Polaris xp 2013 eps Service Manual Download

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5.10

BODY / STEERING / SUSPENSION

9924096 - 2013

RANGER

RZR XP 900 / RZR XP 4 900 Service Manual

Dash Instruments / Controls

A. Instrument Cluster / Speedo

B. Headlight Switch or Hazard Switch (INT’L)

C. AWD/2WD Switch or AWD/2WD/TURF Switch (INT’L)

D. 12 Volt Accessory Receptacle

E. Key Switch

F. Switch; Turn, Lights, Horn (INT’L)

Summary of Contents for xp 2013 eps

Page 1: ...ATION 1 3 VEHICLE INFORMATION 1 4 PUBLICATION NUMBERS 1 4 REPLACEMENT KEYS 1 4 SPECIAL TOOLS 1 5 GENERAL SPECIFICATIONS 1 6 GENERAL 2013 RANGER RZR XP 900 EPS INT L 1 6 DETAILED 2013 RANGER RZR XP 900 EPS INT L 1 7 GENERAL 2013 RANGER RZR XP 4 900 EPS INT L 1 8 DETAILED 2013 RANGER RZR XP 4 900 EPS INT L 1 9 MISC SPECIFICATIONS AND CHARTS 1 10 CONVERSION TABLE 1 10 STANDARD BOLT TORQUE SPECIFICATI...

Page 2: ...n B 2x4 Shaft C 4x4 AC Drive E 4x4 Shaft IRS G 4x4 Chain rear shaft front H 4x4 Shaft IRS J 2x4 Swing arm Manual N 4x4 Shaft ADC P 2x4 IRS Manual R 6x6 Shaft IRS T 4x4 Shaft Trailing Arm X 4x4 Shaft EBS Displacementinccdivided by 10 and rounded to two digits i e 50 498cc For electric vehicles 08 48 Volt 12 72 Volt A ORV D Diesel E EU On road F INT L G EV L LSV M Military S Scandinavian V EU On roa...

Page 3: ...fer to the vehicle identification number VIN and the engine serial number The VIN can be found stamped on a portion of the left rear frame behind the lower shock mounting location Refer to Figure 1 1 The engine serial number can be found on a decal applied to the front of the engine crankcase A or stamped into the crankcase on the PTO side of the engine B Refer to Figure 1 2 VIN Figure 1 1 Figure ...

Page 4: ...take the first two digits on the original key and refer to the chart to the right for the proper part number Model Model No Owner s Manual Parts Manual 2013 RANGER RZR XP 900 R13JT87AD AL AT 9924093 9924094 2013 RANGER RZR XP 900 EPS R13JT9EAK AO 9924093 9924094 2013 RANGER RZR XP 900 INT L R13JT9EFX 9924093 9924094 2013 RANGER RZR XP 4 900 R13XT87AA 9924107 9924108 2013 RANGER RZR XP 4 900 EPS R1...

Page 5: ...d or depicted are mandatory while other tools may be substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may order special tools through Polaris official tool supplier SPX Corporation by phone at 1 800 328 6657 or on line at http polaris spx com Select SPX Website Tools diagnostics from the Service and Warranty...

Page 6: ...ity Payload 740 lbs 335 6 kg Includes driver passenger cargo and accessories Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads Do not use this vehicle for towing Do not modify the vehicle by adding a hitch Hitch Tongue Capacity Category Dimension Capacity Length 108 4 in 275 cm Width 64 in 162 5 cm Height 73 in 185 cm Wheel Base 81 4 in 207 cm Ground Clearance 13 in ...

Page 7: ...mp Drive 10 Amp Fuel Pump 20 Amp Lights 20 Amp EFI 20 Amp Accessory Fuses Power Fuse Holder 30 Amp EFI 30 Amp Chassis 30 Amp EPS OPT Drivetrain Transmission Type Polaris Automatic PVT Drive Ratio Front 3 82 1 Drive Ratio Final 3 53 1 Shift Type In Line Shift H L N R P Front Gearcase Fluid Type Capacity Polaris Demand Drive Plus 6 75 oz 200 ml Transmission Fluid Type Capacity Polaris AGL Plus XP 90...

Page 8: ...900 lbs 408 kg Includes driver passengers cargo and accessories Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads Do not use this vehicle for towing Do not modify the vehicle by adding a hitch Hitch Tongue Capacity Category Dimension Capacity Length 134 4 in 341 4 cm Width 64 in 162 5 cm Height 77 in 195 6 cm Wheel Base 107 4 in 272 8 cm Ground Clearance 12 5 in 31 8...

Page 9: ...T Circuit Breaker 20 Amp Fan Motor Fuses Fuse Relay Box 10 Amp Drive 10 Amp Fuel Pump 20 Amp Lights 20 Amp EFI 20 Amp Accessory Fuses Power Fuse Holder 30 Amp EFI 30 Amp Chassis 30 Amp EPS OPT Drivetrain Transmission Type Polaris Automatic PVT Drive Ratio Front 3 82 1 Drive Ratio Final 3 53 1 Shift Type In Line Shift H L N R P Front Gearcase Fluid Type Capacity Polaris Demand Drive Plus 6 75 oz 20...

Page 10: ... 10 GENERAL INFORMATION 9924096 2013 RANGER RZR XP 900 RZR XP 4 900 Service Manual Copyright 2012 Polaris Sales Inc MISC SPECIFICATIONS AND CHARTS Conversion Table C to F C x 9 5 32 F F to C F 32 x 5 9 C ...

Page 11: ... 3 8 24 23 32 35 48 50 69 7 16 14 30 40 50 69 70 97 7 16 20 35 48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 Bolt Size Grade 4 6 4 8 8 8 8 9 10 9 12 9 Ft Lbs Nm Dry Threads M3 3 5 5 7 1 1 3 1 5 2 1 5 2 M4 8 1 1 1 1 5 2 3 3 4 5 4 5 M5 1 5 2 5 2 3 4 5 6 6 5 9 7 5 10 M6 3 4 4 5 5 7 5 10 11 15 13 18 M8 7 9 5 10 13 18 25 26 35 33 45 M10 14 19 18 25 37 50 55 75 63 85 M12 26 35 ...

Page 13: ...BAFFLE BOX DRAIN INSPECTION 2 16 AIR BOX AIR FILTER EXPLODED VIEW 2 17 ENGINE 2 18 ENGINE OIL LEVEL 2 18 ENGINE OIL AND FILTER CHANGE 2 19 ENGINE CRANKCASE BREATHER HOSE INSPECTION 2 20 ENGINE CYLINDER LEAKDOWN TEST 2 20 VALVE CLEARANCE INSPECTION 2 21 EXHAUST SPARK ARRESTOR 2 24 TRANSMISSION AND FRONT GEARCASE 2 25 TRANSMISSION LUBRICATION 2 25 FRONT GEARCASE LUBRICATION 2 26 COOLING SYSTEM 2 28 ...

Page 14: ...LIGNMENT INSPECTION 2 38 WHEEL TOE ADJUSTMENT 2 39 SUSPENSION FOX 2 40 SPRING PRELOAD ADJUSTMENT 2 40 SHOCK COMPRESSION ADJUSTMENT 2 41 SUSPENSION WALKER EVANS 2 42 SPRING PRELOAD ADJUSTMENT 2 42 SHOCK COMPRESSION ADJUSTMENT 2 43 BRAKE SYSTEM 2 44 BRAKE FLUID INSPECTION 2 44 BRAKE PAD DISC INSPECTION 2 44 BRAKE HOSE AND FITTING INSPECTION 2 44 PARKING BRAKE CABLE ADJUSTMENT INT L 2 45 PARKING BRAK...

Page 15: ...ants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Break In Period The break in period consists of the first 25 hours of operation Careful treatment of a new engine and drive components will result in more efficient performance and longer lif...

Page 16: ... Pad Wear Inspect Parking Brake Pads INT L 10 H Monthly 100 160 Inspect periodically Parking Brake Cable Adjustment INT L 25 H Inspect adjust tension after first 25 hours E Air Filter 25 H Monthly 250 400 Inspect replace as needed Battery 25 H Monthly 250 400 Check terminals clean test E Engine Oil Filter Change Break In Period 25 H 1 M 250 400 Perform a break in oil and filter change at 25 hours ...

Page 17: ...l cap fuel line rail and fuel pump E Spark Plug Inspection 100 H 12 M 1000 1600 Inspect replace as needed torque to specification Radiator 100 H 12 M 1000 1600 Inspect clean external surfaces Cooling Hoses 100 H 12 M 1000 1600 Inspect for leaks pressure test system Engine Mounts 100 H 12 M 1000 1600 Inspect torque to specification Exhaust Silencer Pipe 100 H 12 M 1000 1600 Inspect Wiring 100 H 12 ...

Page 18: ...r severe loads III Item Lube Rec Method Frequency 1 Engine Oil Polaris PS 4 Plus or Polaris PS 4 Extreme Duty 4 Cycle Engine Oil Add oil to proper level on dipstick Perform a break in oil and filter change at 25 hrs or one month perform every 50 hrs thereafter 2 Engine Coolant Polaris 60 40 Coolant Maintain coolant level in coolant reservoir bottle Check level daily change coolant every two years ...

Page 19: ...4 Brake Fluid Maintain fluid level between MAX and MIN lines on the master cylinder reservoir Check level during pre ride inspection change fluid every two years 4 Front Gearcase Polaris Demand Drive Plus Add lubricant until it is visible at the fill hole threads Initial level check at 25 hours or 1 month Change lubricant at 100 hours or every 12 months whichever comes first 5 Transmission Polaris...

