Polaris Sportsman 850 Touring EPS Service Manual Download | Manualshive

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INDICATOR LAMPS

q

Check Engine

This indicator appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears.
Serious engine damage could result. Your authorized POLARIS dealer can assist.

w

EPS Warning (if equipped)

This indicator illuminates when a fault has occurred in the EPS system. Your authorized POLARIS
dealer can assist. EPS operation is possible with key on/engine off for up to 5 minutes.

e

Engine Hot

This lamp illuminates to indicate an overheated engine. If the indicator flashes, a severe overheating
condition exists.

r

Neutral

This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.

t

Helmet/Seat Belt

This lamp flashes for several seconds when the key is turned to the ON position. The lamp is a
reminder to wear helmet and seat belt (if equipped) before operating.

y

High Beam

This lamp illuminates when the headlamp switch is set to high beam.

u

Chassis Fault

If applicable.

i

Performance Limited

If applicable.

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Summary of Contents for Sportsman 850 Touring EPS

Page 1: ... perspective when seated in a normal riding position Some procedures outlined in this manual require a sound knowledge of mechanical theory tool use and shop procedures in order to perform the work safely and correctly Technicians should read the text and be familiar with the service procedures before starting any repair Certain procedures require the use of special tools Use only the proper tools...

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

Page 3: ...ed Trademark of Textron Hilliard Trademark of the Hilliard Corporation Warn Trademark of Warn Industries FOX Registered Trademark of FOX RACING SHOX RydeFX Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www polarisindustries com purchased from www purepolaris com or by contacting the nearest Polaris dealer REVISION INDEX 2018 SPORTSMAN REV RELEASE DAT...

Page 4: ......

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

Page 6: ......

Page 7: ...ECIAL TOOLS 1 5 POLARIS MOBILE DIGITAL WRENCH PMDW 1 6 MASTER TORQUE TABLE 1 7 VEHICLE SPECIFICATIONS 1 10 2018 SPORTSMAN 850 1 10 2018 SPORTSMAN 850 SP 1 12 2018 SPORTSMAN 850 TOURING 1 14 2018 SPORTSMAN 1000 XP 1 16 2018 SPORTSMAN 1000 XP TOURING 1 18 2018 SPORTSMAN XP 850 HIGH LIFTER 1 20 2018 SPORTSMAN XP 1000 HIGH LIFTER 1 22 MISC SPECIFICATIONS AND CHARTS 1 24 CONVERSION TABLE 1 24 SAE TAP D...

Page 8: ... base First 3 digits and 10th digit are used in model number only They are not used with the 17 digit VIN Digits 1 through 8 determine Digital Wrench calibration VEHICLE IDENTIFICATION NUMBER VIN DESIGNATION Example 4XAKA09A0F3000000 WORLD MFG ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS CHASSIS DRIVELINE ENGINE SIZE ENGINE MODIFIER CATEGORY CHECK DIGIT MODEL YEAR MFG LOCATION INDIVIDUAL SERIAL NO 1...

Page 9: ...r to the vehicle identification number VIN and the engine serial number The VIN can be found stamped on the lower frame rail on the front LH side of the ATV see Figure 1 1 The engine serial number can be found on the rear portion of the engine located on the valve cover see Figure 1 2 GENERAL INFORMATION 1 ...

Page 10: ...UAL 2018 SPORTSMAN 850 A18SXA85B1 B7 9928123 SPORTSMAN 850 SP A18SXE85B9 BM BS 9928123 SPORTSMAN 1000 XP A18SXE95BR BL BP 9928123 SPORTSMAN 850 TOURING A18SYE85BB 9928122 SPORTSMAN 1000 TOURING A18SYE95BU 9928122 SPORTSMAN 850 HIGH LIFTER A18SXN85B8 9928123 GENERAL INFORMATION ...

Page 11: ...other tools may be substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may order special tools through the Polaris official tool supplier Bosch Automotive Service Solutions 1 800 345 2233 or https polaris service solutions com GENERAL INFORMATION 1 ...

Page 12: ...ications Minimum operating system Android 3 1 Honeycomb or higher Android 4 0 or higher preferred Dual core processor 2 GB internal memory external microSD 32 or 64 GB slot 500 MB RAM Rear facing camera with minimum 3 0 mega pixel resolution with auto continuous focus Video Microphone and Voice to text capable Internet and Bluetooth wireless technology capable PMDW App Notes PMDW will not work on ...

Page 13: ...lbs 59 Nm Step 3 Additional 180 Step 4 M6 bolts 7 ft lb 10 Nm Camshaft Sprocket Fastener 28 ft lbs 38 Nm ENGINE COOLING SYSTEM ITEM TORQUE Cam Chain Tensioner Fasteners 7 ft lbs 10 Nm Camshaft Carrier Fasteners 13 ft lbs 18 Nm Spark Plug 18 ft lbs 25 Nm Valve Cover Bolts 12 14 ft lbs 16 19 Nm Exhaust System Exhaust Head Pipe Nuts Torque in sequence Step 1 Front to Rear 8 ft lbs 11 Nm Step 2 Rear t...

Page 14: ...ts 19 ft lbs 26 Nm Transmission Mount Torx Fasteners 36 ft lbs 49 Nm FINAL DRIVE ITEM TORQUE Lug Nut Aluminum Wheel 75 ft lbs 102 Nm Lug Nut Steel Wheel 45 ft lbs 61 Nm Hub Nut 80 ft lbs 108 Nm Front Gearcase Fill Drain Plug 10 ft lbs 14 Nm Front Gearcase Mount Fasteners 36 ft lbs 49 Nm Front Gearcase Cover Fasteners 8 ft lbs 11 Nm Rear Gearcase Mount Fasteners 40 ft lbs 54 Nm Rear Gearcase Cover ...

Page 15: ...3 ft lbs 17 Nm Master Cylinder Cover Fasteners 7 in lbs 1 Nm Master Cylinder Clamp Fasteners 70 in lbs 8 Nm Brake Bleeder 47 in lbs 5 Nm Brake Pedal Fastener 38 ft lbs 52 Nm Rear Master Cylinder Fasteners 8 ft lbs 11 Nm BODY FRAME ITEM TORQUE Body Fasteners Until Fully Seated Upper Frame Rail Fasteners 36 ft lbs 49 Nm ELECTRICAL ITEM TORQUE Voltage Regulator Fasteners 75 in lbs 7 Nm Starter Mounti...

Page 16: ...RPM Cooling System Cap Liquid Cooled 2 7 qt 2 6 l Overheat Warning Instrument Cluster Indicator ENGINE Lubrication Pressurized Wet Sump Engine Oil Requirement PS 4 2 qt 1 9 l Exhaust System Stainless Steel Dual Header Pipe w Dual Outlet Silencer FUEL SYSTEM Fuel System Type Bosch Multi Port Sequential EFI Throttle Body Size Mikuni Dual Bore 42 mm Fuel Delivery Electronic Fuel Pump in tank Fuel Pre...

Page 17: ...in 6 4 12 7 mm Front Suspension Dual A arm Front Travel 9 2 in 23 cm Rear Suspension Dual A arm w Rolled IRS Rear Travel 10 2 in 26 cm Shock Preload Adjustment Front Rear Cam Adjustable WHEELS BRAKES Front Wheel Size Bolt Pattern Steel 14 x 6 4 156 Front Tire Model Size Maxxis AT 26 x 8 14 Rear Wheel Size Bolt Pattern Steel 14 x 8 4 156 Rear Tire Model Size Maxxis AT 26 x 10 14 Tire Air Pressure F...

Page 18: ...t Cluster Indicator Lubrication Pressurized Wet Sump ENGINE Engine Oil Requirement PS 4 2 qt 1 9 l Exhaust System Stainless Steel Dual Header Pipe w Dual Outlet Silencer FUEL SYSTEM Fuel System Type Bosch Multi Port Sequential EFI Throttle Body Size Mikuni Dual Bore 42 mm Fuel Delivery Electronic Fuel Pump in tank Fuel Pressure 58 psi 400 kPa Fuel Capacity 5 25 gal 20 l Fuel Requirements 87 Octane...

Page 19: ...A arm w Rolled IRS Rear Travel 10 2 in 26 cm Shock Preload Adjustment Front Rear Cam Adjustable WHEELS BRAKES Front Wheel Size Bolt Pattern Aluminum 14 x 5 5 4 156 Front Tire Model Size Carlisle AT 489 II 26 x 8 14 Rear Wheel Size Bolt Pattern Aluminum 14 x 7 5 4 156 Rear Tire Model Size Carlisle AT 489 II 26 x 10 14 Tire Air Pressure Front 7 psi 48 kPa Rear 7 psi 48 kPa Brakes Single Control Hydr...

Page 20: ...er Indicator Lubrication Pressurized Wet Sump ENGINE Engine Oil Requirement PS 4 2 qt 1 9 l Exhaust System Stainless Steel Dual Header Pipe w Dual Outlet Silencer FUEL SYSTEM Fuel System Type Bosch Multi Port Sequential EFI Throttle Body Size Mikuni Dual Bore 42 mm Fuel Delivery Electronic Fuel Pump in tank Fuel Pressure 58 psi 400 kPa Fuel Capacity 5 25 gal 20 l Fuel Requirements 87 Octane minimu...

Page 21: ... arm w Rolled IRS Rear Travel 10 25 in 26 cm Shock Preload Adjustment Front Rear Cam Adjustable WHEELS BRAKES Front Wheel Size Bolt Pattern Aluminum 14 x 5 5 4 156 Front Tire Model Size Carlisle AT 489 II 26 x 8 14 Rear Wheel Size Bolt Pattern Aluminum 14 x 7 5 4 156 Rear Tire Model Size Carlisle AT 489 II 26 x 10 14 Tire Air Pressure Front 7 psi 48 kPa Rear 7 psi 48 kPa Brakes Single Control Hydr...

Page 22: ...ling System Cap Liquid Cooled 2 7 qt 2 6 l Overheat Warning Instrument Cluster Indicator Lubrication Pressurized Wet Sump ENGINE Engine Oil Requirement PS 4 2 qt 1 9 l Exhaust System Stainless Steel Dual Header Pipe with Silencer FUEL SYSTEM Fuel System Type Bosch Multi Port Sequential EFI Throttle Body Size Mikuni Dual Bore 42 mm Fuel Delivery Electronic Fuel Pump in tank Fuel Pressure 58 psi 400...

Page 23: ...7 mm Front Suspension Dual A arm Front Travel 9 in 22 9 cm Rear Suspension Dual A arm w Rolled IRS Rear Travel 10 25 in 26 cm Shock Preload Adjustment Front Rear Cam Adjustable WHEELS BRAKES Front Wheel Size Bolt Pattern Aluminum 14 x 5 5 4 156 Front Tire Model Size Carlisle AT 489 II 26 x 8 14 Rear Wheel Size Bolt Pattern Aluminum 14 x 7 5 4 156 Rear Tire Model Size Carlisle AT 489 II 26 x 10 14 ...

Page 24: ...ument Cluster Indicator Lubrication Pressurized Wet Sump ENGINE Engine Oil Requirement PS 4 2 qt 1 9 l Exhaust System Stainless Steel Dual Header Pipe with Silencer FUEL SYSTEM Fuel System Type Bosch Multi Port Sequential EFI Throttle Body Size Mikuni Dual Bore 42 mm Fuel Delivery Electronic Fuel Pump in tank Fuel Pressure 58 psi 400 kPa Fuel Capacity 5 25 gal 20 l Fuel Requirements 87 Octane mini...

Page 25: ...A arm w Rolled IRS Rear Travel 10 in 25 4 cm Shock Preload Adjustment Front Rear Cam Adjustable WHEELS BRAKES Front Wheel Size Bolt Pattern Aluminum 14 x 5 5 4 156 Front Tire Model Size Carlisle AT 489 II 26 x 8 14 Rear Wheel Size Bolt Pattern Aluminum 14 x 7 5 4 156 Rear Tire Model Size Carlisle AT 489 II 26 x 10 14 Tire Air Pressure Front 7 psi 48 kPa Rear 7 psi 48 kPa Brakes Single Control Hydr...

Page 26: ...er Indicator Lubrication Pressurized Wet Sump ENGINE Engine Oil Requirement PS 4 2 qt 1 9 l Exhaust System Stainless Steel Dual Header Pipe w Dual Outlet Silencer FUEL SYSTEM Fuel System Type Bosch Multi Port Sequential EFI Throttle Body Size Mikuni Dual Bore 42 mm Fuel Delivery Electronic Fuel Pump in tank Fuel Pressure 58 psi 400 kPa Fuel Capacity 5 25 gal 20 l Fuel Requirements 87 Octane minimu...

Page 27: ...spension Dual A arm w Rolled IRS Rear Travel 6 7 in 17 cm Shock Preload Adjustment Front Rear Cam Adjustable WHEELS BRAKES Front Wheel Size Bolt Pattern Aluminum 14 x 5 5 4 156 Front Tire Model Size Carlisle AT 489 II 29 5 x 9 5 14 Rear Wheel Size Bolt Pattern Aluminum 14 x 7 5 4 156 Rear Tire Model Size Carlisle AT 489 II 29 5 x 9 5 14 Tire Air Pressure Front 7 psi 48 kPa Rear 7 psi 48 kPa Brakes...

Page 28: ...ing System Cap Liquid Cooled 2 7 qt 2 6 l Overheat Warning Instrument Cluster Indicator Lubrication Pressurized Wet Sump ENGINE Engine Oil Requirement PS 4 2 qt 1 9 l Exhaust System Stainless Steel Dual Header Pipe with Silencer FUEL SYSTEM Fuel System Type Bosch Multi Port Sequential EFI Throttle Body Size Mikuni Dual Bore 42 mm Fuel Delivery Electronic Fuel Pump in tank Fuel Pressure 58 psi 400 ...

Page 29: ...t 1 4 1 2 in 6 4 12 7 mm Front Suspension Dual A arm Front Travel 7 4 in 19 cm Rear Suspension Dual A arm w Rolled IRS Rear Travel 6 7 in 17 cm Shock Preload Adjustment Front Rear Cam Adjustable WHEELS BRAKES Front Wheel Size Bolt Pattern Aluminum 14 x 5 5 4 156 Front Tire Model Size 29 5 x 9 5 14 Rear Wheel Size Bolt Pattern Aluminum 14 x 7 5 4 156 Rear Tire Model Size 29 5 x 9 5 14 Tire Air Pres...

Page 30: ... mile ounces oz x 28 35 grams g fluid ounces fl oz x 29 57 cubic centimeters cc cubic centimeters cc x 03381 fluid ounces grams g x 0 035 ounces pounds lb x 0 454 kg kilogram kg x 2 2046 lbs cubic inches cu in x 16 387 cc cubic centimeters cc x 0 061 cubic inches US quarts x 0 946 liters L liters L x 1 057 US quarts US gallons x 3 785 liters L liters L x 0 264 US gallons PSI x 6 895 kilopascals kP...

Page 31: ... 4 20 7 1 3 4 12 1 43 64 1 4 28 3 2 4 1 2 1 25 32 5 16 18 F 2 12 1 59 64 5 16 24 I 2 1 4 4 1 2 2 1 32 3 8 16 O 2 1 2 4 2 1 4 3 8 24 Q 2 3 4 4 2 1 2 7 16 14 U 3 4 2 3 4 7 16 20 25 64 METRIC TAP DRILL SIZES TAP SIZE DRILL SIZE DECIMAL EQUIVA LENT NEAREST FRACTION 3 x 50 39 0 0995 3 32 3 x 60 3 32 0 0937 3 32 4 x 70 30 0 1285 1 8 4 x 75 1 8 0 125 1 8 5 x 80 19 0 166 11 64 5 x 90 20 0 161 5 32 6 x 1 0...

Page 32: ...11 mm 0 4331 7 16 0 4375 29 64 0 4531 15 32 0 4688 12 mm 0 4724 31 64 0 4844 1 2 0 500 13 mm 0 5118 33 64 0 5156 17 32 0 5313 35 64 0 5469 14 mm 0 5512 9 16 0 5625 37 64 0 5781 15 mm 0 5906 19 32 0 5938 39 64 0 6094 5 8 0 625 16 mm 0 6299 FRACTION DECIMAL MM TO INCHES 41 64 0 6406 21 32 0 6563 17 mm 0 6693 43 64 0 6719 11 16 0 6875 45 64 0 7031 18 mm 0 7087 23 32 0 7188 47 64 0 7344 19 mm 0 7480 3...

Page 33: ...ENT LINE 2 13 THROTTLE OPERATION 2 13 THROTTLE RELEASE SWITCH TRS THROTTLE CABLE ADJUSTMENT 2 14 AIR FILTER PRE FILTER SERVICE 2 14 ENGINE 2 16 ENGINE OIL LEVEL 2 16 ENGINE OIL AND FILTER CHANGE 2 16 ENGINE BREATHER HOSE 2 17 VALVE CLEARANCE ADJUSTMENT 2 18 COMPRESSION AND LEAKDOWN TESTS 2 20 SPORTSMAN SILENCER CLEANING 2 20 ENGINE MOUNT FASTENER TORQUE 2 21 COOLING SYSTEM 2 22 COOLING SYSTEM OVER...

Page 34: ...Y OFF SEASON STORAGE 2 32 STEERING 2 33 STEERING INSPECTION 2 33 POWER STEERING UNIT EPS MODELS 2 33 TIE ROD END STEERING INSPECTION 2 33 TOE ALIGNMENT 2 34 TOE ALIGNMENT ADJUSTMENT 2 35 SUSPENSION 2 36 SUSPENSION INSPECTION 2 36 SUSPENSION SPRING PRE LOAD ADJUSTMENT 2 36 FOX SHOCK SPRING PRELOAD ADJUSTMENT 2 36 SHOCK COMPRESSION ADJUSTMENT 2 37 BRAKE SYSTEM 2 38 BRAKE FLUID INSPECTION 2 38 BRAKE ...

Page 35: ...he oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer BREAK IN PERIOD The break in period consists of the first 20 hours of operation Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Drive vehicle slowly at first while varying the t...

Page 36: ... Wheels fasteners Inspect ensure fastener tightness Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation Indicator lights switches Ensure operation Engine stop switch Ensure proper operation Air filter pre filter Inspect clean Air box sedim...

Page 37: ...djust lubricate replace if necessary E Throttle Body Intake Duct 50 H 6 M 500 800 Inspect ducts for proper sealing air leaks Drive belt 50 H 6 M 500 800 Inspect replace as needed Cooling System 50 H 6 M 500 800 Inspect coolant strength seasonally pressure test system yearly Radiator 50 H 6 M 500 800 Inspect clean external surfaces Cooling Hoses 50 H 6 M 500 800 Inspect for leaks Engine Oil Change ...

Page 38: ...M Replace coolant 50 50 Extended Life Coolant E Valve Clearance 1000 H 10000 16000 Inspect adjust Toe Adjustment Inspect periodically adjust as needed Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California Have an authorized Polaris dealer perform these services Service Note Under extreme use change deman...

Page 39: ...pply grease until all traces of water have been purged out at each of these areas ITEM RECOMMENDED LUBE METHOD FREQUENCY q Front Propshaft Yoke Polaris Premium U Joint Grease Grease fittings every 500 miles 800 km Grease before long periods of storage and after thoroughly washing or submerging the ATV w Rear Bearing Carrier e Front A Arms r Rear A Arms MAINTENANCE ...

Page 40: ...ere duty conditions or short trip cold weather operation w Transmission Polaris AGL Add fluid until it is visible at the fill hole threads Check level every 25 hours change fluid yearly e Engine Coolant Polaris 50 50 Extended Life Antifreeze Maintain coolant level in coolant reservoir bottle Check level daily change coolant every 2 years More often under severe use such as operated in water or und...

Page 41: ...at the fill hole threads Check level every 25 hours change according to intervals y Rear Gearcase Polaris Angle Drive Fluid Add fluid until it is visible at the fill hole threads Check level every 25 hours change fluid yearly u Brake Fluid DOT 4 Brake Fluid Maintain fluid level in both master cylinder reservoirs to indicated levels Check level during pre ride inspection change fluid every two year...

Page 42: ...ine coolant system components are located in different locations than other models Side View REF DESCRIPTION 1 Recovery Bottle Cap 2 Recovery Bottle 3 MAX Coolant Level 4 MIN Coolant Level Top View REF DESCRIPTION 1 Pressure Cap 2 Recovery Bottle Hose 3 Radiator MAINTENANCE ...

Page 43: ...rt 12 count 2872276 ATV Angle Drive Fluid 2 5 Gallon 2 count 2870465 Pump for Gallon Jug Coolant 2880514 50 50 Extended Life Coolant Quart 12 count 2880513 50 50 Extended Life Coolant Gallon 6 count 2880512 50 50 Extended Life Coolant 55 US Gallon Drum Grease Specialized Lubricants 2871312 Grease Gun Kit 2871322 Premium All Season Grease 3 oz cartridge 24 count 2871423 Premium All Season Grease 14...

Page 44: ...owever mixing the two will not extend the service interval To receive the full five year service interval benefit the vehicles s entire cooling system must be drained and replenished with the new 50 50 Extended Life antifreeze To quickly determine if a vehicle is using 60 40 or 50 50 Extended Life antifreeze simply note the color of the coolant 60 40 antifreeze will be green while 50 50 Extended L...

Page 45: ... not kinked or pinched 3 Replace all fuel lines every two years FUEL FILTERS This machine uses a serviceable high volume high pressure fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator If the fuel pump filters require service the fuel pump must be replaced as an assembly NOTE Refer to Chapter 3 for fuel pump replacement and all other informa...

Page 46: ...ld be 079 118 2 3 mm gap between throttle arm and throttle arm stop 6 Reinstall the RH control cover and ensure the O ring is properly in place Securely tighten the 4 screws 7 Place the vehicle in Park and start the engine Turn the handlebars from full left to full right while listening for any change in engine speed If engine speed changes loosen the locknut and turn the adjuster sleeve clockwise...

Page 47: ... Installation 8 Inspect airbox cover seal for damage It should adhere tightly to the cover and seal all the way around Replace seal as needed 9 Reinstall pre filter screen over main filter Be sure the screen covers entire surface of main filter without folds creases or gaps NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before reinstalling 10 Install air fil...

Page 48: ... OIL AND FILTER CHANGE Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart Always change the oil filter whenever changing the engine oil 1 Position the ATV on a level surface 2 Place the transmission in park 3 Start engine and allow it to run for two to three minutes until the engine is warm 4 Stop the engine 5 Remove the fasteners q and guard platew fro...

Page 49: ...ng surface then turn an additional 3 4 turn 14 Replace the guard plate 15 Remove dipstick and fill engine with 2 qts 1 9 l of the recommended engine oil FLUID CAPACITY Recommended Engine Oil PS 4 Synthetic 4 Cycle Engine Oil PN 2876244 Quart 16 Start the engine and allow it to idle for one to two minutes 17 Stop the engine and check for leaks 18 Re check the oil level on the dipstick and add oil a...

Page 50: ...b assembly 7 Remove the rubber strap retaining the ECU to the airbox 8 Remove the breather hose q from the side of the airbox 9 Remove the spark plug wires and spark plugs from the cylinder head NOTE Step 11 does not apply for Models with Electronic Throttle Control 10 Disconnect the chassis harness q from the IAC valve Remove the two hoses from the valve ports w 11 Remove the two air box mounting...

