line NOTE The cam lobe should be pointing down and valves should have clearance at this point 5 Remove cam chain tensioner plug sealing washer and spring CAUTION The plug is under spring tension Maintain inward pressure while removing 6 Remove the two 6x25 mm cam chain tensioner flange bolts 7 Tap lightly on tensioner body with a soft face hammer and remove tens...

Page 78: ...ce If there is any damage or uneven wear replace the rocker arm NOTE Always inspect camshaft lobe if rocker arms are worn or damaged 3 Measure O D of rocker shaft Inspect it for wear or damage Compare to specifications 4 Measure I D of each rocker arm and compare to specifications 5 Measure I D of both rocker arm shaft supports and visually inspect surface Compare to specifications Tensioner Sprin...

Page 79: ...procket bolts 4 Remove camshaft end cap and O ring 5 Inspect camshaft end cap thrust face for wear Replace if worn or damaged 6 Place a clean shop towel in the area below cam chain sprocket and remove sprocket retaining bolts 7 Slide camshaft inward to allow removal of cam sprocket and remove sprocket from camshaft and chain 8 Secure cam chain with a wire to prevent it from falling into the crankc...

Page 80: ...y engine oil to release lever shaft The actuator ball must be held outward to allow installation of the release lever shaft If Camshaft is Removed From Engine 3 Turn the camshaft until the actuator ball is in the lowest position and install the release lever shaft If Camshaft is Installed in the Engine 4 Use a small magnet to draw the actuator ball outward or rotate the engine until the cam lobes ...

Page 81: ...cessively Cylinder Head Removal 1 Remove the two 6mm flange bolts A from cylinder head See exploded view on next page 2 Loosen each of the four cylinder head bolts evenly 1 8 turn each time in a criss cross pattern until loose 3 Remove bolts B and tap cylinder head lightly with a plastic hammer until loose IMPORTANT Tap only in reinforced areas or on thick parts of cylinder head casting to avoid d...

Page 82: ...3 23 ENGINE 3 Cylinder Head Exploded View EH50PL EFI Shown A A ...

Page 83: ...n in the cylinder head 1 Using a valve spring compressor C compress the valve spring and remove the split keeper NOTE To prevent loss of tension do not compress the valve spring more than necessary 2 Remove spring retainer and spring NOTE The valve springs should be positioned with the tightly wound coils against the cylinder head on progressively wound springs D 3 Push valve out keeping it in ord...

Page 84: ...three places and in two different directions six measurements total Compare to specifications 6 Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer Measure in two directions front to back and side to side 7 Subtract valve stem measurement to obtain stem to guide clearance NOTE Be sure to measure each guide and valve combination indiv...

Page 85: ... be used Keep all valves in order with their respective seat NOTE Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the entire circumference of the seat and the seat must be the proper width all the way around If the seat is uneven compression leakage will result If the seat is too wide seat pressure is reduced c...

Page 86: ...he contact area of the initial cut is greater than 75 continue to cut the seat until all pits are removed and a new seat surface is evident NOTE Remove only the amount of material necessary to repair the seat surface 11 To check the contact area of the seat on the valve face apply a thin coating of Prussian Blue paste to the valve seat If using an interference angle 46o apply black permanent marke...

Page 87: ... Do this four to five times until the valve is fully seated and repeat process for the other valve s 18 Clean cylinder head valves and camshaft oil supply passage A thoroughly 19 If oil passage blind plug was removed apply Crankcase Sealant PN 2871557 or equivalent sealer to the threads and install torquing to 8 ft lbs 11 Nm CAUTION Do not allow sealant to enter oil passage 20 Spray electrical con...

Page 88: ... two feeler gauges 1 Insert 006 feeler gauge s between end of the valve stem and adjuster screw s 2 Loosen locknut s and turn adjuster screw s until there is a slight drag on feeler gauge s The Valve Clutch Adjuster Tool PA 44689 can be used to adjust the 500 engines valves NOTE Both feeler gauges should remain inserted during adjustment of each exhaust valve 3 When clearance is correct hold adjus...

Page 89: ...ecessary heat the crown of the piston slightly with a propane torch CAUTION Do not apply heat to the piston rings The ring may lose radial tension 3 Remove top compression ring Using a piston ring pliers Carefully expand ring and lift it off the piston CAUTION Do not expand the ring more than the amount necessary to remove it from the piston or the ring may break By hand Placing both thumbs as sho...

Page 90: ...ements If cylinder is tapered or out of round beyond 002 the cylinder must be re bored oversize or replaced Piston to Cylinder Clearance 1 Measure piston outside diameter at a point 40 mm down from the top of the piston at a right angle to the direction of the piston pin 2 Subtract this measurement from the maximum cylinder measurement obtained in Step 5 above Cylinder Warpage 002 05 mm 1 2 Down F...

Page 91: ... to push ring squarely into place as shown at right 2 Measure installed gap with a feeler gauge at both the top and bottom of the cylinder Piston Pin Bore 9055 9057 23 0 23 006 mm Piston Pin O D 9053 9055 22 994 23 0 mm Piston Pin Bore Piston Pin Measurement Locations Piston Ring to Groove Clearance Top Ring Std 0016 0031 040 080 mm Limit 0059 15 mm Second Ring Std 0012 0028 030 070 mm Limit 0059 ...

Page 92: ... the rear of the drive mechanism 3 Inspect the thrust washer for wear or damage and replace if necessary 4 Measure the OD of the starter drive shaft on both ends and record 5 Measure the ID of the bushing in the recoil housing A and in the crankcase and record Measure in two directions 90o apart to determine if bushing is out of round Calculate bushing clearance Replace bushing if clearance exceed...

Page 93: ...crankshaftslotted nut NOTE The slotted nut is a left hand thread 5 Remove cam chain drive sprocket and woodruff key from crankshaft 6 Inspect sprocket teeth for wear or damage 7 Inspect woodruff key for wear 8 Replace any worn or damaged parts One Way Valve The one way valve prevents oil from draining out of the oil tank and into the crankcase when the engine is off It must be clean and have adequ...

Page 94: ... also be necessary to tap the oil pump shaft lightly to separate the crankcase 4 Remove the Mag RH crankcase from the PTO case Oil Pump Removal Inspection 1 Remove pump shaft bearing A and thrust washer B from pump shaft 2 Remove 2 bolts holding pump drive gear C 3 Inspect drive gear teeth for cracks damage or excessive wear 4 Remove three oil pump retaining bolts and pump 5 Inspect mating surface...

Page 95: ...scavenge rotor drive pin 3 Install outer scavenge rotor inner scavenge rotor and scavenge casing 4 Install outer feed rotor and inner feed rotor drive pin 5 Install inner feed rotor and feed chamber cover with screw 6 Tighten screw securely 7 Install screen on pump body 8 Install oil pump on crankcase and torque bolts to 6 ft lbs 8 Nm Counter Balancer Shaft Removal Inspection 9 Remove the shim was...

Page 96: ... detectable up and down movement Crankshaft Removal Inspection 1 Remove the shim washer C from the crankshaft 2 Support the PTO side crankcase and crankshaft press the crankshaft out Be careful not to damage the crankcase mating surface or connecting rod 3 Use a feeler gauge to measure the connecting rod big end side clearance 4 Place the crankshaft in a truing stand or V blocks and measure the ru...

Page 97: ... the water pump mechanical seal out of the crankcase from inside to outside Note The new mechanical seal must be installed after the crankcases are assembled using a special tool See Mechanical Seal Installation Crankcase Inspection 1 Remove all traces of gasket sealer from the crankcase mating surfaces Inspect the surfaces closely for nicks burrs or damage 2 Check the oil pump and oil passage mat...

Page 98: ... Step 4 and record Mag Case Depth______________________ 6 Add the readings recorded in Step 3 and Step 5 and record below Total Case Width______________________ 7 Measure the width of the crankshaft at the bearing seats with a micrometer or dial caliper and record Crankshaft Width______________________ 8 Subtract the Crankshaft Width measured in Step 7 from the Total Case Width recorded in Step 6 ...

Page 99: ...obtained in Step 5 7 Subtract the thickness of the existing shim from the result of Step 6 to determine if a different shim is needed The result must be within the specified range listed at below Oil Pump Shaft End Play Adjustment 8 Make sure the pump shaft bearing is firmly seated in the Magneto side crankcase 9 Measure the distance from the magneto crankcase mating surface to the bearing using a...

Page 100: ...sket sealer on the pump mating surfaces NOTE After engine is assembled and the vehicle is prepared for field operation oil pump MUST be primed Follow oil pump priming procedure on Page 3 12 6 Align the drive gear with the drive pin on the pump shaft and install the gear Be sure the gear is fully seated and properly engaged 7 Install the proper shim washer on the pump shaft Crankcase Assembly 1 App...

Page 101: ...r T Handle clockwise until it contacts the water pump shaft Continue rotating until the remaining portion of mechanical seal has been removed from the cases Pump shaft oil seal can also be replaced at this time if necessary 7 The Water Pump Install Kit PN 5131135 is required to install the new mechanical seal This tool is available separately and it is also included in the Crankshaft Water Pump Se...

Page 102: ...gap facing forward The expander has no up or down marking and can be installed either way The ends should butt squarely together and must not overlap 2 Install the oil ring top rail NOTE The top rail has a locating tab to prevent rotation The tab must be positioned in the notch on the side of the piston as shown C 3 Install the bottom rail with the gap at least 30o from the end of the expander on ...

Page 103: ...he clips are properly seated in the groove Cylinder Installation 1 Place the dowel pins in the crankcase and install a new cylinder base gasket 2 Position the Piston Support Block PN 2870390 A beneath the piston skirt to support the piston during cylinder installation 3 Apply clean engine oil to the ring compressor Snap On PN RCL30 and install the compressor following manufacturers instructions CA...

Page 104: ...ensioner guide Be sure bottom end of guide is located properly in crankcase 2 Install the two dowel pins and a new cylinder head gasket 3 Place the cylinder head on the cylinder Apply a film of engine oil to the cylinder head bolt threads and washers and hand tighten the bolts The following procedure must be used to torque the cylinder head properly Cam Chain Camshaft Installation Install the cam ...

Page 105: ...ocket with the dots on the sprocket facing outward and the alignment pin notch facing directly upward 5 Before positioning the sprocket on the camshaft check the position of the cam sprocket alignment pin When the cam is positioned properly the cam sprocket alignment pin A is directly in line with the crankshaft camshaft centerline B 6 Install the sprocket on the camshaft Apply Loctite 242 PN 2871...

Page 106: ...3 47 ENGINE 3 Camshaft Timing Illustration Dots Crankshaft to Camshaft Centerline Sprocket Alignment Pin TDC mark Rotation Do Not Use Advance Marks Single TDC Mark Aligned ...

Page 107: ...O Ring in the oil passage recess in the crankcase 3 Apply Crankcase Sealant PN 2871557 or an equivalent sealer to the stator plate outer surface and install a new O Ring 4 Install the stator plate being careful not to damage the seal Align timing reference marks on the plate and crankcase Be sure the plate is fully seated NOTE This is a static timing mark Strobe timing should be performed after st...

Page 108: ...l to the threads of the bolts and tighten evenly 7 Adjust valves according to the valve adjustment procedure found in Chapter 2 Maintenance 8 Apply clean engine oil liberally to the valve springs cam chain rocker arms and camshaft 9 Place a new rocker cover gasket on the cylinder head and install the cover and bolts Thermostat Installation Install the thermostat with one of the air bleed holes pos...

Page 109: ...speed limiter limiting speed Carburetor vacuum slide sticking diaphragm damaged Incorrect ignition timing Restricted exhaust system Engine Has Low Power Spark plug fouled Cylinder piston ring or valve wear or damage check compression PVT not operating properly Restricted exhaust muffler Carburetor vacuum slide sticking diaphragm damaged Dirty carburetor Piston Failure Scoring Lack of lubrication D...

Page 110: ... Fuel quality poor old or octane too high Low compression Restricted exhaust Weak ignition loose coil ground faulty coil stator or ETC switch ETC switch mis adjusted Restricted air filter main or pre cleaner or breather system Improperly assembled air intake system Restricted engine breather system Oil contaminated with fuel Restricted oil tank vent Cooling Troubleshooting Overheating Low coolant ...