Page 20: ... Lube Frequency Front A arm Pivot Bushings Grease 3 fittings on each side of the vehicle Polaris All Season Grease Greasefittingsevery500miles 800 km Grease before long periods of storage and after thoroughly washing or submerging the vehicle Propshaft Yokes Grease middle and rear fittings Polaris Premium U Joint Grease FrontStabilizerBar Bushings INT L Grease the fitting on each side of the vehic...

Page 21: ...Kit PS 4 Extreme Duty Gearcase Transmission Lubricants 2878068 AGL Plus Gearcase Lubricant 1 Qt 12 Count 2878069 AGL Plus Gearcase Lubricant 1 Gal 4 Count 2878070 AGL Plus Gearcase Lubricant 2 5 Gal 2 Count 2877922 Demand Drive Plus Quart 2877923 Demand Drive Plus 2 5 Gallon 2870465 Oil Pump for 1 Gallon Jug Grease Specialized Lubricants 2871312 Grease Gun Kit 2871322 Premium All Season Grease 3 o...

Page 22: ...s in any area Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fasteners Engine coolant check for proper level at the recovery bottle Drive Shaft Boots Inspect inner and outer boots for tears or damage on both front and rear drive shafts Check all front and rear suspension components for wear or damage Frame Nuts Bolts and Fasteners Periodically inspect the torque of all...

Page 23: ...h exhaust temperatures 1 Remove the seats and the engine service panel 2 Locate and inspect the in line filter A Note the direction of the arrow on the filter if removed NOTE Be sure to install the filter in the orientation shown in the previous photo WARNING Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refuel outdoors or in a well ventilated ar...

Page 24: ...ume high pressure fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator NOTE Neither filter is servicable individually Must replace the fuel pump as an assembly NOTE Refer to Chapter 4 for fuel pump replacement and all other information related to the EFI System Fuel Lines 1 Check both quick connect fuel lines at the fuel tank for signs of wear ...

Page 25: ...e a few degrees of freeplay prior to engaging the throttle arm that pulls the throttle cable Always check that the throttle pedal moves independently of the cable pull lever at the start of throttle pedal travel and that the throttle pedal returns normally before starting the engine There should be minimal freeplay between the throttle cable and the cable pull lever If there is excessive play due ...

Page 26: ...re attempting to perform this procedure 2 Locate the throttle freeplay adjustment through the right rear wheel well behind the exhaust header pipe 3 Slide back the cable adjuster boot C 4 Using a 14 mm open end wrench loosen the adjustment jam nut D Using a 12 mm open end wrench move the cable adjuster E until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle arm A NOTE While adjusting ...

Page 27: ...n intake grill cover tab to access pre filter 3 Inspect the pre filter If necessary clean with soapy water and dry with low pressure compressed air Air Filter Service Inspect the air filter at the intervals outlined in the Periodic Maintenance Chart In extremely dusty conditions air filter replacement will be required more often 1 Remove the cargo box access panel A 2 Loosen the 5 air box cover re...

Page 28: ...ecessary IMPORTANT DO NOT attempt to clean the air filter 6 Place the air filter into the air box and reinstall the air box cover NOTE Be sure the lower tabs on the air box cover are properly engaged into the airbox 7 Engage the cover latches and tighten the retaining knobs 8 Reinstall the cargo box access panel Intake Baffle Box Drain Inspection It is recommended that the intake baffle box drain ...

Page 29: ...2012 Polaris Sales Inc Air Box Air Filter Exploded View Pivot Nut 5 Flange Grommet 2 Air Box Knob 5 Drain Cap Intake Baffle Box Clamps Dual Round Intake Tubes Air Box Cover Bolts Intake Hose Clamp Intake Pre Filter Clamps Snap Bushing Air Filter Clamp Seal Throttle Body Boot Bushing 2 Base ...

Page 30: ... clean cloth 5 Reinstall the dipstick and push it into place Do not lock the dipstick NOTE Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent 6 Remove the dipstick and check the oil level 7 Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick Do not overfill see NOTE below NOTE A rising oil ...

Page 31: ...emove the drain plug C Allow the oil to drain completely 5 Remove the seats and engine service panel to access the oil filter and dipstick 6 Using the Oil Filter Wrench PU 50105 turn the oil filter D counter clockwise to remove it 7 Using a clean dry cloth clean the filter sealing surface on the engine crankcase 8 Lubricate the O ring on the new oil filter with a film of fresh engine oil Check to ...

Page 32: ... reinstall the oil fill cap oil dipstick and lock the lever 20 Reinstall the cargo box access panel engine service panel and seats 21 Dispose of used oil and filter properly Engine Crankcase Breather Hose Inspection The engine crankcase is equipped with a breather hose Inspect the breather hose for possible kinks or wear The hose is form fitted for proper fit Follow the breather hose A from the cr...

Page 33: ... rear shock is NOT necessary to perform this procedure 6 Loosen the hose clamp and remove the PVT outlet duct A 7 Remove the harness B and hoses C from the IAC motor and valve 8 Remove the 2 screws D that mount the air box to the upper frame cross member 9 Remove the 2 tie straps E retaining the harness to the rear cross member 10 Remove the screw F retaining the throttle cable to the IAC valve 11...

Page 34: ...sition NOTE Remove spark plugs to aid engine rotation 18 Rotate the drive clutch counter clockwise until the cam lobes above the valves you are inspecting are facing up 19 Measure the valve clearance using a feeler gauge 20 If the valve clearance is out of specification proceed to Valve Clearance Adjustment see Chapter 3 21 Repeat steps 18 20 until all 8 valves have been inspected MAG Intake PTO I...

Page 35: ...IMPORTANT The engine will misfire if the spark plug wires are installed incorrectly The spark plug wires are marked with PTO and MAG and should be installed to the corresponding cylinder 28 Route the injector leads and vent hoses through the rear cross member Connect the injector leads to the main harness 29 Install 4 new tie straps as shown to secure the harness to the rear cross member 30 Instal...

Page 36: ...estor screen A synthetic brush may melt if components are warm If necessary blow debris from screen with compressed air 4 Inspect the screen for wear and damage Replace if needed 5 Reinstall the arrestor and torque the retaining screw to 8 ft lbs 11 Nm WARNING Do not clean spark arrestor immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result fro...

Page 37: ...Maintain lubricant level even with the bottom of the fill plug hole 1 Position vehicle on a level surface 2 Remove the fill plug and check the lubricant level 3 If lubricant level is not even with bottom threads add recommended lubricant as needed Do not overfill 4 Reinstall the fill plug and torque to specification Transmission Lubricant Change The drain plug is located on the bottom of the trans...

Page 38: ...ections should be performed as well The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule Be sure vehicle is positioned on a level surface when checking or changing the fluid Check vent hose to be sure it is routed properly and unobstructed Front Gearcase Fluid Level Check The fill plug is located on the bottom right side of the front gearcase Acc...

Page 39: ... front gearcase drain plug 3 Remove the drain plug and allow fluid to drain completely 4 Clean the drain plug magnetic surface 5 Reinstall drain plug with a new O ring and torque to specification 6 Add the recommended amount of fluid through the fill hole Maintain the fluid level even with the bottom threads of the fill plug hole 7 Reinstall fill plug with a new O ring and torque to specification ...

Page 40: ...ntifreeze or straight water in the system Tap water contains minerals and impurities which build up in the system Straight water or antifreeze may cause the system to freeze corrode or overheat Coolant Level Inspection The pressure cap A and recovery bottle B are located under the front hood of the vehicle The coolant level must be maintained between the minimum and maximum levels indicated on the...

Page 41: ...as required start engine and check for leaks Make sure radiator fins are clean to prevent overheating Cooling System Pressure Test Refer to cooling system pressure test procedures provided in Chapter 3 Engine Cooling Cooling System Hoses 1 Inspect all vehicle hoses for cracks deterioration abrasion or leaks Replace if necessary 2 Inspect all engine hoses for cracks deterioration abrasion or leaks ...

Page 42: ...lant hose from the radiator as shown 5 Allow coolant to drain completely Properly dispose of the used coolant 6 Reinstall coolant hose and reposition the spring clamp 7 Remove the pressure cap Using a funnel add the recommended coolant to the top of the filler neck and fill the recovery bottle to the MAX level 8 Refer to Cooling System Bleeding Procedure provided in Chapter 3 CAUTION Washing the v...

Page 43: ...ug is located at the bottom of the outer clutch cover Access the drain plug through the left rear wheel well 1 Using a flat blade screwdriver remove the PVT drain plug and O ring from the outer clutch cover 2 Allow the water to drain out completely 3 Reinstall the drain plug and O ring 4 Place the transmission in PARK apply the brake and start the engine 5 Apply varying throttle for 10 15 seconds ...

Page 44: ...e wheel Wheel Installation 1 Verify the transmission is still in PARK 2 Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 3 Attach the wheel nuts and finger tighten them 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts and or hub nut to the proper torque specificatio...

Page 45: ...heck tire pressure using the tire pressure gauge included in the vehicle s tool kit WARNING Operating with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the useable tread depth has worn out CAUTION Maintain proper tire pressure Refer to the warning tire pressure decal applied to the v...

Page 46: ...negative battery cable s 3 Disconnect the red positive battery cable s WARNING CALIFORNIA PROPOSITION 65 WARNING Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WASH HANDS AFTER HANDLING WARNING Battery electrolyte is poisonous It contains sulf...

Page 47: ...n also hinder vehicle performance Follow the battery charging procedure in Chapter 10 Electrical before installing the battery 1 Ensure the battery is fully charged 2 Place the battery in the battery holder and secure with hold down strap 3 Coat the terminals with dielectric grease or petroleum jelly 4 Connect and tighten the red positive cable s first 5 Connect and tighten the black negative cabl...