Page 51: ...he engine can be rotated see Drive Belt Removal procedure within this chapter MAG i i PTO o o ADJUSTMENT PROCEDURE 19 Turn the drive clutch counter clockwise until the cam sprocket is in the MAG adjustment position both marks parallel with the valve cover sealing surface 20 NOTE The exhaust rocker arm moves both exhaust valves Ensure you do not rely on the play up and down of the rocker after adju...

Page 52: ...PRESSION AND LEAKDOWN TESTS NOTE This engine does NOT have decompression components Compression readings will vary in proportion to cranking speed during the test Smooth idle generally indicates good compression Low engine compression is rarely a factor in running condition problems above idle speed Abnormally high compression can be caused by worn or damaged exhaust cam lobes A cylinder leak down...

Page 53: ...gine momentarily a few more times 6 Stop the engine and allow the silencer to cool 7 Use compressed air and a non synthetic brush to clean the arrestor screen 8 Reinstall the arrestor and fastener and torque the retaining screw to specification TORQUE Spark Arrestor Fastener 8 ft lbs 11 Nm ENGINE MOUNT FASTENER TORQUE Check engine mount fasteners q and ensure they are tight Also inspect the condit...

Page 54: ...lant level between the MIN and MAX levels indicated on the recovery bottle With the engine at operating temperature the coolant level should be between the MAXq and MINw marks on the coolant recovery bottle If not perform the following procedure 1 Position the vehicle on a level surface 2 View the coolant level in the recovery bottle The coolant level can be viewed from inside the front right whee...

Page 55: ...surface 2 View the coolant level in the recovery bottle The coolant level can be viewed from inside the left right wheel well Side View REF DESCRIPTION q Recovery Bottle Cap w Recovery Bottle e MAX Coolant Level r MIN Coolant Level 3 If the coolant level is below the MIN line on the bottle remove the front rack assembly to access the radiator pressure cap and recovery bottle cap NOTE If overheatin...

Page 56: ...ks Replace if necessary 2 Check tightness of all hose clamps CAUTION Do not over tighten hose clamps at radiator or radiator fitting may distort causing a restriction to coolant flow TORQUE Radiator Hose Clamp 35 in lbs 4 Nm COOLANT STRENGTH TYPE Test the strength of the coolant using an antifreeze hydrometer A 50 50 mixture of antifreeze and distilled water will provide the optimum cooling corros...

Page 57: ...y varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches NOTE Do not hold the throttle wide open for more than 5 seconds 7 Allow the engine RPM to return to idle then shift into low gear 8 Test the PVT system for belt slippage If the belt slips repeat the process DRIVE SHAFT BOOT INSPECTION Inspect the front and rear drive shaft boots for damage tears wear or le...

Page 58: ...he wheel nut on a steel rim without the nut being centered in the hole Be sure to center the wheel nuts before applying torque to prevent wheel nuts from coming loose 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts and or hub nut to the proper torque specification listed in the Wheel and Hub Torque Table Wheel and Hub Torque Specification page 2 25 WARNING Improperly installed ...

Page 59: ...nge 3 If lubricant level is not even with the bottom threads add the recommended lubricant as needed Do not overfill 4 Reinstall the fill plug and torque to specification TORQUE Drain Fill Plug 14 ft lbs 19 Nm Transmission Lubricant Change Access the drain plug through the rear right hand wheel well The plastic skid plate can be removed for better access to the drain plug 5 Remove the fill plug re...

Page 60: ...ted on the bottom side of the front gearcase Access the drain plug through the access hole in the front skid plate 5 Remove the fill plug refer to Front Gearcase Fluid Level Check 6 Place a drain pan under the front gearcase drain plug 7 Remove the drain plug and allow fluid to drain completely 8 Clean the drain plug magnetic surface 9 Reinstall drain plug with a new O ring and torque to specifica...

Page 61: ...eck 6 Place a drain pan under the rear gearcase drain plug 7 Remove the drain plug w and allow the fluid to drain completely 8 Clean the drain plug magnetic surface 9 Reinstall drain plug with a new O ring and torque to specification TORQUE Drain Fill Plug 14 ft lb 19 Nm 10 11 Add the recommended amount of fluid through the fill hole Maintain the fluid level even with the bottom threads of the fil...

Page 62: ...Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE Never attempt to open the battery If the seal is broken the battery will be ruined and will fail within a few weeks If battery voltage is below 12 6V fully charge the battery before putting in...

Page 63: ... wire gauge Refer to specifications in the following illustration for proper spark plug type and gap Adjust gap if necessary by carefully bending the side electrode 8 If necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark plug is used Recommended Spark Plug for 850 Engine Champion REA6MC Spark Plug Torque 18 1 5 ft lbs 24 2 Nm Gap 035 0 90 mm...

Page 64: ...lace Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Battery charge can be maintained by using a Polaris battery tender charger or by charging once a month to make up for normal self discharge Battery tenders can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined poi...

Page 65: ...nt repair and adjustment be performed by an authorized Polaris Dealer Only a qualified technician should replace worn or damaged steering parts Use only genuine Polaris replacement parts POWER STEERING UNIT EPS MODELS The power steering unit q can be accessed through the front right wheel well by removing the mud guard Frequently clean the areas around and on top of the power steering unit w to al...

Page 66: ...lebars in this position NOTE The steering post frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 3 Tie a length of string between two stands as shown in the following illustration Position the stands so the string is flush or parallel with the side of the rear tire NOTE If available you may use a long straight ...

Page 67: ...s be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and may break To adjust toe alignment Hold tie rod end to keep it from rotating Loosen jam nuts at both ends of the tie rod Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe out setting Important When tightening the tie rod end jam nuts the rod ends must...

Page 68: ...ner Wrench PN 2877408 FOX SHOCK SPRING PRELOAD ADJUSTMENT The front and rear shocks on EPS and International models have a spring preload adjustment Suspension spring preload may be adjusted to suit different riding conditions or vehicle payloads WARNING Uneven adjustment may cause poor handling of the vehicle which could result in an accident and serious injury or death Always adjust both the lef...

Page 69: ...spension height will negatively impact vehicle stability when operating without a load SHOCK COMPRESSION ADJUSTMENT The compression damping adjustment is located on top of the shock Piggyback reservoir of each shock Turn the clicker adjuster knob to make damping adjustments NOTE When clicker adjuster is turned clockwise until it stops damping is in the fully closed position Turn the clicker clockw...

Page 70: ... can reduce the fluid level If required add brake fluid to 25 30 6 8 mm from the top of the reservoir Check the fluid level of the auxiliary brake master cylinder reservoir Add fluid to the indicated level Use Polaris DOT 4 Brake Fluid PN 2872189 CAUTION DO NOT OVERFILL Excess brake fluid may cause brake drag Fill to the indicated fill line or specification Check brake system for fluid leaks exces...

Page 71: ...ion and leaks Tighten any loose fittings and replace any worn or damaged parts AUXILIARY BRAKE PEDAL The hydraulic auxiliary brake system requires no adjustment It is controlled by the foot brake pedal q Frequently check the brake fluid level for the auxiliary brake system by viewing the level in the master cylinder reservoir located underneath the front rack assembly Check the effectiveness of th...

Page 72: ...2 40 NOTES MAINTENANCE ...

Page 73: ...IGH LIFTER 3 16 RADIATOR REMOVAL HIGH LIFTER 3 16 RADIATOR INSTALLATION HIGH LIFTER 3 17 WATER PUMP SERVICE 3 17 WATER PUMP IMPELLER REMOVAL 3 17 WATER PUMP MECHANICAL SEAL REPLACEMENT 3 18 STATOR COVER INSTALLATION 3 20 WATER PUMP ASSEMBLY TORQUE SPECIFICATIONS 3 21 STATOR COVER ASSEMBLY TORQUE SPECIFICATIONS 3 22 THERMOSTAT 3 23 THERMOSTAT REPLACEMENT 3 23 INTAKE EXHAUST SYSTEM 3 24 AIR INTAKE A...

Page 74: ... HEAD REMOVAL 3 49 CYLINDER HEAD CLEANING 3 49 CYLINDER HEAD WARP INSPECTION 3 50 CYLINDER HEAD DISASSEMBLY 3 50 VALVE INSPECTION 3 51 COMBUSTION CHAMBER 3 52 VALVE GUIDE REMOVAL INSTALLATION 3 52 VALVE SEAT RECONDITIONING 3 52 CRANKCASE DISASSEMBLY 3 55 CRANKCASE LOWER OIL PUMP DISASSEMBLY 3 56 CRANKCASE DISASSEMBLY UPPER 3 57 PISTON CONNECTING ROD REMOVAL 3 57 COUNTERBALANCE SHAFT REMOVAL INSPEC...

Page 75: ...3 70 BALANCE SHAFT TIMING 3 71 CRANKCASE PREPARATION LOWER 3 72 CRANKCASE SEALANT AND TORQUE VALUES 3 73 CRANKCASE ASSEMBLY 3 74 CYLINDER HEAD ASSEMBLY 3 74 VALVE SEALING TEST 3 75 CYLINDER HEAD INSTALLATION 3 75 CAMSHAFT CARRIER ASSEMBLY 3 76 CAMSHAFT CAMSHAFT CARRIER INSTALLATION 3 76 CAMSHAFT TIMING 3 77 CAM CHAIN TENSIONER INSTALLATION 3 79 TROUBLESHOOTING 3 80 ENGINE 3 80 COOLING SYSTEM 3 80 ...

Page 76: ...Quick Release VALVE SPRING COMPRESSOR PV 43513 A VALVE SPRING COMPRESSOR ADAPTOR PA 49378 WATER PUMP BEARING AND COUPLER PRESS PA 49316 WATER PUMP DRIVE NUT FLYWHEEL PULLER PA 44995 A WATER PUMP MECHANICAL SEAL INSTALLER PA 50995 WATER PUMP DRIVE BOLT TOOL Bosch Automotive Service Solutions 1 800 345 2233 or www polaris service solutions com ENGINE LUBRICATION SPECIFICATIONS FLUID CAPACITY Capacit...

Page 77: ...pump and the restriction of the engine oil passages 4 If oil pressure is too low this indicates either not enough flow or not enough resistance to flow This could be due to using oil with lighter viscosity than recommended If not there may be excessive clearances in the pump bearings or a leak in the oil delivery passages before bearing restrictions Leaks that could cause this are a gallery plug r...

Page 78: ...3 6 OIL FLOW DIAGRAM ENGINE COOLING SYSTEM ...

Page 79: ... 010 9 18 0 25 mm Valve Guide Protrusion Above Head Exhaust 0 276 0 010 7 00 0 25 mm Valve Valve Lash Cold Intake 0 000 000 mm Refer to Chapter 2 Valve Clearance Adjustment Valve Lash Cold Exhaust Valve Margin Thickness Intake 0 016 40 mm Valve Margin Thickness Exhaust 0 024 60 mm Valve Stem Diameter Intake 0 2163 0 0003 5 495 0 0075 mm Valve Stem Diameter Exhaust 0 2159 0 0003 5 485 0 0075 mm Val...

Page 80: ...1 0 25 mm Oil Ring Rails Service Limit 0 032 0 81 mm Ring to Groove Clearance Top Ring Standard 0 0024 0 0008 0 060 0 020 mm Second Ring Standard 0 0028 0 0008 0 070 0 020 mm Connecting Rod Connecting Rod Small End I D 0 7886 0 000 015 20 030 000 015 mm Connecting Rod Small End Diametral Clearance 0 00098 0004 0 025 0 010 mm Connecting Rod Big End Side Clearance 0 012 0 0039 0 30 10 mm Connecting ...

Page 81: ...Contacting Width Exhaust 0 047 0 008 0 0039 1 20 0 20 mm Valve Seat Angle 45 5 0 25 Valve Guide Valve Guide Inner Diameter 0 217 0005 0 0 5 52 012 0 0 mm Valve Guide Protrusion Above Head Intake 0 361 0 010 9 18 0 25 mm Valve Guide Protrusion Above Head Exhaust 0 315 0 010 8 00 0 25 mm Valve Valve Lash Cold Intake 0 000 000 mm Refer to Chapter 2 Valve Clearance Adjustment Valve Lash Cold Exhaust V...

Page 82: ...andard 0 012 0 022 0 30 0 55 mm Top Ring Service Limit 0 024 0 60 mm Second Ring Standard 0 039 0 047 1 00 1 20 mm Second Ring Service Limit 0 049 1 25 mm Oil Ring Rails Standard 0 008 0 028 0 20 0 70 mm Oil Ring Rails Service Limit 0 029 0 75 mm Ring to Groove Clearance Top Ring Standard 0 0006 0 0024 0 015 0 060 mm Second Ring Standard 0 0006 0 0024 0 015 0 060 mm Connecting Rod Connecting Rod S...

Page 83: ...ger If pressure loss is evident within five minutes check the radiator all cooling system hoses hose clamps and water pump seal for leakage Radiator Cap Pressure Test WARNING Never remove radiator cap when engine is warm or hot The cooling system is under pressure and serious burns may result Allow the engine and cooling system to cool before servicing 4 Remove radiator pressure cap and test using...

Page 84: ...antly 6 Squeeze coolant lines to help purge the system of air 7 With engine still idling top off the radiator with Polaris Premium Antifreeze If no air bubbles are seen at the radiator filler neck the system should be purged of air 8 Reinstall the radiator pressure cap NOTE Be sure to install the radiator pressure cap before shutting off the engine Coolant may spit out of the radiator 9 Stop the e...

Page 85: ...e return line w from the radiator 5 Carefully pull rearward on the lower portion of the recovery bottle to disengage the lower tab Then lift up on the bottle and remove it from the radiator fan shroud 6 Remove the fasteners e retaining the upper portion of the radiator 7 Disconnect the fan motor 8 Remove the RF headlight 9 Lift up and lift the radiator upward to allow the lower grommets to clear t...

Page 86: ...tallation and reassembly remove the pressure cap and fill the radiator and recovery bottle with coolant 4 Refer to the Cooling System Bleeding Procedure Cooling System Bleeding Procedure page 3 12 ENGINE COOLING SYSTEM ...

Page 87: ...SYSTEM ASSEMBLY VIEW REF DESCRIPTION NOTES q RADIATOR w COOLANT HOSE ENGINE IN e SPRINGBAND CLAMP r GEAR CLAMP t COOLANT HOSE ENGINE OUT y HOSE CLAMP u SCREW Torque until fully seated i SCREWS Torque until fully seated o SURGE TANK a FLANGE NUTS s BOLTS Torque until fully seated ENGINE COOLING SYSTEM ...

Page 88: ...vious 11 Fill the cooling system and overflow and run the engine up to operating temp Verify the level is correct before re assembly Refer to the cooling system bleeding procedure earlier in this chapter WARNING Never open the cooling system when the engine and radiator are warm or hot Hot coolant can cause severe burns Allow engine and radiator to cool 12 Fit the lower shroud fan assembly loosely...

Page 89: ...nt of the lower shroud fan assembly lifted reconnect both fan electrical connectors 5 Position the fuse block from the underside of the shroud and install both fasteners Torque to specification Ensure the fuse block cap is re installed as well TORQUE Fuse Block Fastener Torque until fully seated 6 Install all 4 lower shroud fan assembly fasteners q and torque to specification TORQUE Lower Shroud F...

Page 90: ...TER PUMP MECHANICAL SEAL REPLACEMENT Perform Water Pump Impeller Removal procedure Water Pump Impeller Removal page 3 17 1 Disconnect the stator wire harness and remove the CPS from the stator cover 2 Remove the 8 stator cover screws 3 Carefully remove the stator cover taking care not to damage the plastic coolant pipe CAUTION The flywheel contains powerful magnets Use caution when removing the st...

Page 91: ... inside the stator housing as shown Do not attempt to press water pump shaft out of stator housing without first supporting the cover by the stator boss or cover may be damaged 6 Press shaft down until flush with end of mechanical seal or until the seal spring starts to compress 7 Select a suitable arbor D and press the shaft through the seal until the shaft assembly is removed ENGINE COOLING SYST...

Page 92: ...ler and torque bolt to specification TORQUE Water Pump Impeller Bolt 10 ft lbs 13 5 Nm 13 Rotate impeller and check for smooth rotation STATOR COVER INSTALLATION 1 Install new O rings on the plastic coolant pipe Lubricate the O rings with P80 rubber lubricant or lithium grease CAUTION The flywheel contains powerful magnets Use caution when installing the stator cover DO NOT place fingers between c...

Page 93: ...3 3 21 WATER PUMP ASSEMBLY TORQUE SPECIFICATIONS ENGINE COOLING SYSTEM ...

Page 94: ...3 22 STATOR COVER ASSEMBLY TORQUE SPECIFICATIONS ENGINE COOLING SYSTEM ...

Page 95: ...assembly from the injector ports 6 Plug the injector ports with clean shop towels to prevent debris from entering the clean side of the intake 7 Remove the fasteners o that retain the thermostat housing then the housing 8 Replace the thermostat and seal 9 Torque fasteners to specification TORQUE Thermostat Housing Fastener 7 ft lbs 10 Nm TORQUE Fuel Rail Mounting Screws 44 in lbs 5 Nm TORQUE Plenu...

Page 96: ... q AIR INTAKE BOOT High Lifter only w AIR IN DUCT High Lifter only e BOLTS Torque until fully seated r AIRBOX INTAKE DUCT SEAL High Lifter only t U NUT High Lifter only y CLOSEOUT PLATE u AIRBOX COVER SEAL i AIRBOX COVER o RETAINER BOLT High Lifter only a SCREW High Lifter only ENGINE COOLING SYSTEM ...

Page 97: ...mp sensor and IAC valve 4 Remove the two screws that retain the air box to the frame 5 Remove the two hoses y from the IAC valve 6 Disconnect the spark plug wires 7 Remove the rubber strap that retains the ECU to the front of the air box 8 Remove the screws u that retain the intake runners to the throttle body 9 Lift up on the air box and rotate it towards the left side of the vehicle Open the wir...

Page 98: ...IELDS Inspect the heat shields Ensure they are not damaged and are properly secured If any heat shields are found to be damaged or missing they must be replaced q Silencer Heat Shield w Rear Cab Heat Shield HIGH LIFTER HEAT SHIELDS Inspect the heat shields Ensure they are not damaged and are properly secured If any heat shields are found to be damaged or missing they must be replaced q Exhaust Spr...

Page 99: ...11 Nm Step 2 43 ft lbs 59 Nm Step 3 Additional 180 Step 4 M6 bolts 7 ft lb 10 Nm CYLINDER HEAD 13 ft lbs 18 Nm CAMSHAFT CARRIER 9 ft lbs 12 Nm OIL PUMP COVER 89 in lbs 10 Nm WATER PUMP COVER 89 in lbs 10 Nm STATOR COVER 14 ft lbs 19 Nm COUPLER STARTER GEAR M9 Step 1 71 in lbs 8 Nm M9 Step 2 26 ft lbs 35 Nm M6 89 in lbs 10 Nm CRANKCASE ENGINE COOLING SYSTEM ...

Page 100: ...3 28 VALVE COVER ENGINE COOLING SYSTEM ...

Page 101: ...3 3 29 CAMSHAFT CARRIER CAMSHAFT ROCKER ARM ENGINE COOLING SYSTEM ...

Page 102: ...3 30 CYLINDER HEAD VALVES INTEGRATED THROTTLE BODY ENGINE COOLING SYSTEM ...

Page 103: ...3 3 31 VALVE AND SPRING HEIGHT DETAIL SPM850 ENGINE COOLING SYSTEM ...

Page 104: ...3 32 VALVE AND SPRING HEIGHT DETAIL SPM1000 ENGINE COOLING SYSTEM ...

Page 105: ...3 3 33 PISTON CONNECTING ROD ENGINE COOLING SYSTEM ...

Page 106: ...3 34 CRANKSHAFT ENGINE COOLING SYSTEM ...

Page 107: ...3 3 35 CRANKCASE ENGINE COOLING SYSTEM ...

Page 108: ...3 36 CRANKCASE UPPER ENGINE COOLING SYSTEM ...

Page 109: ...3 3 37 BALANCE SHAFT BALANCE SHAFT TIMING ENGINE COOLING SYSTEM ...

Page 110: ...3 38 CRANKCASE LOWER WITH OIL PUMP ENGINE COOLING SYSTEM ...

Page 111: ...3 3 39 STATOR COVER FLYWHEEL WATER PUMP COUPLER ENGINE COOLING SYSTEM ...

Page 112: ...3 40 WATER PUMP WATER PUMP COUPLER STATOR ENGINE COOLING SYSTEM ...

Page 113: ...3 3 41 DRIVE COUPLER REAR STARTER GEAR ENGINE COOLING SYSTEM ...

Page 114: ...OVAL IMPORTANT Some engine repair procedures can be performed without removing the engine from the vehicle Refer to Accessible Engine Components for further information NOTE Upon engine removal use a mechanical lift or have an assistant help remove the engine from the vehicle to prevent personal injury or damage to vehicle components 1 If vehicle was recently operated allow it to cool down before ...

Page 115: ...rtion of the airbox to the frame 12 Remove the breather hose from the side of the airbox 13 Disconnect wire harness r from ignition coil intake air temp sensor and IAC valve 14 Remove the two hoses y from the IAC valve 15 Remove the screws u that retain the intake runners to the throttle body 16 Lift up on the air box and rotate it towards the left side of the vehicle Open the wire harness retaine...

Page 116: ... Chapter 3 Fuel Pump Fuel Tank Removal 21 Remove the 4 screws retaining the engine skid plate and remove the plate from the vehicle 22 Place a drain pan under the front portion of the engine 23 Loosen the hose clamp and remove the coolant inlet hose o rom the water pump housing 24 Slowly drain the coolant into the drain pan Dispose of used coolant properly 25 The following steps may require you to...

Page 117: ...e support Doing so allows the TPS T MAP fuel injectors IAC hoses and throttle cable to remain connected to the throttle body 31 Remove the screws j hat retain the throttle body to the cylinder head Replace the gaskets upon installation Insert a clean shop towel into each intake track of the engine to prevent debris from entering 32 Remove the spade wire white red and battery cable from starter mot...

Page 118: ...uts to specification TORQUE Exhaust Retaining Nuts Step 1 Front to Rear 8 ft lbs 11 Nm Step 2 Rear to Front 14 ft lbs 19 Nm Bleed Cooling System 9 Remove radiator cap and slowly add coolant to top of filler neck 10 Fill coolant reservoir tank to full mark 11 Install radiator cap and squeeze coolant lines to force air out of system 12 Again remove radiator cap and slowly add coolant to top of fill ...

Page 119: ...e from camshaft lobes IMPORTANT DO NOT rotate the engine using the camshaft sprocket retaining bolt 2 Using an 8mm socket remove cam chain tensioner bolts r evenly and remove tensioner Note TOP marked on plate t for assembly 3 Using a 12mm socket remove the cam sprocket bolt u and lift the chain and sprocket off camshaft Secure cam chain with a wire to prevent it from falling off the crankshaft ge...

Page 120: ...roller movement Roller should turn smoothly without binding Replace rocker arm if roller surface is damaged or if roller does not turn smoothly 4 Measure I D of rocker arms and O D of rocker arm shafts Measure shaft bore in cam carrier Compare to specifications See Engine Specifications page 3 7 CAMSHAFT CAMSHAFT BORE INSPECTION 1 After camshaft carrier is removed lift camshaft from cylinder head ...