Page 111: ... MAIN SYSTEM 4 9 PILOT SCREW 4 9 CARBURETOR SERVICE 4 10 CARBURETOR REMOVAL 4 10 CARBURETOR DISASSEMBLY 4 10 CARBURETOR CLEANING 4 11 CARBURETOR INSPECTION 4 12 FLOAT HEIGHT ADJUSTMENT 4 12 NEEDLE AND SEAT LEAKAGE TEST 4 12 FUEL LEVEL 4 13 CARBURETOR ASSEMBLY 4 13 AIR BOX ASSEMBLY 4 14 EXPLODED VIEW 4 14 FUEL TANK ASSEMBLY 4 15 FUEL TANK FUEL PUMP EXPLODED VIEW 4 15 FUEL TANK REMOVAL 4 16 FUEL TAN...

Page 112: ...5 3130555 42 5 3130526 117 5 3130556 120 3130557 122 5 3130558 125 3130559 127 5 3130560 130 3130561 132 5 3130562 135 3130563 137 5 3130564 140 3130527 142 5 3130566 145 3130567 147 5 3130568 150 3130569 152 5 3130570 155 3130571 157 5 3130572 160 3131141 162 5 3131142 165 3131143 167 5 3131144 170 3131145 PART NUMBER TOOL DESCRIPTION 2870975 Mity VacTM Pressure Test Tool 2872314 Carburetor Float...

Page 113: ...e 100 1 5 Packing 1 21 Spring 1 6 Seal 2 22 Ring 1 7 Float Pin 1 23 Screw 2 8 Pilot Jet 42 5 1 24 Throttle Shaft Asm 1 9 O Ring 1 25 Cable Guide 1 10 Needle Valve 1 26 Screw 4 11 Plate 1 27 Cover 1 12 Screw 10 1 28 Guide Holder 1 13 O Ring 1 29 Spring 1 14 Screw 4 30 Plunger Asm 1 15 Float Body Asm 1 31 Screw Washer Asm 10 2 16 Screw 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 6 21 22 23 ...

Page 114: ...r of the vacuum slide dampens the slide movement and assists the return of the slide Carburetor Component Function System Main Components Main Function Main Affect Float System Level Control InletPipe Needle and Seat Float Float Pin Maintains specified fuel level in float chamber carburetor float bowl All systems All throttle ranges Venting Passages in Carburetor Vent lines to frame Supplies atmos...

Page 115: ...enturi is kept relatively constant This provides improved fuel atomization and optimum fuel air ratio Pilot System Idle and Slow Speed This system supplies fuel during engine operation with throttle valve closed 1 or slightly opened The fuel from float chamber 2 is metered by pilot jet 3 where it mixes with air coming in through pilot air jet 4 The mixture then goes up through pilot passage to pil...

Page 116: ...r outlet 6 in the main bore Float System Fuel enters the float chamber 3 by means of the inlet pipe and passage through a screen on the back of the inlet needle seat 4 and around the inlet needle 2 As the fuel fills the float chamber the float 1 rises and forces the inlet needle against the seat shutting off the orifice in the seat When fuel level is up in float chamber floats are up and needle va...

Page 117: ...ugh which the emulsified fuel must flow is determined ultimately by throttle position and vacuum slide height Pilot Screw The pilot system supplies fuel during engine operation with the throttle valve closed or slightly opened The fuel air mixture is metered by pilot screw and discharged into the main bore through the pilot outlet 1 2 3 4 5 6 7 A CAUTION Thepilot screw is calibratedat the factory ...

Page 118: ... Disassembly NOTE RANGER 2x4 and 4x4 models will have tamper resistant screws on Diaphragm Cover per 2003 CARB standards for LSI large spark ignition engines All RANGERs are classified within LSI The existence of these tamper resistant screws will require customers to purchase a complete carburetor if they desire to replace jet needle or piston slide A main jet change is the only requirement for a...

Page 119: ...hot water 3 Replace the jets if they have a buildup of fuel residue or bacterial growth that cannot be removed Even a small amount of residue will reduce the flow characteristics of the jet 4 Verify all passages and jets are unobstructed by spraying electrical contact cleaner through the passages CAUTION Do not use wire or welding tip cleaners as the orifice size may be altered 5 Use low pressure ...

Page 120: ... of float should be parallel to each other The measurement should be made at the mid point on the top of the float using Float Adjustment Tool PN 2872314 or a vernier caliper When measuring the height be sure the inlet needle valve spring is not compressed 3 If adjustment is necessary bend the tongue slightly Be sure float measurement is even on left and right side Needle and Seat Leakage Test 1 I...

Page 121: ...engine for 3 to 5 seconds to allow fuel level to stabilize in the line If level is out of specification remove carburetor and inspect inlet needle and seat float height passages etc NOTE If a line was removed to perform this procedure it must be replaced Carburetor Assembly NOTE Refer to the exploded view of the BST 34 carburetor at the beginning of this chapter for reference 1 Install the pilot m...

Page 122: ...AIR BOX ASSEMBLY Exploded View A Cover Seal B Air Filter C Air Box Assembly D Narrow Band Clamp E Carb Boot F Breather Hose G Hose Clamp H Breather Filter J P Clamp K Breather Line L O Ring M Hose Clamp A B C D E F G H J K L M ...

Page 123: ...n Line Fuel Filter D Hose Clamp E Fuel Pump F Fuel Line with Conduit G Heat Shield Foil H Fuel Tank J Tank Mounting Screws K Fuel Line A B C D E D F G H J D K K Fuel Tank Vent Fuel Tank Fuel Pick Up Filter Fuel Fitting Fuel Pump Carburetor Carburetor Vent Located Above Fuel Tank In Line Filter Engine FUEL FLOW DIAGRAM ...

Page 124: ...me 7 Remove the two outer lower bolts that hold the fuel tank to the frame 8 Reinstall the fuel cap and carefully pull the fuel tank out the RH side of the frame Fuel Tank Installation 1 Reinstall the tank assembly 2 Reinstall the four fuel tank mounting bolts that were removed 3 Reconnect the electrical harness Install the fuel line and vent line and verify they are secure 4 Reinstall the RH rear...

Page 125: ...harness A 3 Remove the fuel line clamps and remove the fuel lines from each side of the fuel pump B 4 Remove two screws that secure the fuel pump B to the main floor 5 To install the fuel pump B repeat Step 1 through Step 4 in reverse order CAUTION Be careful not to damage fuel pump Passenger Side B A ...

Page 126: ...filter dirty plugged Choke plunger sticking incorrectly adjusted choke Choke cable binding or improperly routed Incorrect pilot air fuel screw adjustment Faulty inlet needle and seat Faulty inlet needle seat O Ring Float level too high Poor fuel quality old fuel Loose jets Worn jet needle needle jet or other carburetor parts Dirty carburetor air bleed passages or jets Weak or damaged vacuum piston...

Page 127: ...Y REPLACEMENT 4 32 FUEL PRESSURE REGULATOR 4 34 GENERAL INFORMATION 4 34 FUEL INJECTOR 4 34 GENERAL INFORMATION 4 34 CRANKSHAFT POSITION SENSOR CPS 4 35 GENERAL INFORMATION 4 35 MANIFOLD AIR PRESSURE SENSOR MAP 4 36 GENERAL INFORMATION 4 36 MAP SENSOR TEST 4 36 MAP SENSOR REPLACEMENT 4 36 INTAKE AIR TEMPERATURE SENSOR IAT 4 37 GENERAL INFORMATION 4 37 INTAKE AIR TEMPERATURE SENSOR TEST 4 37 INTAKE...

Page 128: ...44 CRANKSHAFT POSITION SENSOR CPS CIRCUIT 4 44 FUEL PUMP CIRCUIT 4 45 IGNITION COIL CIRCUIT 4 45 IDLE AIR CONTROL IAC CIRCUIT 4 46 THROTTLE POSITION SENSOR TPS CIRCUIT 4 46 MANIFOLD AIR PRESSURE SENSOR MAP CIRCUIT 4 47 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT 4 47 INTAKE AIR TEMPERATURE SENSOR IAT CIRCUIT 4 48 MALFUNCTION INDICATOR LIGHT MIL CIRCUIT 4 48 DIAGNOSTIC CONNECTOR CIRCUIT 4 49 ...

Page 129: ...47470 Digital Wrench PC Interface Cable PU 47469 Digital Wrench Vehicle Interface Cable PU 47468 Digital Wrench SmartLink Module 2201519 Throttle Position Sensor Tester WARNING Gasoline is extremely flammable and explosive under certain conditions EFI components are under high pressure Verify system pressure has been relieved before disassembly Never drain the fuel system when the engine is hot Se...

Page 130: ...tware Polaris dealers can also order separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 For use on all 15 pin connector based Polaris EFI systems Digital Wrench Diagnostic Connector Located Under the Hood Throttle Position Sensor Tester 2201519 This tester allows the use of a digital multi meter to test TPS function as well perform initialization ...

Page 131: ...ngine components Do not use dielectric grease on sealed connectors connectors with a rubber grommet as it may displace the rubber seal and allow contaminants to enter the connector Never attempt to service any fuel system component while engine is running or ignition switch is turned to on USE CARE when removing or installing the ECM connector as well as all other harness connections on the unit D...

Page 132: ...Sensor MAP 3 Intake Air Temperature Sensor IAT 4 Idle Air Control IAC 5 Crankshaft Position Sensor CPS inside cover 6 Fuel Injector 7 Fuel Line 8 Fuel Pump Tank Assy 9 Engine Coolant Temperature Sensor ECT 10 Throttle Position Sensor TPS LH side of Throttle body 11 Throttle Body 12 Fuel Rail 1 2 3 4 5 6 12 9 11 10 8 3 ...

Page 133: ...d on top of the intake manifold 3 Intake Air Temperature Sensor IAT Located in the rubber intake boot between the air box and throttle body 4 Idle Air Control IAC Located on top of the Throttle body 5 Crankshaft Position Sensor CPS Located inside the magneto cover on the right hand side of the engine 6 Fuel Rail Attached to the fuel injector located in the intake manifold 4 7 2 9 10 3 4 7 2 9 10 3...

Page 134: ... 8 Fuel Pump Regulator Gauge Sender Assembly Located in the fuel tank as an assembly 9 Throttle Position Sensor TPS Located on the left hand side of the throttle body 10 Engine Coolant Temperature Sensor ECT Located in the cylinder head 4 7 2 9 10 3 4 7 2 9 10 3 4 7 2 9 10 3 11 ...

Page 135: ...ploded View 1 Gas Cap w Gauge 2 Fuel Tank w Pump 3 Vent Line 4 Tank Foil 5 Fuel Line 6 Fuel Tank Brackets 1 2 3 5 6 4 Fuel Tank Fuel Filter 30 micron Fuel Pump Pressure Regulator Fuel Supply Rail Injectors Fuel Flow component located in fuel tank ...

Page 136: ...led injection of the fuel occurs every other crankshaft revolution or once for each 4 stroke cycle The total amount of fuel needed for one firing of a cylinder is injected during each cycle When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned The ECM controls the amount of fuel being injected and the ignition timing by monitoring the primary sens...

Page 137: ...its memory and determines the appropriate fuel and spark requirements for the immediate operating conditions The ECM then sends output signals to set the injector duration and ignition timing During operation the ECM continually performs a diagnostic check of itself each of the sensors and system performance If a fault is detected the ECM turns on the Malfunction Indicator Light MIL Check Engine L...

Page 138: ...damage the harness connector or locking mechanism NOTE Should the black slider become broken replacement parts are available 5 To install reverse the procedures DO NOT apply dielectric grease to the connector as it is a sealed connector Install the upper left retaining screw spacer and screws Tighten screws to 10 in lbs 1 1 Nm ECM Service Never attempt to disassemble the ECM It is sealed to preven...

Page 139: ...s on Fuel Pump Test NOTE The fuel pump tank assembly is a non serviceable assembly and must be replaced if determined to be faulty If a fuel delivery problem is suspected make certain the filters are not plugged that the pump is being activated through the ECM all electrical connections are properly secured the fuses are good and a minimum of 7 0 volts is being supplied If during starting the batt...