Page 48: ...terminals B 2 Inspect the ground terminals Be sure they are clean and tight Spark Plug Service Inspect and replace the spark plugs at the intervals outlined in the Periodic Maintenance Chart 1 Remove the cargo box access panel A 2 Remove both spark plug caps B IMPORTANT Note MAG and PTO reference decals C on spark plug wires for reassembly 3 Clean out plug wells with compressed air to remove any l...

Page 49: ...nts should be checked periodically for loose fasteners worn tie rod ends ball joints and damage Also check to make sure all cotter pins are in place If cotter pins are removed they must be replaced Replace any worn or damaged steering components Steering should move freely through the entire range of travel without binding Check routing of all cables hoses and wiring to be sure the steering mechan...

Page 50: ...el surface and set steering wheel in a straight ahead position Secure the steering wheel in this position 2 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible NOTE It is important the height of both marks be equally positioned to get an accurate measurement 3 Measure the distance between the marks and...

Page 51: ...sen jam nuts at both end of the tie rod Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in Wheel Toe Alignment IMPORTANT When tightening the tie rod end jam nuts the rod ends must be held parallel to prevent rod end damage and premature wear Damage may not be immediately apparent if done incorrectly After alignment is complete torque ja...

Page 52: ...Turn the lower adjustment ring 1 clockwise to increase preload or counter clockwise to decrease preload IMPORTANT DO NOT increase the spring preload by more than one inch 25 4 mm over the factory setting 4 Once you have obtained the correct preload hold the lower adjustment ring while tightening the upper adjustment ring to lock them in place IMPORTANT Always return the spring preload to the facto...

Page 53: ...cker adjuster is turned clockwise until it stops damping is in the fully closed position Turn the clicker clockwise to increase compression damping Turn the clicker counter clockwise to decrease compression damping NOTE The factory setting is 10 clicks from closed Refer to the Compression Adjustment Table Compression Adjustment Table Setting Compression Damping Softest Full counter clockwise posit...

Page 54: ...ng the shock spanner spreader tool PN 2878925 included in the vehicle s tool kit turn the adjustment collar 1 to increase or decrease preload IMPORTANT DO NOT increase the spring preload by more than one inch 25 4 mm over the factory setting IMPORTANT Always return the spring preload to the factory setting after the load is removed from the vehicle The increased suspension height will negatively i...

Page 55: ... knob counter clockwise to decrease compression damping NOTE The recommended factory setting for the front and rear shocks are provided in the following compression adjustment tables Walker Evans 2 0 Front Shock Compression Adjustment Table Setting Compression Damping Softest Full counter clockwise position Factory 6 clicks from softest position Firmest Full clockwise position Adjuster Knob Front ...

Page 56: ... If the fluid level is lower than the MIN level line add brake fluid until it reaches the MAX level line 5 Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings Brake Pad Disc Inspection 1 Check the brake pads for wear damage or looseness 2 Inspect the brake pad surface for exc...

Page 57: ...l connector Reconnect the connector as soon as practicable and adjust the parking brake cable to proper tension 1 Pull back on the parking brake lever located in dash 2 After 3 to 4 clicks BRAKE should display on the instrument cluster and the wheels of the vehicle should not rotate when turning by hand After 8 full clicks of lever travel the vehicle should not roll while parked 3 If the vehicle m...

Page 59: ...N PERIOD 3 31 ENGINE LUBRICATION SPECIFICATIONS 3 31 ENGINE DISASSEMBLY INSPECTION TOP END 3 32 VALVE COVER REMOVAL 3 32 CAMSHAFT REMOVAL 3 32 CAMSHAFT SPROCKET INSPECTION 3 34 CAMSHAFT CAMSHAFT BORE INSPECTION 3 34 CYLINDER HEAD REMOVAL 3 36 CYLINDER HEAD WARP INSPECTION 3 36 CYLINDER HEAD DISASSEMBLY 3 37 VALVE INSPECTION 3 38 COMBUSTION CHAMBER CLEANING 3 39 VALVE SEAT RECONDITIONING 3 39 ENGIN...

Page 60: ...STON INSTALLATION 3 63 CRANKSHAFT INSTALLATION 3 64 BALANCE SHAFT INSTALLATION 3 66 LOWER CRANKCASE PREPARATION 3 67 CRANKCASE ASSEMBLY 3 67 FLYWHEEL INSTALLATION 3 71 STATOR COVER INSTALLATION 3 72 ENGINE ASSEMBLY TOP END 3 73 CYLINDER HEAD ASSEMBLY 3 73 VALVE SEALING TEST 3 74 CYLINDER HEAD INSTALLATION 3 74 CAMSHAFT INSTALLATION TIMING 3 75 CAMSHAFT TIMING QUICK REFERENCE 3 79 VALVE CLEARANCE A...

Page 61: ...e Stand PU 50625 Engine Stand Sleeve Adapter Use With 2 375 Bore Stand PW 47054 Flywheel Puller PA 49316 Mity Vac Pressure Test Tool 2870975 Oil Filter Wrench PU 50105 Oil Pressure Gauge PV 43531 Oil Pressure Gauge Adapter PU 50565 Piston Ring Compressor Pliers PV 43570 1 Valve Spring Compressor PV 1253 or PV 4019 Quick Release Valve Spring Compressor Adapter PV 43513 A Water Pump Mechanical Seal ...

Page 62: ...plug A and insert the oil pressure adapter 5 Start engine and allow it to reach operating temperature monitoring gauge indication NOTE Test results are based on the use of the recommended engine oil Polaris PS 4 Plus or PS 4 Extreme Duty at operating temperature and may vary considerably if any other oil is used or if engine is not up to temperature 6 Upon assembly torque the crankcase gallery plu...

Page 63: ...MAG bearing 1 Cam bearings Piston spray jet 1 Balancer bearing Crank big end 1 Piston small end bearings 1 Cyl head drains S U M P Chain tensioner Coolant in Coolant out Oil Pump Assembly Main CENTER bearing 2 Main PTO1 bearing 3 Cam chain chest Stator bolt jet feed Starter gear bearing Crank big end 2 Cylinder Head Breather Assembly Piston spray jet 2 Piston small end bearings 2 Main PTO2 bearing...

Page 64: ...5 mm Valve Seat Valve Seat Contacting Width Intake Standard 0 0393 0 0039 1 0 0 10 mm Valve Seat Contacting Width Intake Service Limit 0 0551 1 4 mm Valve Seat Contacting Width Exhaust Standard 0 0590 0 0039 1 5 0 10 mm Valve Seat Contacting Width Exhaust Service Limit 0 0748 1 9 mm Valve Seat Angles 30 0 1 5 45 0 0 5 60 0 1 5 Valve Guide Valve Guide Inner Diameter 0 2165 0 2171 5 500 5 515 mm Val...

Page 65: ...Standard Service Limit 0 0047 0 12 mm Connecting Rod Connecting Rod Small End I D Standard 0 7879 0 7885 20 015 20 030 mm Connecting Rod Small End I D Service Limit 0 7897 20 06 mm 1 Marking Connecting Rod Big End Bore I D 1 7318 1 7321 43 989 43 996 mm 2 Marking Connecting Rod Big End Bore I D 1 7321 1 7323 43 996 44 003 mm 3 Marking Connecting Rod Big End Bore I D 1 7323 1 7326 44 003 44 010 mm ...

Page 66: ...ce 26 ft lbs 35 Nm Step 1 9 ft lbs 12 Nm 9 ft lbs 12 Nm 7 ft lbs 10 Nm 26 ft lbs 35 Nm 9 ft lbs 12 Nm 9 ft lbs 12 Nm Step 1 9 ft lbs 12 Nm Step 2 26 ft lbs 35 Nm Step 3 180 1 2 turn 7 ft lbs 10 Nm 26 ft lbs 35 Nm CAM CARRIER TORQUE SEQUENCE CRANKCASE SPLIT LINE TORQUE SEQUENCE SUMP COVER TORQUE SEQUENCE STATOR COVER TORQUE SEQUENCE 7 ft lbs 10 Nm CYLINDER HEAD TORQUE SEQUENCE Step 3 90 1 4 turn St...

Page 71: ...and pressure test the cooling system using a commercially available pressure tester 3 The system must maintain 10 psi for five minutes or longer If pressure loss is evident within five minutes check the filler neck radiator hoses clamps and water pump weep hole for leakage Condition Coolant Temperature F C Room Temperature 68 F 20 C Thermostat Open 180 F 82 C Fan Off 192 F 89 C Fan On 198 F 92 C T...

Page 72: ...Installation 1 Remove the hood and front bumper see Chapter 5 2 Remove the 4 fasteners that secure the front bumper support to the main frame 3 Remove the 5 fasteners B that secure the upper radiator cover C to the front cab Remove the upper radiator cover C from the vehicle 4 Drain radiator by removing lower radiator hose D Be sure to catch and dispose of coolant properly 5 Disconnect cooling fan...

Page 73: ... the small radiator bypass hose F 8 Lift radiator up to disengage it from its lower mounting points Tilt top of radiator outward and remove the radiator from the vehicle 9 Separate the fan motor assembly from the radiator Inspect fan blades for damage 10 Reverse this procedure for installation Be sure to properly fill and bleed cooling system as outlined in this chapter E F ...

Page 74: ...nsion remove the front bolt C retaining the thermostat cover 8 Lift the cover from the housing and remove the thermostat NOTE Thermostat has a pop off relief to allow the bypass system to operate until thermostat opens 9 Install a new thermostat with the bleed hole D positioned closest to the engine NOTE Image shown above is with engine removed for clarity 10 Reverse this procedure for installatio...