Page 121: ...inder crankcase without removing cam carrier C but the center two cylinder head bolts cannot be removed from the head unless carrier is removed CYLINDER HEAD CLEANING Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon CAUTION Use care not to damage gasket sealing surface All gasket surfaces must be clean dry and free of any oil or grease upon assembly Clean s...

Page 122: ...ve springs NOTE Keep mated parts together for assembly It is important to put cylinder head parts back in the same location Mark parts or place them in a rack as you remove them Valve Spring Compressor PV 1253 or PV 4019 with adapter PV 43513 A 1 Compress valve spring and remove split keepers w 2 Remove compressor then remove top retainer spring and seal e Discard seals Repeat for all remaining va...

Page 123: ...5 Measure diameter of valve stem with a micrometer in three places then rotate 90 degrees and measure again six measurements total Compare to specifications MEASUREMENT Valve Stem Diameter In 0 2163 0 0003 5 495 0 0075 mm Ex 0 2159 0 0003 5 485 0 0075 mm 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 ...

Page 124: ...ide of head to proper installed height Note difference between intake and exhaust guide height MEASUREMENT Intake Valve Guide Height 9 18 mm 0 25 mm MEASUREMENT Exhaust Valve Guide Height 7 00 mm 0 25 mm 5 Ream or hone new valve guides to size to obtain specified stem to guide clearance Ream from combustion chamber side of head CAUTION Do not tilt the reamer while reaming the guide Always rotate t...

Page 125: ...0 and make another light cut If the cutter now contacts the uncut portion of the seat check the pilot Look for burrs nicks or runout If the pilot is bent it must be replaced If the contact area of the cutter is in the same place the valve guide is distorted from improper installation If the contact area of the initial cut is greater than 75 continue to cut the seat until all pits are removed and a...

Page 126: ...at When contact area is centered on the valve face measure seat width If the seat is too wide or uneven use both top and bottom cutters to narrow the seat If the seat is too narrow widen using the 45 cutter and re check contact point on the valve face and seat width after each cut NOTE When using an interference angle the seat contact point on the valve will be very narrow and is a normal conditio...

Page 127: ...nd crankcase at any time during the removal installation process or injury could result CAUTION Do not attempt to lift the upper crankcase cylinder from the lower crankcase for piston ring access without first removing the lower crankcase and connecting rod caps from the crankshaft Pistons must be removed through the top of the cylinders with the connecting rod attached 1 Remove cylinder head begi...

Page 128: ...twelve outer crankcase bolts i evenly 1 2 turn then loosen the two longer case bolts o then the six main crankcase bolts a Remove all the bolts 9 Tap lower crankcase in reinforced areas with a soft faced hammer to loosen then lift straight upward to remove CRANKCASE LOWER OIL PUMP DISASSEMBLY 1 Remove oil pump cover plate screws q Note location of two longer M6x20 screws w for assembly These screw...

Page 129: ...damage 9 Remove oil pressure relief from crankcase Replace if debris has entered or if oil pressure was outside of specified range TORQUE Oil Pressure Relief Valve 20 ft lbs 27 Nm CRANKCASE DISASSEMBLY UPPER 1 Remove the oil passage connecting tube with O rings 2 Note connecting rod and cap marks so they can be oriented properly and assembled in the same manner as matched sets on proper rod journa...

Page 130: ...ft bearings NOTE Due to extremely close tolerances balance shaft bearings must be inspected visually and by feel Look for signs of discoloration scoring galling or contamination from moisture or dirt Turn bearings on shaft Bearings should turn smoothly and quietly The outer race should be firm with minimal side to side movement and no detectable up and down movement Replace the balance shaft as an...

Page 131: ...cord measurements for bearing selection on page 5 49 page 3 62 Calculate the difference between the two measurements for each journal to determine concentricity C Replace crankshaft if any journal is worn below the minimum diameter specification or if journal out of round exceeds maximum specification MEASUREMENT A Crankshaft Main Journal Diameter 2 1642 2 1650 54 970 54 990 mm C Crankshaft Main J...

Page 132: ... galling of surface or pitting 6 Measure small end I D in two directions as shown Record measurements The difference between measurements is concentricity Compare to specifications MEASUREMENT Connecting Rod Small End Diameter 0 7886 0 0 015 20 03 0 0 015 mm Connecting Rod Small End Concentricity 0 00027 0 007 mm Out Of Round 7 Install matching rod cap on connecting rod without bearings Lubricate ...

Page 133: ...bearing insert color from table Connecting Rod Bearing Selection Chart page 3 62 MEASUREMENT Connecting Rod Big End Diameter 1 8892 1 8902 47 987 48 011 mm Connecting Rod Big End Concentricity 0 00047 0 012 mm ENGINE COOLING SYSTEM ...

Page 134: ...g Rod Big End ID measurement page 3 59 Connecting Rod Bearing Selection Chart Bearing Size Selection Chart Inches mm Connecting rod journal must be within standard size limits as determined by crankshaft measurements Con Rod Letter R W B Y Con Rod Big End Bore Diameter 1 8892 1 8895 47 987mm 47 993mm 1 8895 1 8897 47 993mm 47 999mm 1 8897 1 8899 47 999mm 48 005mm 1 8899 1 8902 48 005mm 48 011mm Ta...

Page 135: ...trol ring e Remove top rail first then bottom rail then the expander PISTON RING INSTALLED GAP 1 Place each piston ring q inside the cylinder Use the piston to push the ring squarely into cylinder 2 Measure installed gap with a feeler gauge w at both the top and bottom of the cylinder NOTE A difference between top and bottom end gap measurements is a general indication of cylinder taper wear The c...

Page 136: ...agonally MEASUREMENT Cylinder Warp 0 002 0 05 mm Max 4 Inspect cylinder for wear scratches or damage IMPORTANT DO NOT hone the cylinders or attempt to repair a damaged cylinder by honing 5 Inspect taper and out of round with a dial bore gauge 6 Measure in two directions front to back and side to side on three levels and record measurements If cylinder is tapered or out of round beyond 001 the cran...

Page 137: ...point 33 mm down from piston crown at a right angle to piston pin bore Subtract measurement from maximum measurement obtained in Step 6 of Cylinder Inspection Piston to Cylinder Clearance 0013 0008 033 02 mm Piston O D Standard 3 4239 0008 86 967 02 mm ENGINE COOLING SYSTEM ...

Page 138: ...ace oil control ring expander in oil ring groove Tips of expander gap A must face piston crown so scraper edge B of expander faces piston skirt 2 Rotate expander in groove until butt ends are on intake side of piston Ends must butt squarely together and must not overlap 3 Install bottom rail first then top rail with end gap located as shown at right 4 Install second ring with undercut facing botto...

Page 139: ...necting rod Warm piston crown with a heat gun if pin cannot be installed by hand or use a piston pin installation tool DO NOTapply heat directly to piston rings or a loss of radial tension could result 5 Install the remaining circlip with gap at the top or bottom Push the piston pin in both directions to make sure the clips are properly seated in the groove IMPORTANT Never re use a piston circlip ...

Page 140: ...nstall seals on both ends of crankshaft with spring side of seal facing IN toward crankshaft 6 Carefully lower crankshaft into upper crankcase Guide connecting rods onto rod journals of crankshaft as necessary 7 Adjust crankshaft seals so each is flush with end of crankcase 8 Install rod caps on connecting rods with marks aligned 9 Install new connecting rod bolts apply clean engine oil to threads...

Page 141: ...3 3 69 CRANKCASE ASSEMBLY UPPER ENGINE COOLING SYSTEM ...

Page 142: ...d in position 4 Install balance shaft placing the tooth with the single dot between the two dots on the crankshaft gear 5 Align bearing locating ring in groove on crankcase and fully seat the shaft 6 Rotate crankshaft until SINGLE dot on crankshaft gear is visible 7 Align single dot of drive gear between two dots of balance gear 8 Align bearing locating ring in groove on crankcase and fully seat t...

Page 143: ...3 3 71 BALANCE SHAFT TIMING ENGINE COOLING SYSTEM ...

Page 144: ...gram and trace the oil path from the through the lower crankcase Flush all passages with solvent and then warm soapy water Rinse with clear warm water and dry with compressed air Be sure passages are clean and dry before assembling the lower crankcase Assemble parts in order A J ENGINE COOLING SYSTEM ...

Page 145: ...3 3 73 CRANKCASE SEALANT AND TORQUE VALUES ENGINE COOLING SYSTEM ...

Page 146: ...ankcase Sealant and Torque Values page 3 73 to final torque value then repeat the sequence to verify final torque TORQUE M6 Bolts 7 ft lb 10 Nm M8 Bolts 14ft lb 17 Nm 14 Install cylinder head Cylinder Head Installation page 3 75 CYLINDER HEAD ASSEMBLY NOTE Assemble valves one at a time to maintain proper order 1 Apply engine oil to valve guides and seats 2 Coat valve stem with Premium Starter Grea...

Page 147: ...ry free from oil or grease NOTE Do not touch sealing surfaces of gasket 2 Reinstall two head alignment pins in upper crankcase 3 Install cam chain tensioner blade in upper crankcase Install a new O ring on pivot bolt and lubricate with engine oil Torque bolt q to specification 4 Lift cam chain and install chain guide 5 Be sure tabs w are engaged in slots Secure cam chain with a wire so it will not...

Page 148: ...in the cylinder head 3 Lubricate rocker arms rollers and shafts with engine oil Lay out in proper location as marked upon disassembly 4 Assemble camshaft carrier with rocker arms and shafts Slots q must face outward of carrier to allow bolt installation and to properly orient the oiler holes in shafts CAMSHAFT CAMSHAFT CARRIER INSTALLATION 1 Loosen all valve adjuster lock nuts 2 Turn adjuster scre...

Page 149: ...2 ft lb 17 Nm CAMSHAFT TIMING Refer to Camshaft Timing Quick Reference Either the href or the keyref attribute should be set on xref elements page IMPORTANT Valve and or piston damage can occur if engine is rotated with camshaft incorrectly timed 1 Using an open end wrench across the flats on the end of the camshaft rotate camshaft clockwise until pin q is facing UP ENGINE COOLING SYSTEM ...

Page 150: ...lign two sprocket marks with valve cover gasket surface 6 Slide sprocket onto camshaft aligning slot in sprocket with pin 7 Screw in the sprocket bolt r finger tight Sprocket bolt must be fully tightened after cam chain tensioner is installed 8 Verify flywheel TDC mark is still aligned be sure the crankshaft has not rotated from TDC and that sprocket marks are aligned with gasket surface note that...

Page 151: ...d NOTE Top mark on tensioner cap plate faces UP 3 Rotate plate and gasket into position and start the inner bolt 4 Slowly draw bolts evenly until snug 5 Torque tensioner cap bolts to specification TORQUE Tensioner Cap Bolts 7 ft lb 10 Nm 6 Rotate crankshaft through two revolutions and verify camshaft timing is correct 7 Torque camshaft sprocket bolt e to specification TORQUE Camshaft Sprocket Bolt...

Page 152: ...e wear or damage check compression PVT not operating properly Restricted exhaust muffler Camshaft worn excessively Piston Failure Scoring Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated water Excessive Smoke and Carbon Buildup Excessive piston to cylinder clearance Worn rings piston or cylinder Worn valve guides or seals Restricted br...

Page 153: ... circuit Thermostat stuck closed or not opening completely Temperature Too Low Thermostat stuck open Leak at Water Pump Weep Hole Faulty water pump mechanical seal Worn pump shaft or pump shaft bearing ENGINE COOLING SYSTEM ...

Page 154: ...3 82 NOTES ENGINE COOLING SYSTEM ...

Page 155: ...P REPLACEMENT 4 9 FUEL TANK INSTALLATION 4 12 FUEL LINE HOSE 4 13 QUICK DISCONNECT SERVICE 4 13 FUEL VENT LINE CHECK VALVE TESTING 4 13 FUEL VENT LINE ROUTING 4 14 FUEL SUPPLY LINE ROUTING 4 15 EFI SYSTEM LAYOUT 4 16 EFI SYSTEM ASSEMBLY VIEW 4 16 EFI COMPONENTS 4 17 IDENTIFICATION LOCATION 4 17 EFI SERVICE NOTES 4 19 ELECTRONIC FUEL INJECTION 4 20 GENERAL INFORMATION 4 20 EFI OPERATION OVERVIEW 4 ...

Page 156: ...DLE AIR CONTROLLER IAC 4 32 OPERATION OVERVIEW 4 32 IAC TEST 4 32 IAC REPLACEMENT 4 32 THROTTLE POSITION SENSOR TPS 4 33 OPERATION OVERVIEW 4 33 TPS RESISTANCE TESTS 4 33 TPS REPLACEMENT AND ADJUSTMENT 4 34 ENGINE COOLANT TEMPERATURE SENSOR ECT 4 35 OPERATION OVERVIEW 4 35 ECT SENSOR TEST 4 35 ECT SENSOR REPLACEMENT 4 35 IGNTION COIL 4 36 OPERATION OVERVIEW 4 36 IGNITION COIL TESTS 4 36 IGNITION C...

Page 157: ...AL WRENCH FEATURE MAP 4 44 ECU REPLACEMENT 4 45 ETC LEARN PROCEDURE 4 45 ECU REPROGRAMMING REFLASH 4 45 POLARIS MOBILE DIGITAL WRENCH PMDW 4 48 FUEL SYSTEM TROUBLESHOOTING 4 49 FUEL STARVATION LEAN MIXTURE 4 49 RICH MIXTURE 4 49 POOR IDLE 4 49 FUEL SYSTEM ...

Page 158: ...verfill the tank The tank is at full capacity when the fuel reaches the bottom of the filler neck Leave room for expansion of fuel Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Do not smoke or allow open flames or sparks in or near the area where refueling is performed or wh...

Page 159: ...LINK MODULE KIT PU 47471 This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench diagnostic software Polaris dealers can also order the following separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 This kit is available to Polaris dealers through our tool supplier SPX 1 800 328 6657 D...

Page 160: ...4 6 FUEL TANK FUEL TANK ASSEMBLY VIEW FUEL SYSTEM ...

Page 161: ... is not working or if the display reading differs in large comparison to the fuel in the tank perform a resistance test on the fuel sender Disconnect the fuel pump sending unit connection and measure the resistance between PIN 1 and PIN 2 on the fuel pump connector If out of specification replace the fuel pump assembly Fuel Sender Resistance Specifications Full 6 1Ω Empty 90 4 5Ω FUEL PUMP TEST NO...

Page 162: ...de Turn on the key switch and observe voltage to ensure a minimum of 7 volts is present NOTE If the voltage was below 7 VDC test battery ignition switch EFI relay and wiring harness 6 If the reading is between 7 and 14 volts turn key switch off and connect an ohmmeter between the terminals 3 and 4 in the plug on the pump to check for continuity within the fuel pump NOTE If there was no continuity ...

Page 163: ...sconnect the fuel pump electrical harness 11 While holding a shop towel over the fuel line connector disconnect the quick connect fuel line from the fuel pump CAUTION It is possible for pressurized fuel to be present when disconnecting the fuel line It is recommended to allow the vehicle to sit for a period of one hour after shutting off the engine before servicing the fuel pump This allows the ex...

Page 164: ...ng removed be aware of float arm and pump pre filter Hold the float arm to the pump body as you lift and tilt the pump to ensure that the float arm is not bent when removed from the tank 5 Transfer old fuel pump to a suitable container capable of safely holding fuel The fuel pump will retain some fuel 6 Drain fuel from tank and wipe with a clean rag before inspecting the inside of the fuel tank fo...

Page 165: ...evel float arm and cause incorrect function 13 While maintaining downward pressure thread new PFA nut y onto fuel tank and hand tighten Use care when starting PFA nut ensuring threads are properly aligned Verify orientation marks are still aligned between fuel pump and fuel tank 14 Torque PFA nut w to specification using the Fuel Pump Service Tool PU 50326 q and a calibrated torque wrench Hold or ...

Page 166: ...ss 4 Reinstall the vent line w to the tank fitting 5 Install the fuel tank mounting screws q and tighten securely 6 Install the 4 screws into the bottom portion of the right hand footwell 7 Remove the shop towel from the fuel tank inlet and reinstall the front cab assembly 8 Connect the fuel fill hose and tighten hose clamp securely 9 Reinstall the front rack or storage box assembly 10 Install the...

Page 167: ...epared to clean the fuel that will be spilled when removing the fuel line 4 When installing ensure that the collar is fully installed 5 Gently pull on the line to ensure it is fully seated 6 Cycle the ignition key to prime the pump and ensure there are no leaks before re assembly FUEL VENT LINE CHECK VALVE TESTING In Tank Check Valveq q In Line Check Valvew w If Equipped The fuel vent line and che...

Page 168: ...ING The primary fuel tank vent hose q runs from the tank vent nipple up to the vent tee The vent splits to the upper line w that runs into the headlight pod and the lower line e that runs down along the frame rail FUEL SYSTEM ...

Page 169: ...4 4 15 FUEL SUPPLY LINE ROUTING The line routes under the frame rail There are no anchor retention fasteners related to this line FUEL SYSTEM ...

Page 170: ...4 16 EFI SYSTEM LAYOUT EFI SYSTEM ASSEMBLY VIEW FUEL SYSTEM ...

Page 171: ...AG end front of the throttle body w 3 Idle Air Control IAC Mounted to the RH side of the airbox e 4 Crankshaft Position Sensor CPS Mounted in the top portion of the magneto cover on the front of the engine r 5 Fuel Injectors Mounted in the throttle body assembly t 6 Fuel Rail Fuel Pressure Valve Attached to the top portion of the fuel injectors Lo cated on the PTO end of the fuel rail y FUEL SYSTE...

Page 172: ...fuel tank as an assembly 9 Engine Coolant Temperature Sensor ECT Mounted in the cylinder head below the throttle body o 10 Throttle Position Sensor TPS Mounted on the MAG end front of the throttle body a 11 Throttle Body Mounted to the cylinder head on the side of the en gine s 12 Ignition Coil Mounted to the RH side of the airbox d The high tension leads are retained by the airbox FUEL SYSTEM ...

Page 173: ...including a thorough inspection of the ECU connector for contamination or damage 6 If the sensor and wiring passes inspection and reconnecting the ECU does not resolve the issue use a known good ECU from another Polaris 850 to test for problem resolution Never attempt to service any fuel system component while engine is running or ignition switch on USE CARE when removing or installing the ECU con...

Page 174: ...very 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 ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for intake air temperat...

Page 175: ...m performance If a fault is detected the ECU turns on the Check Engine light in the speedometer and stores the fault code in its fault memory Depending on the significance or severity of the fault normal operation may continue or Fail Safe operation slowed speed richer running may be initiated A technician can determine the cause of the Check Engine light by referencing the Instrument Cluster Trou...

Page 176: ...d it will be permanently set it as an EPS cluster leaving the EPS warning light on with no way of turning it off ECU REMOVAL REPLACEMENT 1 Remove the seat and upper side panels from the vehicle 2 Remove the 4 push rivets from each front mud guard and remove the mud guards from the vehicle 3 Remove the front rack or storage box assembly 4 Disconnect the negative battery cable NOTE Be sure to cover ...

Page 177: ...nal 23 Air Temp Sensor Signal 24 IAC Signal Pin 3 25 IAC Signal Pin 4 26 CPS Signal In 27 AWD Switch On Signal 28 Thermister Gear Position TRS Ground 30 TPS Ground 31 TRS Signal In 32 Temp CAN Low 35 CAN High Signal 36 IAC Signal Pin 1 37 IAC Signal Pin 6 38 CSP Signal Out 39 ATS T MAP Ground 42 Thermister Signal 44 Vehicle Speed Sensor Signal 45 Temp CAN High 47 CAN Low Signal 48 Chassis Ground 5...

Page 178: ...No internal servicing or adjustments may be performed If a problem is encountered and you determine the ETC to be faulty contact the Polaris Service Department for specific handling instructions Do not replace the ETC under warranty without factory authorization Use Digital Wrench to perform all troubleshooting of this component Use a Volt Ohm meter to test the vehicle harness continuity between t...

Page 179: ...ch will default to Standard mode 1 Disconnect the drive mode switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test the resistance between pins 3 and 11 3 If the resistance is out of specification for any mode replace the switch The Drive Mode Switch is a three way rocker switch with internal resistors which allow the ECU to monitor voltage d...

Page 180: ...is a rocker switch and will be mounted on either the dash or in the headlight pod of an ATV Remove the component it is mounted to remove the connector and disengage the switch from the panel by depressing the retention tabs Reverse to install FUEL SYSTEM ...

Page 181: ... on for at least 15 seconds and engine not running the Throttle Position will read approximately 9 6 when the throttle lever is released THROTTLE CONTROL SENSOR REPLACEMENT NOTE The Throttle Control Sensor is calibrated to the right hand control If the Throttle Control Sensor is faulty the throttle lever assembly must be replaced 1 Disconnect the negative battery cable 2 Disassemble the headlight ...

Page 182: ...tors with the ignition on The injectors will open if the EFI relay is energized If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows Injector leakage is very unlikely but in rare instances it can be internal past the tip of the valve needle or external weeping around the injector body The loss of system pressure from the l...

Page 183: ... injector Resistance specification is 12Ω 5 20 C 68 F Fuel Injector Resistance Specification 12Ω 5 20 C 68 F INJECTOR REPLACEMENT 1 Remove the intake plenum page 3 25 2 Thoroughly clean the area on top of the throttle body and around the injectors 3 Disconnect the fuel line i by disengaging the quick disconnect clips CAUTION Ensure you have a shop rag to clean up the fuel that will spill when remo...

Page 184: ...lutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will stop running CPS SERVICE 1 Remove the intake plenum page 3 25 2 To perform a static test on the CPS disconnect the CPS electrical connector Set your digital multimeter to Ohms and test the resistance of the internal circuit of the se...

Page 185: ...ure and manifold absolute pressure sensor T MAP is a non serviceable item If it is faulty it must be replaced This sensor requires a 5 Vdc input to operate therefore the T MAP sensor should only be tested using the Digital Wrench Diagnostic Software dealer only TMAP REPLACEMENT 1 Remove the intake plenum page 3 25 2 Thoroughly clean around the TMAP to avoid getting dirt in the intake 3 Disconnect ...

Page 186: ... of the following pin locations of the IAC If any of the readings are out of specification replace the IAC PINS RESISTANCE PINS RESISTANCE 1 2 30Ω 1 2Ω 4 5 30Ω 1 2Ω 2 3 30Ω 1 2Ω 5 6 30Ω 1 2Ω 1 3 60Ω 2 4Ω 4 6 60Ω 2 4Ω IAC REPLACEMENT 1 Remove the seat and upper RH side panel 2 Disconnect the wire harness from the IAC motor connector q remove the two hoses from the IAC valve tubes w and remove the s...

Page 187: ... body TPS RESISTANCE TESTS The TPS is a non serviceable item If it is faulty it must be replaced It can be tested with a Ohm meter using the following method With the test leads connected and the meter set to read Ohms compare the resistance readings with those given in the tables NOTE Resistance readings may vary slightly from vehicle to vehicle The important thing to remember when testing the TP...