Page 140: ...nd ECM 4 If voltage at the plug was good and there was continuity across the pump terminals reconnect the plug to the pump making sure you have good clean connections Turn on the key switch and listen for the pump to activate NOTE If the pump starts repeat steps 1 and 2 to verify correct pressure NOTE If the pump still does not operate check for correct ECM operation by plugging in a known good EC...

Page 141: ... hold the fuel tank to the frame 9 Reinstall the fuel cap and carefully pull the fuel tank out the RH side of the frame Fuel Tank Installation 1 Reinstall the pump tank assembly 2 Reinstall the four fuel tank mounting bolts that were removed 3 Reconnect the electrical harness Install the fuel line and vent line and verify they are secure 4 Reinstall the RH rear fender 5 Reconnect the negative batt...

Page 142: ...of fuel needed for one firing is injected during each opening The amount of fuel injected is controlled by the ECM and determined by the length of time the valve needle is held open also referred to as the injection duration or pulse width It may vary in length from 1 5 8 milliseconds depending on the speed and load requirements of the engine Fuel Injector Service Injector problems typically fall ...

Page 143: ...t onto the flywheel The inductive crankshaft sensor is mounted 0 4 1 2 mm 0 015 047 in away from this ring gear During rotation an AC pulse is created within the sensor for each passing tooth The tooth gap creates an interrupt input signal corresponding to specific crankshaft position for PTO cylinder This signal serves as a reference for the control of ignition timing by the ECM Within one 1 revo...

Page 144: ... and provides the ECM with the manifold pressure during engine operation This allows the ECM to adjust the fueling according to actual engine load as well as identify which stroke is the intake stroke The MAP sensor also provides the ECM with the ability to compensate for high altitude operation without any recalibration During initial start up the ECM is in a waste spark waste fuel mode until the...

Page 145: ...rness from sensor 2 Using a suitable tool remove the sensor from the air box boot 3 To reinstall lightly coat the grommet with soapy water and install a new sensor using a twisting motion to properly seat the sensor in the air box boot 4 Re connect the harness IDLE AIR CONTROL IAC General Information The Idle Air Control IAC is used to stabilize the idle quality of the engine at cold start up and ...

Page 146: ... for the amount of engine load Throttle Position Sensor Test The throttle position sensor TPS is a non serviceable item If it is faulty it must be replaced It can be tested using the following method Using an ohmmeter With the test leads connected and the meter set to the ohms scale observe the reading at the following pin locations of the TPS Using TPS Test Adapter Harness 2201519 Set up the TPS ...

Page 147: ...he correct position of the TPS is established and set at the factory If the TPS is repositioned replaced or loosened it must be recalibrated 1 Remove the seat 2 Disconnect sensor from the engine harness 3 Loosen and rotate the throttle body B to gain access to the retaining screws if required 4 Remove the retaining screws and replace the sensor but do not tighten the screws at this point 5 Refer t...

Page 148: ...ssed by the ECM and compared to it s programming for determining the fuel and ignition requirements during operation The ECM also uses this signal to determine when to activate the fan during operation If for any reason the engine temperature sensor circuit is interrupted the fan will default to ON Engine Temperature Sensor Test Polaris dealers can test the sensor by using the Digital Wrench Diagn...

Page 149: ...umber will flash first then a pause and the second digit number will flash Example For a Code 42 The Orange MIL light will flash 4 times pause then flash 2 times A code 61 will signal the end of the blink codes The Orange MIL light will then remain lit when finished 3 When the diagnostic mode is complete the Orange MIL light will remain illuminated until the key is switched off NOTE To clear codes...

Page 150: ...High Voltage Yes 44 CPS Circuit Fault Yes 45 Barometric Pressure Sensor MAP Circuit Low Input Yes 46 Barometric Pressure Sensor MAP Circuit High Input Yes 47 IAC Open Load Yes 47 IAC Short to Ground Yes 51 Injector 1 Open Load Short Circuit to Ground Yes 51 Injector 1 Short Circuit to Battery Yes 55 Diagnostic Lamp Open Load Yes 55 Diagnostic Lamp Short Circuit to Ground Yes 55 Diagnostic Lamp Sho...

Page 151: ...sor or disconnected wiring Throttle stop screw tampering replace throttle body Poor Idle Symptom Idle Too High If greater than 1300 RPM when engine is warm Throttle stop screw tampering replace throttle body Throttle cable sticking improperly adjusted routed incorrectly Failed Sensor or disconnected wiring IAC stuck or inoperative Intake air leak Symptom Idle Too Low if less than 900 RPM when engi...

Page 152: ...4 44 ELECTRONIC FUEL INJECTION EFI SYSTEM BREAK OUT DIAGRAMS Fuel Injector Circuit Crankshaft Position Sensor CPS Circuit ...

Page 153: ...4 45 ELECTRONIC FUEL INJECTION 4 Fuel Pump Circuit Ignition Coil Circuit ...

Page 154: ...4 46 ELECTRONIC FUEL INJECTION Idle Air Control IAC Circuit Throttle Position Sensor TPS Circuit ...

Page 155: ...4 47 ELECTRONIC FUEL INJECTION 4 Manifold Air Pressure Sensor MAP Circuit Engine Coolant Temperature Sensor Circuit ...

Page 156: ...4 48 ELECTRONIC FUEL INJECTION Intake Air Temperature Sensor IAT Circuit Malfunction Indicator Light MIL Circuit ...

Page 157: ...4 49 ELECTRONIC FUEL INJECTION 4 Diagnostic Connector Circuit ...

Page 158: ... 5 8 SEAT HEAD REST 5 9 SEAT BASE SEAT BACK HEAD REST ASSEMBLY 5 9 STEERING ASSEMBLY 5 10 EXPLODED VIEW 5 10 STEERING AND SUSPENSION 5 11 EXPLODED VIEW 5 11 FRONT A ARM 5 12 REPLACEMENT 5 12 FRONT STRUT 5 13 EXPLODED VIEW 5 13 FRONT STRUT CARTRIDGE REPLACEMENT 5 14 BALL JOINT REPLACEMENT 5 14 REAR A ARM 5 15 REPLACEMENT 5 15 REAR STABILIZER BAR 5 17 REMOVAL INSTALLATION 5 17 REAR CARGO BOX 5 18 CA...

Page 159: ...nting Bolt 30 ft lbs 41 Nm Lower Rear Wheel Bearing Carrier Bolt 30 ft lbs 41 Nm Upper Rear Wheel Bearing Carrier Bolt 30 ft lbs 41 Nm Strut Rod Retaining Nut Top 15 ft lbs 21 Nm Strut Casting Pinch Bolt 15 ft lbs 21 Nm Tie Rod End Jam Nut 12 14 ft lbs 17 19 Nm Tie Rod End Castle Nut 40 ft lbs 54 Nm Seat Belt to Seat Base 40 ft lbs 54 Nm Steering Wheel to Shaft 25 31 ft lbs 34 42 Nm Upper Steering...

Page 160: ... liner darts and screws 2 Disconnect the wiring harnesses 3 Remove the air baffling boxes FRONT BUMPER 1 Lift the hood 2 Remove the 3 front Torx screws from LH and RH wheel well panels 3 Remove the 2 top bumper mounting bolts 4 Remove the 3 lower bumper mounting bolts CARGO BOX 1 Place box in the dump position 2 Remove the pin and clip from the shock at the cargo box 3 Disconnect light harnesses 4...

Page 161: ...r Fender Front Fender Wheel Well Panel Skid Plate 6 8 ft lbs 8 10 Nm Main Frame Foil Cover Engine Access Cover 4 5 ft lbs 5 6 Nm T 27 4 5 ft lbs 5 6 Nm T 27 Main Floor Foil T 27 Front Fender 4 5 ft lbs 5 6 Nm T 27 Rear Fender 20 30 in lbs 2 3 5 Nm T 25 T 25 20 30 in lbs 2 3 5 Nm ...

Page 162: ...SPENSION 5 Hood Dash Components Glove Box Assembly Cup Holder Hood Hood Liner Hood Latch Strap Headlights Hinges T 27 4 5 ft lbs 5 6 Nm 8 10 in lbs 0 9 1 0 Nm T 30 T 27 Torx 4 5 ft lbs 5 6 Nm T 27 4 5 ft lbs 5 6 Nm Grille ...

Page 163: ...Y STEERING SUSPENSION Dash Instruments and Controls A B C D E F G A Indicator Panel B Hour Meter C Headlight Switch D 2WD AWD Switch E 12 Volt Accessory Receptacle F Malfunction Indicator Lamp MIL G Key Switch ...

Page 164: ...me onto the vehicle and align the rear mount holes Secure the rear of the frame using the two 2 1 4 bolts on the outer tubes two 3 4 bolts on the inner mounts and nuts Tighten all 5 16 bolts to 16 18 ft lbs 20 24 Nm NOTE Tighten all nuts finger tight then tighten to specification 5 Secure the front flanges to the vehicle with 5 16 x 3 4 bolts and nuts Tighten all 5 16 bolts to 16 18 ft lbs 20 24 N...

Page 165: ...FRAME Exploded View Seat Base Front Cab Support Bumper Grills LH Floor Support Oil Tank Support 45 ft lbs 61 Nm RH Floor Support 28 32 ft lbs 38 43 Nm 28 32 ft lbs 38 43 Nm 13 15 ft lbs 17 20 Nm Frame Extension Main Frame T 27 4 6 ft lbs 6 8 Nm ...

Page 166: ... base and seat back cover onto the cab frame NOTE Be sure the indented section of the seat back is positioned upward 4 Insert T 27 nuts through the mounting strap and into the seat back Install all of the T 27 nuts loosely then tighten to 4 6 ft lbs 5 8 Nm 5 Install the bolts and nuts that secure the seat belt assemblies to the rear of the seat frame Tighten to 38 42 ft lbs 51 57 Nm 6 Check all nu...

Page 167: ...w Rod End Jam Nut Tie Rod Boots Steering Box Tie Rod End Bolt Lower Steering Shaft Upper Steering Shaft Cap Nut Steering Wheel Wave Washers Bushing Screw Lock Washer 25 30 ft lbs 34 41 Nm 30 ft lbs 41 Nm 15 22 ft lbs 20 30 Nm Bolt 40 45 ft lbs 54 61 Nm Screw Nut ...

Page 168: ...nents be sure to install tie rod end bolts in the proper direction The stee ring post arm bolt B points up the rod end bolts A point down Be sure inner rod ends are placed between the steering post arms Apply LoctiteTM 242 15 22 ft lbs 20 30 Nm 30 ft lbs 41 Nm Front 12 14 ft lbs 16 19 Nm 30 ft lbs 41 Nm 30 ft lbs 41 Nm 25 30 ft lbs 34 41 Nm 40 45 ft lbs 54 61 Nm 25 ft lbs 35 Nm 8 ft lbs 11 Nm 20 3...

Page 169: ... Torque new bolts to 30 ft lbs 41 4 Nm 8 Attach A arm to hub strut assembly Tighten ball joint nut to 25 ft lbs 35 Nm If cotter pin holes are not aligned tighten nut slightly to align Install a new cotter pin with open ends toward rear of machine Bend both ends in opposite directions around nut WARNING The locking features on the existing bolts were destroyed during removal DO NOT reuse old bolts ...

Page 170: ...NSION 5 FRONT STRUT Exploded View Nut 15 ft lbs 21 Nm Washer Spacer Rubber Top Pivot Ball Spacer Bottom Pivot Ball Spring Retainer Spring Washer Bolt Bearing Retaining Ring Washer Clamp Front Strut Strut Bumper 18 ft lbs 25 Nm ...

Page 171: ...t castlenut 5 Remove castle nut B and separate A arm C from ball joint stud 6 Remove screws D and ball joint retaining plate E 7 Using ball joint removal installation tool kit PN 2870871 remove ball joint F from strut housing Install puller guide G with extension cap H Apply grease to extension cap and threads of puller bolt to ease removal Thread bolt K with nut J onto ball joint stud as shown Ap...

Page 172: ... spindle bolt and washer 4 Remove the brake caliper Suspend the brake caliper from the frame with a wire NOTE Do not let the brake caliper hang from the brake line or damage may occur 5 Remove the hub and brake disc assembly by sliding it off of the axle 6 Remove the bolt that secures the shock and coil to the upper A arm 7 Remove the bolt that secures the wheel carrier to the upper A arm 8 Loosen...