Page 75: ...opyright 2012 Polaris Sales Inc Cooling System Exploded View Coolant Flow Diagram Radiator Recovery Bottle Engine Bypass active when thermostat closed Engine Outlet active when thermostat open Thermostat Housing Cylinder Fitting Engine Water Pump Housing Engine Oil Cooler Filler Neck ...

Page 76: ...o idle until the coolant fan has cycled two times 9 Allow engine and cooling system to completely cool down see CAUTION 10 Remove the pressure cap Add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck 11 Open the bleed screw to allow any trapped air to escape Close the bleed screw once a steady stream of coolant begins to drain out 12 Tighten the bleed screw to specifi...

Page 77: ... to engine block Note different bolt lengths for installation 12 Remove water pump from engine by gently twisting and rocking the water pump housing while pulling outward 13 Maneuver water pump downward and remove it through the access hole in the skid plate 14 Plug the water pump drive access hole in the engine block with a clean shop towel Water Pump Installation 1 Replace the 2 sealing O rings ...

Page 78: ...es that attach to the water pump Be sure orientation and routing are correct 13 Install the right rear lower shock bolt and new nut Torque mounting bolt to specification 14 Install the right rear wheel Torque wheel nuts to specification 15 Connect the negative battery cable 16 Fill and bleed cooling system as outlined in this chapter 17 Install the hood engine service panel and seats Chapter 5 CAU...

Page 79: ...om the impeller side 7 Extract the mechanical seal and the oil seal from the water pump housing NOTE A 5 32 4 mm diameter punch will fit in the lubrication slot to aid in the removal of the oil seal Be sure not to damage the water pump shaft bearing surface 8 Inspect the water pump shaft bore for excessive wear or damage Replace water pump housing assembly if necessary 9 Clean and inspect water pu...

Page 80: ... new water pump cover gasket C 20 Install the water pump cover and 3 retaining bolts Torque bolts in sequence to specification 21 Install 2 new water pump O rings and lubricate them with fresh engine oil 22 Install water pump assembly into engine as shown in the Water Pump Installation procedure T Water Pump Impeller Bolt 89 18 in lbs 10 2 Nm Apply Loctite 204 to bolt threads A B C T Water Pump Co...

Page 81: ...rmation NOTE The use of an overhead or portable engine hoist is the only recommended method for removing and installing the engine NOTE Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components 1 If vehicle was recently operated allow it to cool down before attempting to perform any work 2 Thoroughly cle...

Page 82: ...h cover and clutch outlet duct see Chapter 6 IMPORTANT Be sure to use the correct Drive Clutch Puller PN 2872085 to prevent damage to crankshaft 12 Disconnect the IAC valve C MAQS D ECT sensor E and CPS sensor F connectors fuel injector harness leads G and ignition coil harness lead Remove wire ties retaining harness to the fuel rail and rear cross member 13 Disconnect the stator harness H 14 Remo...

Page 83: ...tallation 19 Remove spark plug wires from the engine IMPORTANT The spark plug wires are marked with MAG and PTO Note during installation procedure 20 Remove the breather hose from the crankcase 21 Remove the 6 fasteners that attach the exhaust head pipe to the engine Remove the 2 exhaust springs that attach the head pipe to the muffler Remove exhaust head pipe towards the front of the vehicle Disc...

Page 84: ...2 coolant hoses from the engine Dispose of engine coolant properly 25 Use an overhead or portable engine hoist and suitable engine straps to secure engine in its current position 26 Remove the 4 rear mounting bolts J that attach the rear of the engine to the transmission NOTE It is not necessary to remove the bolts that retain the bracket K to the transmission 27 Remove the 4 front engine mounting...

Page 85: ...er engine stand sleeve adapter and install it onto the engine stand adapter Sleeve adapter for a 2 bore engine stand PU 50625 Sleeve adapter for a 2 375 bore engine stand PW 47054 33 Place engine onto the engine stand PU 50624 for service Engine Installation Use the following procedure to reinstall the engine assembly 1 Attach engine with suitable lifting straps to an overhead or portable engine h...

Page 86: ...e 6 Align transmission joint mounting holes with the transmission front mounting holes 7 Install the Clutch Center Distance Tool PU 50658 onto the crankshaft and transmission input shaft to properly position the clutch center distance The pictures below show the tool PU 50658 properly installed 8 Loosen the 2 bolts N retaining transmission joint bracket to the transmission on the right side 9 Alig...

Page 87: ... portable engine hoist 16 Install the 2 coolant hoses onto the engine 17 Install both front and rear cross members onto the vehicle frame Torque fasteners to specification 18 Install push rivet through heat shield into rear cross member 19 Install the exhaust heat shield and retaining screw 20 Replace exhaust gaskets seals Install exhaust head pipe Install the 6 fasteners that attach the exhaust h...

Page 88: ...nting bolt and new nut Torque to specification 32 Install the left rear wheel and torque wheel nuts to specification 33 Install the rear bumper and cargo box as an assembly see Chapter 5 NOTE Be sure to connect the engine intake hose and clutch air intake hose to the rear cargo box asm upon installation 34 Connect the negative battery cable 35 Remove the pressure cap and fill the cooling system th...

Page 89: ... in period Engine Lubrication Specifications Additional oil may be required after complete engine disassembly Check level after filling and add oil as needed 40 ft lbs 17 ft lbs 23 Nm 54 Nm 18 ft lbs 24 Nm 44 ft lbs 60 Nm 40 ft lbs 54 Nm 44 ft lbs 60 Nm Reference Engine Installation procedure for torque sequence 44 ft lbs 60 Nm 64 ft lbs 87 Nm CAUTION Use only Polaris PS 4 Plus or PS 4 Extreme Dut...

Page 90: ...eaks are evident 3 Remove the spark plugs D Stuff spark plug holes with shop towels to prevent anything from falling into the combustion chamber Camshaft Removal NOTE The camshafts can be removed with the engine installed in the chassis 1 Rotate the engine so the PTO cylinder is at Top Dead Center TDC to relieve most of the valve spring pressure The camshaft lobes should face out and the slots on ...

Page 91: ...n end wrench and remove the top bolt from the camshaft sprockets I 6 Rotate the engine using the flywheel and remove the remaining bolt from each camshaft sprocket I 7 Lift the chain and sprockets off the camshafts to allow each sprocket to be removed 8 Using a paperclip J or other tool hold cam chain up NOTE The crankcase has a built in lower guide to prevent the chain from falling off the cranks...

Page 92: ...sually inspect each cam lobe for wear or damage 2 Measure the height of each cam lobe from the base circle to highest point on the lobe using a micrometer Compare to specification NOTE Replace camshafts if damaged or if any part is worn past the service limit 3 Visually inspect each camshaft journal for scoring wear or damage 4 Measure the diameter of the camshaft journals using a micrometer Compa...

Page 93: ...re and compare to specifications NOTE Replace cylinder head if camshaft journal bores are damaged or if worn past the service limit 7 Calculate oil clearance by subtracting camshaft journal O D s from camshaft carrier bore I D s Compare to specification T Camshaft Carrier Bolts 89 in lbs 10 Nm In mm Camshaft Carrier Bore I D 0 9055 0 9063 23 000 23 021 mm Service Limit 0 9072 23 044 mm In mm Calcu...

Page 94: ... nothing retains the cylinder to the engine DO NOT rotate the engine without using the Cylinder Holding Camshaft Timing Plate PU 50563 Refer to Cylinder Piston Removal Cylinder Head Warp Inspection Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon 1 Lay a straight edge E across the surface of the cylinder head at several different points and measure warp by ...

Page 95: ...ress the valve spring by hand using valve spring compressor adapter PV 43513 A 3 Push down on spring and remove split keepers H 4 Slowly release valve spring pressure and remove the compressor adapter 5 Remove the valve retainer I valve spring J valve stem seal K and valve spring seat L Discard the valve seal NOTE Replace valve seals whenever cylinder head is disassembled Hardened cracked or worn ...

Page 96: ...e stems mount valve in a drill or use V blocks and a dial indicator 3 Check the end of the valve stem for flaring pitting wear or damage 4 Inspect split keeper groove for wear or flaring in the keeper seat area NOTE The valves can be re faced or end ground if necessary They must be replaced if extensively worn burnt bent or damaged 5 Measure diameter of valve stem with a micrometer in three places...

Page 97: ...oning techniques vary so follow the instructions provided by the valve reconditioning equipment manufacturer Do not grind seats more than necessary to provide proper seat surface width and contact point on valve face Valve Seat Inspection Inspect valve seat in cylinder head for pitting burnt spots roughness and uneven surface If any of the above conditions exist the valve seat must be reconditione...

Page 98: ...he valve seat If using an interference angle 46 apply black permanent marker to the entire valve face A 6 Insert valve into guide and tap valve lightly into place a few times 7 Remove valve and check where the Prussian Blue indicates seat contact on the valve face The valve seat should contact the middle of the valve face or slightly above and must be the proper width If the indicated seat contact...

Page 99: ... reconditioning method is used 10 Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem 11 Rotate the valve rapidly back and forth until the cut sounds smooth Lift the valve slightly off of the seat rotate 1 4 turn and repeat the lapping process Do this four to five times until the valve is fully seated and repeat process for ...

Page 100: ...ngs A and output wires B If replacement is required refer to Chapter 10 4 Inspect the ball bearing C that supports the starter motor shaft 5 If bearing replacement is required remove the retaining ring and heat the stator cover around the bearing evenly with a heat gun Tap cover on a soft work surface to remove the bearing from the housing A blind bearing puller can also be used Replace bearing if...