Page 188: ...e TPS is set correctly 5 Install new TPS and finger tighten the mounting screw Reconnect the TPS wire harness 6 Secure wire harness as noted during disassembly 7 Assemble SmartLink Module and connect the diagnostic interface cable to the vehicle to allow Digital Wrench use see Digital Wrench Diagnostic Connector page 4 5 8 Turn the ignition key on and open Digital Wrench Select the appropriate veh...

Page 189: ... few seconds the fan should turn on and the Check Engine indicator should display on the instrument cluster This indicates all other components are working properly Refer to Chapter 4 for additional ECT information Polaris dealers can test the sensor by using the Digital Wrench Diagnostic Software dealer only TEMPERATURE F C RESISTANCE 32 F 0 C 5 9kΩ 5 68 F 20 C 2 5kΩ 5 176 F 80 C 323Ω 5 212 F 100...

Page 190: ... the secondary coil windings to fire the spark plugs IGNITION COIL TESTS The ignition coil can be tested by using an ohm meter Use the following illustrations and specification table to test the ignition coil Remove the seat and upper right hand side panel to access the ignition coil Ignition Coil Resistance Readings TEST PIN CONNECTION RESISTANCE Primary Between 1 2 Between 2 3 0 4Ω Secondary Bet...

Page 191: ...ing on the coil side end caps 7 Install the spark plug wires NOTE Be sure to install the PTO long wire e on the coil terminal nearest the airbox 8 Install the coil assembly and securely tighten the mounting screw 9 Upon assembly make sure the spark plug wires are retained by the airbox 10 Reinstall shift linkage upper right hand side panel and seat FUEL SYSTEM ...

Page 192: ...r equates to the fault mode or the Failure Mode Identifier FMI 3 If more than one code exists press the MODE button to advance to the next trouble code 4 To exit the diagnostic mode press and hold the MODE button or turn the ignition key OFF once the codes are recorded Analog Digital Instrument Cluster 1 The reverse override button on the LH control acts as the MODE button when pressed and release...

Page 193: ...Speed Engine Speed Too High 190 0 C1059 Received Engine Speed Has Error 19 C1066 Gear Sensor Signal Voltage Too High 523 3 P0917 Voltage Too Low 4 P0916 Signal Fault 2 P0914 ECU Memory EEProm Read Write Failure 628 12 C1073 Calibration Checksum CRC Error 630 13 C1074 Idle Air Control IAC Driver Circuit Open Grounded 634 5 P0505 Driver Circuit Short to B 3 P0509 Driver Circuit Grounded 4 P0508 Posi...

Page 194: ...it Open Grounded 520207 5 P1836 Driver Circuit Short to B 3 P1835 Driver Circuit Grounded 4 P1834 Chassis Relay Driver Circuit Open Grounded 520208 5 P1611 Driver Circuit Short to B 3 P1614 Driver Circuit Grounded 4 P1613 Idle Speed Speed Too High 520211 3 P0507 Speed Too Low 4 P0506 Steering Over Current Shut Down Current Above Normal or Grounded 520221 6 C1050 Steering Excessive Current Error Cu...

Page 195: ...ation files Perform guided diagnostic procedures Create customer service account records Perform output state control tests some models SPECIAL TOOLS DIGITAL WRENCH DIGITAL WRENCH DIAGNOSTIC SOFTWARE PART NUMBER Digital Wrench Diagnostic Kit PU 47063 B PU 47063 B listed above INCLUDES Digital Wrench Software PU 48731 Standard Interface Cable PU 47151 SmartLink Module Kit PU 47471 USB Serial Adapte...

Page 196: ...t should be downloaded before using Digital Wrench see Chapter 4 DIGITAL WRENCH UPDATES Updates are released for Digital Wrench via the Internet at http polaris diagsys com The Digital Wrench website can also be accessed through the dealer website at www polarisdealers com NOTE Only authorized Polaris dealers and distributors can access the dealer website 1 Log on to www polarisdealers com 2 Locat...

Page 197: ...rtLink Module and attach the PC Interface Cable to your laptop see page 3 3 2 Remove the protective cap from the Digital Wrench connector 3 Connect the Vehicle Interface Cable to the Digital Wrench diagnostic connector 4 Turn the ignition key to the ON position select the appropriate vehicle and wait for the status to display Connected in the lower left corner of the screen 5 Once connected procee...

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

Page 199: ...nd require a reflash for them to work Reprogramming Reflash Tips BATTERY VOLTAGE The majority of problems with reprogramming can be attributed to a low battery Be sure the battery voltage no load is at least 13 volts and at least 12 5 volts with the key ON Connect a battery charger if necessary to bring voltage level above minimum Fully charge the battery before you attempt to reprogram DEDICATED ...

Page 200: ...scription by selecting the Change Vehicle Type icon 5 Select the Special Tests icon 6 Select Engine Controller Reprogramming 7 Select the file you want to load into the ECU then click the Continue icon to proceed to the Integrity Check and obtain a Request Code 8 Copy CTRL C the Request Code that will be required on the dealer website in the next step DO NOT CLOSE Digital Wrench or the Request Cod...

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

Page 202: ...ecifications Minimum operating system Android 3 1 Honeycomb or higher Android 4 0 or higher preferred Dual core processor 2 GB internal memory external microSD 32 or 64 GB slot 500 MB RAM Rear facing camera with minimum 3 0 mega pixel resolution with auto continuous focus Video Microphone and Voice to text capable Internet and Bluetooth wireless technology capable PMDW App Notes PMDW will not work...

Page 203: ...oor fuel economy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug TPS setting incorrect Injector failure Failed sensor or disconnected wiring Throttle stop screw tampering POOR IDLE Symptom Idle Too High If greater than 1400 RPM when engine is warm Throttle stop scr...

Page 204: ...4 50 NOTES FUEL SYSTEM ...

Page 205: ...T CLUTCHES 5 10 DRIVE BELT REMOVAL 5 10 BELT INSPECTION 5 11 DRIVE BELT INSTALLATION 5 11 DRIVE CLUTCH SERVICE 5 13 DRIVE CLUTCH EXPLODED VIEW ALL MODELS 5 13 DRIVE CLUTCH DISASSEMBLY 5 15 DRIVE CLUTCH SPRING INSPECTION 5 16 SHIFT WEIGHT INSPECTION 5 16 SPIDER REMOVAL 5 17 ROLLER PIN AND THRUST WASHER INSPECTION 5 18 BUTTON TO TOWER CLEARANCE INSPECTION 5 18 BEARING INSPECTION 5 18 DRIVE CLUTCH IN...

Page 206: ...800 345 2233 or www polaris service solutions com GENERAL OPERATION WARNING All PVT maintenance or repairs should be performed by a certified Polaris Master Service Dealer MSD technician who has received the proper training and understands the procedures outlined in this manual Because of the critical nature and precision balance incorporated into the PVT components it is absolutely essential that...

Page 207: ...t and backshift In this respect the PVT system is similar to a power governor Rather than vary throttle position as a conventional governor does the PVT system changes engine load requirements by either upshifting or backshifting SHIFT WEIGHTS Shift weights have many factors designed into them for controlling engagement RPM and shifting patterns Shift weights should not be changed or altered witho...

Page 208: ... 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 clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to Low carefully use fast ag...

Page 209: ...TCH COVER Apply RTV silicone sealant to the outside edge of the inner PVT cover to ensure a water tight fit between the cover and the transmission y SCREW 7 ft lbs 10 Nm u CLUTCH COVER SEAL i OUTER CLUTCH COVER o O RING a PLUG s SCREW 48 in lbs 5 3 Nm PVT DISASSEMBLY Some fasteners and procedures will vary Refer to the appropriate parts manual for proper fastener placement 1 Remove the seat PVT SY...

Page 210: ...e left rear wheel 8 Remove the lower LH frame support 9 Loosen the clamp q retaining the PVT Duct w to the PVT Housing 10 Loosen the clamp securing the rubber duct w to the plastic ducte 11 Remove the rubber bootw between the PVT housing and plastic duct 12 Lift the rear cab and storage compartment and support them with a block of wood or similar non marring material 13 Remove the plastic PVT duct...

Page 211: ...nd threads Turn the bolt clockwise to remove it 18 Insert the Drive Clutch Puller PA 48595 into the drive clutch and use it to remove the clutch from the shaft Drive Clutch Puller PA 48595 19 If removing the inner PVT cover continue with this procedure a Remove the 10 screws that retain the inner PVT cover to the transmission case and remove the cover b Remove the old silicone material from the in...

Page 212: ...nsmission 4 Install the cover i and torque the inner PVT cover screwsu to specification TORQUE Inner Clutch Cover Fasteners 5 ft lbs 7 Nm 5 Wipe away any excess silicone sealant 6 Clean end of taper on crankshaft and the taper bore inside drive clutch using a tapered reamer 7 Install the drive clutchy bushing washer lock washer and the left hand threaded retaining boltt Torque retaining bolt to sp...

Page 213: ...s Torque screws to specification TORQUE Outer PVT Cover Screws 30 in lbs 3 5 Nm 15 Reinstall the rear cab tail light bulbs and fasteners 16 Reinstall the lower left hand frame support and torque bolts to specification TORQUE Lower Left Hand Frame Support Bolts 36 ft lbs 49 Nm 17 Install the left rear wheel and torque wheel nuts to specification TORQUE Wheel Nuts Steel 45 ft lbs 61 Nm Aluminum 75 f...

Page 214: ...r wheel from the vehicle 4 Remove the 4 bolts retaining the lower left hand frame support and remove it from the frame 5 TOURING MODELS Remove the rear skid plate 6 Remove the seat 7 Remove the 11 screws retaining the PVTcover 8 Using care pull the outer PVT cover out the left hand wheel well TIP Flexing the PVToutlet duct aids PVTcover removal NOTE TOURING MODELS remove the clutch cover throught ...

Page 215: ...ts burn marks etc should be replaced to eliminate noise vibration or erratic PVT operation See the Troubleshooting Chart at the end of this chapter for possible causes Troubleshooting page 5 29 DRIVE BELT INSTALLATION IMPORTANT Orient the Belt as it was removed or orient the new belt so you may read the text 1 Spread the sheaves and walk the drive belt on to the drive clutch and driven clutch Clut...

Page 216: ...nd Frame Support Bolts 36 ft lbs 49 Nm 6 Install rear wheel and torque wheel nuts Torque to specification TORQUE Wheel Nuts Steel 45 ft lbs 61 Nm Aluminum 75 ft lbs 102 Nm 7 Install the seat 8 TOURING MODELS Reinstall the rear skid plate and the 6 T40 Torx headed screws 9 Safely lower the ATV 10 Test the operation of the PVTsystem PVT SYSTEM ...

Page 217: ...5 5 13 DRIVE CLUTCH SERVICE DRIVE CLUTCH EXPLODED VIEW ALL MODELS PVT SYSTEM ...

Page 218: ...ch EBS models r Spacer t Bushing y Moveable Sheave u Spider 225 ft lb 305 Nm Apply 0 4 mL Loctite 7088 Primer and 0 4 mL Loctite 620 i Shift Weight o Shift Weight Bolt 20 in lb 2 Nm a Pin s Washer d Button f Limiter Spacer g Clutch Spring h Cover Bushing j Cover k Cover Bolt 100 in lb 12 Nm PVT SYSTEM ...

Page 219: ...d the assembly MUST be replaced 3 Remove cover bolts evenly in a cross pattern and remove cover plate 4 Inspect cover bushing q The outer cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing Cover Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this ch...

Page 220: ... that spring coils are parallel to one another using a straight edge Distortion of the spring indicates stress fatigue requiring replacement SHIFT WEIGHT INSPECTION Remove shift weight bolts and weights Inspect the contact surface of the weight q The surface should be smooth and free of dents or gall marks Inspect the weight pivot bore and bolts w for wear or galling If weights or bolts are worn o...

Page 221: ...2870341 Spider Removal Tool NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly Be sure to note the number and thickness of these washers 2 Inspect the Teflon coating on the moveable sheave bushing Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replac...

Page 222: ...CTION 1 Inspect for any clearance between spider button to tower If clearance exists replace all buttons and inspect surface of towers Button to Tower Clearance 000 012 2 Inspect sheave surfaces Replace the entire clutch if worn damaged or cracked BEARING INSPECTION 1 Rotate the clutch bearing in both clockwise and counter clockwise directions Non EBS The non braking bearing should rotate both dir...

Page 223: ...n assembly if worn damaged or if problems were noted 4 Inspect surface of shaft for pitting grooves or damage Measure the outside diameter and compare to specifications Replace the drive clutch assembly if shaft is worn or damaged MEASUREMENT Shaft Diameter Standard 1 3745 1 375 34 91 34 93 mm Service Limit 1 3730 34 87 mm 5 Visually inspect PTFE thrust washers for damage Measure the thickness and...

Page 224: ...0 Driven Clutch Cover Bushing Removal Tool 5020631 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller Adapter 5020633 NOTE Bushings are installed at the factory using Loctite 648 In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing Clean all residual Loctite from bushing bore prior to installing new bushing CAUTION Cl...

Page 225: ...bushing is drawn straight into bore Continue until bushing is seated 18 Remove nut from puller rod and set aside 19 Remove sheave from puller 20 Remove installation tool Cover Bushing Removal 21 Install main adapter 8 on puller 22 Install adapter reducer 9 23 From outside of clutch cover insert removal tool 3 into cover bushing 24 With inside of cover toward vise slide cover onto puller With insid...

Page 226: ...nto stationary sheave shaft Be sure the movable sheave slides freely on the spacer 4 Apply 0 4 mL of Loctite 620 and 0 4 mL of Loctite 7088 Primer in 90º apart in vertical stripes to the shaft threads 5 Install the spider assembly onto the shaft threads Be sure all of the alignment marks u are in alignment ITEM DESCRIPTION t Moveable Sheave y Spider u Alignment Marks 6 Install clutch onto holding ...

Page 227: ...er f aligning X mark with other marks IMPORTANT If the aligning marks are not in alignment the clutch will not be in balance The drive clutch assembly must be replaced 10 Torque cover bolts d evenly to specification TORQUE Drive Clutch Cover Bolt 100 in lb 12 Nm PVT SYSTEM ...

Page 228: ...rvice limit MEASUREMENT Slider to Sheave Clearance q Service Limit 0 175 4 5 mm Slider Width w Service Limit 0 975 24 8 mm DRIVEN CLUTCH DISASSEMBLY 1 Remove driven clutch from the transmission input shaft Do NOT attempt disassembly of the driven clutch from the outside snap ring q The driven clutch must be disassembled from the helix side NOTE If driven clutch is difficult to remove use 2871056 D...

Page 229: ...top of the spider assembly pushing the spider onto the shaft Remove snap ring e and slowly release the assembly 6 Remove the spider assembly and spring NOTE Spring is compression only and has no torsional wind 7 Remove the E clips washers and the clutch rollers Inspect the rollers for wear replace if worn 8 Press out the spring pins o in the inner sheave 9 Pull out the clutch slider pins a and sli...

Page 230: ...g g for wear If the bushing is worn or the shaft does not fit snug into the bushing replace the cam helix assembly 13 Inspect the sheaves for excessive wear or damage DRIVEN CLUTCH ASSEMBLY BEARING INSTALLATION 1 Install a new bearing q onto the clutch shaft using an arbor press Once bearing is fully seated install a new snap ring w 2 Install the shaft and bearing assembly into the outer sheave us...

Page 231: ...e spring pins r to retain the slider pins 4 If removed install the rollers t washers y and E clips u onto the spider 5 Install the spring so the arm i rests into the notch in the moveable sheave 6 Align the X s o on the spider and moveable sheave 7 Install the universal clutch compressor on the clutch and compress the helix cover PVT SYSTEM ...

Page 232: ...gn the marks previously made on the helix cover and moveable sheave Install the helix cover and the four fasteners a Torque fasteners to specification TORQUE Helix Retaining Screws 48 in lb 5 Nm 9 Once back together verify the grease tape marks made during disassembly are properly aligned 10 Install the drive clutch on the vehicle PVT SYSTEM ...

Page 233: ...ven clutch binding Clutch sheaves greasy belt slipage Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassemble clean and inspect driven clutch Clean sheaves with denatured alcohol or brake cleaner i...

Page 234: ...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 PVTsystem Inspect and clean PVT noise Belt worn or separated thin spots loose belt Broken or worn clutch components cover hitting clutches Replace belt Inspect and repair as necessary Engagement erratic or stabby Thin spots on belt worn be...

Page 235: ...6 3 GEAR SELECTOR REMOVAL SPORTSMAN 6 3 TRANSMISSION SERVICE 6 4 TRANSMISSION VENT ROUTING 6 4 TRANSMISSION REMOVAL 6 5 TRANSMISSION DISASSEMBLY 6 8 TRANSMISSION SHAFT SERVICE 6 10 TRANSMISSION ASSEMBLY 6 13 TRANSMISSION INSTALLATION 6 18 TRANSMISSION EXPLODED VIEW 6 20 TRANSMISSION TROUBLESHOOTING 6 22 TROUBLESHOOTING CHECKLIST 6 22 ...

Page 236: ...6 2 TRANSMISSION SPECIFICATIONS LUBRICATION SPECIFICATIONS TRANSMISSION CAPACITY AGL Gearcase Lubricant PN 2878068 Quart 37 oz 1100 ml TRANSMISSION ...

Page 237: ...ve the seat and upper RH side panel 2 Push linkage rod out of the snap linkage at the gear selector 3 Remove the retaining screw from the back side and pull the gear selector out from the frame support as an assembly NOTE Remove RH frame support to ease removal TRANSMISSION ...

Page 238: ... headlight pod The upper vent pictured tees into the vent for the rear gear case The lower vent pictured located near the starter vents the bell housing If there is oil present in the bell housing vent either the engine or transmission seals are leaking and service is required NOTE Clutch intake removed for visibility of vents TRANSMISSION ...

Page 239: ...the PVToutlet duct from the inner PVTcover 9 Using a 6 mm Ball Allen remove the 4 bolts retaining the rear propshaft to the rear gearcase input shaft Slide the shaft off the transmission output shaft and out from the vehicle 10 Disconnect the wheel speed sensor located on the lower right hand side of the transmission 11 Disconnect the gear selector switch from the top of the transmission 12 Discon...

Page 240: ...ing the right hand frame support and remove the support from the vehicle 19 Remove the 3 screws retaining the rear right hand footwell support and remove the support from the frame TOURING Models Only 20 Remove the 2 through bolt fasteners that mount the transmission to the isolator mount on the lower LH side 21 Using a T45 driver remove the screw from the top of the isolator mount on the lower RH...

Page 241: ...ay from the engine and remove the front propshaft from the transmission shaft 23 Once you have disengaged the transmission input shaft from the engine coupler carefully lift the transmission assembly out the right side the of vehicle TRANSMISSION ...

Page 242: ...up and remove the bolts retaining the transmission cover NOTE Take note of any shims that may have fallen into the case during cover removal Be sure to reinstall during Transmission Assembly 5 Carefully lift up on the cover Use a soft faced hammer to tap on the input shaft and rear output shaft to ease cover removal 6 Lift up on the rear output shaft assembly and remove the front output shaft asse...

Page 243: ...y and remove it from the transmission 10 Remove the 2 screws retaining the oil deflector plate 11 Remove the springs shift shaft rail and park shaft rail 12 Lift up on each end of the shift fork and rotate the fork out of the shift shaft cam 13 Repeat the previous step to remove the lower shift fork TRANSMISSION ...

Page 244: ...detent plug snap ring washer and gear selector switch 18 Remove the retaining ring and washer from the cam shift shaft Remove the nut bellcrank and washer from the bellcrank shift shaft 19 Remove both shift shafts from the transmission as an assembly Lightly tap on each shaft to ease removal TRANSMISSION SHAFT SERVICE Use the exploded views within this section when servicing the transmission shaft...

Page 245: ...6 6 11 Primary Shaft Rear Output Shaft Reverse Shaft Coupler Input Shaft TRANSMISSION ...

Page 246: ...6 12 Cam Shift Shaft Bellcrank Shift Shaft TRANSMISSION ...

Page 247: ... and O rings for damage If transmission was disassembled seal and O ring replacement is recommended see exploded view above 3 If the cam shift shaft was disassembled install the detent gear with the step facing the O ring NOTE Both shift shafts have skip tooth keyed splines for assembly purposes TRANSMISSION ...

Page 248: ...Gently rock or twist the shift shafts upon installation to prevent from damaging the new O rings Forcing the shift shafts straight into the transmission housing may cut the O rings 8 Install the washer over the bellcrank shift shaft and install the bellcrank by aligning the skip tooth splines 9 Install the retaining nut and torque to specification TORQUE Bellcrank Retaining Nut 15 ft lbs 20 Nm 10 ...

Page 249: ... the input shaft and reverse shaft with the lower shift fork and park pawl installed 14 Place the assembly into the transmission housing making sure to move the park pawl arm behind the shift shaft cam during installation 15 Lift up on the lower shift fork and rotate the end into the cam 16 Install the upper shift fork and rotate the end into the cam TRANSMISSION ...

Page 250: ...71557 to mating surfaces 26 Carefully install the transmission cover onto the transmission Apply even pressure to cover while setting into place A soft faced hammer can be used once the cover is started and aligned NOTE Take care not to damage seals during cover installation 27 Install the retaining bolts and torque to specification TORQUE Transmission Cover Bolts 18 ft lbs 25 Nm 28 Remove the old...

Page 251: ...tween the cover and the transmission 32 Install the cover and torque the inner PVT cover screws to specification TORQUE Inner PVT Cover Screws 5 ft lbs 7 Nm 33 Wipe away any excess silicone sealant 34 Install the drive clutch driven clutch and drive belt see Chapter 7 PVT SYSTEM SERVICE Disassembly TRANSMISSION ...

Page 252: ...that retain the transmission to the engine 7 Torque transmission to engine bolts to the specified torque value using a criss cross pattern TORQUE Transmission to Engine Retaining Bolts 19 ft lbs 26 Nm 8 Install the 2 through bolt fasteners on the lower LH side and torque to specification TORQUE Transmission Through Bolt Fasteners 19 ft lbs 26 Nm 9 Install a new T45 mounting screw in the isolator m...

Page 253: ...g with a new O ring and torque to specification 16 Add the recommended amount of lubricant through the fill plug hole Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission Do not overfill FLUID CAPACITY Recommended Transmission Lubricant AGL Gearcase Lubricant PN 2878068 Quart Capacity 37 oz 1100 ml 17 Reinstall fill plug with a new O ring and torque to spe...

Page 254: ...6 20 TRANSMISSION EXPLODED VIEW TRANSMISSION ...

Page 255: ...ng 57 1 Rail Shift Shaft 17 1 Retaining Ring 58 1 Detent Plug 18 1 Washer Thrust 59 1 Rail Park Shaft 19 1 Shim 60 1 Engagement Dog Low 20 1 Washer Thrust 61 1 Engagement Dog Reverse Low 21 2 Shim 62 1 Shift Fork 22 1 Shim 63 2 Pipe Knock 23 1 Washer Thrust 64 1 Shift Fork 24 1 Washer Thrust 65 1 Engagement Dog High 25 2 Ball Bearing 66 1 Switch Shaft 26 3 Ball Bearing 69 1 Shim Pack Primary 27 1 ...