Page 173: ...ighten shock bolt to 30 ft lbs 41 Nm 17 Re install wheel and caliper Refer to Chapter 2 for wheel toque specifications Stabilizer Bar WARNING The locking features on the existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation WARNING Upon A arm installation completion test vehicle at low speeds before putting...

Page 174: ...side 4 Remove the two bolts that secure the stabilizer bar to the main frame each side 5 Remove the stabilizer from the frame 6 Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed 7 Inspect the rubber bushings on the linkage rod and replace if needed 8 Reverse the procedure for installation Torque the stabilizer bolts to 16 18 ft lbs 21 25 Nm Stabilizer Bar Stabi...

Page 175: ... Cargo Box Panels Taillight Tailgate Support Seal Foam Side Panel Front Panel T 27 8 10 in lbs 0 9 1 0 Nm T 30 T 30 8 10 in lbs 0 9 1 0 Nm 8 10 in lbs 0 9 1 0 Nm T 20 8 10 in lbs 0 9 1 0 Nm T 20 T 20 8 10 in lbs 0 9 1 0 Nm T 20 4 6 ft lbs 5 8 Nm ...

Page 176: ...lgate Box Support Tailgate Cap Latch Tailgate Cable Tailgate Tube Inner Panel Rod Outer Panel T 20 20 25 in lbs 2 3 Nm 8 10 in lbs 0 9 1 0 Nm Box Box Support T 20 Box Latch Assembly Shock Pins Shock 8 10 ft lbs 10 13 Nm Heat Bolt Hinge Pin Shield ...

Page 177: ...with the pin and clip 2 Place the cargo box onto the frame Align the hinges of the box with the bracket on the frame 3 Install the box hinges on both sides 4 Secure the box hinges with the hinge screws on both sides 5 With the hinges installed attach the shock to the cargo box by inserting the pin and clip 6 Lower the box and secure the latch CAUTION Safely support the box during the remainder of ...

Page 178: ...h quickly over the area where the decal is to be applied until the surface appears slightly glossy This should occur after just a few seconds of flame treating Do not hold the torch too close to the surface Keep the torch moving to prevent damage 2 Apply the decal NOTE Refer to your parts manual for decal part number WARNING The following procedure involves the use of an open flame Perform this pr...

Page 179: ...STALLATION 6 9 CLUTCH ALIGNMENT OFFSET 6 9 CLUTCH ALIGNMENT 6 9 CLUTCH OFFSET 6 10 DRIVE CLUTCH SERVICE 6 11 SPRING SPECIFICATIONS 6 11 SHIFT WEIGHTS 6 12 EXPLODED VIEW 6 13 CLUTCH INSPECTION 6 13 CLUTCH DISASSEMBLY 6 14 SPIDER REMOVAL 6 15 ROLLER PIN AND THRUST WASHER INSPECTION 6 15 BUSHING SERVICE 6 16 MOVEABLE SHEAVE BUSHING REMOVAL 6 16 MOVEABLE SHEAVE BUSHING INSTALLATION 6 16 CLUTCH COVER B...

Page 180: ...in turn rotates the driven clutch At lower RPM the drive belt rotates low in the drive clutch sheaves As engine RPM increases centrifugal force causes the drive belt to be forced upward on drive clutch sheaves TOOL DESCRIPTION PART NUMBER Clutch Puller 2870506 Clutch Holding Wrench 9314177 Clutch Holding Fixture 2871358 Spider Nut Socket 2870338 Drive Clutch Spider Removal and Install Tool 2870341...

Page 181: ... as a conventional governor does the PVT system changes engine load requirements by either upshifting or backshifting Maintenance Inspection Under normal operation the PVT system will provide years of trouble free operation Periodic inspection and maintenance is required to keep the system operating at peak performance The following list of items should be inspected and maintained to ensure maximu...

Page 182: ...ttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Towing Pushing at low RPM low ground speed Use Low only Plowing snow dirt etc utility use Use Low only Stuck in mud or snow Shift the transmission to Low carefully use fast aggressive throttle application to engage...

Page 183: ...t hose 4 Remove outer PVT cover screws 5 Mark the drive belt direction of rotation and remove drive belt See Drive Belt Removal 6 Install the Drive Clutch Holder PN 9314177 A 7 Remove drive clutch retaining bolt and remove drive clutch using the Drive Clutch Puller PN 2870506 B 8 Remove the driven clutch retaining bolt and driven clutch Inner Cover Clutch Outlet Duct Clamps Inner Cover Seal Retain...

Page 184: ...Apply RTV silicone sealant to outside edge of inner cover to engine seal to ensure a water tight fit between the seal and the cover Surfaces must be clean to ensure adhesion of silicone sealant 4 Reinstall cover and tighten rear cover bolts just enough to hold it in place 5 Fit lip of inner cover seal A to engine Install seal retainer plate and tighten screws securely 6 Torque rear inner cover bol...

Page 185: ...e and driven clutch 2 Push down on drive belt until it is lightly tensioned 3 Measure belt deflection as shown in photo If belt deflection is out of specification adjust by removing or adding shims between the driven clutch sheaves Remove shims to decrease belt deflection Add shims to increase belt deflection See Driven Clutch Service At least one shim must remain between the inner and outer sheav...

Page 186: ...pect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt 4 Measure belt length with a tape measure around the outer circumference of the belt Belts which measure longer than nominal length may require driven shimming or engine adjustment for a longer center dist...

Page 187: ...nment must be adjusted as follows 3 Remove drive and driven clutch See PVT System Service Disassembly 4 Remove PVT inner cover 5 Loosen all engine mounts Move front of engine to the right or left slightly until alignment is correct 6 Tighten engine mounts and verify alignment is correct 7 Measure belt deflection and measure offset both above and below sheave centerlines Adjust if necessary NOTE On...

Page 188: ...ool contacts rear of inner sheave with driven clutch pushed completely inward on shaft and bolt torqued Adjust offset by adding or removing spacer washers between back of driven clutch and spacer as shown Spacer Washer PN 7556401 Clutch Alignment Tool should contact rear edge of driven clutch sheave To adjust add or remove washers from behind the driven clutch Driven Clutch Offset ...

Page 189: ...ing operation it should always be inspected for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from the outer coil surfaces as shown Refer to the spring specification chart for specific free length measurements and tolerances Also check to see that spring coils are parallel to one another Distortion of the spring i...

Page 190: ...controlling engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance clutch balance and shifting pattern PN 5630514 PN 5630515 PN 5630095 PN 5630509 48 gr 45 gr 53 gr 55 gr PN 5630513 PN 5630709 PN 5630710 PN 5630711 50 5 gr 44 gr 46 gr 47 gr ...

Page 191: ...ve shift weight bolts and weights Inspect as shown The contact surface of the weight should be smooth and free of dents or gall marks Inspect the weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or broken replace in sets of three with new bolts NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See Roller Pin and Thru...

Page 192: ...y not have been in alignment before disassembly 2 Remove cover bolts evenly in a cross pattern and remove cover plate 3 Inspect cover bushing A The outer cover bushing is manufactured with a Teflon coating Bushing wear is determined by the amount of Teflon remaining on the bushing 4 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or dam...

Page 193: ...ice resistance galling or flat spots replace rollers pins and thrust washers in sets of three Also inspect to see if roller and bushing are separating Bushing must fit tightly in roller Use the Roller Pin Tool PN 2870910 to replace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation 2 Rubber backed buttons can be used in all ATV RANGER clut...

Page 194: ...Remove nut from puller rod and set aside 8 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard Moveable Sheave Bushing Installation 1 Place the Main Puller Adapter 8 PN 5020632 onto the puller 2 Apply Loctite 680 PN 2870584 to the back side of new bushing Push bushing into center of sheave on tower side by hand 3 Insert the Clutch Bushing Installation Tool 2 ...

Page 195: ...uller rod and hand tighten Turn puller barrel to increase tension as needed 5 Turn clutch cover counterclockwise on puller rod until bushing is removed 6 Remove nut from puller rod and set aside 7 Remove bushing and bushing removal tool from puller Discard bushing Clutch Cover Bushing Installation 1 Apply Loctite 680 PN 2870584 to the back side of new bushing Working from inside of cover insert bu...

Page 196: ...ider buttons for each tower and install spider making sure that X or the marks that were made earlier on spider aligns with X or the marks that were made earlier in moveable sheave 4 Torque spider to specification using the holding fixture and spider tool Torque with smooth motion to avoid damage to the stationary sheave Refer to Page 6 2 for torque specification 5 Install shift weights using new ...

Page 197: ...on of the spring and remove helix 4 Note the location of the spring in the moveable sheave and remove the spring 5 Check alignment of tabs on spring Replace the spring if tabs are misaligned or the spring coils are distorted Button Ramp Inner Sheave Spacer Shims Outer Sheave Driven Clutch Bolt Moveable Bearing Stationary Ramp Clutch Spring DRIVEN CLUTCH CAUTION Wear eye protection when removing sn...

Page 198: ...t the factory using Loctite In order to remove the bushing it will be necessary to apply heat A press can be used to remove and install some of the bushings Be sure to support the sheave or cover as close as possible to the bushing bore when using a press 1 Install Main Puller Adapter 8 PN 5020632 onto the Piston Pin Puller PN 2870386 2 Insert Adapter Reducer 9 PN 5010279 onto the puller sliding i...

Page 199: ...tch sheave counterclockwise until bushing is removed Repeat Steps 5 8 for other bushing 9 Remove nut from puller rod and set aside 10 Remove adapters from puller 11 Remove bushing and removal tool from adapters Discard bushing Moveable Sheave Bushing Installation 1 Working from the top insert Puller Adapter 10 PN 5020633 onto the puller 2 Start new bushing evenly in moveable sheave Apply Loctite 6...

Page 200: ...tall spring inserting spring tab into proper hole in moveable sheave 3 Insert spring tab into proper hole in helix See Clutch Chart of the specifications page in Chapter 1 The driven clutch helix moveable assembly has several different spring locations which affect clutch shifting and RPMs The greatest amount of spring tension will raise engine RPMs during clutch upshift and allow quicker backshif...

Page 201: ...p boss spline and push helix down until it engages the splines 1 2 to 3 4 5 While holding downward pressure on helix wind moveable sheave counterclockwise approximately 1 3 turn 120 6 Push helix into place and install snap ring ...

Page 202: ...plication too light Drive clutch binding Driven clutch binding Converter sheaves greasy belt slippage Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassemble clean and inspect driven clutch noting ...

Page 203: ...and Maintenance Manual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt slippage Belt worn out Water ingestion Belt contaminated with oil or grease Replace belt Inspect and seal PVT system Inspect and clean PVT noise Belt worn or separa...

Page 204: ...EMBLY 7 14 FRONT GEARCASE CENTRALIZED HILLIARD 7 15 AWD OPERATION 7 15 CENTRALIZED HILLIARD EXPLODED VIEW 7 16 AWD DIAGNOSIS 7 17 GEARCASE REMOVAL 7 18 GEARCASE DISASSEMBLY INSPECTION 7 19 GEARCASE REASSEMBLY INSPECTION 7 21 BACKLASH PAD THRUST PAD ADJUSTMENT 7 23 GEARCASE INSTALLATION 7 24 REAR DRIVE 7 25 EXPLODED VIEW 7 25 REAR HUB BEARING CARRIER 7 25 HUB INSPECTION REMOVAL 7 25 HUB DISASSEMBLY...

Page 205: ...he spindle from the backside of the strut Rotate each bearing by hand and check for smooth rotation Visually inspect bearing for moisture dirt or corrosion Replace bearing if moisture dirt corrosion or roughness is evident Inspect the spindle splines for wear PART NUMBER TOOL DESCRIPTION 2872608 Roller Pin Removal Tool 8700226 CV Boot Clamp Pliers ITEM NUT TYPE SPECIFICATION Aluminum Wheels Cast L...

Page 206: ...fication Refer to Torque Specifications on Page 7 2 7 Torque the spindle nut to 70 ft lbs 95 Nm 8 Rotate wheel and check for smooth operation There should not be any binding rough spots or side play 9 Install the cotter pin and bend both ends of cotter pin around end of spindle in different directions 10 Install hub cap 11 Install brake caliper using new bolts Tighten bolts to specified torque Gre...