Page 101: ...lts retaining the water pump housing to the engine 3 Remove the water pump assembly from the engine by using a twisting motion as you pull out on the housing 4 If water pump service is required impeller or mechanical seal refer to ENGINE COOLING SYSTEM Flywheel Removal NOTE The flywheel can be serviced with the engine installed in the chassis 1 Remove the stator cover assembly 2 Remove the starter...

Page 102: ...on NOTE The starter one way clutch can be serviced with the engine installed in the chassis 1 Remove the stator cover and flywheel see Stator Cover Removal Inspection and Flywheel Removal 2 Place flywheel on a work bench with the one way clutch facing up Grasp clutch gear and rotate clockwise It should turn smoothly without binding 3 Rotate one way gear counterclockwise The gear should immediately...

Page 103: ...way clutch component is worn or damaged replace the clutch and starter gear as an assembly Starter One Way Clutch Assembly 1 Install one way clutch in clutch hub with flange of clutch F engaged in recess 2 Clean screw threads in flywheel to remove all oil or grease 3 Place one way clutch on flywheel and install the 3 screws Torque screws to specification 4 Reassemble starter one way clutch and gea...

Page 104: ... cooler A from the crankcase 2 Remove the crankcase drain plug B to drain any oil remaining in the engine 3 Remove the oil filter 4 Install the Cylinder Holding Camshaft Timing Plate PU 50563 onto the cylinder The cylinder holding tool retains the cylinder and pistons when the engine is rotated 5 Rotate engine to access the crankcase sump cover 6 Remove the 13 M6 and 3 M8 bolts retaining the sump ...

Page 105: ...nable to extract the dowel pins from the oil pump the oil pump sprocket must be removed Access the sprocket bolt by removing the case plug 11 Lift the oil pump drive chain and remove the oil pump 12 Visually inspect the oil pump and drive sprocket I for wear or damage Replace oil pump drive chain and sprocket if worn or damaged If any part of the oil pump is damaged the entire assembly must be rep...

Page 106: ...e lower crankcase in reinforced areas with a soft faced hammer to loosen Carefully lift up and remove the lower crankcase half Balance Shaft Removal Inspection 1 Perform Crankcase Disassembly Inspection procedure 2 Note timing marks K on balance shaft and crankshaft drive gears Shafts must be properly timed upon assembly 3 Carefully rotate the balance shaft L and remove it from the crankcase 4 Ins...

Page 107: ...sembly Inspection procedure 2 Perform Balance Shaft Removal Inspection procedure 3 For ease of assembly mark each connecting rod and end cap 4 Loosen remove and discard the 4 connecting rod bolts M Remove the end caps from the crankshaft 5 Carefully lift the crankshaft N out of the crankcase 6 Remove the cam chain P oil pump drive chain Q and PTO main seal R from the crankshaft 7 Inspect the crank...

Page 108: ... sprocket in any orientation to the depth shown in the following illustration 11 Support crankshaft on V blocks or on centers in a crankshaft stand or lathe Measure crankshaft runout and replace if runout exceeds maximum listed below 12 Visually inspect surface of crankshaft main and connecting rod journals Replace crankshaft if any journal is scratched or pitted In mm Auxiliary Sprocket Installed...

Page 109: ...n Bearing Selection and Connecting Rod Bearing Selection procedures Journal 1 Main Bearing Journal 2 Rod Bearing Journal 3 Main Bearing Journal 4 Rod Bearing Journal 5 Main Bearing Journal 6 Main Bearing MAG PTO Crankshaft Bearing Journal Diameters B Main Bearing Standard 1 6140 1 6143 in 40 996 41 004 mm Service Limit 1 6129 in 40 970 mm Conn Rod Bearing Standard 1 6118 1 6122 in 40 942 40 950 mm...

Page 110: ...ent pins are in place where used 4 Be sure oil passages are clean and free of any cleaning solvent see Engine Oil Flow Chart 5 Remove and discard the plain bearings located in the upper crankcase B lower crankcase C and connecting rods D Replace the crankcase assembly if a bearing bore is galled or if bearing inserts have rotated in the case Refer to bearing selection procedures upon assembly IMPO...

Page 111: ...d in the same cylinder bore and direction from which they were removed MAG PTO Cylinder Inspection 1 Lay a straight edge E across the top surface of the cylinder at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder surface If warp exceeds the service limit replace the cylinder 2 Inspect cylinder for wear scratches or damage CAUTION Pis...

Page 112: ... must be replaced Piston Disassembly Inspection NOTE New pistons are directional intake vs exhaust but can be placed in either cylinder 1 Note location of the piston circlip gap A at the top 12 00 position or bottom 6 00 position 2 Remove piston circlip and push piston pin out of piston If necessary heat the crown of the piston slightly with a heat gun if pin cannot be removed by hand Discard circ...

Page 113: ...and lift it off the piston By hand Placing both thumbs on the ring ends spread the ring open and push up on opposite side Do not scratch ring lands 2 Repeat procedure for second compression ring C 3 The oil control ring D is a three piece design consisting of a top and bottom steel rail and a center expander section Remove top rail first then bottom rail then the expander In mm Piston Pin Bore I D...

Page 114: ...th the top and bottom of the cylinder IMPORTANT A difference between top and bottom end gap measurements is a general indication of cylinder taper wear The cylinder should be measured for taper and out of round 3 If the installed gap measurement exceeds the service limit replace the rings NOTE Always check piston ring installed gap when installing new rings and or a new cylinder In mm Piston Ring ...

Page 115: ...onto the intake side of the connecting rod are serial numbers used to match the rod stem with the rod cap 2 The number and letter stamped onto the exhaust side of the connecting rod represent the bore diameter and weight grading of the connecting rod 3 Inspect the small end and big end of connecting rod and matching rod cap for damage galling of surface or pitting In mm Piston O D Standard 3 6597 ...

Page 116: ...mpare to specifications 8 Refer to the number stamped onto the exhaust side of the connecting rod This number represents the bore diameter 9 The table below lists the big end bore diameter specifications 10 Whether using new connecting rods or re installing the original ones refer to the bearing selection chart provided in the Connecting Rod Bearing Selection procedure in this chapter In mm Connec...

Page 117: ...ht 2012 Polaris Sales Inc ENGINE ASSEMBLY LOWER END Bearing Selection Identification Letters and Numbers Connecting Rod Bearing Identification Number Crankcase Bearing Identification Numbers Crankshaft Bearing Identification Letters X X X X X X 6 Numbers X X X X X X 6 Letters X X 1 Number ...

Page 118: ...mple you would use the number 2 as the crankcase codes case journals 1 2 3 4 You would use letters G Y G Y as the crankshaft codes crank journals 1 3 5 and 6 Based off the bearing selection chart you would use Green bearing for Main 1 Yellow bearing for Main 2 Green bearing for Main 3 Yellow bearing for Main 4 Bearing Selection Chart Rod Bearings Crankshaft Rod Code B G Y 1 Blue Blue Green 2 Blue ...

Page 119: ...trace the oil paths through the crankcase and cylinder 6 Flush all oil passages with solvent and then warm soapy water Rinse with clear warm water and dry with compressed air 7 Be sure passages are clean and dry before assembling the upper crankcase Piston Ring Installation NOTE Apply clean engine oil to all ring surfaces and ring lands upon installation Always check piston ring installed gap befo...

Page 120: ...ngs rotate freely in their grooves and do not bind when compressed by hand Piston Connecting Rod Assembly 1 Lubricate connecting rod small end piston pin bore and piston pin with engine oil 2 Install a new circlip on one side of piston with gap at the top 12 00 position or bottom 6 00 position Upper Rail Gap Position Lower Rail Gap Position Spring Expander Gap Position Second Ring Gap Position CAU...

Page 121: ...oove Cylinder Piston Installation NOTE If the pistons are being reused reassemble in the same cylinder bore and direction from which they were removed MAG PTO NOTE New pistons are directional intake vs exhaust but can be placed in either cylinder 1 Apply clean engine oil to each piston assembly cylinder bore and bottom tapered portion of each cylinder sleeve 2 Verify that all ring end gaps are cor...

Page 122: ...et 9 Verify piston orientation arrow pointing toward exhaust one last time prior to installation 10 Carefully place the cylinder and pistons into the upper crankcase 11 Install the Cylinder Holding Camshaft Timing Plate PU 50563 onto the cylinder The cylinder holding tool retains the cylinder and pistons when the engine is rotated Crankshaft Installation IMPORTANT Whether installing a new cranksha...

Page 123: ...is PS 4 engine oil to each main and rod bearing journal of crankshaft 7 Loop cam chain D and oil pump drive chain E over crankshaft sprockets 8 Apply Polaris PS 4 engine oil to the new crankshaft oil seal F and install the seal on the PTO end of the crankshaft 9 Carefully lower the crankshaft into upper crankcase Guide connecting rods onto the rod journals of crankshaft as necessary 10 Adjust the ...

Page 124: ... see Balance Shaft Bearing Selection procedure in this chapter 1 Clean the upper crankcase balance shaft bearing bore surfaces 2 Align tab of new balance shaft bearings A with the slot in each bearing bore of crankcase Press bearing insert firmly into place 3 Rotate the crankshaft until the alignment dot B on the crankshaft MAG end gear is visible 4 Apply Polaris PS 4 engine oil to both balance sh...

Page 125: ...il or crankcase sealant 3 Inspect crankcase bearing bores Replace the crankcase assembly if a bearing bore is galled or if bearing inserts have rotated in the case 4 Be sure alignment pins are in place where used 5 Refer to Oil Flow Chart at the beginning of this chapter and trace the oil paths through the crankcase and cylinder 6 Flush all oil passages with solvent and then warm soapy water Rinse...