Page 256: ...ive clutch one way bearing Worn drive belt Clutch alignment NOTE To determine if shifting difficulty is caused by an internal transmission problem isolate the transmission by disconnecting linkage rod from transmission bellcrank Manually select each gear range at the transmission bellcrank and test ride vehicle If it functions properly the problem is outside the transmission If transmission proble...

Page 257: ...OPSHAFT U JOINT SERVICE 7 16 PROPSHAFT U JOINT DISASSEMBLY 7 16 PROPSHAFT U JOINT ASSEMBLY 7 17 FRONT GEARCASE REMOVAL INSTALLATION 7 19 NON EPS 7 19 FRONT GEARCASE REMOVAL NON EPS MODELS 7 19 FRONT GEARCASE INSTALLATION NON EPS MODELS 7 20 EPS 7 22 FRONT GEARCASE REMOVAL EPS MODELS 7 22 FRONT GEARCASE INSTALLATION EPS MODELS 7 23 HIGHLIFTER 7 26 FRONT GEARCASE REMOVAL HIGHLIFTER 7 26 FRONT GEARCA...

Page 258: ...HAFT 7 54 REMOVAL 7 54 INSTALLATION 7 55 DRIVESHAFT SERVICE 7 56 DRIVE SHAFT CV JOINT HANDLING TIPS 7 56 OUTER CV JOINT BOOT REPLACEMENT 7 56 INNER PLUNGING JOINT BOOT REPLACEMENT 7 58 REAR PROPSHAFT 7 61 REMOVAL 7 61 INSTALLATION 7 61 REAR GEARCASE 7 62 GEARCASE REMOVAL 7 62 GEARCASE REMOVAL TOURING 7 64 GEARCASE DISASSEMBLY AND INSPECTION 7 66 GEARCASE BEARING AND SEAL REPLACEMENT 7 67 GEARCASE ...

Page 259: ...IAL TOOLS PART NUMBER TOOL DESCRIPTION 2872608 Roller Pin Removal Tool PU 48951 Axle Boot Clamp Tool 8700226 CV Boot Clamp Pliers Ear Bosch Automotive Service Solutions 1 800 345 2233 or www polaris service solutions com FINAL DRIVE ...

Page 260: ...toward forward rotation 3 Install wheel nuts and finger tighten them Align the center of wheel holes with center of the tapered nuts NOTE It is possible to torque the wheel nut on a steel rim without the nut being centered in the hole Be sure to center the wheel nuts before applying torque to prevent wheel nuts from coming loose 4 Carefully lower the vehicle to the ground 5 Torque wheel nuts to th...

Page 261: ... machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing and installing bearings and seals 3 Remove the wheel nuts q wheel w and tire e from the hub r 4 Remove any damaged stud s t from hub r and discard 5 Obtain new wheel stud s t Thoroughly clean stud t to remove all oil 6 Clean brake disc y hub r 7 Mount wheel to hub and torque l...

Page 262: ... set the stud in the hub may damage the knurling seat in the hub 11 Without backing off the lug nut continue to torque the lug nut to specification to properly seat the stud in the brake disc TORQUE 2nd Torque Application 50 ft lbs 68 Nm 12 Without backing off the lug nut continue to torque the lug nut to specification TORQUE 3rd Torque Application 75 ft lbs 101 Nm 13 Properly lower vehicle and ve...

Page 263: ...ON NOTES q Bearing Carrier w Bearing e Snap Retaining Ring Install with sharp edge out r Wheel Stud t Brake Disc y Hub u Cone Washers i Castle Nut 80 ft lbs 108 Nm o Cotter Pin a Air Valve s Hub Cover d Dust Cover f Wheel Nuts 75 ft lbs 102 Nm FINAL DRIVE ...

Page 264: ...S q Bearing Carrier w Bearing e Snap Retaining Ring Install with sharp edge out r Wheel Stud t Brake Disc y Hub u Cone Washers i Castle Nut 80 ft lbs 108 Nm o Cotter Pin a Air Valve s Hub Cover d Dust Cover f Wheel Nuts 75 ft lbs 102 Nm FINAL DRIVE ...

Page 265: ... cotter pin and loosen the front wheel hub castle nut Remove the nut and 2 cone washers from the front wheel hub assembly 5 Remove the 2 brake caliper mounting bolts and caliper CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 6 Remove the front wheel hub assembly 7 Remove cotter pin from the bottom of the tie rod end 8 Hold the top of ...

Page 266: ...ace 14 Replace bearing if moisture dirt corrosion or roughness is evident BEARING REPLACEMENT Bearing Removal 1 Remove the outer retaining ring from the bearing carrier 2 Support the bearing carrier in an arbor press and remove the bearing by pressing it out from the back side 3 Inspect the bearing carrier housing for scratches wear or damage Replace front bearing carrier if damaged Bearing Instal...

Page 267: ...e through the backside of the bearing carrier 2 Install the upper and lower ball joint ends into the bearing carrier 3 Install new pinch bolts and fastener hardware Torque new pinch bolts to specification NOTE Refer to the Polaris Electronic Parts Catalog for replacement pinch bolts and fastener hardware TORQUE Pinch Bolts 17 ft lbs 24 Nm Plus 90 Degrees 4 Apply grease to drive shaft axle splines ...

Page 268: ... specification and install a new cotter pin TORQUE Tie Rod End Fastener 42 ft lbs 58 Nm 8 Torque the wheel hub castle nut to specification and install a NEW cotter pin Tighten nut slightly if necessary to align cotter pin holes TORQUE Wheel Hub Castle Nut 80 ft lbs 108 Nm 9 Install the front wheel and 4 wheel nuts Torque wheel nuts to specification TORQUE Lug Nuts Aluminum Wheels 75 ft lbs 102 Nm ...

Page 269: ...rs from the front wheel hub assembly 4 Remove the 2 brake caliper mounting bolts and caliper CAUTION Do not hang the caliper by the brake line as it mar result in brake line damage Use wire to hang caliper to prevent damage to the brake line 5 Remove the front wheel hub assembly 6 Remove the upper ball joint pinch bolt 7 Using a soft faced hammer lightly tap on the upper A arm to remove it from th...

Page 270: ...ines of the drive shaft with the front gearcase and reinstall the drive shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 3 Install the drive shaft into the front bearing carrier 4 Refer to the FRONT BEARING CARRIER Installation procedure within this chapter to properly reassemble the vehicle FINAL DRIVE ...

Page 271: ...d RH footwell 4 Pull shaft back towards the transmission to remove it from the front gearcase input shaft then pull it forward to remove it from the transmission output shaft INSTALLATION 1 Apply anti seize compound to all splines Slide propshaft back onto the transmission output shaft then slide it up onto the front gearcase input shaft verify pin holes are aligned 2 Using Roll Pin Tool PN 287260...

Page 272: ... remove the retaining rings q from both sides of the yoke 2 Using a commercially available Ball Joint U Joint Press Set place a receiving cup adapter w with a larger ID than the U joint cap OD on one end 3 Place a remover adapter e on other end of U joint with a smaller OD than the U joint cap 4 Position clamp r over receiving cup adapter and remover adapter 5 Tighten clamp with hand tools to forc...

Page 273: ...oves are clean before installing new U joint 3 Place U joint ends w without caps into yoke bores 4 Place caps e into yoke bores and align with U joint ends by hand 5 Place clamp and installer adapters r with smaller OD than caps over each cap 6 Tighten clamp to install caps simultaneously into yoke bores 7 Push U joint side to side during clamping to seat into caps properly 8 Tighten clamp until b...

Page 274: ...ve 10 Place larger adapter u with ID larger than yoke bore on side with retaining ring 11 Tighten clamp until other cap is below retaining ring groove 12 Install second retaining ring i with sharp square edge facing away from U joint 13 Verify the U joint moves freely and does not bind FINAL DRIVE ...

Page 275: ...isconnect the wire harness above the front gearcase and remove the plastic tie strap retaining the wires to the frame 6 Remove and discard the cotter pins q and nuts w from each tie rod end at the steering post frog 7 Remove the 2 bolts retaining the lower steering post bracket to the front gearcase 8 Remove the bolts and flange nuts retaining the steering post assembly plate to both sides of the ...

Page 276: ...per and lower A arms FRONT GEARCASE INSTALLATION NON EPS MODELS 1 Install the gearcase between the A arms as shown 2 Install the vent line and the 4 bolts that secure the front gearcase to frame Torque bolts to specification TORQUE Front Gearcase Mounting Bolts 36 ft lbs 49 Nm 3 Connect and route the AWD wire harness along the frame and install a plastic tie strap to attach it to the frame 4 Place...

Page 277: ...ation TORQUE Front Gearcase to Post Fasteners 18 ft lbs 24 Nm Bracket to Frame Fasteners 18 ft lbs 24 Nm 9 Install the steering tie rod ends into the steering frog plate Torque the tie rod end fasteners to specification and install new cotter pins TORQUE Tie Rod to Steering Frog 42 ft lbs 57 Nm 10 Install the front cover and front rack see Chapter 9 11 Install the front propshaft onto the front ge...

Page 278: ... selector in Park CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Always wear eye protection 2 Remove both front drive shafts from the front gearcase See page 7 13 3 Remove the front propshaft from the front gearcase input shaft See page 7 15 4 Disconnect the gearcase wiring harness 5 Remove and discard the cotter pins q ...

Page 279: ...vehicle 10 Remove the vent line and the 4 bolts securing the front gearcase to frame 11 Lay the gearcase on its side and rotate it in the frame so the input shaft is facing you 12 Remove the gearcase from the front LH wheel well area and carefully slide it between the upper and lower A arms FRONT GEARCASE INSTALLATION EPS MODELS 1 Install the gearcase between the A arms as shown FINAL DRIVE ...

Page 280: ... a plastic tie strap to attach it to the frame 4 Place the lower steering post assembly into the front gearcase 5 Loosely install the two screws and flange nuts that attach the lower steering post assembly to the frame 6 Loosely install the bolts retaining the lower steering post assembly to the front gearcase TORQUE Steering Post to Gearcase Fasteners 18 ft lbs 24 Nm Lower Steering Post to Frame ...

Page 281: ...propshaft onto the front gearcase input shaft See Installation page 7 15 11 Install both front drive shafts into the front gearcase See Installation page 7 14 12 Reinstall the front gearcase drain plug with a new O ring and torque to specification 13 Add the recommended amount of fluid Maintain fluid level even with the bottom threads of the fill plug hole FLUID CAPACITY Recommended Front Gearcase...

Page 282: ... shaft fasteners to EPS unit 13 Disconnect two EPS wiring harnesses 14 Remove EPS fasteners and remove EPS unit 15 Remove prop shaft roll pin from the yoke to front gearcase using special tool 16 Remove lower steering shaft frog mount from the front gearcase Bearing is a snug fit to the front gearcase and it should wiggle loose 17 Remove four front gearcase mounting bolts 18 Remove right side driv...

Page 283: ...asteners 18 ft lbs 24 Nm Lower Steering Post to Frame Fasteners 18 ft lbs 24 Nm 6 Install the steering tie rod ends into the steering frog Torque the tie rod end fasteners q and w to specification and install new cotter pins TORQUE Tie Rods to Steering Frog 42 ft lbs 58 Nm 7 Install the vent line and the 4 bolts that secure the front gearcase to frame Torque bolts to specification TORQUE Front Gea...

Page 284: ...f fluid Maintain fluid level even with the bottom threads of the fill plug hole FLUID CAPACITY Recommended Front Gearcase Fluid Polaris Demand Drive Fluid PN 2877922 Quart Capacity 9 3 oz 275 ml 17 Reinstall fill plug with a new O ring and torque to specification TORQUE Drain Fill Plug 10 ft lbs 14 Nm 18 Install the fuel tank NOTE There are two hidden upper mounting fasteners 19 Disconnect fuel li...

Page 285: ...Spring retainer 1 6 Needle roller bearing 1 32 Nylon spacer 2 7 Bushing 1 33 Pinion gear 1 8 Bushing 1 34 Armature plate 1 9 Oil seal 1 35 4WD coil 1 10 Oil seal 2 36 Grommet 1 11 Shaft ring 1 37 Vent tube 1 12 T30 Torx screw 10 38 Fill plug 1 13 Set screw 1 39 Magnetic drain plug 1 14 Cover 1 40 Clip 1 15 Input cover 1 41 Connector 1 16 Gearcase housing 1 17 Ring gear 1 18 Roll cage 1 19 Hub asse...

Page 286: ...ivated the AWD coil is powered by a 12 Vdc input which creates a magnetic field This magnetic field attracts an armature plate that is keyed to the roll cage When the ring gear and roll cage are spinning vehicle is moving the energized coil and armature plate will apply drag to the roll cage that indexes the rollers inside the ring gear to an engagement position While in the engagement position th...

Page 287: ...ere should be two distinct wear bands one band inside the other If only one band of wear is present or if there is wear between the two bands inspect the coil area as indicated in Step 5 A wear band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation 5 Check to make sure the AWD coil is seated in the U shaped insert that is pressed into the gearcase cov...

Page 288: ...t 2 Remove the 6 screws retaining the cover plate assembly and open the wire retaining clip 3 Remove the cover plate assembly from the gearcase 4 Remove the female LH output hub assembly Inspect the thrust bearing A for wear Inspect the output hub ball bearings contact surfaces and splines for signs of wear or damage NOTE Excessive noises coming from the front drive on deceleration are key indicat...

Page 289: ...ed 9 Place a shop towel over the ring gear assembly and slowly remove the roll cage and rollers from the ring gear NOTE Rollers are spring loaded Take care not to allow them to fall out or lose them upon removal of the roll cage 10 Inspect the rollers B for nicks scratches and flat spots Inspect the roll cage C for damage or cracks The rollers must slide up and down freely within the roll cage sur...

Page 290: ...late indicates a warped plate which may cause intermittent operation refer to AWD Diagnosis for inspection 14 Inspect the magnetic coil F in the cover plate assembly refer to AWD Diagnosis for inspection 15 Inspect the backlash thrust button G and thrust plate for excessive wear NOTE Ring gear backlash is set at the factory No adjustment is required unless the front cover is replaced or the backla...

Page 291: ...isassembly Inspection procedure when needed while assembling the front gearcase 1 Thoroughly clean all gearcase components before beginning reassembly 2 Install new seals and O rings as shown included in the Seal Repair Kit 3 Apply assembly grease to the seal lips to prevent from damaging the seals upon assembly 4 Install the input shaft assembly 5 Torque the input cover screws to specification TO...

Page 292: ...op of the torsion spring 10 Check the action of the torsion spring by rotating in both directions to ensure the spring and retainer are installed properly 11 Install the male RH output hub assembly into the main gearcase NOTE Take care not to damage the seal lip or seal spring while installing the output hub 12 Carefully install the ring gear and roll cage assembly into the gearcase housing FINAL ...

Page 293: ...l the large O ring onto the cover plate 15 Lightly crimp the thrust pad to hold the pad on the cover plate during installation 16 Place the cover plate assembly on the main gearcase and install the 6 screws Torque screws to specification NOTE Take care not to damage the seal lip or seal spring while installing the cover plate TORQUE Cover Plate Screws 8 ft lbs 11 Nm NOTE If the cover plate was rep...

Page 294: ...M OUTPUT HUB r KIT FASTENERS Torque 7 11 ft lbs t KIT SEAL REPAIR y PLATE ARMATURE u PLATE ARMATURE BD i BEARINGS o KIT ROLLER SET OF 24 a ASM ROLL CAGE INCL CAGE 24 CLIPS s ASM GEARCASE d ASM PLUG DRAIN Torque 8 30 ft lbs 11 40 Nm f PLUG OIL FILL Torque 8 30 ft lbs 11 40 Nm g ASM GEAR HOUSING PINION GEAR h KIT SPRING j INPUT COVER FINAL DRIVE ...

Page 295: ...e vehicle When the vehicle is in 4x4 ADC the AWD coil is turned on and the ADC coil remains off until necessary When descending a hill the EBS slows the driveline and rear wheels The ADC coil detects the speed difference and locks the front wheels to the driveline The front wheels can now assist in controlling the descent Turning on the ADC Coil applies drag to 2 inner armature plates One armature...

Page 296: ... plate assembly NOTE Press on the output hub assembly e while lifting up on the outer cover plate 4 to prevent removing more than the cover plate 4 Remove the output hub assembly e 5 Inspect the bearing and contact surfaces of the output hub for signs of wear or damage Replace component if found to be worn or damaged 6 Remove and inspect the armature plates t Refer to AWD Diagnosis for detailed in...

Page 297: ... hub s 11 Inspect the bearing and contact surfaces of the output hub for signs of wear or damage Replace component if found to be worn or damaged 12 Thoroughly clean all parts Inspect the bearing surfaces of the output hub Inspect the rollers a for nicks scratches and flat spots Inspect the roll cage o for damage or cracks The rollers must slide up and down freely within the roller cage surfaces F...

Page 298: ...ern Uneven wear of the armature plate indicates a warped plate which may cause intermittent operation NOTE See FRONT GEARCASE DIAGNOSIS later in this chapter for more details 16 Drill a hole in the input shaft seal d and remove the seal using a pry bar or seal puller 17 Remove the snap ring retaining the input shaft assembly 18 Remove the input shaft assembly Inspect the pinion gear g for chipped ...

Page 299: ... NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement side to side 4 Install input shaft bearing and snap ring 5 Press the pinion shaft seal into the gearc...

Page 300: ...with the ring gear dowel pin and install the retainer y on top of the torsion spring 11 Check the action of the torsion spring by rotating in both directions to ensure the spring and retainer are installed properly 12 Install the armature plates t Be sure the armature plate tabs are fully engaged into the roll cage assembly NOTE Verify armature plate tabs are in the slots on the roll cage and are ...

Page 301: ...f the O ring is twisted fluid leaks may occur 15 Torque the cover plate bolts w to specification TORQUE AWD Cover Screws 8 ft lbs 11 Nm 16 Fill the gearcase with fluid FLUID CAPACITY Demand Drive Hub Fluid 8 97 oz 265 ml 17 Install the drain plug Torque to specification TORQUE Fill Plug 8 10 ft lbs 11 14 Nm Drain Plug 11 ft lbs 15 Nm FINAL DRIVE ...

Page 302: ...onal problems listed Check to see if front differential is plugged into wire harness Unplugged Plug wire harness into front drive connector Drive vehicle with ADC mode on to determine if problem has been fixed If not continue onto additional problems listed No power from vehicle to front differential blown fuse Unhook wire connector to front differential Using multimeter determine if vehicle wire ...

Page 303: ...prings off old cage and put onto new cage Drive vehicle with ADC mode on to determine if problem has been fixed If not continue onto additional problems listed Torsion Spring Make sure Spring is installed properly Make sure Spring is able to index properly in both directions Plastic retainer should index with some force from spring Retainer should also index far enough to allow clutch to engage If...

Page 304: ...ear between the two bands inspect the coil area as indicated in Step 4 A band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation 4 Check to make sure the coil t is seated in the U shaped y insert that is pressed into the gearcase cover u The top of the coil should be seated below the U shaped insert The U shaped insert controls the pole gap If the top ...

Page 305: ...e tire should rotate smoothly without binding or rough spots 3 Remove the 4 wheel nuts and the rear wheel 4 Remove the cotter pin and loosen the rear wheel hub castle nut Remove the nut and 2 cone washers from the rear wheel hub assembly 5 Remove the two brake caliper mounting bolts CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 6 Rem...

Page 306: ...moisture dirt corrosion or roughness is evident BEARING REPLACEMENT Bearing Removal 1 Remove outer retaining ring from the bearing carrier 2 Support the bearing carrier in an arbor press and remove the bearing by pressing it out from the back side 3 Inspect the bearing carrier housing for scratches wear or damage Replace rear bearing carrier if damaged Bearing Installation 1 Thoroughly clean the r...

Page 307: ...EMENT 1 Check bearing carrier bushings and shafts for excessive wear or damage 2 If replacement is required slide shafts out and remove the bushings with a drift punch 3 Thoroughly clean the bearing carrier and inspect for excessive wear or damage Replace rear bearing carrier if damaged 4 Install new shafts and bushings Press the bushings into the bearing carrier until they are flush with the mati...

Page 308: ...ing Carrier Bolts 37 ft lbs 50 Nm 3 Apply grease to drive shaft axle splines 4 Install rear wheel hub assembly cone washers and hand tighten the castle nut Install washers with domed side out 5 Install the brake caliper and torque the new mounting bolts to specification CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts up...

Page 309: ...s TORQUE Wheel Hub Castle Nut 80 ft lbs 108 Nm 7 Install the rear wheel and 4 wheel nuts Torque wheel nuts to specification TORQUE Wheel Nuts Steel Wheels 45 ft lbs 61 Nm Aluminum Wheels 75 ft lbs 102 Nm 8 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions FINAL DRIVE ...

Page 310: ... the cotter pin and loosen the rear wheel hub castle nut Remove the nut and 2 cone washers from the rear wheel hub assembly 4 Remove the two brake caliper mounting bolts 5 CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 6 Remove the rear wheel hub assembly 7 Remove the bolt that attaches the upper A arm to the rear bearing carrier 8 Ti...

Page 311: ...1 Install a new spring ring on the end of the drive shaft and apply an anti seize compound to the splines 2 Align the splines of the drive shaft with the rear gearcase and reinstall the drive shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 3 Install the drive shaft into the rear bearing carrier 4 Refer to the REAR BEARING CARRIER Installation procedure within t...

Page 312: ...s and splines of shaft are protected during handling to avoid damage Do not allow boots to come into contact with sharp edges or hot engine and exhaust components The drive shaft is not to be used as a lever arm to posi tion other suspension components Never use a hammer or sharp tools to remove or to in stall boot clamps Be sure joints are thoroughly clean and that the proper amount and type of g...

Page 313: ...ng galling play between the ball and its cage window any cracking or damage to the cage pitting or galling or chips in raceways call for joint replacement NOTE Shiny areas in ball tracks and on the cage spheres are normal Do not replace CV joints because parts have polished surfaces Replace CV joint only if components are cracked broken worn or otherwise unserviceable 9 Clean the splines on the en...

Page 314: ...e large clamp e using the appropriate clamp tool Axle Boot Clamp Tool PU 48951 or CV Boot Clamp Pliers 8700226 19 While pulling out on the CV shaft fully extend the CV joint and slide a straight O ring pick or a small slotted screw driver between the small end of the boot and the shaft This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its...

Page 315: ... reassembly 9 Visually inspect the joint for damage Replace if needed 10 Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly 11 Slide the small boot clamp and boot small end first onto the drive shaft and position the boot in its groove machined in the shaft 12 Install a new circlip on the end of the shaft 13 Grease the joint with the special joint grease...

Page 316: ... 19 Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 20 Install and tighten the large clamp r using the appropriate clamp tool 21 Pull out on the drive shaft to center the joint in the housing Slide a straight O ring pick or a small slotted screw driver between the large end of the boot and the jo...

Page 317: ...upler and discard the bolts 3 Slide the shaft towards the transmission and pivot the propshaft down Slide the propshaft off the transmission output shaft and out from the vehicle INSTALLATION 1 Apply anti seize compound to all splines Slide propshaft back onto the transmission output shaft and then lift it up and align it with the rear gearcase input shaft coupler 2 Install 4 new bolts and torque ...