Page 207: ...E Exploded View 2X4 18 ft lbs 24 9 Nm Use new bolts with pre applied locking agent Disc Brake Stud Front Hub Rim Tire Wheel Nut Spec on page 7 2 Dust Cover Cotter Pin Washer Slotted Nut 70 ft lbs 95 Nm Spindle Shaft ...

Page 208: ...hang the caliper to prevent possible damage to the brake line 5 Remove hub cap cotter pin front spindle nut and washer 6 Rotate each bearing by hand and check for smooth rotation Visually inspect bearing for moisture dirt or corrosion Replace bearing if moisture dirt corrosion or roughness is evident Hubstrut Bearing Replacement Bearing Removal 1 Remove outer snap ring 2 From the back side tap on ...

Page 209: ...Loctite RC 680 to the outer circumference of the new bearing race and carefully install the new bearing into the strut housing NOTE Use care to not allow any of the Loctite compound to get in the bearing 7 Wipe the housing clean of any excess compound and install the retaining ring Hub Installation 1 Inspect the hubstrut bearing surface for wear or damage 2 Apply grease to drive axle spindle 3 Ins...

Page 210: ...Exploded View 4X4 Brake Caliper Bolt Torque 18 ft lbs 24 Nm 18 ft lbs 24 Nm CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly Flange Nuts Flat side against wheel 18 ft lbs 24 Nm Use new bolts with pre applied locking agent Disc Brake Stud Front Hub Rim Tire Wheel Nut Dust Cover Cotter Pin Washer Slotted Nut ...

Page 211: ...X4 Front Driveshaft CV Joint 30g Grease Packet Inner Clamps Plunging Joint Circlip Clamp Clamp Boots 30g Grease Packet RANGER 4X4 Front Propshaft Joint Kit Front Yoke Shaft Yoke Grease Zerk O ring RANGER 2X4 4X4 Rear Propshaft Cross Bearing Kit Spring Pin O ring ...

Page 212: ...her suspension components Never use a hammer or sharp tools to remove or to install boot clamps Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned Refer to text for grease capacity of CV joints and CV joint boots FRONT DRIVE SHAFT 4X4 Removal 1 Elevate front end and safely support machine und...

Page 213: ...rive shaft from front gearcase CV Joint Boot Replacement 1 Remove wheel brake caliper and wheel hub Refer to Front Hub Removal for procedure 2 Remove cotter pin and castle nut from A arm ball joint 3 Disconnect A arm from ball joint using a tie rod fork 4 Slide strut off end of drive shaft and tie it up out of the way of the shaft 5 Remove clamps from rubber boot using the proper boot clamp pliers...

Page 214: ...t area and shaft NOTE It is very important to use the correct type and quantity of grease by using the grease contained in the boot kit DO NOT use a substitute grease and DO NOT overfill or underfill the CV joint 9 Slide the new clamp and boot small end first over the splined shaft then slide tap the CV joint into the splines of the axle Install small boot clamp 10 Add grease through large end of ...

Page 215: ...area 2 Remove wheel nuts and wheel 3 Remove cotter pin and nut from lower A arm ball joint Remove lower A arm from ball joint See below 4 Use the Roll Pin Removal Tool PN 2872608 to remove the roll pin from prop shaft at the front housing Slide prop shaft back and away from front housing Pull sharply forward to remove from transmission shaft NOTE The roll pin can also be accessed through the hole ...

Page 216: ...earing caps NOTE If yoke or bearing is removed cross bearing must be replaced Note orientation of grease fitting and mark inner and outer yoke for correct re positioning during installation 2 Support inner yoke as shown and drive outer yoke down bearing cap out with a soft face hammer 3 Support U joint in vise as shown and drive inner yoke down to remove remaining bearing caps 4 Force U joint cros...

Page 217: ...movement of bearing cross as bearing caps are assembled 3 Install snap ring to contain bearing cap just installed Repeat procedure for other side 4 Install outer yoke aligning marks made before disassembly 5 Repeat Steps 1 3 to install bearing caps on outer yoke 6 Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown 7 When installation is complete ...

Page 218: ...d to a roller cage that contains 14 rollers and roller cam The difference in rpm by input shaft and front axles the forces the rollers up the external cam The rollers engage themselves to the output hubs that link both front axles resulting in True All Wheel Drive Roller Cage and Roller s Rotate Inward and Grip the Output hub for AWD Engagement Disengagement As the front and rear wheels gain tract...

Page 219: ...r Ball Bearing 2 19 Bushing 1 7 Race Output Hub Asm 1 20 Gearcase LH 1 8 Dowel Pin 1 21 Oil Fill Plug 1 9 Clutch Housing Ring Gear 1 22 Drain Plug Asm Includes Plug and Washer 1 10 Roll Cage Asm Includes H Springs 1 23 Roller Thrust Needle Bearing 1 11 Rollers 14 24 Clutch Asm 1 12 Bushing 1 25 Internal Retaining Ring 1 13 Vent Fitting 1 26 Armature Plate 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1...

Page 220: ...ear mark may indicate a warped plate which may cause intermittent operation See the following illustrations 4 Check to make sure the coil is seated in the U shaped insert that is pressed into the gearcase cover The top of the coil should be seated below the U shaped insert The U shaped insert controls the pole gap If the top of the coil is above the surface of the U shaped insert it raises the arm...

Page 221: ...NT DRIVE SHAFT REMOVAL procedure earlier in this chapter 8 The front gearcase and drive shafts can be accessed from both sides of the vehicle and limited access from the top 9 Remove the access panel on the side of the vehicle T 25 screws secure the panel to the frame 10 Remove the roll pin from the front drive shaft Remove the front drive shaft from the front gearcase splines 11 Remove bolts secu...

Page 222: ...TE Be careful not to misplace the thrust bearing located between the two output shafts 5 Clean all parts and inspect spacers for wear Inspect ring gear for chipped broken or missing teeth 6 Remove the roll cage assembly rollers and H springs 7 Thoroughly clean all parts Inspect the rollers A for nicks and scratches The rollers must slide up and down freely within the roller cage surfaces B 8 Inspe...

Page 223: ...the cover remove the thrust bearing F from the output hub G Inspect the thrust bearing F and the dowel H 14 Inspect the magnetic coil I in the output housing NOTE See FRONT GEARCASE DIAGNOSIS earlier in this chapter for more details on the coil 15 Inspect the back lash pad J for excessive wear NOTE The backlash for the centralized hilliard is set at the factory No adjustment is required unless the...

Page 224: ...y Inspection 1 As mentioned in the disassembly section replace all O rings seals and worn components 2 Press the pinion shaft seal into the pinion cover until the seal is flush with the sealing surface 3 Inspect bearings on output and pinion shafts To replace press new bearing on to shaft NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel Wh...

Page 225: ...ring 7 Install the armature plate D and spacer washer E into the output cover NOTE Be sure backlash plate is in place 8 Install the retaining ring F into the output cover Be sure the retaining ring is properly seated into the cover 9 Install the ring gear G onto the output hub on the output cover 10 Install the rollers and roll cage into the ring gear Insert the rollers as the roll cage is install...

Page 226: ...sh Pad Thrust Pad Adjustment 1 Lay the gearcase on the side with the output cover facing up 2 The backlash screw is loctited into place Use a heat gun to lightly heat up the loctite on the screw A 3 Using a hex wrench turn the back lash screw out 3 4 turns Re apply red loctite onto the bottom screw threads 4 Turn the screw in until it is lightly seated then turn the screw out 1 4 turn 5 Set the ge...

Page 227: ...ase Installation 1 To install gearcase reverse removal procedure Use new spring pin in front prop shaft 2 Torque mounting bolts to 30 ft lbs 41 Nm 3 Add the proper lubricant to the front gearcase Check drain plug for proper torque Refer to Chapter 2 for fluid fill and change information Front Housing Mount Bolt Toque 30 ft lbs 41 Nm Premium Front Drive Hub Fluid PN 2871654 Front Housing Capacity 5...

Page 228: ...e tire wheel firmly and checking for movement Grasp the top and bottom of the tire The tire should rotate smoothly without binding or rough spots 3 Remove wheel nuts and wheel Rear Gearcase A arm bolts Rear Drive Axle A arm bolts Nuts Bushings Lower A arm Carrier Bolt Shaft Bushings Snap Ring Coil 30 ft lbs 41 Nm Shock Shaft Bearing Bushings 30 ft lbs 41 Nm Bushings Shaft Upper A arm Caliper 18 ft...

Page 229: ...le 7 Remove the upper and lower control arm bolts from the rear hub bearing carrier 8 Remove the bearing carrier Inspect the bearing again for smoothness and side to side movement replace as needed Hub Disassembly 1 Remove outer snap ring A 2 From the back side tap on the outer bearing race with a drift punch in the reliefs as shown NOTE Drive bearing out evenly by tapping on outer race only Once ...

Page 230: ...A Bearing Carrier Housing B Bearing C Snap Ring 2 Start bearing B in housing A 3 Press bearing into place until outer race bottoms on housing 4 Install snap ring into groove Hub Installation 1 Start the wheel bearing carrier onto the drive shaft 2 Align the bottom of carrier housing and lower control arm Slide the lower control arm bushings into place Secure with the lower control arm bolt 3 With ...

Page 231: ...110 ft lbs 149 Nm Install a new cotter key and the hub cap REAR DRIVE SHAFT Removal 1 Repeat all of the steps in the Rear Hub Bearing Carrier Hub Removal section 2 Remove upper carrier bolt Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft 3 Pull the rear drive shaft straight out of the frame Use short shar...

Page 232: ...contaminated the boot can be replaced without cleaning the CV joint Use the recommended amount of grease for boot replacement only 4 Remove boot from the shaft 5 Thoroughly clean and dry the CV joint and inspect ball tracks and cages for wear cracks or other damage NOTE Shiny areas in ball tracks and on the cage spheres are normal Do not replace CV joints because parts have polished surfaces Repla...

Page 233: ... tightening boot clamp on inboard joint make sure any air pressure which may have built up in joint boot has been released The air should be released after the plunging joint has been centered properly Tighten boot clamp using boot clamp pliers 11 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 th...

Page 234: ...oard end of the driveshaft if necessary 4 Lift bearing carrier into place and install the bolt into the upper control arm Torque bolt to 30 ft lbs 41 Nm 5 Install hub domed washer domed side out and nut Torque rear spindle nut to 110 ft lbs 149 Nm Install new cotter pin and hub cap 6 Install rear wheel and torque washers and wheel nuts to specification See Torque Specifications on page 7 2 Apply A...

Page 235: ...t it s parallel with the frame supports as shown below 5 Remove the shaft by placing the brake disc over the top of the rear frame support and under the front frame support Installation 1 When installing the propshaft ensure that the shaft is touching the rear frame support and reinstall the shaft the same way it was removed with the brake disc over the top of the rear frame support and under the ...

Page 236: ...electrical solenoid mounted on the rear axle housing actuates the shift yoke and slides the clutch gear to lock and unlock the rear axle housing When the clutch gear is unlocked the rear axle becomes a differential When it s locked it becomes a solid rear axle increasing traction See images below AWD Differential Unlocked Differential Locked When switch position is set to Unlock the solenoid is po...

Page 237: ...erential Locked Differential Unlocked AWD Mode Both rear wheels rotate at same speed Rear wheels can rotate at different speeds Allow for sharper turning Rear Wheels rotate as same speed Front Wheels rotate as same speed when AWD activated ...

Page 238: ...l Disassembly IMPORTANT The pinion gear assembly is NOT intended to be disassembled from the case as it requires special OEM tooling in order to properly reassemble If there is any damage to the pinion gear bearings or case the assembly must be replaced Pinion and ring gear shimming information is NOT provided due to OEM manufacturing requirements 1 Drain and properly dispose of used gearcase flui...

Page 239: ... bearings D for smoothness and wear Be sure to keep the shims E together for reassembly 6 Remove the differential lock solenoid F from the carrier housing by turning the solenoid counterclockwise 7 Inspect the tip of the solenoid F for wear If the tip of the solenoid is flat the solenoid may need to be replaced 8 Remove the clutch gear G from the carrier cover B and shift yoke H C C E D C D E F F ...