Page 126: ...in is fed through the lower crankcase 7 Tap lower crankcase with a rubber hammer to seat the case halves together 8 Inspect crankcase mating surfaces to be sure they are joined properly Investigate the cause of any gaps 9 Install the 8 M10 2 M8 and 1 M6 lower crankcase bolts Tighten all bolts lightly by hand IMPORTANT Install new M10 lower crankcase bolts 10 Torque lower crankcase bolts in sequenc...

Page 127: ...peat the sequence to verify final torque 14 Rotate the engine so the cylinder is facing down 15 Install a new seal on the oil pump 16 Lift the oil pump drive chain and install the oil pump 17 Install dowel pins C into oil pump mounting holes 18 Install the 3 bolts D that retain oil pump E to the crankcase Torque mounting bolts to specification T Upper Crankcase Bolts M8 Bolts 26 1 ft lbs 35 2 Nm M...

Page 128: ...e upon assembly to keep oil away 21 Apply a thin continuous film of Crankcase Sealant PN 2871557 to sump cover mating surface as shown Do not allow sealant to dry before assembly 22 Install the oil sump cover G onto the crankcase 23 Install the 13 M6 and 3 M8 bolts that retain the oil sump cover H to the crankcase 24 Torque the oil sump cover bolts in sequence to specification Repeat the sequence ...

Page 129: ...he flywheel key 2 Clean taper of crankshaft to remove all oil or grease 3 Clean flywheel taper to remove all oil or grease 4 Align flywheel key way with key and install the flywheel seating it fully on taper 5 Install flywheel retaining bolt Using a commercially available strap wrench A hold the flywheel and torque the flywheel retaining bolt B to specification IMPORTANT If the Cylinder Holding Ca...

Page 130: ...ly 2 Install a new stator cover gasket over alignment pins 3 Install stator cover and 13 screws Torque screws in sequence to specification CAUTION The flywheel contains powerful magnets Use caution when removing and installing the stator cover DO NOT place fingers between cover and crankcase at any time during the removal installation process or injury could result T Stator Cover Screws 106 18 in ...

Page 131: ...l damage 5 Dip the seat C valve spring D and retainer E in clean engine oil 6 Install the valve spring seat C 7 Install the valve spring D with tightly spaced coils facing down toward the cylinder head NOTE Valve springs to be installed with paint mark facing up 8 Place the valve retainer E on the spring 9 Compress the valve spring by hand using valve spring compressor adapter PV 43513 A Compress ...

Page 132: ... A 2 Pour a small amount of clean solvent into each intake port B and check for leakage around the valves The valve seats should hold fluid with no seepage 3 Repeat for exhaust valves by pouring fluid into each exhaust port C Cylinder Head Installation 1 Rotate the engine so the cylinder is facing up 2 Remove the Cylinder Holding Camshaft Timing Plate PU 50563 from the cylinder IMPORTANT Once the ...

Page 133: ...MPORTANT Install new cylinder head bolts 8 Torque cylinder head bolts in sequence to specification Camshaft Installation Timing IMPORTANT If any valve train components were replaced refer to Valve Clearance Adjustment procedure prior to Camshaft Installation Timing 1 Rotate the engine until the flywheel Top Dead Center TDC mark A is aligned or centered in the Crankshaft Position Sensor CPS mountin...

Page 134: ...s should face out as shown 5 Carefully install the rear camshaft carriers onto the camshafts Carrier openings should face each other when installed properly 6 Install the 4 bolts that retain each rear camshaft carrier C and tighten the bolts evenly until snug 7 Install the Cylinder Holding Camshaft Timing Plate PU 50563 into the end of camshafts as shown Use a 13 16 open end wrench to rotate camsh...

Page 135: ...and the exhaust cam sprocket should have E marks aligned with gasket surface IMPORTANT Install the exhaust cam sprocket first opposite the cam chain tensioner to ensure proper cam timing 12 Use new camshaft sprocket retaining bolts upon assembly Install the top bolt in each camshaft sprocket D Do not torque the bolts at this time IMPORTANT Use new sprocket retaining bolts upon assembly 13 Verify c...

Page 136: ... remaining sprocket bolts to specification 18 Install the front camshaft carrier E and 2 outer retaining bolts 19 Install the fixed cam chain guide F and 2 retaining bolts 20 Torque the camshaft carriers bolts in sequence to specification 21 Apply Polaris PS 4 engine oil to the cam chain tensioner bore prior to assembly Use a new tensioner sealing washer G 22 Install the hydraulic cam chain tensio...

Page 137: ...ris Sales Inc Camshaft Timing Quick Reference Align Marks with Surface Align Marks with Surface Exhaust Cam Intake Cam Align Flywheel Mark in Mounting Hole CPS Mounting Hole IMPORTANT DO NOT use the V mark located I mark should be used of the I mark Only the on the flywheel opposite as a TDC reference ...

Page 138: ...TO camshaft lobes should face out as shown 4 Carefully install the rear camshaft carriers onto the camshafts Carrier openings should face each other when installed properly 5 Install the 4 bolts that retain each rear camshaft carrier A and tighten the bolts evenly to specification 6 Rotate the camshaft until the cam lobes above the valves you are inspecting are facing up 7 Measure the valve cleara...

Page 139: ...igit shim number 13 Refer to the appropriate shim selection matrix Intake or Exhaust on the following pages and select the proper shim 14 Install the new adjustment shim and valve bucket NOTE Lubricate the outer portion of the valve bucket upon installation 15 Repeat steps 10 14 until all necessary valves have been adjusted 16 Reinstall the camshafts and camshaft carriers and tighten the bolts eve...

Page 140: ...5 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300 0 426 0 450 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300 0 451 0 475 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300 0 ...

Page 141: ... 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 0 501 0 525 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300 0 526 0 550 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285...

Page 142: ...lug threads 2 Install spark plugs A and torque to specification 3 Prepare valve cover sealing surfaces by cleaning thoroughly to remove all residue 4 Install a new valve cover seal B 5 Install the 4 valve cover shoulder bolts C and isolators D using a T40 driver 6 Torque valve cover bolts to specification T Spark Plugs 7 ft lbs 10 Nm Valve Cover Bolts 89 in lbs 10 Nm B A C D ...

Page 143: ... Not Turn Over Dead battery Starter motor does not turn Engine seized rusted or mechanical failure Engine Runs But Will Not Idle Restricted fuel supply Low compression Crankcase breather restricted Engine Idles But Will Not Accelerate Spark plug fouled weak spark Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Incorrect ignition timing Restricted exh...

Page 144: ...n coil faulty Ignition or kill switch circuit faulty Poor connections in ignition system Ignition timing incorrect Sheared flywheel key Cooling System Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiator lines pump or water jacke...

Page 145: ...S REPLACEMENT 4 19 IDLE AIR CONTROL VALVE IAC 4 20 IAC TEST REPLACEMENT 4 20 ENGINE COOLANT TEMPERATURE SENSOR ECT 4 21 ECT SENSOR TEST REPLACEMENT 4 21 DUAL THROTTLE BODY ASSEMBLY 4 23 THROTTLE BODY SERVICE REMOVAL 4 23 FUEL INJECTORS 4 25 FUEL INJECTOR TROUBLESHOOTING TEST 4 26 FUEL INJECTOR REPLACEMENT 4 27 FUEL PUMP 4 30 FUEL SENDER TEST 4 30 FUEL PUMP TEST 4 31 FUEL PUMP REPLACEMENT 4 32 IGNI...

Page 146: ...Verify system pressure has been relieved before disassembly Never drain the fuel system when the engine is hot Severe burns may result Do not overfill 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 los...

Page 147: ...468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 This module kit is used on all 8 pin connector based Polaris EFI systems This kit is available to Polaris dealers through our tool supplier SPX at http polaris spx com or 1 800 328 6657 Digital Wrench Diagnostic Connector Located under the dash connected to a sealed plug Digital Wrench Download Website Located at www polaris diag...

Page 148: ...p any open joints with plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Clean any connector before opening to prevent dirt from entering the system Although every precaution has been taken to prevent water intrusion failure avoid direct water or spray contact with system components Do not disconnect or re...

Page 149: ...old Air Quality Sensor MAQS 3 Crankshaft Position Sensor CPS 4 Idle Air Control Valve IAC 5 Engine Coolant Temperature Sensor ECT 6 Dual Throttle Body Assembly 7 Fuel Injectors 8 Fuel Rail Regulator 1 2 3 5 6 7 9 10 11 14 15 12 13 9 Fuel Pump Regulator 10 Fuel Level Sender 11 Fuel Filter 12 Fuel Supply Line 13 Fuel Return Line 14 Ignition Coil 15 Spark Plug Wires 16 Spark Plugs 4 8 16 ...

Page 150: ...ted on the PTO end of the throttle body assembly 3 Crankshaft Position Sensor CPS Located on top of the stator cover 4 Idle Air Control Valve IAC Located above the engine underneath the cargo box access panel 5 Engine Coolant Temperature Sensor ECT Located on the left side of the thermostat housing The sensor can be accessed with the air box assembly removed 6 Dual Throttle Body Assembly Located b...

Page 151: ... of the fuel injectors 9 Fuel Pump Regulator Fuel Gauge Sender Assembly RZR XP Located under the passenger seat RZR XP 4 Located under right rear passenger seat 10 Ignition Coil High Tension Leads Located behind the engine service panel on the driver s side of the vehicle Fuel Injectors Fuel Rail Fuel Supply Fuel Return Regulator Fuel Pump Asm RZR XP Shown Located in Fuel Tank Fuel Pump Regulator ...