Page 318: ...ive clutch and driven clutch 8 Remove the stabilizer bar linkage rod and rotate the stabilizer bar out of the way 9 Remove upper shock mounting bolts from each side 10 Remove the 3 through bolt fasteners retaining the left rear upper and lower A arms to the frame 11 Remove the left rear suspension and drive shaft from the vehicle as an assembly 12 Remove the through bolt fastener retaining the rig...

Page 319: ...down and remove the vent line 17 Using your hand press down on the inner PVT cover and continue to rotate the gearcase down and forward until it is removed from the frame NOTE Do not use a pry bar to flex the inner PVTcover as damage to the cover will occur 18 Rotate the gearcase so the input shaft is facing down and remove the rear gearcase from the vehicle FINAL DRIVE ...

Page 320: ...e procedure Always wear eye protection 5 Remove the 4 wheel nuts retaining each wheel and remove both rear wheels 6 Remove the 4 bolts retaining the rear propshaft 7 Slide the shaft towards the transmission and pivot the propshaft down Slide the propshaft off the transmission output shaft and out from the vehicle 8 Remove the stabilizer bar linkage and rotate the stabilizer bar back out of the way...

Page 321: ...e while removing the drive shaft 13 Remove the drive shaft from the rear gearcase by pulling sharply 14 Remove the 4 through bolts retaining the rear gearcase to the frame 15 Move the gearcase forward in the frame and remove the vent line from the gearcase 16 Using care remove the rear gearcase through the bottom of the frame NOTE Be sure to move the rear brake line out of the way upon removal to ...

Page 322: ...off the main gearcase half and note the shim between the cover and the ring gear 4 Remove the ring gear from the main gearcase half 5 Inspect the ring gear teeth for chipped worn or broken teeth 6 Inspect the pinion shaft by rotating the assembly in the gearcase housing while checking for any looseness or roughness Inspect the pinion gear teeth for chipped worn or broken teeth NOTE In the event da...

Page 323: ...ining ring and lift the pinion shaft and bearing from the main gearcase see Figure 8 27 NOTE If the pinion shaft will not lift out of the gearcase reinstall the coupler and finger tighten the retaining nut Use two pry bars to lift the pinion shaft assembly out 5 Support the pinion shaft and press the bearing off the shaft see Figure 8 27 6 Thoroughly clean the pinion shaft WARNING Wear appropriate...

Page 324: ...n the gearcase halves WARNING Wear appropriate safety equipment while installing bearings to reduce the risk of injury 11 Support the gearcase cover and carefully press in the new cover bearing see Figure 8 28 Support the ring gear and carefully press on the new main gearcase bearing 12 Install the seals into the case halves using a standard seal installer or other suitable method Seal depth shoul...

Page 325: ... onto the ring gear 4 Thoroughly clean the gearcase mating surfaces and be sure the alignment pins are in place 5 Apply Crankcase Sealant PN 2871557 to mating surfaces 6 Install the gearcase cover onto the main gearcase half 7 Install the cover screws and torque to specification TORQUE Cover Screws 18 ft lbs 25 Nm 8 Proceed to Gearcase Installation before installing the coupler lock washer and ret...

Page 326: ... ring Magnetic 1 12 Main Case Machined 1 3 Screw 8 13 Cover Machined 1 4 Nut 1 14 Pinion Shaft 10T Straight Bevel 1 5 Lock Washer 1 15 Ring Gear 37T Straight Bevel 1 6 Dowel Pin 2 16 Vent Tube 1 7 Retaining Ring 1 17 Coupler 1 8 Shim 1 18 Triple Lip Seal 2 9 Needle Bearing 1 19 Triple Lip Seal 1 10 Ball Bearing 1 20 O Ring 1 FINAL DRIVE ...

Page 327: ...ean them up with a flat hand file 6 Continue the installation procedure by reversing the Gearcase Removal procedure at the beginning of this section Refer to the following installation steps for torque specifications Gearcase Removal XP Models page 7 62 7 Install the gearcase through bolt mounting fasteners and torque to specification NOTE Use the longer bolts 150 mm in the top and the shorter bol...

Page 328: ...haft coupler retaining nut to specification TORQUE Coupler Retaining Nut 100 ft lbs 136 Nm 14 Install the rear propshaft and torque bolts to specification TORQUE Rear Propshaft Bolts 18 ft lbs 25 Nm 15 Install the drive clutch driven clutch and drive belt 16 Install the outer PVT cover lower left hand frame support and the left rear wheel 17 Install the rear wheels and torque wheel nuts to specifi...

Page 329: ... ft lbs 50 Nm 5 Install the rear upper shock through bolts Torque bolts to specification TORQUE Rear Upper Shock Bolts 30 ft lbs 54 Nm 6 Install the rear stabilizer bar onto the linkage rods Torque the linkage retaining nuts to specification TORQUE Stabilizer Bar Linkage Bolts 37 ft lbs 50 Nm 7 Install the propshaft coupler onto the rear gearcase pinion shaft splines Install the lock washer and re...

Page 330: ...7 74 NOTES FINAL DRIVE ...

Page 331: ...T INSTALLATION HIGHLIFTER 8 14 STEERING TIE RODS 8 16 TIE ROD TIE ROD END REPLACEMENT 8 16 FRONT CONTROL ARMS 8 17 EXPLODED VIEW 8 17 REMOVAL REPLACEMENT 8 18 BALL JOINT SERVICE 8 20 SERVICE PREPARATION 8 20 TO SERVICE THE UPPER BALL JOINT 8 20 TO SERVICE THE LOWER BALL JOINT 8 20 BALL JOINT REMOVAL 8 20 BALL JOINT INSTALLATION 8 21 REAR CONTROLS ARMS 8 23 EXPLODED VIEW 8 23 REMOVAL 8 24 INSTALLAT...

Page 332: ...SHOCK SERVICE INFORMATION 8 33 7044080 7044081 SHOCK SERVICE INFORMATION 8 33 GENERAL SERVICE INFORMATION 8 34 FOX SHOCK REBUILD INFORMATION 8 34 SPECIAL TOOLS 8 34 FOX SHOCK DISASSEMBLY 8 34 FOX SHOCK BODY AND RESERVOIR SERVICE 8 36 FOX SHOCK COMPONENT REBUILD 8 36 FOX SHOCK ASSEMBLY 8 38 STEERING SUSPENSION ...

Page 333: ...ke line while the handlebar is removed 5 If replacing the handlebar Remove the RH and LH controls Remove the hand grips Pry open the upper and lower handlebar blocks and remove them from the handlebar INSTALLATION 1 Locate the alignment pin on the bottom side of the upper block The pin should line up with the alignment hole in the lower block and should face the front 2 Position handlebar properly...

Page 334: ...8 4 6 Reassemble the headlight pod NOTE Make sure to route all vent lines wire harness and throttle cable correctly into the lower headlight pod STEERING SUSPENSION ...

Page 335: ... Nut Torque 12 ft lbs 16 Nm w Cotter Pin Replace with new when removed e Tie Rod Flange Nuts 42 ft lbs 57 Nm r Washers t Flange Nuts 18 ft lbs 24 Nm y Upper Steering Bushings u Upper Steering Bracket i Carriage Bolts o Flange Bolts Front Gearcase Bolts 18 ft lbs 24 Nm a Steering Post Assembly Bearing not serviceable STEERING SUSPENSION ...

Page 336: ...front cab NOTE Take care not to bend the throttle cable or brake line while the handlebar is removed 5 Remove and discard the cotter pins q and nuts w from each tie rod end at the steering post frog 6 Remove the 2 bolts retaining the lower steering post bracket to the front gearcase 7 Remove the bolts and flange nuts retaining the steering post assembly plate to both sides of the frame 8 Remove th...

Page 337: ...wer headlight pod 2 When installing the headlight be sure to install the O rings q prior to installing the headlight 3 Place the headlight into the bracket mounting tabs and press firmly until the headlight snaps into place 4 Lift the O ring up and over the headlight mounting tab to secure it 5 Reinstall the adjustment screw w and be sure to adjust the upper headlight after reassembly STEERING SUS...

Page 338: ...8 8 STEERING EPS STEERING ASSEMBLY VIEW EPS MODELS STEERING SUSPENSION ...

Page 339: ...ashers o Cotter Pin Replace with new when removed a Flange Nuts 42 ft lbs 57 Nm s Upper Steering Bracket d Upper Steering Bushings f Carriage Bolts g Flange Nuts 20 ft lbs 27 Nm h Bolts Front Gearcase Bolts 18 ft lbs 24 Nm j Lower Steering Post Assembly Not Serviceable k Power Steering Unit l Power Steering Bracket 1 Flange Nuts 20 ft lbs 27 Nm 2 Bolts 2 Bolts STEERING SUSPENSION ...

Page 340: ...Non High Lifter page 11 73 6 Remove the pinch bolts retaining the upper steering post to the power steering unit 7 Remove the 2 fasteners retaining the upper steering post bushing bracket 8 Lift the upper steering post up from the power steering unit remove it from the chassis UPPER STEERING POST INSTALLATION 1 Reverse the Upper Steering Post Removal procedure to reinstall the steering post 2 Appl...

Page 341: ...nd footwell 4 Remove the fuel tank 5 Remove the pinch bolts retaining the upper steering post to the power steering unit 6 Disconnect the 2 electrical harnesses from the power steering unit 7 Remove the 2 fasteners retaining the upper steering post bushing bracket 8 Lift the upper steering post up from the power steering unit 9 Remove the lower steering post pinch bolt and nut 10 Remove the mounti...

Page 342: ...o the power steering unit 7 Align the mark on the upper steering post nut side with the skip tooth spline on the upper power steering shaft upon installation NOTE Apply anti seize to the shaft splines to aid assembly 8 Position the upper steering post on the shaft so the pinch bolts are aligned with the recess in the power steering shaft CAUTION Striking the steering post can permanently damage th...

Page 343: ...eering operation for binding again If no binding is present proceed if binding is still present repeat this procedure 16 Install front mud guards upper side panels front cab if removed and right hand footwell 17 Install the front rack cover EPS UNIT REMOVAL HIGHLIFTER 1 Remove the fan snorkel cover lock and ride fasteners 2 Remove six screws holding on the front cover 3 Disconnect both fans and re...

Page 344: ...haft 3 Apply anti seize to the shaft splines to aid assembly 4 Align the two marks and install the power steering unit onto the lower steering post assembly q Upper Steering Post w Lower Steering Post e Power Steering Unit A Alignment Marks Skip Tooth 5 Install the 4 mount plate fasteners by hand but do not torque fasteners at this time 6 Reconnect the 2 electrical harnesses to the power steering ...

Page 345: ...d Bolts 18 ft lbs 24 Nm 13 Turn the ignition key to the ON position and move the handlebar from left to right several times to ensure the power steering doesn t bind If binding occurs Loosen the 4 mounting fasteners Move handlebars from left to right several times to position the power steering unit Torque the 4 mounting fasteners to specification Refer to Steering Exploded View EPS Models See Che...

Page 346: ...en removed e Flange Nuts Replace with new when removed r Washers t Steering Post y Bearing Carrier If replacing just the tie rod end loosen the jam nut and remove the rod end Install new rod end and torque jam nuts to specification TORQUE Tie Rod Jam Nuts 14 ft lbs 19 Nm 5 Install the new tie rod assembly q 6 Install the rod ends and fasteners in the proper orientation see illustration 7 Torque th...

Page 347: ...REF DESCRIPTION NOTES 1 Upper A arm 2 Lower A arm 3 Retaining Ring 4 Ball Joint 5 Nut 28 ft lbs 6 Bolt Replace if loosened or removed 7 Grease Fitting 8 Bushing 9 Pivot Shaft 10 Bolt 11 Nut 37 ft lbs 12 CV Shield 13 Screw 14 Washer 15 Steering Knuckle STEERING SUSPENSION ...

Page 348: ...Refer to Ball Joint Replacement section page 8 21 10 Insert new bushings and pivot shafts into new A arm 11 Install new upper A arm assembly onto vehicle frame Torque new bolts to specification TORQUE Tie Rod End Fastener 42 ft lbs 58 Nm 12 Insert upper A arm ball joint end into bearing carrier Install new pinch bolt and fastener hardware Torque new pinch bolt to specification TORQUE New Pinch Bol...

Page 349: ...arm ball joint end into bearing carrier Install new pinch bolt and fastener hardware Torque new pinch bolt to specification TORQUE New Pinch Bolt Fastener 17 ft lbs 24 Nm Plus 90 Degrees 23 Grease all 4 A arm grease fittings after reassembly CAUTION Upon A arm installation completion test vehicle at low speeds before putting into service STEERING SUSPENSION ...

Page 350: ...upper ball joint pinch bolt 3 If necessary remove the lower front shock fastener from the A arm to gain enough clearance to install ball joint tool PU 50506 on the upper ball joint TO SERVICE THE LOWER BALL JOINT 1 Remove and discard the lower ball joint pinch bolt 2 If necessary remove the lower front shock fastener from the A arm to gain enough clearance to install ball joint tool PU 50506 on th...

Page 351: ...e Installation Adapter and Spacer 5 Tighten the Press Asm screw and fully install the ball joint into the arm 6 After the new ball joint is fully installed into the A arm install a new retaining ring 7 Repeat the ball joint service procedure for any additional A arm ball joint replacements 8 Insert upper lower A arm ball joint end into the bearing carrier Install new pinch bolts and nuts Torque to...

Page 352: ... locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly TORQUE Front Caliper Mounting Bolts 37 ft lbs 50 Nm 10 Install wheel and 4 wheel nuts Torque wheel nuts to specification TORQUE Wheel Nuts Steel Wheel 45 ft lbs 61 Nm Aluminum Wheel 75 ft lbs 102 Nm STEERING SUSPENSION ...

Page 353: ...TES 1 Bolt 2 Nut 37 ft lbs 50 Nm 3 Bushing LCA 4 Upper A arm 5 Grease Fitting 6 Pivot Shaft 7 Bolt 8 Lower A arm 9 Bolt 10 Pivot Shaft Upper 11 Pivot Shaft Lower 12 Bushing Lower 13 Pivot Tube 14 Bushing UCA 15 Bolt 16 Bushing Upper 17 90 Grease Zerk 18 Bearing Carrier STEERING SUSPENSION ...

Page 354: ...aching the lower A arm to the bearing carrier 8 Remove the lower shock fastener from lower A arm 9 Remove the brake line retainer from the lower A arm if applicable 10 Remove the fastener retaining the stabilizer linkage to the lower A arm 11 Remove through bolt fasteners attaching lower A arm to the frame and remove the A arm from the vehicle 12 Examine A arm bearing carrier bushings and pivot sh...

Page 355: ...astener see Figure 10 19 to specification Torque linkage fastener to specification TORQUE Shock Mounting Fastener 37 ft lbs 50 Nm Linkage Fastener 37 ft lbs 50 Nm 7 Install the wheel and torque wheel hub retaining nuts to specification TORQUE Wheel Hub Retaining Nuts 80 ft lbs 108 Nm CAUTION Upon A arm installation completion test vehicle at low speeds before putting into service STEERING SUSPENSI...

Page 356: ... BAR ASSEMBLY VIEW REF DESCRIPTION NOTE 1 Bolt 2 Stabilizer Bar Bracket 3 Upper Bushings 4 Nut Torque 20 ft lbs 27 Nm 5 Stabilizer Bar 6 Bushing 7 Linkage 8 Lower Bushings 9 Bolts Torque 37 ft lbs 50 Nm STEERING SUSPENSION ...

Page 357: ...ners to specification TORQUE Rear Stabilizer Linkage Nuts 37 ft lbs 50 Nm TORQUE Rear Stabilizer Bracket Fasteners 37 ft lbs 50 Nm STABILIZER BAR REMOVAL INSTALLATION 1 Elevate the rear of vehicle and safely support machine under the frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Always wear eye protection 2 R...

Page 358: ... remove the stabilizer bar from the frame 6 Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed Inspect the rubber stabilizer linkage bushings and replace if needed 7 Reverse this procedure to reinstall the stabilizer bar Refer to the Exploded View for torque values STEERING SUSPENSION ...

Page 359: ...ew fasteners to specification TORQUE Shock Mounting Bolts 37 ft lbs 50 Nm SHOCK SPRING REPLACEMENT 1 Using a spring compressor compress the shock spring far enough to remove the spring retainer 2 Remove the spring and adjusting cam from the existing shock and install components onto the new shock 3 Compress the shock spring and install the spring retainer 4 Reinstall the shock onto the vehicle and...

Page 360: ...ve the shock and note the spring preload distance 2 Loosen the jam nut if applicable and adjustment ring until the spring is loose If needed use a spring compressor to compress the spring far enough to remove the spring retainer 3 Remove the spring and spring retainer from the existing shock and install components onto the new shock 4 Install the spring s and spring retainer NOTE The spring retain...

Page 361: ...ock 4 1 Eyelet 18 2 Bushing 5 1 Body Bearing Cap Asm 19 1 Sleeve 6 1 Bearing Cap Asm 20 2 Bushing 7 1 Piston Valve Asm 21 1 Sleeve 8 1 Lock Nut 22 1 Retaining Ring 9 1 Reservoir 23 1 Retaining Ring 10 1 Reservoir End Cap Asm 24 N A Decal 11 1 Piston Asm Floating IFP 25 1 Spring Guide 12 1 Damping Adjuster Asm N A Shock Oil 2870995 13 1 Damping Adjuster Cartridge Asm 14 1 Bumper STEERING SUSPENSION...

Page 362: ... 2 Shock Body 14 Washer 3 Shock Rod 15 Preload Ring 4 Eyelet Apply Loctite 638 Primer N Torque 50 ft lbs 68 Nm 16 Preload Ring Lock Torque 10 ft lbs 14 Nm 5 Body Bearing Cap Asm 17 Bushings 6 Bearing Cap Asm 18 Sleeve 7 Piston Valve Asm 19 Bushings 8 Lock Nut Use new part Torque 18 ft lbs 24 Nm 20 Sleeve 9 Reservoir 21 Retaining Ring 10 Reservoir End Cap Asm 22 Retaining Ring 11 Piston Asm Floatin...

Page 363: ...x 0 093 Back Up 1 0 x 0 008 0 950 x 0 050 0 9 x 0 008 0 8 x 0 008 1 23 x 0 082 Top Out 7044080 7044081 SHOCK SERVICE INFORMATION SHOCK DESIGN DETAILS Travel 6 16 Extended Length 19 44 IFP Location 2 90 73 6 mm Factory Clicker Setting 10 Nitrogen Pressure 100 psi 5 Gas Shock Oil 2870995 qt SHOCK VALVING COMPRESSION REBOUND 1 3 x 0 008 DB 1 1 x 0 008 1 3 x 0 08 1 1 x 0 008 1 3 x 0 08 0 8 x 0 004 1 3...

Page 364: ...R DESCRIPTION 2200421 Gas Shock Recharging Kit PS 45259 PS 45259 1 Gas Fill Tool Replacement Needles 20 2871351 IFP Tool 2871071 1 5 8 Shock Body Holding Tool Front and Rear 2871352 1 2 Shock Rod Holding Tool 2201639 Shock Seal Protector Sleeve Bosch Automotive Service Solutions 1 800 328 6657 or www polaris service solutions com FOX SHOCK DISASSEMBLY NOTE To prevent damage or marks to the shock t...

Page 365: ... the shock rod so the threaded end is facing upward 18 Remove and discard the lock nut from the end of shock rod NOTE Keep the rebound and compression valve stacks in the order they were removed If unsure of order refer to Shock Valving under the Shock Service Information provided earlier in this section 19 Remove the shims and piston from the shock rod Note that the valve shim closest to the pist...

Page 366: ...ctite 638 to the first two threads on shock body and reservoir threads Do not allow thread lock to contact the o rings 10 Use a spanner or strap wrench to torque the reservoir body to specification TORQUE Reservoir Body 30 ft lbs 40 Nm Shock Body 50 ft lbs 40 Nm 11 Remove excess Loctite 638 from surfaces 12 Install and torque the compression adjuster assembly to specification TORQUE Compression Ad...

Page 367: ... insure proper installation 8 Refer to the assembly instructions for component installation onto the shock asm Bearing Assembly 9 Use a small pick to remove the U cup seal C internal D and external E O rings from the bearing assembly NOTE If the bearing bushing requires replacement replace the bearing assembly 10 Lubricate and install the O rings and U cup seal 11 Push the Shock Seal Protector Sle...

Page 368: ...ammable materials Be sure the area to be flame treated is clean and free of gasoline or flammable residue 1 Secure the shock rod in a vise so the threaded end is facing upward 2 Install the washer and bumper onto the shock rod 3 Install the Shock Seal Protector Sleeve 2201639 onto the shaft threads 4 Lubricate the shock rod and the Shock Seal Protector Sleeve with new shock oil 5 Lubricate and ins...

Page 369: ...on ports Note the orientation of the bleed shim tabs as the assembly would be installed on the shock shaft 10 Install the piston valve as shown in the photo Install the lock nut and torque to specification Keep the bleed shim tab aligned with the piston valve when tightening the lock nut 11 Install the rebound valve stack onto the shock shaft Tighten the lock nut to specification NOTE Verify the b...

Page 370: ...ys in the proper position Do not install bearing assembly at this time 22 Press shaft downward Rotate and wiggle the shaft as it submerges in the shock oil until no more air bubbles rise out of the shock oil 23 Hold pressure downward on IFP tool Stroke shock rod assembly up and down 1 4 6 35 mm to work the air bubbles out of the piston and piston ports 24 Slide the bearing assembly partially into ...

Page 371: ...oir cap past the retaining ring groove 42 Install the reservoir cap retaining ring WARNING CHARGE THE SHOCK USING NITROGEN GAS ONLY DO NOT FILL WITH ANY OTHER GASES Doing so compromises the performance of the shock and may be EXTREMELY DANGEROUS 43 Use the Gas Fill Tool PS 45259 and charge the shock to the recommended pressure for 10 seconds Nitrogen Pressure Reference shock specifications 44 Stro...

Page 372: ...8 42 NOTES STEERING SUSPENSION ...

Page 373: ...RATION 9 10 FOOT MASTER CYLINDER HYDRAULIC OPERATION 9 10 BRAKE FLUID BLEEDING 9 11 FLUID REPLACEMENT 9 11 FRONT BRAKE SYSTEM BLEEDING 9 11 REAR BRAKE SYSTEM BLEEDING 9 12 HAND BRAKE MASTER CYLINDER 9 14 REMOVAL 9 14 DISASSEMBLY 9 14 INSTALLATION 9 14 BRAKE SWITCH REPLACEMENT 9 15 FOOT BRAKE MASTER CYLINDER 9 16 FOOT MASTER CYLINDER REMOVAL INSTALLATION 9 16 BRAKE PEDAL REMOVAL INSTALLATION 9 16 B...

Page 374: ...9 2 BRAKE SYSTEM TROUBLESHOOTING 9 25 BRAKE SYSTEM TROUBLESHOOTING 9 25 BRAKE NOISE TROUBLESHOOTING 9 26 BRAKE SYSTEM ...

Page 375: ... 1 250 31 75 mm 1 246 31 65 mm Caliper Bore Diameter INT L Models 1 254 31 85 mm 1 256 31 90 mm REAR BRAKES ITEM STANDARD SERVICE LIMIT Brake Pad Thickness 030 762 mm Brake Disc Thickness 187 4 75 mm 167 4 24 mm Brake Disc Thickness Variance Between Measurements 002 051 mm Brake Disc Runout 010 254 mm Caliper Piston Diameter 1 500 38 1 mm 1 498 38 05 mm Caliper Bore Diameter 1 505 38 23 mm 1 507 3...