Page 240: ...t L Use a 1 4 in 20 coarse thread bolt approximately 3 in long to thread into the pivot shaft 12 Thread the bolt into the shift yoke pivot shaft L 13 Carefully pull the shift yoke pivot shaft L out of the carrier cover 14 Remove the shift lever M and springs N from the shift yoke H Inspect the components for wear and replace as needed H J K L L M N H ...

Page 241: ...d Differential Assembly 1 Replace all O rings seals and worn components Replace the O ring and oil seal on the carrier housing NOTE Grease all seals and O rings with Polaris All Season Grease PN 2871322 upon assembly 2 Install the original shims A onto the differential assembly B on both sides Install the bearings C replace with new bearings if needed 3 Install the differential assembly into the c...

Page 242: ...to the carrier cover Torque solenoid to 30 40 ft lbs 41 54 Nm 8 Install the new lightly greased O ring K onto the carrier cover 9 Install the carrier cover bolts Tighten and torque the bolts in a criss cross pattern to 25 35 ft lbs 34 48 Nm 10 Install the rear differential mount brackets from the rear differential onto the rear differential Torque the bracket to differential bolts to 26 33 ft lbs ...

Page 243: ...edure for the rest of the installation 4 Add Polaris ATV Angle Drive Fluid PN 2871653 to rear carrier Refer to maintenance information in Chapter 2 for more details Torque drain plug to 30 45 in lbs 3 5 Nm Torque fill plug to 40 ft lbs 54 Nm Rear Gearcase capacity 18 fl oz 532 ml or 0 75 1 9 cm below bottom of fill plug hole threads See Chapter 2 Bracket to Frame 38 42 ft lbs 35 45 Nm Fill Plug Dr...

Page 244: ...1 Fill Check Plug 1 30 Diff Lock Solenoid 1 12 Gear Side Differential 2 31 Hex Bolt 8 13 Gear Pinion Mate Differential 2 32 Differential Case Half 1 14 Differential Case Half Cover 1 33 Differential Cross Pin 1 15 Differential Bearing Spacer AR 34 Differential Roll Pin 1 16 Tapered Roller Bearing 1 35 Pinion Spacer AR 17 O Ring Housing Halves 1 36 Differential Bearing Spacer AR 18 Shift Yoke Pivot...

Page 245: ...SHIFT LINKAGE 8 2 INSPECTION 8 2 ADJUSTMENT 8 3 TRANSMISSION SERVICE 8 3 TRANSMISSION REMOVAL 8 3 TRANSMISSION DISASSEMBLY 8 5 TRANSMISSION ASSEMBLY 8 10 TRANSMISSION INSTALLATION 8 14 TROUBLESHOOTING 8 15 TROUBLESHOOTING CHECKLIST 8 15 TRANSMISSION EXPLODED VIEW 8 16 EXPLODED VIEW 2X4 8 16 EXPLODED VIEW 4X4 8 18 ...

Page 246: ...selectors moving out of desired range NOTE Remove necessary components to gain access to shift linkage cable ends i e exhaust heat shield exhaust pipe etc 1 Inspect shift linkage cable clevis pins and pivot bushings and replace if worn or damaged 2 Be sure idle speed is adjusted properly ITEM TORQUE VALUE Transmission Fill Plug 10 14 ft lbs 14 19 Nm Transmission Drain Plug 10 14 ft lbs 14 19 Nm Tr...

Page 247: ...nsmission cable 5 Use this procedure to loosen or tighten the shift linkage cable as needed TRANSMISSION SERVICE Transmission Removal 1 Remove the PVT system from the left side of the transmission 2 Drive roll pin from rear driveshaft yoke NOTE On the 4x4 transmission the front output shaft yolk slides off during the transmission removal 3 Remove the air intake hose from the air box that is locate...

Page 248: ...ission cable Remove the cable from the mounting bracket 7 Remove the mounting bolts from the transmission mounting on both sides of the transmission 8 Remove the four bottom transmission to frame bolts 9 Remove the rear transmission to frame bolt 10 Remove front transmission to engine mount bolt 11 Remove transmission from right side of frame Transmission Switch Jam Nuts General Transmission Mount...

Page 249: ... Remove the bellcrank 3 Remove the five bolts that secure the cover and remove the cover from the transmission 4 Remove the detent spring 5 Mark the detent gear with a white pen Remove the detent gear from the case NOTE It may be helpful to place a mark just above the keyed spline 6 Mark the lockout disc this will indicate which side of the disc faces outward during assembly Remove the disc NOTE I...

Page 250: ...9 Remove the bolts on the LH transmission case cover Tap the cover off with a soft face hammer if necessary 10 Lift shift rail 0 5 1 12 70 25 40 mm Then rotate the shift rail forks and shift drum so the forks pins disengage from the drum 11 Remove the shift drum NOTE You may have to tap the shift drum from the backside of the case to aid in removal 12 Remove the upper gear cluster and shift forks ...

Page 251: ...ave a regular shift dog in the location indicated by the arrow in the photo 15 Remove the bearing from the reverse shaft with a puller 16 Remove the park lock engagement dog Remove the wave spring and reverse engagement dog 17 Remove the bearing from the input shaft with a puller 18 Remove the snap ring and washer from the reverse shaft 19 Remove low gear 33T and the needle bearing 20 Remove the r...

Page 252: ... Use a press to remove the gear from the shaft 23 Make note of the direction of the gear and hub location 24 Remove the gear split bearing and washer from the reverse shaft 25 Slide off the shift dogs and wave springs 26 Remove the snap ring washer gear and split bearing ...

Page 253: ...him thrust button and thrust button shim 31 Remove the shafts as an assembly 32 Remove the silent chain from the assembly for shaft inspection 33 Clean all components in a parts washer and inspect for wear 34 Inspect engagement dogs of gears and replace if edges are rounded 35 Inspect gear teeth for wear cracks chips or broken teeth Note the location of the hubs on the gear Note Location of Hubs ...

Page 254: ...y seated in the transmission case Apply Polaris Crankcase Sealant to the mating surfaces 4 Reinstall the thrust button shim thrust button and other shims into the cover Reinstall cover and torque bolts in a criss cross pattern in 3 steps to 27 34 ft lbs 37 46 Nm NOTE Make sure that the case locating pins knock pipes are in place 5 Apply grease to the seal lips Apply electricians tape or somehow co...

Page 255: ...ternal damage to the transmission 11 Slide the reverse shaft assembly through the silent chain 12 Install a new needle bearing the low gear the thrust washer and the snap ring Use of a new snap ring is recommended 13 Install the engagement dogs wave springs and bearing 14 Install the ball bearing onto the end of the input shaft 15 As the engagement dogs are installed onto the shaft place the wave ...

Page 256: ... it meshes with the tracks on the shift drum Be sure the wave springs are properly in place and that the shift rail is seated into the pocket on the backside of the case 21 Install the helical gear and bearing onto the pinion shaft 22 Clean the mating surfaces of the case and cover Apply Crankcase Sealant PN 2871557 to the mating surfaces Be sure the locating pins knock pipes are in place Reinstal...

Page 257: ... white mars that was previously applied for reference 29 Install the detent gear with the raised edge facing outward Note the keyed spline on the end of the shaft 30 Install the detent lever spring Install a new o ring onto the shift shaft after the detent lever is assembled to the shaft Place a small amount of grease on the small O ring on the shift shaft and on the detent gear Grease the o ring ...

Page 258: ... Tighten mounting fasteners in order A D as shown NOTE Be sure to tighten the lower transmission bolts first this ensures that the transmission is tight against the lower frame and helps to properly align the transmission NOTE Align clutches as outlined in Chapter 6 7 Align the front input shaft to the front propshaft yoke on the vehicle 8 Align rear output shaft to rear propshaft yoke and roll pi...

Page 259: ...kage rod adjustment and rod end positioning Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting linkage rod from transmission bellcrank Manually select each gear range at the transmission bellcrank and test ride vehicle If it fun...

Page 260: ...ASSEMBLY Apply White Lithium Based Grease Apply Polaris Crankcase Sealant Apply LoctiteTM 262 to the bolt threads GREASE 12 18 ft lbs 16 24 Nm 7 9 ft lbs 10 12 Nm 15 19 ft lbs 20 26 Nm 27 34 ft lbs 37 46 Nm 6 12 ft lbs 8 16 Nm 27 34 ft lbs 37 46 Nm 10 14 ft lbs 14 19 Nm ...

Page 261: ...g Ring 13 1 Gearcase Main 45 1 Washer 14 1 Vent Tube 46 1 33T 6 Face Gear 15 1 O ring 47 2 Needle Cage Bearing 16 1 Shift Drum 48 1 Reverse Shaft 17 1 External Retaining Ring 49 1 Needle Cage Bearing 18 1 6 Pin Switch 50 1 24T 6 Face Sprocket 19 1 O ring 51 1 Washer 20 1 Detent Star 52 1 Washer 21 1 Lockout Disc 53 1 30T 6 Face Gear 22 1 16T Sector Gear 54 1 47T Mid Output Gear 23 2 Lock Nut 55 1 ...

Page 262: ...y White Lithium Based Grease Apply Polaris Crankcase Sealant Apply LoctiteTM 262 to the bolt threads 12 18 ft lbs 16 24 Nm 7 9 ft lbs 10 12 Nm 15 19 ft lbs 20 26 Nm 27 34 ft lbs 37 46 Nm 6 12 ft lbs 8 16 Nm GREASE 27 34 ft lbs 37 46 Nm 10 14 ft lbs 14 19 Nm ...

Page 263: ...haft 14 1 Vent Tube 48 1 Needle Cage Bearing 15 1 O Ring 49 1 24T 6 Face Sprocket 16 1 Shift Drum 50 1 Washer 17 1 External Retaining Ring 51 2 External Retaining Ring 18 1 6 Pin Switch 52 4 6 Face Engagement Dog 19 1 O ring 53 2 Wave Spring 20 1 Detent Star 54 1 Washer 21 1 Lockout Disc 55 2 Needle Cage Bearing 22 1 16T Sector Gear 56 1 30T 6 Face Gear 23 2 Lock Nut 57 1 47T Mid Output Helical Ge...

Page 264: ...TION 9 12 PARKING BRAKE DISC SERVICE 9 12 DISC REMOVAL INSPECTION 9 12 FRONT BRAKE PADS 9 13 PAD REMOVAL DISASSEMBLY INSPECTION 9 13 PAD ASSEMBLY INSTALLATION ADJUSTMENT 9 14 FRONT CALIPER 9 15 FRONT CALIPER EXPLODED VIEW 9 15 CALIPER REMOVAL DISASSEMBLY 9 15 CALIPER INSPECTION ASSEMBLY 9 16 CALIPER INSTALLATION 9 17 FRONT BRAKE DISC 9 18 DISC INSPECTION REMOVAL REPLACEMENT 9 18 REAR BRAKE PAD 9 1...

Page 265: ... Pad Thickness Inboard 304 7 72 mm Outboard 360 9 14 mm 240 6 1 mm 310 7 87 mm Park Brake Disc Thickness 0 150 0 164 3 81 4 16 mm 140 3 56 mm Rear Brake Disc Runout 010 254 mm Item Torque ft lbs Torque Nm Front Caliper Mounting Bolts 18 24 Rear Caliper Mounting Bolts 18 24 Parking Brake Mounting Bolts 18 24 Parking Brake Assembly Bolts 25 34 Brake Line Flare 12 15 16 21 Brake Line Banjo Bolts Cali...

Page 266: ...most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise Permatex Disc Brake Quiet PN 2872113 can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust Brake Noise Troubleshooting Possible Cause Remedy Dirt dust or im...

Page 267: ... cylinder piston assembly The port is open when the lever is released and the master cylinder piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion heated fluid or contraction cooled fluid During system service be sure this port is open Due to the high temperatures created within the system during heavy braking it is very important that ...