Page 152: ...GER RZR XP 900 RZR XP 4 900 Service Manual Copyright 2012 Polaris Sales Inc FUEL TANK Exploded View Fuel Flow Fuel Filters Fuel Pump Assembly Fuel Supply Line Fuel Rail Fuel Injectors Pressure Regulator Fuel Tank Pressure Regulator Fuel Return Line ...

Page 153: ...locking mechanism back into place Verify the connector tabs snap back into place 6 Be sure fuel line is routed and retained properly Fuel Return Line 1 Place a shop towel around the fuel line to catch any dripping fuel 2 If removing either end of return line B squeeze the connector tabs C together and push the white locking slide back to release the line 3 Pull on the fuel line for removal 4 To in...

Page 154: ...of the fuel lines or pump fitting Properly drain fuel into a suitable container 4 Remove the fuel tank vent line C from the tank fitting 5 Disconnect the fuel pump electrical harness D 6 Remove the push rivets and Torx screws retaining the right hand rocker panel using the multi function pliers and a T27 Torx driver Remove the rocker panel from the vehicle 7 Remove the fastener retaining the seat ...

Page 155: ...tank for removal 12 Lift the rear of the fuel tank up first 13 Carefully pull the fuel tank out of the vehicle Fuel Tank Installation RZR XP 1 Carefully reinstall the fuel tank assembly Install the inner tank bracket with the fuel tank to ensure the bracket is inserted properly into the lower fuel tank mount as shown 2 Reinstall the 2 fuel tank brackets and fasteners 3 Reinstall right rear fender ...

Page 156: ...s disconnect the fuel supply line A from the pump and the fuel return line B from the tank see Fuel Lines Quick Connect Fittings for specific removal procedures NOTE A small amount of fuel may come out of the fuel lines or pump fitting Properly drain fuel into a suitable container 4 Remove the fuel tank vent line C from the tank fitting 5 Disconnect the fuel pump electrical harness D 6 Remove the ...

Page 157: ...ar seat base assembly F to the frame Remove the rear seat base assembly from the vehicle Take note of the 2 spacers G located between the seat base and frame 11 Remove the Torx screws and push rivets retaining the rear right hand divider panel Remove the divider panel from the vehicle 12 Remove the 2 fasteners retaining the frame support and remove the support from the vehicle 13 Lift up on the re...

Page 158: ...embly F and spacers G IMPORTANT Be sure to install the 2 washer spacers G between the seat base and frame as shown above 6 Torque the seat base fasteners E to specification 7 Reinstall seat belt mechanism Torque retaining bolt to specification 8 Reinstall right hand rocker panel and all previously removed Torx screws and push rivets 9 Install the fuel lines vent line and clamp Verify the line conn...

Page 159: ...t the injectors are on This range can vary depending on fuel requirements The controlled injection of the fuel occurs every other crankshaft revolution or once for each 4 stroke cycle When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor sig...

Page 160: ...ECU is operational the moment the battery cables are connected To prevent engine over speed and possible failure an RPM limiting feature is programmed into the ECU If the maximum RPM limit is exceeded the ECU suppresses the injection signals cutting off the fuel flow and retards the ignition timing This process repeats it self in rapid succession limiting operation to the preset maximum ECU Servic...

Page 161: ...of the dual throttle body assembly the MAQS performs three functions in one unit The MAQS detects intake air temperature manifold absolute pressure and throttle position These sensor signals comprised of separate intake air temperature manifold absolute pressure readings and throttle plate position are processed by the ECU and compared to its programming for determining the fuel and ignition requi...

Page 162: ...e CPS and crankshaft position takes place during the first two revolutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will stop running CPS Test The CPS is a sealed non serviceable assembly If fault code diagnosis indicates a problem with this sensor test as follows 1 Locate the CPS harne...

Page 163: ...ctor see CPS Test 2 Using an 8mm socket remove the CPS retaining bolt A and remove the sensor B from the stator cover 3 Unclip the wire harness retainer C and remove the CPS harness from the retainer to allow replacement 4 Install new sensor using a light coating of oil on the O ring to aid installation 5 Torque the CPS retaining bolt to specification T CPS Retaining Bolt 106 in lbs 12 Nm A B C ...

Page 164: ... be replaced It can be bench tested using the following method Set your meter to read Ohms Check the resistance values at each of the following pin locations of the IAC If any of the readings are out of specification replace the IAC IAC Replacement 1 Remove the cargo box access panel A 2 Locate the IAC valve above the engine and disconnect the vehicle harness C from the IAC motor 3 Remove the 3 Ph...

Page 165: ...ooling fan during operation ECT Sensor Test To quickly rule out other components and wiring related to the ECT disconnect the harness from the ECT sensor and start the engine After a few seconds the fan should turn on and the Check Engine indicator should display on the instrument cluster This indicates all other components are working properly Refer to Chapter 3 and 10 for additional ECT sensor i...

Page 166: ...CT sensor to specification and connect the vehicle harness to the sensor 9 Reinstall the air box assembly Be sure the lower air box post in placed properly into the rubber grommet G Be sure the air box boots fully seat onto the dual throttle body before tightening the hose clamps 10 Reinstall the breather into the air box and tighten the hose clamps retaining the air box to the throttle body 11 Re...

Page 167: ...uel injectors can be serviced separately see Fuel Injectors The Manifold Air Quality Sensor MAQS attached to the end of the throttle body is non serviceable If the sensor is faulty the entire throttle body assembly must be replaced Refer to Throttle Body Removal procedure Throttle Body Removal 1 Remove the cargo box access panel A 2 Be sure the engine has cooled enough to work on 3 Remove the brea...

Page 168: ...t of the throttle body assembly taking care not to damage the fuel injector ends NOTE It is not necessary to disconnect fuel lines or the injector harnesses to perform this procedure 10 Using a T20 Torx driver remove the 4 screws retaining the throttle body cover plate Remove the cover plate 11 Rotate the throttle plate arm and remove the throttle cable end H to allow for throttle cable removal 12...

Page 169: ...ors from heat and vibration When the key switch is on the fuel rail is pressurized and the EFI relay provides voltage to the injectors During engine operation the ECU completes the ground circuit energizing the injectors The valve needle in each injector is opened electromagnetically and the pressure in the fuel rail forces fuel down through the inside The director plate at the tip of the injector...

Page 170: ...rom the leakage can cause hot restart problems and longer cranking times Injector problems due to dirt or clogging are unlikely due to the design of the injectors the high fuel pressure the use of filters and the detergent additives in the gasoline Symptoms that could be caused by dirty clogged injectors include rough idle hesitation stumble during acceleration or triggering of fault codes related...

Page 171: ...en the hose clamp E retaining the intake hose to the air box Remove air box assembly from vehicle 5 Remove the driver s seat and disconnect the negative battery cable 6 Disconnect the fuel injector harness leads 7 Hold a shop towel over the fuel line fittings and remove the fuel return and supply lines from each end of the fuel rail Remove the vent line from the fuel pressure regulator 8 Remove ti...

Page 172: ...e fuel rail and reinstall the retaining clip NOTE Be sure the retaining clip is positioned on the injector and fuel rail as shown above 13 Thoroughly clean the area around the fuel injector ports on the throttle body 14 Lightly lubricate the injector O rings and reinstall the fuel rail injector assembly into the throttle body 15 Install the fuel rail mounting screws and torque to specification 16 ...

Page 173: ...stall the air box assembly Be sure the lower air box post is placed properly into the rubber grommet Be sure the air box boots fully seat onto the dual throttle body before tightening the hose clamps 22 Reinstall the breather into the air box and tighten the hose clamps retaining the air box to the throttle body assembly 23 Reinstall the 2 screws retaining the air box assembly 24 Position the inta...

Page 174: ... not promptly turned to the start position If the engine fails to start If the engine is stopped with the key switch on as in the case of an accident In these situations the check engine light will go on but will turn off after 4 cranking revolutions if system function is OK Once the engine is running the fuel pump remains on Fuel Sender Test If the fuel gauge reading on the instrument cluster is ...

Page 175: ...TE If the fuel pressure is out of specification replace the fuel pump assembly 6 If the pump did not activate Step 5 disconnect the harness connector from the fuel pump Connect a DC voltmeter across terminals 3 and 4 in the plug on the vehicle fuel pump harness 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 the battery ...

Page 176: ...res NOTE A small amount of fuel may come out of the fuel lines or pump fitting Properly drain fuel into a suitable container 6 Remove the fuel tank vent line C from the tank fitting 7 Disconnect the fuel pump electrical harness D 8 Place the Fuel Pump Service Tool PU 50326 over the fuel pump PFA nut Using a 1 2 drive ratchet or breaker bar loosen and remove the PFA nut Discard the PFA nut NOTE App...

Page 177: ...r debris may require flashlight and mirror If debris like mud or sand is present fuel tank should be flushed and cleaned out prior to installation of new fuel pump assembly IMPORTANT It is recommended to remove the fuel tank from the vehicle and rinse it with a small amount of clean fuel Do not use water or any other chemicals to remove debris 12 Remove new fuel pump assembly gasket and PFA nut fr...

Page 178: ...nk 19 Torque PFA nut to specification using the Fuel Pump Service Tool PU 50326 and a calibrated torque wrench 20 Verify alignment of fuel pump and tank orientation marks 21 Connect the fuel supply line to the pump and the fuel return line to the tank see Fuel Lines Quick Connect Fittings for specific installation procedures IMPORTANT Be sure to engage the retainers on each fuel line until each sn...