Page 376: ...in the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the pistons located in the brake calipers move outward and apply pressure to the moveable brake pads These pads contact the brake discs and move the calipers in their floating bracket pulling the stationary side pads into the brake discs The resulting friction reduces brake disc and ...

Page 377: ...9 9 5 BRAKE SYSTEM ASSEMBLY VIEWS SPORTSMAN SCRAMBLER 850 BRAKE SYSTEM BRAKE SYSTEM ...

Page 378: ...9 6 SPORTSMAN SCRAMBLER 1000 BRAKE SYSTEM BRAKE SYSTEM ...

Page 379: ...9 9 7 SPORTSMAN SCRAMBLER INTERNATIONAL BRAKE SYSTEM BRAKE CALIPER EXPLODED VIEW BRAKE SYSTEM ...

Page 380: ...9 8 HAND MASTER CYLINDER EXPLODED VIEW BRAKE HOSE ROUTING Retainers are indicated with a q The first image is the front routing the second image is the rear BRAKE SYSTEM ...

Page 381: ...9 9 9 BRAKE SYSTEM ...

Page 382: ...9 10 INTERNATIONAL BRAKE SYSTEM OPERATION HAND MASTER CYLINDER HYDRAULIC OPERATION FOOT MASTER CYLINDER HYDRAULIC OPERATION BRAKE SYSTEM ...

Page 383: ... bleeders with a Mity Vac or similar tool NOTE Do not move brake lever when reservoir fluid level is low 5 Add brake fluid to 25 30 6 8 mm from the top of the reservoir Polaris DOT 4 Brake Fluid PN 2872189 FRONT BRAKE SYSTEM BLEEDING 1 Remove the reservoir cover from the hand brake master cylinder and verify fluid is at specified level 2 If fluid level is low add brake fluid to 25 30 6 8 mm from t...

Page 384: ...e procedure on the two remaining front calipers 10 Add DOT 4 brake fluid to 25 30 6 8 mm from the top of the reservoir 11 Install diaphragm cover and screws Torque the screws to 7 in lbs 0 8 Nm 12 Proceed to Rear Brake System Bleeding to complete bleeding procedure REAR BRAKE SYSTEM BLEEDING 1 Remove the front rack or front storage box and locate the foot brake fluid reservoir for the foot master ...

Page 385: ...er hose and all air has been purged Add fluid as necessary to maintain level in reservoir 11 Tighten bleeder screw securely and remove bleeder hose Torque bleeder screw to specification TORQUE Bleeder Screw 47 in lbs 5 Nm 12 Repeat the procedure on the remaining rear caliper 13 Using a funnel add brake fluid to the MAX level mark on the reservoir 14 Field test machine at low speed before putting i...

Page 386: ...rebuild this style of master cylinder Refer to the Polaris Electronic Parts Catalog INSTALLATION NOTE Use only OEM parts that were designed for the model ATV being serviced There are different hand master cylinders for the different Polaris ATV models Refer to the Electronic Parts Catalog Some master cylinders are not serviceable and are replaced only as an assembly 1 Install master cylinder on ha...

Page 387: ...1 Set the parking brake lock and locate the brake switch behind the hand brake lever 2 Using a small screwdriver or similar tool push up on the mounting tabs through the holes on the bottom side while rotating the switch to disengage the tabs from the holes 3 Install the new switch The tabs should snap in place BRAKE SYSTEM ...

Page 388: ...tall the brake line and torque the banjo bolt with new sealing washers installed to specification TORQUE Brake Line Banjo Bolts 15 ft lbs 20 Nm 6 Bleed the master cylinder following the procedure outlined in the Brake Bleeding section of this chapter Front Brake System Bleeding page 9 11Rear Brake System Bleeding page 9 12 BRAKE PEDAL REMOVAL INSTALLATION 1 Remove the RH mud guard and footwell 2 R...

Page 389: ... measurements Measure the thickness of the friction material and backing plate then measure the thickness of just the backing plate Subtract the backing plate thickness from the plate and friction thickness to get the thickness of just the pad friction material Compare to the specification Replace pads if worn thinner than the service limit MEASUREMENT Brake Pad Material Thickness Service Limit 03...

Page 390: ...er making contact back off set screw 1 2 turn counterclockwise 6 Verify fluid level in reservoir is at specified level inside reservoir and install reservoir cap 7 Install the wheel s and wheel nuts Torque wheel nuts to specification TORQUE Lug Nuts Aluminum Wheels 75 ft lbs 102 Nm Steel Wheels 45 ft lbs 61 Nm BRAKE BURNISHING PROCEDURE It is required that a burnishing procedure be performed after...

Page 391: ...atch brake fluid draining from brake line Using a wrench loosen and remove brake line from the caliper 5 Remove 2 caliper mounting bolts and remove the caliper assembly from the bearing carrier CALIPER DISASSEMBLY 1 Push mount bracket inward and slip outer brake pad past the edge of the pin Remove the inner brake pad 2 Remove mount bracket pin assembly and dust boot 3 Apply force to the back of th...

Page 392: ...r damage Measure diameter and replace if damaged or worn beyond service limit 3 Inspect the brake pad and disc MEASUREMENT Front Calipers Caliper Piston O D Rear Caliper s Caliper Piston O D General Brake Specifications page 9 3 CALIPER ASSEMBLY 1 Install new O rings in the caliper body Be sure grooves are clean or brakes may drag upon assembly 2 Coat piston with DOT 4 Brake Fluid Install piston w...

Page 393: ...AUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 2 Install brake line with new seals and torque the banjo bolt fitting to specification TORQUE Brake Line Banjo Fastener 37 ft lbs 50 Nm 3 Perform brake bleeding procedure as outlined earlier in this chapter page 9 11 4 Install the wheel and 4 wheel nuts Torque...

Page 394: ...Replace disc if worn beyond service limit MEASUREMENT Brake Disc Thickness New 187 4 75 mm Service Limit 167 4 24 mm MEASUREMENT Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements 3 Mount a dial indicator and measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specification MEASUREMENT Brake D...

Page 395: ...ine 6 Remove the wheel hub assembly from the bearing carrier 7 Press out the wheel studs and remove the brake disc 8 Clean the wheel hub mating surface 9 Install the new disc and press new wheel studs into the hub until they are flush with the mating surface CAUTION Always use new wheel studs if removed from the wheel hub assembly 10 Install wheel hub assembly cone washers and hand tighten the cas...

Page 396: ...stall the wheel and 4 wheel nuts Torque wheel nuts to specification TORQUE Lug Nuts Aluminum Wheels 75 ft lbs 102 Nm Steel Wheels 45 ft lbs 61 Nm 14 Field test the ATV for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when lever is released If the brake drags re check assembly and installation BRAKE SYSTEM ...

Page 397: ... Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Lever Pedal Vibration Disc damaged Disc worn warped runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port plugged Brake lever or pedal binding or unable to return fully Parking brake left on Residue build up under caliper seals Operator riding brakes Brakes Lock Alignment...

Page 398: ...ean imbedded material from disc or pads Pad s dragging on disc noise or premature pad wear because of improper adjustment Master cylinder reservoir overfilled Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston not returning Operator error riding the brake Adjust pad stop Set to proper level Clean compensating port Clean inspect and repair as...

Page 399: ...CK STORAGE BOX 10 6 FRONT RACK REMOVAL 10 6 FRONT RACK INSTALLATION 10 7 FRONT BUMPER 10 8 FRONT BUMPER REMOVAL 10 8 FRONT BUMPER INSTALLATION 10 8 MUD GAURDS 10 9 MUD GUARD REMOVAL 10 9 MUD GUARD INSTALLATION 10 9 FRONT CAB 10 10 FRONT CAB REMOVAL 10 10 FRONT CAB INSTALLATION 10 11 REAR RACK STORAGE BOX 10 12 REAR RACK REMOVAL 10 12 REAR RACK INSTALLATION 10 12 REAR CAB 10 13 REAR CAB REMOVAL 10 ...

Page 400: ...stic components Painted plastic surfaces should only be wiped clean prior to decal adhesion To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the 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 2 3 inches from the fl...

Page 401: ...nt lines wire harness and throttle cable routings for reassembly purposes HEADLIGHT POD ASSEMBLY 1 Install and electrical components removed form the pod 2 Reconnect all electrical components 3 Route and refasten the wiring harnesses vent lines and throttle cables as they were prior to disassembly 4 Align the rear half of the pod with the mounting holes and install the screws TORQUE Pod Screws Unt...

Page 402: ...he seat and squeeze 2 Lift the rear of the seatw and slide the seat rearward SEAT INSTALLATION 1 Align the seat with the tabs and pin 2 Slide the seat forward and lower the rear 3 Press the rear of the seat down firmly to seat the pin in the latchq BODY FRAME ...

Page 403: ...rear of the panel and rotate then pull to the rear of the vehicle SIDE PANEL INSTALLATION 1 With the side panel tipped as shown insert the front tab begin to lower the rear 2 Continue to lower the rear of the panel Align the tabs that align the side panel assembly as the rear of the panel is lowered in to place 3 Install the push rivets that retain the side panels BODY FRAME ...

Page 404: ... the front rackq 2 Open the front rack 3 Remove the pins retaining the front rack 4 Remove the screws retaining the travel limiter cablese 5 Turn the quarter turns r at the back of the storage tray to the unlock position 6 Remove the storage trayt BODY FRAME ...

Page 405: ... the slots on the front cab then lower the back of the tray 2 Align the quarter turn fasteners w then turn them to the lock position 3 Install the screws that retain the travel limiter cablese 4 Install the pins r that retain the front rack 5 Close the front rack 6 Latch the straps that retain the front rack BODY FRAME ...

Page 406: ...bumper mounted headlights from the main wiring harness 4 Remove the fasteners e retaining the upper bumper cover r FRONT BUMPER INSTALLATION 1 Install the upper bumper cover q then install the fasteners that retain the upper bumper cover w 2 Install the lower bumper cover e then install the fasteners that retain the lower bumper cover r BODY FRAME ...

Page 407: ...of the mud guard w 2 Remove the remaining Tuflock fasteners e 3 Remove the mud guard MUD GUARD INSTALLATION 1 Align the mud guard with the mounting holes 2 Install the front top Tuflock fastener q that retains the mud guard w 3 Install the remaining Tuflock fasteners e that retain the mud guard BODY FRAME ...

Page 408: ... w fastening the front cab to the fender flares and footwells NOTE Right side shown 5 Remove the gas cap and cover opening with tape to prevent debris from entering the fuel tank 6 Remove the fasteners e r retaining the front cab 7 Remove the center cover t located under the pod 8 Remove the diagnostic port cover y from the front cab 9 Remove the front cab BODY FRAME ...

Page 409: ...front cab and center cover 4 Install the Tuflock fasteners r and screws t that fasten the front cab to the footwells and fender flares 5 Install the diagnostic connector tree clip y in the hole in the cab 6 Remove the tape from the gas tank inlet 7 Install the gas cap 8 Install the storage tray 9 Install the front rack 10 Install the side panels 11 Install the seat BODY FRAME ...

Page 410: ...tment 2 Remove the screws retaining the rear rack 3 Remove rack REAR RACK INSTALLATION 1 Place the rear rack in place and align the mounting holes 2 Loosely install the fasteners that retain the rear rack 3 Torque fasteners to specification TORQUE Until Fully Seated BODY FRAME ...

Page 411: ... Remove the seat 2 Remove the side panels 3 Remove the rear rack 4 Remove the Tuflock fasteners q retaining the rear cab 5 Remove the fasteners w retaining the fender flares 6 Remove the fastener e retaining the footwell sheild BODY FRAME ...

Page 412: ...hat retain the rear cab 3 Install the fasteners w that retain the fender flares TORQUE Fender Flare Fasteners Until Fully Seated 4 Install the fastener e retaining the footwell shield TORQUE Footwell Shield Fastener Until Fully Seated 5 Install the rear rack 6 Install the side panels 7 Install the seat BODY FRAME ...

Page 413: ...taining the rear bumper cover REAR BUMPER COVER INSTALLATION 1 align the rear bumper cover with the mounting holes and loosely install the fastenersq 2 Toque to specification TORQUE Until Fully Seated 3 Install the tail lights 4 Connect the tail lights to the main wiring harness 5 align the rack with the mounting holes and loosely install fasteners 6 Torque to specification TORQUE Until Fully Seat...

Page 414: ...10 16 MAIN FRAME FRAME SUPPORTS MAIN FRAME ASSEMBLY VIEW REF DESCRIPTION NOTES q Screw 30 ft lbs 41 Nm w Screw 30 ft lbs 41 Nm e Screw BODY FRAME ...

Page 415: ... TESTING FOR INTERMITTENT CONDITIONS 11 12 TESTING CURRENT FLOW AMPERAGE 11 13 TESTING PARASITIC DRAW 11 13 TESTING VOLTAGE DROP 11 14 DISPLAYS 11 15 INSTURMENT CLUSTER 11 15 INSTRUMENT CLUSTER OVERVIEW 11 15 RIDER INFORMATION DISPLAY SPORTSMAN SCRAMBLER 11 16 INFORMATION DISPLAY AREA 11 17 DIAGNOSTIC MODE 11 20 INSTRUMENT CLUSTER PINOUTS 11 21 INSTERMENT CLUSTER TROUBLESHOOTING 11 22 INSTRUMENT C...

Page 416: ...INTERNATIONAL 11 46 DRIVE MODE SWITCH 11 46 OFF RUN SWITCH 11 47 LEFT HAND SWITCH CONTROLS 11 48 LEFT HAND SWITCH CONTROLS INTERNATIONAL 11 49 REVERSE MODE BUTTON 11 50 HEADLAMP SWITCH 11 50 THROTTLE RELEASE SWITCH TRS 11 51 GEAR SELECTOR SWITCH 11 52 GEAR SELECTOR RESISTOR MODULE 11 52 SPEED SENSOR 11 53 VEHICLE SPEED SENSOR 11 53 ALL WHEEL DRIVE AWD AND ADC COILS 11 54 OPERATION OVERVIEW 11 54 D...

Page 417: ...TOR ALTERNATOR REMOVAL 11 69 STATOR ALTERNATOR INSTALLATION 11 70 STARTER MOTOR 11 71 STARTER STARTER LOCKOUT SYSTEM DIAGRAM 11 71 TROUBLESHOOTING 11 71 STARTER MOTOR REMOVAL REPLACEMENT 11 71 BATTERY SERVICE 11 73 BATTERY SPECIFICATIONS 11 73 GENERAL BATTERY INFORMATION 11 73 BATTERY REMOVAL NON HIGH LIFTER 11 73 BATTERY INSTALLATION NON HIGH LIFTER 11 74 BATTERY REMOVAL HIGH LIFTER 11 74 BATTERY...

Page 418: ...OSTIC CIRCUIT CAN BUS 11 84 EFI AND CHASSIS POWER 11 84 ELECTRONIC THROTTLE SIGNAL INPUT 11 84 ELECTRONIC THROTTLE OUTPUT 11 84 ENGINE TEMP SENSOR 11 84 IGNITION COIL ETC 11 84 IGNITION COIL NON ETC 11 84 INTAKE AIR TEMP SENSOR ETC 11 84 INTAKE AIR TEMP SENSOR NON ETC 11 85 THROTTLE POSITION SENSOR NON ETC 11 85 TMAP ETC 11 85 TMAP NON ETC 11 85 ELECTRICAL ...

Page 419: ...N SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION PV 43568 Fluke 77 Digital Multimeter PA 49466 Test Relay PV 43526 Connector Test Kit Bosch Automotive Service Solutions 1 800 345 2233 or www polaris service solutions com ELECTRICAL ...

Page 420: ...11 6 CHASSIS HARNESS HARNESS RETENTION LOCATIONS Tie strap retainers indicated by q FRONT RETENTION POINTS REAR RETENTION POINTS ELECTRICAL ...

Page 421: ...11 11 7 HARNESS ROUTING NOTE If replacing the harness noting routing during removal will aid in proper installation ELECTRICAL ...

Page 422: ...esters Fuse piggy back devices Testers beside a DMM will only work in one scenario and slight variables can provide you with misleading results The testing practices described in this chapter are more certain and rely only on the DMM and your knowledge STATIC AND DYNAMIC TESTING There are many methods for testing a DC circuit These methods fall into one of two categories either static or dynamic S...

Page 423: ...ation that the female connector in the harness has insufficient tension and will cause connection issues You can either replace that harness or service it by replacing the terminal or attempting to adjust tighten the tang in the female terminal For a video demonstration scan the QR code below or right click it and select open in new tab BACK PROBING Back probing is typically not advisable on seale...

Page 424: ...art of the circuit This means if you are testing internal resistance of a component it cannot be connected to the harness If you are measuring a wire typically from the ECU to a sensor both the sensor and ECU would need to be unplugged Most Ohmmeters provides a precise amount of current to determine resistance Any other sources will make your reading inaccurate Ensure you are making good contact b...

Page 425: ...g an EFI DTC It can also be used to help diagnose concerns about blowing fuses Ensure you are able to duplicate the concern before testing so that your results point you in the right direction page 11 12 TESTING PROCEDURE 1 Consult the wiring diagram Determine which circuit you will be testing 2 Ensure that any static voltage checks advised in relation to the DTC or concern you are diagnosing have...

Page 426: ... circuit you may not have the circuit failing to indicate where the issue is Intermittent electrical failures are almost always related to a poor connection that only goes open in specific situations such as going over a certain kind of bump at a certain temperature or when the machine is torque loaded in one way Here is a list of possible failures that can be associated with an intermittent elect...

Page 427: ...B instead of switched there can be electronic component failures that can cause this as well TESTING PROCEDURE 1 Remove the negative cable from the battery 2 Connect a jumper from the negative battery cable terminal to the negative battery post 3 Ensure your meter leads and selector dial are set to measure amperage 4 Connect your red lead to the battery negative cable terminal 5 Connect your black...

Page 428: ...oltage coming into the load should be near battery voltage with current flowing There will be some loss from moving through electrical contacts in connectors and relays but it will be minimal NOTE You will need to backprobe to perform this test For information about doing this safely refer to page 11 9 Voltage should be near fully depleted by the load This means that when measuring on the ground s...

Page 429: ...applicable to all models The use of a high pressure washer may damage the instrument cluster Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the instrument cluster lens Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on...

Page 430: ...overheating The indicator will stay lit and not flash if a severe overheating condition exists i Service Interval Indicator Preset at the factory and adjustable by the user a flashing wrench symbol alerts the operator that the preset service interval has been reached and maintenance should be performed The wrench icon will flash for 10 seconds upon start up once it reaches 0 o Check Engine MIL Ill...

Page 431: ...n reverse when using the override button as a MODE button Odometer The odometer records and displays the total distance traveled by the ATV The odometer can not be reset Trip Meters Trip 1 Trip 2 The trip meters records the miles traveled by the ATV on each trip To reset the trip meters 1 Toggle the MODE button to Trip 1 2 To reset to 0 push and hold the MODE button until the distance display chan...

Page 432: ... clock displays the time in a 12 hour or 24 hour format Refer to Units of Measurement to change the format Standard 12 hour Metric 24 hour To set the clock follow these steps 1 Toggle the MODE button until the odometer is displayed 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 P...

Page 433: ... RPM too low to keep the battery charged It may also occur when the engine is at idle and a high electrical load is applied lights cooling fan or other accessories If battery voltage drops below 11 volts a warning screen will display Lo and provide the present battery voltage If voltage drops below 8 5 volts LCD backlighting and icons will turn off If battery voltage rises above 15 volts a warning...

Page 434: ...rea 2 Press and hold the MODE button to enter the diagnostics code menu 3 A set of three numbers will appear in the information display area The first number located far left can range from 0 to 9 This number represents the total number of trouble codes present example 2 means there are 3 codes present The second number located top right can be 2 to 6 digits in length This number equates to the su...

Page 435: ...CLUSTER PINOUTS FUNCTION PIN CAN High 1 CAN Low 2 Switched Power Vdc 3 Constant Power Vdc 4 Ground 5 High Beam Input 8 Fuel Level Sensor 11 International Models Only Turn Signal Input LH 6 Turn Signal Input RH 7 ELECTRICAL ...

Page 436: ...11 22 INSTERMENT CLUSTER TROUBLESHOOTING INSTRUMENT CLUSTER KEY OFF NO POWER ELECTRICAL ...

Page 437: ...11 11 23 INSTRUMENT CLUSTER KEY ON NO POWER ELECTRICAL ...

Page 438: ...11 24 INSTRUMENT CLUSTER NO HIGH BEAM INDICATOR ELECTRICAL ...

Page 439: ...11 11 25 INSTRUMENT CLUSTER NO INCORRECT FUEL LEVEL ELECTRICAL ...

Page 440: ... hour meter programmable service hour interval ground speed or engine RPM e Display Area 1 This area displays engine RPM ground speed or coolant temperature r Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately t Service Indicator A flashing ...

Page 441: ...ne off for up to 5 minutes e Engine Hot This lamp illuminates to indicate an overheated engine If the indicator flashes a severe overheating condition exists r Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position t Helmet Seat Belt This lamp flashes for several seconds when the key is turned to the ON position The lamp is a reminder to wear h...

Page 442: ...11 28 DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 q Speed Engine Temperature RPM Ambient Temperature Optional ELECTRICAL ...

Page 443: ...PLAY AREA 2 Toggle the Up Down buttons to change the information displayed in Area 2 w Odometer Engine Temperature Trip 1 Ambient Temperature Optional Trip 2 RPM Voltage Speed Engine Hours Service Hours ELECTRICAL ...

Page 444: ...nly displays if fault codes are present or stored Units Distance Select MPH or KPH Units Temp Select between F and C Clock Select between 12H or 24H and set time Backlight Color Select between Blue or Red Backlight Level Set backlight brightness level Service Hours View Set Service hours Exit Menu Exit ELECTRICAL ...

Page 445: ... Reference the image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units MPH or KPH e With the correct unit displayed Press the mode button which will set the unit and return to the Options Menu 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds...

Page 446: ... Reference the image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units F or C e With the correct unit displayed Press the mode button which will set the unit and return to the Options Menu 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds whi...

Page 447: ... the units Cycles Hours t With the correct unit displayed Press the mode button which will set the unit y Toggle the Up Down Buttons to change the units Cycles 10s of Minutes u With the correct unit displayed Press the mode button which will set the unit i Toggle the Up Down Buttons to change the units Cycles 1s of Minutes o With the correct unit displayed Press the mode button which will set the ...

Page 448: ...rence the image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units Blue or Red e With the correct unit displayed Press the mode button which will set the unit and return to the Options Menu 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds whi...

Page 449: ...the image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units Increase or Decrease Level e With the correct unit displayed Press the mode button which will set the unit and return to the Options Menu 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 se...

Page 450: ...Down Buttons to change the units 0 5 10 95 100 e With the correct unit displayed Press the mode button which will set the unit and return to the Options Menu NOTE To reset service hours after they have counted down to 0 0 reselect the existing setpoint or select a new service hour value 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exi...