Page 268: ...Master Cylinder Side View Cross Fitting MC Rear Brake Line RH Rear Line RH Rear Caliper RH Front Brake Line RH Front Caliper Brake Switch MC Front Brake Line Master Cylinder LH Front LH Rear Caliper LH Front Caliper Brake Line LH Rear Line 1 2 1 1 2 2 1 3 All Flare Style Fittings 12 15 ft lbs 16 21 Nm 3 3 3 3 3 1 1 2 2 15 ft lbs 20 Nm ...

Page 269: ...nstalling the foot brake check pedal freeplay Pedal freeplay should not exceed 090 2 286 mm FOOT BRAKE PEDAL Pedal Removal 1 Open the hood Locate the master cylinder 2 Remove the nut bushing tube and bolt from the brake pedal 3 Remove the clevis pin and cotter key from the master cylinder to remove the brake pedal Pedal Installation 1 Reverse Steps 1 3 for foot brake installation Torque the clevis...

Page 270: ...r cylinder 8 Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir 9 Tighten bleeder screw securely and remove bleeder hose 10 Repeat procedure Step 5 through Step 9 for the remaining calipers 11 Add brake fluid to MAX level inside reservoir 12 Install master cylinder reservoir cover 13 Field test machine at low...

Page 271: ... Pin Park Brake Sensor Switch Park Brake Lever Spring Latch Washer Brake Release Grommet Handle Nut Pin Clip Bolt Parking Brake Assembly Clip Pin Cable Park Brake Caliper Assembly Mount Bolt Rear Prop Shaft Park Brake Disc Clip Pin Washer Pin Park Brake Handle Lever Park Brake Assembly ...

Page 272: ...edure 1 Place the vehicle in neutral on a flat level surface 2 Carefully lift the rear of the vehicle off the ground and stabilize on jack stands 3 Locate the parking brake cable located under the front hood and under the dash on the driver side NOTE See Chapter 10 for more information on the parking brake switch 4 Use two wrenches to loosen the bottom jam nut C Hold the top jam nut D with one wre...

Page 273: ...brake cable NOTE Be sure the park brake is not engaged 2 If replacing the brake pads slightly loosen the caliper assembly bolts before removing the complete caliper assembly This will ease the caliper disassembly procedure later Pad Holder Nut Hex Head Mount Bolt Sleeve Thrust Washer Shim Pack 4 Shims Pad Holder Lever Asm Bolt Steel Balls 3 Plain Washer Hex Nut Stationary Actuator Compression Spri...

Page 274: ...the lever and ball bearings for reassembly 7 Inspect the brake pads linings for excessive wear Replace as needed 8 Check the three steel balls for any signs of cracking Replace as needed 9 Check ball seats in lever and stationary actuator If excessively worn replace parts as needed 10 Measure the thickness of the rear caliper parking brake pads Replace assembly or pads as needed See illustration b...

Page 275: ... pad Torque the assembly nuts to 25 ft lbs 34 Nm 3 Ensure the park brake assembly functions properly by actuating the lever before reinstallation Caliper Installation 1 Install the park brake assembly into place Tighten the two mounting bolts in increments for proper installation 2 Torque the two mounting bolts to 18 ft lbs 24 Nm 3 Install the cable pin and clip pin Test the park brake for proper ...

Page 276: ...Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 5 Push upper pad retainer pin inward and slip outer brake pad past edge Remove the pad Pad Inspection 1 Measure the thickness of the pad material Replace pads if worn beyond the service limit CAUTION Use care when supportin...

Page 277: ...ter screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise 2 Be sure fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap 3 Install wheels and torque wheel nuts 4 It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowl...

Page 278: ...assembly 1 Remove brake pad adjuster screw A 2 Push upper pad retainer pin inward and slip brake pads past edge if pads are still installed 3 Remove mounting bracket B and dust boot C Bleeder Screw 30 60 in lbs 3 4 6 8 Nm Adjuster Screw Finger Tight Caliper Body Piston Caliper Mount Pads Dust Boots Square O rings FRONT CALIPER EXPLODED VIEW DURING ASSEMBLY 4 4 CAUTION Use care when supporting vehi...

Page 279: ...ameter and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads as outlined for brake pad replacement in this chapter Caliper Assembly 1 Install new square O rings A in the caliper body Be sure that the grooves are clean and free of residue or brakes may drag 2 Coat the piston with clean DOT 4 Brake Fluid P N 2872189 Install piston B with a twisting motion while pushin...

Page 280: ... the adjuster screw and turn until stationary pad contacts disc then back off 1 2 turn 4 Follow brake bleeding procedure outlined earlier in this chapter 5 Install wheels and torque wheel nuts to specification NOTE If new brake pads are installed it is recommended that a burnishing procedure be performed to extend pad service life and reduce noise Start machine and slowly increase speed to 15 mph ...

Page 281: ...face of disc and hub 3 Install disc on hub 4 Install new bolts and tighten to 18 ft lbs 24 Nm REAR BRAKE PAD Pad Removal 1 Elevate and support rear of machine 2 Remove the rear wheel Loosen pad adjuster screw 2 3 turns Brake Disc Thickness New 150 165 3 81 4 19 mm Service Limit 140 3 56 mm Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements Brake Disc Runout Serv...

Page 282: ...nsating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 6 Remove the brake pads Pad Inspection 1 Clean the caliper with brake cleaner or alcohol 2 Measure the thickness of the pad material Replace pads if worn beyond the service limit Pad Installation 1 Install new pads in caliper body 2 Install caliper and torque mou...

Page 283: ... 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the master cylinder REAR CALIPER Rear Caliper Exploded View Rear Brake Caliper Mounting Bolt Torque 18 ft lbs 24 Nm Pump the Brake Pedal Bleeder Screw 30 60 IN LBS 4 6 5 NM Adjuster Screw Finger Tight Caliper Body Piston Caliper Mount Pads Dust Boots Square O rings DURING ASSEMBLY ...

Page 284: ...er pin inward and slip brake pads past edge if pads are still installed 3 Remove mounting bracket B and dust boot C 4 Remove piston D and square O rings E from the caliper body F 5 Clean the caliper body piston and retaining bracket with brake cleaner or alcohol NOTE Be sure to clean seal grooves in caliper body Caliper Inspection 1 Inspect caliper body for nicks scratches or wear Measure bore siz...

Page 285: ...e mounting bracket pins with Polaris Premium All Season Grease and install the rubber dust seal boots 4 Compress the mounting bracket and make sure the dust seals are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease Caliper Installation 1 Install the rear caliper onto the mounting bolts Torque mounting bolts ...

Page 286: ...er in system brake fluid contaminated Caliper disc misaligned Caliper dirty or damaged Brake line damaged or lining ruptured Worn disc and or friction pads Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Damaged break pad noise insulator Pedal Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensa...

Page 287: ...DELS 10 11 BATTERY VOLTAGE TEST 10 11 GROUND TEST 10 12 STATIC STATOR TEST 10 12 RUN SIGNAL TEST 10 12 DYNAMIC STATOR TEST 10 12 BATTERY TEST 10 13 PROTECTED BATTERY TEST 10 13 IGNITION SWITCH TEST 10 13 ACCESSORY POWER TEST 10 14 PDM TO FAN OUTPUT TEST 10 14 FAN MOTOR TEST 10 14 STATIC THERMISTOR TEST 10 15 DYNAMIC THERMISTOR TEST 10 15 HOT LAMP TEST 10 15 DIFFERENTIAL SOLENOID TEST 10 16 AWD OUT...

Page 288: ...4 CONVENTIONAL BATTERY TESTING 10 34 OCV OPEN CIRCUIT VOLTAGE TEST 10 34 SPECIFIC GRAVITY TEST 10 34 LOAD TEST 10 35 OFF SEASON STORAGE 10 35 CHARGING PROCEDURE 10 35 LOW MAINTENANCE BATTERY 10 36 BATTERY CHECK 10 36 BATTERY INSPECTION 10 36 BATTERY REMOVAL 10 36 BATTERY INSTALLATION 10 37 BATTERY TESTING 10 37 OCV OPEN CIRCUIT VOLTAGE TEST 10 37 LOAD TEST 10 37 OFF SEASON STORAGE 10 38 BATTERY CH...

Page 289: ...more information Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is used for when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc and the position of the decimal point For resistance readings isolate the component to be teste...

Page 290: ...ct the switch harness Grey Orange White Brown White Green by depressing the connector lock and pulling on the connector Do not pull on the wiring 4 Test the switch connections and check for continuity at the following pins shown in the illustration Differential Solenoid The differential solenoid is located on the rear gear case The solenoid actuates the carrier which locks and unlocks the rear car...

Page 291: ...actuating Brake Light Switch 1 The brake light switch is located near the steering gearbox along the frame The brake pressure switch is installed into this block 2 Disconnect wire harness from switch 3 Connect an ohmmeter across switch contacts Reading should be infinite 4 Apply foot brake and check for continuity between switch contacts If there is no continuity or greater than 5 ohms resistance ...

Page 292: ...nd re test Replace switch if necessary Gear Indicator Light Circuit Operation The transmission switch provides the ground path for the indicator panel lamps located on the dashboard For example when neutral is selected the DG WH wire is connected to ground through the switch and the neutral lamp is illuminated If the light does not illuminate when neutral is selected check the bulb If the bulb is ...

Page 293: ...adlight beam is adjustable 1 Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 With the machine in Neutral and park brake applied start the engine and turn the headlight switch to high beam 4 The most intense part of the headlight beam sh...

Page 294: ...on the lamp locates properly in the housing Headlamp Housing Removal 1 Open the hood 2 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 3 Remove the O ring A from the headlamp brackets both sides 4 After the O rings are removed from the headlamp Remove the adjustment screw B and pull the headlamp from the brackets WARNING Due to the nature of light uti...

Page 295: ...ht use a digital multi meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present If the tail light brake light does not work the lamp assembly may need to be replaced 1 From the rear of the tail light remove two screws holding lens cover in place and remove lens cover T 20 Torx 2 Remove lamp by turning the rubber base 1 4 turn and pulling the bulb out Rep...

Page 296: ...10 10 ELECTRICAL POWER DISTRIBUTION MODULE NON EFI MODELS PDM Operation ...

Page 297: ...sitive and negative battery terminals Voltage should be above 12 VDC What does passing this test indicate If battery voltage is at or above 12 VDC the battery and charging system are likely OK What does failing this test indicate If battery voltage is below 12 VDC the battery and charging system may be suspect The battery must be charged and load tested ...

Page 298: ...multimeter check for continuity between the orange wire leaving this connector and the red white wire returning to this PDM connector there should be continuity to pass this test There should be no continuity to ground to pass this test What does passing this test indicate The RUN Signal wires harness and connections are functioning normally Problem likely exists in PDM or Main PDM connection What...

Page 299: ...Test and note your results 2 An Orange wire exits the PDM on pin M in SSCB 2 Check for DC Volts on this Orange wire at the ignition switch the voltage should be at or near BAT voltage to pass What does passing this test indicate 1 ThePDMissupplyingthecorrectamountofprotectedbatteryvoltagetotheorangewire 2 The wiring harness and connections are good What does failing this test indicate 1 ThePDMmayn...

Page 300: ...at or near battery voltage What does passing this test indicate A constant fan voltage of near battery voltage indicates that the fan output is correct What does failing this test indicate Fan voltage less than battery voltage indicates a problem with the fan output circuit of the PDM If the fan output is 12 VDC for a few seconds then falls to zero this means that the PDM is going into a safe mode...

Page 301: ...d a thermometer in the water As the water heats measure the thermistor resistance To pass this test resistance should be 622Ω 760Ω at 131o F 55o C 339Ω 414Ω at 167o F 75o C and 196Ω 240Ω at 203o F 95o C What does passing this test indicate Thermistor resistance within specification at each temperature indicates normal operation What does failing this test indicate Ifthethermistorresistance isis si...

Page 302: ...ge What does passing this test indicate Passing this test indicates the PDM and AWD switch are operating correctly What does failing this test indicate Failing this test indicates there may be a problem with the AWD switch wire harness or PDM AWD Turf Switch Test Test Procedure ThefollowingtestsmustbeperformedwiththeIgnitionswitchintheONposition 1 Verify switch is properly lighting There will be o...

Page 303: ... side of the connection The reading will be approximately 5 5kΩ With the Ignition switch in the off position or the AWD Turf switch in center or upper positions the resistance reading will be approximately 15 5kΩ What does passing this test indicate Passing this test indicates the PDM and AWD Turf Mode switch are operating normally What does failing this test indicate Failing this test indicates t...

Page 304: ...CV to the differential solenoid M DIFF GROUND Provides a ground path for the differential solenoid N GROUND Battery negative Used to ground the PDM R ECU RELAY Powers the ECU relay output Solid State Circuit Breaker SSCB 2 Pin Signal Name Description A COIL 1 AC input from stator coil winding 1 B RUN 12 DCV input signal to the PDM when the ignition switch is in the ON position E FUEL ENABLE Fuel p...

Page 305: ...when the RUN input is activated and EFI input is low Once enabled the output will remain enabled until the EFI input goes high If the maximum ECU output current threshold is exceeded the output current will be reduced until the devise thermally shuts down It will automatically turn back on when it has cooled Ignition Relay Output The IGNITION relay uses a smart high side power switch The IGNITION ...

Page 306: ...ents the HUB COIL output from activating if the stator coil input frequency is too high Once the frequency is below the set limit the HUB COIL output is allowed to sink current Once the hub coil is activated it will remain engaged until current is removed from HUB COIL Engine speed is measured via the stator coil input frequency This provides the coil with short circuit overload and reverse polari...

Page 307: ...retard approximately 2 when the engine is warm If the ignition timing is not within the specified range adjust the stator plate position as described in Stator Adjustment Stator Adjustment 1 Remove the magneto housing 2 Remove the flywheel 3 Loosen the stator plate screws and adjust the stator plate position NOTE Moving the stator plate clockwise retards delays the ignition timing Moving the plate...

Page 308: ...10 22 ELECTRICAL COOLING SYSTEM Non EFI Cooling System Break Out Diagram PDM SSCB 1 SSCB 2 Thermister Input Overheat Indicator Output Fan 12 V Output RD WH Key On 12 V Power ...

Page 309: ...10 23 ELECTRICAL 10 EFI Cooling System Break Out Diagram PDM RD WH Key On 12 V Power ...

Page 310: ... or replace as necessary If the fan runs with the sensor harness disconnected but will not turn on when the engine is hot verify the coolant level is correct and check the coolant temperature sensor and connector terminals Coolant Temperature Sensor Test Non EFI Models If the thermistor circuit is open the engine hot light and fan will both come on With engine cold disconnect lead and measure resi...

Page 311: ...nite with as little as 6 volts of power NOTICE Do not remove the wiring harness from the CDI box while the key switch is on or while the engine is running Damage to the CDI box may occur Ignition System Troubleshooting No Spark Weak or Intermittent Spark Spark plug gap incorrect Fouled spark plug Faulty spark plug cap or poor connection to high tension lead Related wiring loose disconnected shorte...

Page 312: ...ry terminal Using the test table below crank the engine to check for proper CDI output Pulse Coil Output Disconnect the stator connector from the CDI module While cranking the engine test output from the pulse trigger coil Measure between the White Red and White wires and compare the cranking output to the test table below Resistance Tests Perform these tests using an Ohm meter or multimeter with ...

Page 313: ...ngine and coil mount using an ohmmeter The coil mount should have good continuity to ground on the engine 0 2 Ω Disconnect and check the ignition coil Resistance values should be Primary Side Primary Wire Tab to Ground on coil mount or engine 0 11Ω Secondary Side High Tension Wire to Engine Ground Cap installed 11 700Ω Cap removed 6700Ω Are these values within specs If all of the above tests are w...

Page 314: ...tor Plate Pulse Coil Trigger Air Gap 016 030 4 75 mm Ignition Coil Check coil mount for good ground to engine 0 2Ω Meter 6 7 k Ω NOTE CDI boxes may look the same but have different internal circuitry Be sure to always use the correct CDI box part number Refer To Wiring Diagrams For Specified Stator Coil Resistance Meter 5 k Ω ...

Page 315: ...ON position the ammeter should read negative amps battery discharge Reverse meter lead if a positive reading is indicated 4 Shift transmission into neutral with the park brake on and start the engine With the engine running at idle observe meter readings 5 Increase engine RPM while observing ammeter and tachometer 6 Note RPM at which the battery starts to charge ammeter indication is positive 7 Wi...

Page 316: ...PM 1 Set the selector dial to measure AC Voltage 2 Start the engine and let it idle 3 While holding the engine at a specified RPM separately measure the voltage across each leg of the stator by connecting the meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to Y3 4 Refer to the following table for approximate AC Voltage readings according to RPM Test each leg at the specif...

Page 317: ...habits The battery will continually discharge if operated below the Break Even RPM Con tinued problems would call for battery inspection Yes Inspect the wiring harness between the panel and the stator for remove the recoil and flywheel Inspect the flywheel magnets stator coils and stator wires for damage No Check stator PDM ground battery and battery connections Also check wire connections and wir...

Page 318: ...types of batteries require different service procedures Proper servicing and upkeep of your battery is very important for maintaining long battery life Your RANGER may have a Conventional Battery or a Sealed Low Maintenance Battery To identify which type of battery your RANGER has refer to the illustration below and follow the correct service and charging procedures that follow in the manual T Ter...

Page 319: ...ed charging rates 6 Check specific gravity of each cell with a hydrometer to assure each has a reading of 1 270 or higher Battery Inspection The battery is located under the hood Inspect the battery fluid level When the battery fluid nears the lower level remove the battery and fill with distilled water only to the upper level line To remove the battery WARNING Battery electrolyte is poisonous It ...

Page 320: ...uld be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Load Test OCV Open Circuit Voltage Test Battery voltage should be checked with a digital multitester Readings of 12 6 volts or less require further battery testing and charging See charts and Load Test on below NOTE Lead acid batteries should be kept at...

Page 321: ...olyte is at the proper level Add distilled water if necessary Charge at a rate no greater than 1 10 of the battery s amp hr capacity until the electrolyte s specific gravity reaches 1 270 or greater Store the battery either in the machine with the cables disconnected or store in a cool place NOTE Recharge to full capacity every 30 to 60 days during a non use period If the battery is stored during ...

Page 322: ...of lead antimony allows the battery acid to be fully absorbed For this reason a Low Maintenance battery case is dark and the cell caps are not removable since there is no need to check electrolyte level NOTE New Batteries Batteries must be fully charged before use or battery life will be reduced by 10 30 of full potential Charge battery for 3 5 hours at a current equivalent of 1 10 of the battery ...

Page 323: ...oltmeter or multimeter to test batter voltage Load Test NOTE This test can only be performed on machines with electric starters This test cannot be performed with an engine or starting system that is not working properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the elec...

Page 324: ...s the battery may need recharging When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging NOTE Always verify battery condition before and 1 2 hours after the end of charging Battery Charging Reference Table Electrolyte Freezing Points Specific Gravity of Electrolyte Freezing Po...

Page 325: ...oose flywheel Voltage Drop Test The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 1 VDC per connection or component To perform the test place the meter on DC volts...

Page 326: ...Armature Testing 5 Install a new carbon brush assembly in the brush housing NOTE Be sure that the terminal bolt insulating washer is properly seated in the housing and the tab on the brush plate engages the notch in the brush plate housing 6 Place a wrap of electrical tape on the threads of the terminal bolt to prevent O Ring damage during reinstallation 7 Install the O Ring over the bolt Make sur...

Page 327: ... set bolts Make sure O Rings are in good condition and seated in groove Starter Drive Pinion Gear Anti Kick out Shoe Garter Spring Replacement If the garter spring is damaged the overrun clutch may fail to return properly The replacement spring is PN 7042039 Use either of the following methods to remove and install a new garter spring 1 Screw the overrun clutch out to the engaged position on the p...

Page 328: ...ove battery and properly service Install fully charged shop battery to continue test Check voltage on both sides of circuit break er and ignition switch The voltage on both No Test starter solenoid coil by connecting an ohmmeter between the solenoid Brake Pressure Yes Good Reading Yes Replace the diode assembly No No lead to White Red harness wire Turn the ignition battery voltage on White Red wir...

Page 329: ...ack tester lead to solenoid end of battery to solenoid cable Connect red tester lead to solenoid end of solenoid to starter cable Reading should be less than 1 V D C Yes Replace the starter solenoid Connect the black tester lead to the solenoid end of the solenoid to starter cable Connect the red tester lead to the starter end of the same cable The reading should be less than 1 V D C No Clean the ...

Page 330: ...12 Volts between the RED BLACK wire terminal on the back of the switch and the BROWN wire terminal On the main connector behind the dashboard measure for 12 Volts between RED BLACK wire terminal and ground Not 12 Volts between wires Test wiring between the main connector and the circuit breaker 12 Volts between wires Test the accessory and wiring circuit breaker located under the seat Refer to Wir...

Page 331: ...10 45 ELECTRICAL 10 ELECTRICAL BREAKOUT DIAGRAMS EFI MODELS Starting Circuit Key On Power Circuit ...

Page 332: ...10 46 ELECTRICAL Transmission Switch Circuit Differential Solenoid Circuit ...

Page 333: ...10 47 ELECTRICAL 10 Charging System Circuit Cooling Fan Circuit ...

Page 334: ...10 48 ELECTRICAL AWD Circuit ...

Page 335: ...etor Jetting 4 4 Carburetor Mikuni CV 4 5 Carburetor Needle and Seat Test 4 12 Carburetor Removal 4 10 Cargo Box Installation 5 20 Cargo Box Removal 5 20 Centralized Hilliard Exploded View 7 16 Charging System 10 29 Choke Adjustment 2 15 Clutch Alignment 6 9 Clutch Offset 6 10 Clutch Maintenance 6 3 Combustion Chamber 3 25 Compression Test 2 19 Conversions Chart 1 16 Coolant Level Inspection 2 29 ...

Page 336: ... 2 Front Hub 4x4 7 5 Front Propshaft Removal 7 12 Front Propshaft U Joint Service 7 13 Front Strut Cartridge Replacement 5 14 Front Strut Exploded View 5 13 Front Suspension Maintenance 2 36 Fuel Filter 2 14 2 19 Fuel Injection Component Locations 4 25 Fuel Injection Exploded View 4 24 Fuel Injection Service Notes 4 23 Fuel Injection Special Tools 4 21 Fuel Injector 4 34 Fuel Lines 2 14 Fuel Press...

Page 337: ...Rear Propshaft Service 7 32 Rear Spring Adjustment 2 37 Rear Stabilizer Bar 5 17 Rear Suspension Adjustment 2 37 Rear Suspension Maintenance 2 37 Rocker Arm Assembly 3 49 Rocker Arm Inspection 3 19 S Shift Lever Installation 8 2 Shift Lever Removal 8 2 Shift Linkage Inspection 2 13 Shift Linkage Adjustment 8 3 Shift Linkage Inspection 8 2 Solenoid Differential 10 4 Spark Plug Service 2 34 Special ...

Page 338: ...lation 8 14 Transmission Removal 8 3 Troubleshooting Brakes 9 3 Troubleshooting Carburetion 4 18 Troubleshooting Clutching 6 24 Troubleshooting Cooling System 3 51 Troubleshooting Engine 3 50 Troubleshooting Spark Plug Fouling 3 51 Troubleshooting Starter System 10 39 Troubleshooting Transmission 8 15 V Valve Clearance Adjustment 2 23 Valve Sealing Test 3 29 Valve Seat Reconditioning 3 26 Valve In...

Page 339: ...WD 1 WIRE DIAGRAM RANGER 500 2X4 4X4 CHASSIS ...

Page 340: ...WD 2 WIRE DIAGRAM RANGER 500 2X4 4X4 DASH ...

Page 341: ...WD 3 WIRE DIAGRAM RANGER 500 EFI 4X4 CHASSIS PAGE 1 OF 2 ...

Page 342: ...WD 4 WIRE DIAGRAM RANGER 500 EFI 4X4 CHASSIS PAGE 2 OF 2 ...

Page 343: ...WD 5 WIRE DIAGRAM RANGER 500 EFI 4X4 DASH ...

Page 344: ...WD 6 WIRE DIAGRAM RANGER 500 EFI 4X4 BREAKOUTS ...

Page 345: ...WD 7 WIRE DIAGRAM RANGER 500 2X4 4X4 BREAKOUTS ...

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