Page 451: ... to cycle through Code s NOTE This option will only be available if a fault code was set or is active during the current ignition key on cycle Turning off the ignition will clear any save fault codes from the gauge Reference the image shown above q Area A will Display FMI XX w Area B will Display SPN XXXXXX e Clock Area will Display Count XXX 3 To exit the Options Menu the user can select Exit Men...

Page 452: ...11 38 INSTRUMENT CLUSTER PINOUTS FUNCTION PIN CAN High 1 CAN Low 2 Constant Power Vdc 3 Switched Power Vdc 4 Ground 5 Fuel Level Sensor 11 ELECTRICAL ...

Page 453: ... MANUAL For information on how to use the IDD troubleshoot potential issues reference the IDD User s Guide and Owner s Manual part number 9925416 A printed copy of the manual was included with all ATV s equipped with the IDD If the manual is lost a new one can be obtained through normal parts ordering channels The manual can also be viewed by accessing the Polaris Owner s Manual website DOWNLOAD P...

Page 454: ...ownload the RIDER X Maps Trails or IDD update files to the root level of the drive When removing the flash drive from the PC or laptop use the Safely Remove Hardware and Eject Media tool provided by the operating system Updating the IDD does not require the engine to be running if the ATV is equipped with a battery Verify the battery is fully charged If errors are encountered during the update pro...

Page 455: ...en will display the Polaris logo and then display the vehicle home screen ERROR 1 PIDD DISPLAYS BOOTING AFTER TURNING ON DISPLAYS ALL WHITE SCREEN WITH TEXT This concern is caused by the IDD being inadvertently left in diagnostics mode during manufacturing testing ERROR 1 RECOVERY METHOD Perform PIDD Reset Procedure and Update Procedure ERROR 2 PIDD DISPLAYS BOOTING AFTER TURNING ON DISPLAYS ALL B...

Page 456: ... ON SCREEN PIDD screen does not display Booting in the upper left corner of the screen immediately after the PIDD is turned on ERROR 3 RECOVERY METHOD 1 Verify there is power at the PIDD wire harness connector Does the screen or buttons illuminate 2 If the PIDD is not receiving power troubleshoot the wire harness connectors and ignition switch to determine why 3 If the screen and buttons do illumi...

Page 457: ... Insert the USB flash memory stick into the PIDD USB cable port 5 Turn on the PIDD and access the UPDATE function under the SYSTEM SETTINGS menu Update the PIDD with the new files 6 When the update process is complete the PIDD will reboot INTERACTIVE DIGITAL DISPLAY PIDD RESET AND UPDATE PROCEDURE 1 Log on to https www riderx com en us home 2 Download the most current TRAILS UPDATE zip file 3 Extr...

Page 458: ...ctor passes inspection install a new receiver and re test No Satellite Reception DOP Values All Zeros CAN communication link between receiver and PIDD is functional but receiver has not yet acquired satellites This is normal during the first 30 to 90 seconds after power up if the GPS has been off for several days If the receiver has been off for just a few hours the signal should be acquired in a ...

Page 459: ...pins 1 and 3 Verify there is 1 5 to 2 5 volts between these two pins Measure VDC between pins 2 and 3 Verify there is 2 5 to 3 45 volts between these two pins 5 If there is no power at the connector inspect the wire harness for broken wires 6 If either of the CAN data signals are 0 VDC check for a loose connection in the wire harness 7 If either of the CAN data signals are out of range but not 0 c...

Page 460: ...d D IGNITION SWITCH INTERNATIONAL Use a multimeter to test for continuity between the 4 ignition switch outputs OFF ON LIGHTS ON START If any of the tests fail replace ignition switch assembly Turn the ignition key to ON LIGHTS There should be continuity between pins A E and F C and D Turn the ignition key to ON There should be continuity between pins C and D E and F Turn the ignition key to START...

Page 461: ...e the RH throttle switch assembly OFF RUN SWITCH Use a multimeter to test for continuity when the LH switch is moved to the RUN position If the test fails replace the LH control assembly Move the switch to the RUN position and test ELECTRICAL ...

Page 462: ...11 48 LEFT HAND SWITCH CONTROLS Use a multimeter to test for continuity for each of the LH switch functions If any test fails replace the LH control assembly ELECTRICAL ...

Page 463: ... 49 LEFT HAND SWITCH CONTROLS INTERNATIONAL Use a multimeter set to test for continuity for each of the left hand control switch functions If any test fails replace the left hand control assembly ELECTRICAL ...

Page 464: ...d E GY OG HEADLAMP SWITCH Use a multimeter to test for continuity between the head lamp outputs in the LH control assembly If any of the tests fail replace the LH control assembly There should be no continuity when the switch OFF Move the switch to LOW There should be continuity between pins D and F Move the switch to HIGH There should be continuity between pins D and E Move the switch to LOW Ther...

Page 465: ...hrottle lever is moved the contacts will open and allow normal operation If the contacts remain closed or become closed during throttle movement the ECM will limit engine RPM NOTE The throttle cable must have the proper amount of free play adjustment Refer to Chapter 2 Throttle Cable Adjustment procedure TRS SWITCH CONTACT POSITIONS Throttle Lever at Rest idle TRS is CLOSED Pins 1 and 2 2 15kΩ Nor...

Page 466: ...RESISTOR MODULE The resistor module relays a different resistance reading to the ECM depending on which gear is selected by the operator If the module fails the ECM will not be able to determine what gear the transmission is in 1 Disconnect the ECM harness connector from the ECM Locate pins 23 WHITE and 30 VIOLET 2 Set the multimeter to register OHMS resistance Insert the RED probe into pin 23 and...

Page 467: ...is found test the BROWN ground circuit Verify there is continuity between the circuit and chassis ground 4 If all circuits function remove the speed sensor from the transmission Verify the sensor is not damaged 5 Test the speed sensor using the following tools Hall Sensor Probe PN 2460761 Static Timing Light Tool PN 2871745 6 Connect the tools together as shown below 7 Insert the sensor probe s 3 ...

Page 468: ...r case 3 Connect the clamp lead of your test light to battery negative B NOTE The BROWN WHITE BN WH and BROWN YELLOW BN YE wires in the AWD ADC hub coil connector are grounds but they are ECU controlled They will not be consistent and reliable for either this test or trying to read voltage with a DVOM Only use B at the battery or a known good chassis ground for testing this and the ADC circuit 4 T...

Page 469: ...ean and connect properly NOTE Verify all wires and wiring connections have been tested properly with a known good volt ohm meter before suspecting a component failure A high percentage of electrical issues are caused by bad failed connections and grounds ELECTRICAL ...

Page 470: ...des power to the following system Fan Motor COLOR FUNCTION RD WHT 20A Circuit breaker protected 12 Vdc battery voltage ORG YEL ECM control circuit for relay coil RD WHT Constant 12 Vdc battery voltage to relay coil ORG BLK Fan motor power 12 Vdc EFI RELAY The EFI relay provides power to the following systems Ignition Coil Power Fuel Pump Power Fuel Injector Power COLOR FUNCTION RD GRN 20A fuse pro...

Page 471: ...use protected 12 Vdc battery voltage DG 2 Low LH control 12 Vdc battery voltage to relay coil DG 4 Low beam lights power BRN 5 Ground for relay coil HIGH BEAM RELAY INTERNATIONAL MODELS The high beam relay provides power to the high beam light on international models only COLOR FUNCTION RD BRN 1 20A fuse protected 12 Vdc battery voltage YEL 2 High LH control 12 Vdc battery voltage to relay coil RE...

Page 472: ...ss remove the front rack or storage box assembly by unlatching the two locking anchors The cover label identifies the location of each relay and fuse 7180678 SPORTSMAN 850 850 SP 1000 XP SPORTSMAN 850 1000 TOURING Including MD Models 7180704 SPORTSMAN 850 1000 EU MODELS SPORTSMAN 850 TOURING EU MODEL ELECTRICAL ...

Page 473: ...e aimed 2 in 5 cm below the mark placed on the wall in Step 3 6 Loosen the adjustment screw at the rear of the headlamp 7 Adjust the beam to desired position and tighten the screw WARNING Due to the nature of ATVs and where they are operated headlight lenses become dirty Frequent washing is necessary to maintain lighting quality Riding with poor lighting can result in severe injury or death HEADLI...

Page 474: ...t rack 7 Adjust the beam to desired position and tightening or loosening the screws at the top of the lights Adjust each light independently WARNING Due to the nature of ATVs and where they are operated headlight lenses become dirty Frequent washing is necessary to maintain lighting quality Riding with poor lighting can result in severe injury or death HEADLIGHT REPLACEMENT BUMPER Before replacing...

Page 475: ...main wiring harness q Right Rear Left Rear 3 Remove the mounting fasteners w Right Rear Left Rear 4 Remove the tail light 5 Install the NEW tail light TORQUE Tail light Fasteners Until Fully Seated 6 Connect the tail light to the Main Harness 7 Verify proper operation CENTER BRAKE LIGHT WORK LIGHT REPLACEMENT NOTE The LED tail lights are not serviceable and must be replaced as an assembly ELECTRIC...

Page 476: ...n wiring harnessq 3 Remove the tail light fastenersw and the tail light 4 Install the NEW Tail light TORQUE Tail light Fasteners Until Fully Seated 5 Connect the tail light to the Main Harness 6 Install the rear rack TORQUE Rear Rack Fasteners Until Fully Seated 7 Verify proper operation ELECTRICAL ...

Page 477: ...ide panels 9 Remove the left footwell NOTE This step is only required on 2017 sportsman 850 1000 1 UP machines excluding High Lifter 10 Locate the stator wires q near the front of the engine and disconnect the regulator from the stator 11 Tape a string or cable to the regulator harness NOTE The rope or cable used should be long enough to allow the regulator to be fully removed from the front of th...

Page 478: ...ORQUE Battery Terminal 6 ft lbs 8 Connect the battery negative terminal TORQUE Battery Terminal 6 ft lbs 9 Install the center panel below the pod 10 Install the front rack storage compartment HIGH LIFTER VOLTAGE REGULATOR REMOVAL HIGH LIFTER Applies to High Lifter models 1 Place the vehicle in park 2 Disconnect the battery negative 3 Disconnect the battery positive 4 Remove the fasteners q retaini...

Page 479: ... it back towards the steering post and rotate the front of the panel towards the left side of the vehicle and remove the center panel 15 Remove the seat 16 Remove the left side panels 17 Remove the left footwell 18 Loosen the worm clamps u that clamp the clutch duct connector inside of the left front wheel well Disconnect the clutch duct 19 Remove the left mud guard 20 Loosen the worm clamps i tha...

Page 480: ...isassembly 2 Draw the voltage regulator wiring harness through the chassis as it was removed NOTE Do not apply excessive force while installing the regulator wiring Ensure the regulator harness routes correctly through the front cab support bracket 3 Remove the string or cable used to route the regulator wiring harness 4 Connect the regulator to the stator 5 Install the left mud guard 6 Reconnect ...

Page 481: ...urrent draw with the key off If the draw is excessive loads should be disconnected from the system one by one until the draw is eliminated Check component wiring as well as the component for partial shorts to ground to eliminate the draw Current Draw Key Off Maximum of 01 DCA 10 mA BATTERY CHARGE TEST CAUTION Do not allow the battery cables to become disconnected with the engine running Follow the...

Page 482: ...NG Battery Charge Coil Y1 Y2 or Y3 to Ground Open Line Infinity NOTE Any measurement other than Infinity open will indicate a failed or shorted stator leg TEST 3 Measure AC Voltage Output of Each Stator Leg at Charging RPM 3 Set your multimeter meter to measure AC Voltage 4 Disconnect the 3 wire stator connector near the stator housing 5 Start the engine and let it idle 6 While holding the engine ...

Page 483: ...connect the stator wire harness and remove the CPS from the stator cover 7 Remove the coolant by pass hose from the water pump cover fitting 8 Remove the 8 screws retaining the stator cover 9 Carefully remove the stator cover taking care not to damage the plastic coolant pipe CAUTION The flywheel contains powerful magnets Use caution when removing and installing the stator cover DO NOT place finge...

Page 484: ...e stator 2 Use the following steps to ensure proper assembly 3 Torque the stator and wire guide bolts to specification 4 Install new O rings on the coolant pipe and lightly lubricate for ease of installation 5 Torque the 8 stator cover bolts to specification using the torque sequence provided ELECTRICAL ...

Page 485: ...rged Excessive circuit resistance poor connections see Voltage Drop Test Engine problem seized or binding can engine be rotated easily Faulty or worn brushes in starter motor Starter Motor Turns Engine Does Not Rotate Faulty starter drive Faulty starter drive gears or starter motor gear Faulty flywheel gear or loose flywheel STARTER MOTOR REMOVAL REPLACEMENT NOTE The starter motor and solenoid can...

Page 486: ...11 72 9 Be sure to install new O rings on the starter motor bell housing 10 Torque the mounting bolts to specification TORQUE Starter Motor Mounting Bolts 20 ft lbs 27 Nm ELECTRICAL ...

Page 487: ... sparks flame cigarettes etc away Ventilate when charging or using in closed space Always shield eyes when working near batteries Keep out of reach of children 1 Check battery voltage with a volt ohm meter A fully charged battery should be 12 8 V or higher 2 If the voltage is below 12 6 V the battery will need to be recharged see Charging Procedure Charging Procedure page 11 76 NOTE Never attempt ...

Page 488: ...e spacer 2 Place the battery into the ATV on its side with the positive e and negative r cable terminals connected in the orientation shown 3 Coat the battery terminals and bolt threads with Dielectric Grease PN 2871329 or petroleum jelly 4 Connect and tighten the positive red battery cables first followed by the negative black battery cables CAUTION To reduce the chance of sparks Whenever install...

Page 489: ...AGE State of Charge Maintenance Free 100 13 0 V 75 Charged 12 8 V 50 Charged 12 5 V 25 Charged 12 0 V 0 Charged 11 5 V or less LOAD TEST CAUTION To prevent shock or component damage remove spark plug high tension leads and connect securely to engine ground before proceeding A battery may indicate a full charge condition in the OCV test but still may not have the storage capacity necessary to prope...

Page 490: ... battery needs to be replaced WARNING An overheated battery could explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging BATTERY PN 4011496 STATE OF CHARGE VOLTAGE DC ACTION CHARGE TIME 100 12 8 13 0 None check again in 3 months None Required 75 100 12 5 12 8 May need slight ...

Page 491: ... troubleshooting through the vehicle s diagnostic port With the engine off and the key on the power steering unit will operate for up to five minutes After the five minutes you will need to cycle the key switch and restart the engine to regain power steering operation The Power Steering 30A Fuse If the fuse fails the Power Steering Malfunction Indicator Light MIL on the instrument cluster will ill...

Page 492: ...11 78 EPS TROUBLESHOOTING ELECTRICAL ...

Page 493: ...CONNECTOR PIN CONNECTOR PIN Ω VALUE 72 F BRN BLU RED A B 7 6 9 6 12 BRN BLU A C 12 9 16 5 12 Thumb Warmer Element PN 2410420 THUMB WARMER COLORS CONNECTOR PIN CONNECTOR PIN Ω VALUE 72 F BRN WHT GRY A B 40 5 49 5 BRN OR GRY A C 81 99 Passenger Hand Warmer Elements PNs 2411651 2411652 PASSENGER HAND WARMER ELEMENTS COLORS CONNECTOR PIN CONNECTOR PIN Ω VALUE 72 F BRN BLU 3 4 22 3 27 2 LO Pin 1 LO Pin...

Page 494: ...11 80 WINCH WINCH ASSEMBLY VIEW CAUTION Disconnect battery prior to servicing winch Always disconnect the negative BLACK cable from battery first during disassembly and last during assembly ELECTRICAL ...

Page 495: ...Wire Yellow 6 GA Connect at Yellow contactor winch posts NEG s Wire Blue 6 GA Connect at Blue contactor winch posts POS d Wire Black Ground 6 GA Connect at battery Black contactor post f Wire Red Power 6 GA Connect at battery Red contactor post g Contactor h Clips j Screws 20 ft lbs 27 Nm k Screws l Carriage Bolts 1 Flange Nuts 20 ft lbs 27 Nm 2 Washers 2 Lock Washers 2 Bolts 20 ft lbs 27 Nm WINCH...

Page 496: ...tems not working on the instrument cluster No engine speed displayed No vehicle speed displayed No gear position displayed Odometer Tripmeters not working Reverse override button does not toggle between display modes ECM monitored inputs are not displayed when DTCs or problems exist i e check engine LED engine overheat LED etc There is power at the Smart Link connector but it cannot connect to Dig...

Page 497: ...11 11 83 BREAKOUT WIRING DIAGRAMS AWD NON ETC AWD INPUT ETC COOLING FAN CRANKSHAFT POSITION SENSOR ELECTRICAL ...

Page 498: ... DIAGNOSTIC CIRCUIT CAN BUS EFI AND CHASSIS POWER ELECTRONIC THROTTLE SIGNAL INPUT ELECTRONIC THROTTLE OUTPUT ENGINE TEMP SENSOR IGNITION COIL ETC IGNITION COIL NON ETC INTAKE AIR TEMP SENSOR ETC ELECTRICAL ...

Page 499: ...11 11 85 INTAKE AIR TEMP SENSOR NON ETC THROTTLE POSITION SENSOR NON ETC TMAP ETC TMAP NON ETC ELECTRICAL ...

Page 500: ...11 86 NOTES ELECTRICAL ...

Page 501: ...ting Inspection 2 39 Brake Hose Inspection 2 39 Brake Pad Inspection 2 38 Brake Pad Installation 9 17 Brake Pedal Inspection 2 39 Brake System Troubleshooting 9 25 Brake System Assembly View Sportsman Scrambler 1000 9 6 Sportsman Scrambler 850 9 5 Sportsman Scrambler International 9 7 Brake System Inspection 2 38 Brake System Operation 9 4 Break In Period 2 3 Breather Hose 2 17 Breather Engine Rem...

Page 502: ...56 Dynamic 11 8 E ECU ETC Learn Procedure 4 25 4 45 Replacement 4 45 ECU Connector Pinout 4 23 EFI Operation Overview 4 20 EFI Priming Starting Procedure 4 20 EFI Relay 11 56 EFI System Assembly View 4 16 EFI Component Locations 4 17 EFI Service Notes 4 19 Electrical 11 8 11 11 11 14 Electronic Control Unit ECU 4 21 Electronic Throttle Body Learn Procedure 4 25 4 45 Engine Combustion Chamber 3 52 ...

Page 503: ...ector Resistor Module 11 52 Gear Selector Removal 6 3 GPS Receiver Troubleshooting 11 44 Grease Points 2 7 Guide Valve Removal 3 52 H Hand Thumb Warmers Resistance Checks 11 79 Hand Master Cylinder Exploded View 9 8 Hand Master Cylinder Operation INT L Models 9 10 Handlebar Removal Replacement 8 3 Harness 11 6 Routing 11 7 Head Cylinder 3 30 Headlamp Switch 11 50 Headlight Pod Assembly 10 3 Disass...

Page 504: ...llation 3 66 Piston to Cylinder Clearance 3 65 Piston Assembly View 3 33 Plunging Joint Boot Replacement Inner 7 58 Polaris Mobile Digital Wrench PMDW 1 6 4 48 Power Steering Relay 11 57 Power Steering Unit Installation 8 12 Power Steering Unit Removal 8 11 Power Steering Unit Cleaning 2 33 Pre Filter Service 2 14 Pre Ride Checklist 2 4 Probe 11 9 Probing 11 9 Propshaft U Joint Assembly 7 17 Disas...

Page 505: ...ensor Operation Overview 11 53 Sprocket Cam Chain Inspection 3 59 Start Solenoid Relay 11 57 Starter Motor Removal Replacement 11 71 Starter Ring Gear 3 41 Starter System 11 71 Starter System Troubleshooting 11 71 Static 11 8 Stator 3 21 3 40 Stator Cover Installation 3 20 Stator Installation 11 70 Stator Removal 11 69 Steering Non EPS Models 8 6 Steering Assembly View EPS Models 8 8 Non EPS 8 5 S...

Page 506: ...tment 2 18 Valve Cover Removal 3 47 Valve Cover Assembly View 3 28 Valve Guide Inspection 3 51 Removal 3 52 Valve Sealing Test 3 75 Valve Seat Reconditioning 3 52 Valve Spring Removal 3 50 Valve Spring Installation Detail SPM1000 3 32 SPM850 3 31 Valve Assembly View 3 30 Vehicle Identification Model Number Designation 1 2 Vehicle Information VIN Number 1 2 Vent Line 2 13 VIN 1 2 VIN Location 1 3 V...

Page 507: ... 51 RD 52 DG 52 DG 53 YE 53 YE 54 DB 54 DB WIRE COLOR LEGEND BG BK BU DB BN GY GN DG OG PK RD VT WH YE BEIGE TAN BLACK LIGHT BLUE DARK BLUE BROWN GRAY LIGHT GREEN DARK GREEN ORANGE PINK RED VIOLET PURPLE WHITE YELLOW TWO WIRE COLORS ARE SHOWN WITH MAIN TRACE COLORS EXAMPLE RD YE RED WITH YELLOW TRACE 2017 18 SPORTSMAN 850 XP E ENGINE GROUND C CHASSIS GROUND NC SWITCH NORMALLY CLOSED NO SWITCH NORM...

Page 508: ...N GAAH BN E246 BN WH SH 1 SH 2 FPA RD GN KDC OG KDC OG BBB RD BBB RD GBD BN SH 2 SH 1 BBD RD BBD RD E132C YE SH 2 SH 1 GBGA BN SH 2 SH 1 FPB RD GN GAF BN GAF BN XHB YE XHB YE BBG RD BBG RD FLA RD BN FLA RD BN E132B YE SH 2 SH 1 FUE RD BK FUE RD BK FUD RD BK FUD RD BK RJ156 RD DB SH 2 SH 1 FUF RD WH FUF RD WH KDK OG KDK OG XHC YE XHC YE GAAF BN GAAF BN E115 DG YE E115 DG YE SH 2 SH 1 RJB RD DB SH 2...

Page 509: ... 144 123 132 130 107 142 124 122 143 150 151 152 153 154 108 121 103 102 119 101 104 118 117 149 120 126 125 137 138 155 156 105 116 113 114 115 E204C VT WH E204C VT WH ETC THROTTLE BODY 1 2 3 4 5 6 GBGC BN GBGC BN P N 2411589 1 2 3 SENSOR CRANK POSITION N S PTO FUEL INJECTOR 1 2 FUEL INJECTOR RESISTANCE 12 185 p5 MAG FUEL INJECTOR 1 2 B D D R C J R SH 2 SH 1 FUEL INJECTOR RESISTANCE 12 185 p5 1 G...

Page 510: ... 75 185 F SPLICE RESISTOR MODULE 1 2 E223A WH E223A WH A B C D E F A B C D E F 50 OG 50 OG 51 RD 51 RD 52 DG 52 DG 53 YE 53 YE 54 DB 54 DB BRAKE SWITCH ON LEFT HANDLEBAR WIRE COLOR LEGEND BG BK BU DB BN GY GN DG OG PK RD VT WH YE BEIGE TAN BLACK LIGHT BLUE DARK BLUE BROWN GRAY LIGHT GREEN DARK GREEN ORANGE PINK RED VIOLET PURPLE WHITE YELLOW TWO WIRE COLORS ARE SHOWN WITH MAIN TRACE COLORS EXAMPLE...

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