Page 179: ...lacement IMPORTANT The engine will misfire if the spark plug wires are installed incorrectly The spark plug wires are marked with PTO and MAG from the factory and should be installed to the corresponding cylinder and ignition coil post 1 Remove the seats and engine service panel to access the ignition coil 2 Disconnect the ignition coil harness and remove the high tension leads from the coil 3 Rem...

Page 180: ...et of three numbers will appear in the information area The first number located far left can range from 0 to 9 This number represents the total number of trouble code present example 2 means there are 3 codes present The second number located top right can be 2 to 6 digits in length This number equates to the suspected area of fault SPN The third number located bottom right can be 1 to 2 digits i...

Page 181: ...se Sensor Circuit Fault 637 8 P0340 Injector 1 MAG Driver Circuit Open Grounded 651 5 P0261 Driver Circuit Short to B 3 P0262 Driver Circuit Grounded 4 P1262 Injector 2 PTO Driver Circuit Open Grounded 652 5 P0264 Driver Circuit Short to B 3 P0265 Driver Circuit Grounded 4 P1265 Rear Differential Output Driver Circuit Open Grounded 746 5 P1691 Driver Circuit Short to B 3 P1692 Driver Circuit Groun...

Page 182: ...5 EPS CAN Communications Receive Error No RX Message for 2 Seconds 520226 2 U0100 EPS CAN Communications Transmit Error No TX Message for 2 Seconds 520227 2 U1100 Position Encoder Error Position Encoder Error 520228 11 C1065 EPS Software Error Software Error 520229 12 C1070 IC CAN Communication with EPS EPS Off Line EPS DM1 not seen 520230 31 U0131 EPS Power Save Condition EPS Key On Engine Off 5 ...

Page 183: ...ough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug Injector failure Poor Idle Symptom Idle Too High if 1400 RPM when warm Throttle stop screw tampering Throttle cable sticking improperly adjusted routed incorrectly Faulty electrical connection Symptom Idle Too Low if 1100 RPM when...

Page 184: ...l data contained within the original ECU is transferred to the replacement ECU Refer to procedure and carefully follow all instructions provided in Digital Wrench Guided Diagnostic Available Guided diagnostics are available within Digital Wrench for all supported Trouble Codes that is any fault that will turn on the Check Engine indicator In addition guided diagnostics are also available for many ...

Page 185: ...o display Connected in the lower left corner of the screen 5 Once connected proceed with using Digital Wrench Digital Wrench Serial Number Location Open the configuration screen by clicking on the wrench icon The serial number is located on the right side of the screen Digital Wrench Version and Update ID Knowing what Digital Wrench version and update is installed will help determine which updates...

Page 186: ...lick on Digital Wrench Version Updates IMPORTANT You must already have the current version installed before adding an update Updates will not install if you are using an older version loaded on your PC 6 If the update file date listed is newer than your current version and update see Digital Wrench Version and Update ID download the file 7 Click on the link shown above save the file to your hard d...

Page 188: ...around the dealership is more likely to cause a reprogramming problem than one dedicated to Digital Wrench diagnostics only OBTAINING THE LATEST UPDATE Reprogramming updates are provided periodically and contain the most recent calibrations see Digital Wrench Updates CLOSE NON ESSENTIAL PROGRAMS Polaris recommends that you DO NOT install non essential programs on a Service Department laptop Camera...

Page 189: ...ct Engine Controller Reprogramming 7 Select the file you want to load into the ECU then click the Continue icon to proceed to the Integrity Check and obtain a Request Code 8 Copy CTRL C the Request Code that will be required on the dealer website in the next step DO NOT CLOSE Digital Wrench or the Request Code will be invalid NOTE All characters are letters there are no numbers in a request code N...

Page 190: ...n Key will appear in the upper left corner of the screen Copy CTRL C this key exactly as it appears 13 Enter or paste CTRL V the Authorization Key in the box located on the Digital Wrench screen Click the Continue button and follow instructions provided on the screen to complete reprogramming procedure 14 At this point the reflash process will begin Do not touch the vehicle or PC during the proces...

Page 191: ...EAR FENDER FLAIR BOX SIDE REMOVAL 5 23 CARGO BOX ASSEMBLY REMOVAL 5 23 ROCKER PANELS CONSOLE AND FLOOR 5 24 DECAL REPLACEMENT 5 25 STEERING ASSEMBLY 5 26 STEERING WHEEL REMOVAL NON EPS MODELS 5 27 STEERING SHAFT REMOVAL NON EPS MODELS 5 27 STEERING SHAFT BEARING REPLACEMENT 5 28 ELECTRONIC POWER STEERING ASSEMBLY 5 29 UPPER STEERING SHAFT REMOVAL EPS MODELS 5 30 STEERING WHEEL REMOVAL EPS MODELS 5...

Page 192: ...5 50 FOX SHOCK REBUILD INFORMATION 5 51 SPECIAL TOOLS 5 51 FOX SHOCK DISASSEMBLY 5 51 FOX SHOCK BODY AND RESERVOIR SERVICE 5 53 FOX SHOCK COMPONENT REBUILD 5 54 FOX SHOCK ASSEMBLY 5 55 WALKER EVANS SHOCK EXPLODED VIEWS RZR XP 4 5 59 WALKER EVANS 2 0 FRONT SHOCK 5 59 WALKER EVANS 2 5 REAR SHOCK 5 60 WALKER EVANS SHOCK SERVICE RZR XP 4 5 61 GENERAL SERVICE INFORMATION 5 61 FRONT SHOCK SERVICE INFORM...

Page 193: ...t 70 ft lbs 95 Nm Bearing Carrier to Trailing Arm Bolts 40 ft lbs 54 Nm Rear Brake Caliper Mounting Bolts 40 ft lbs 54 Nm Front Brake Caliper Mounting Bolts 40 ft lbs 54 Nm Front Stabilizer Bar Upper Linkage Bolt INT L 40 ft lbs 54 Nm Front Stabilizer Bar Lower Linkage Bolt INT L 43 ft lbs 58 Nm Rear Stabilizer Bar Linkage 31 34 ft lbs 42 46 Nm Rear Stabilizer Bar Bushing Bracket Bolts 17 ft lbs 2...

Page 194: ... four M10x1 5x25 bolts and M10x1 5 nuts Tighten bolts to specification Fasten the two self tapping screws to the rear inner portion of the bracket on each side Tighten screws to specification 3 Place the straps from the safety net over the front coupler posts 4 Fasten the front of the cab frame to the base brackets and secure with four 3 8 16 x 1 1 4 screws and 3 8 16 Nyloc nuts Tighten screws to ...

Page 196: ...cab frame Fasten the front of the cab frame to the base brackets and mid cab frame using the 3 8 16 x 1 1 4 bolts and 3 8 16 Nyloc nuts Tighten bolts to specification 4 Fasten mid cab frame brackets to the vehicle with bolts M10 1 5 x 25 and nuts M10 1 5 Tighten bolts to specification Fasten tap screws M8 1 25 x 20 to the outsides of each bracket Tighten tap screws to specification 5 Fasten side b...

Page 199: ... SUSPENSION 5 9924096 2013 RANGER RZR XP 900 RZR XP 4 900 Service Manual Copyright 2012 Polaris Sales Inc Side Safety Nets RZR XP 4 Nyloc Nut Washers Screw Front LH Net Strap Latch Screw Washer Washer Screw Rear LH Net ...

Page 200: ... 900 Service Manual Copyright 2012 Polaris Sales Inc Dash Instruments Controls A Instrument Cluster Speedo B Headlight Switch or Hazard Switch INT L C AWD 2WD Switch or AWD 2WD TURF Switch INT L D 12 Volt Accessory Receptacle E Key Switch F Switch Turn Lights Horn INT L ...

Page 201: ...rvice Manual Copyright 2012 Polaris Sales Inc Hood Front Body Work Center Access Hood Hood Dash Front Bumper Front RH Fender Flair 1 4 Turn Latch Grommet Washer Push Rivet T25 Screws Hood Retention Panel Mud Shield Front LH Fender Flair Mud Shield Push Rivet T27 Screws T27 Screws ...

Page 202: ...nting RZR XP Seat Base Asm Cap Plate Spring Lever Latch Body Grommets Seat Seat Back Seat Bottom Hoop Tube Nuts 41 57 in lbs 4 6 6 4 Nm 48 in lbs 5 4 Nm 41 57 in lbs 4 6 6 4 Nm Rear Seat Base Latch 3 Point Seat Belt Plunger 40 ft lbs 54 Nm 43 ft lbs 58 Nm 40 ft lbs 54 Nm 40 ft lbs 54 Nm 17 ft lbs 23 Nm Drivers Side Shown Washer Shoulder Bolt Retainer ...

Page 203: ...ing RZR XP 4 Latch 3 Point Seat Belts Plunger 40 ft lbs 54 Nm Front Seats 3 Point Seat Belts 40 ft lbs 54 Nm 40 ft lbs 54 Nm Front Seat Base Rear Seat Base Rear Seat Support Rubber Bumpers 40 ft lbs 54 Nm 40 ft lbs 54 Nm 40 ft lbs 54 Nm 17 ft lbs 23 Nm Rear Seats 40 ft lbs 54 Nm 40 ft lbs 54 Nm Spacer Spacer 40 ft lbs 54 Nm 17 ft lbs 23 Nm ...

Page 204: ...ce Manual Copyright 2012 Polaris Sales Inc Floor Rocker Panels RZR XP RH Rocker Console Cover LH Rocker Lower Floor Push Rivets U Type Push Rivets Self Tapping Screws T27 Screws T27 Screws Nuts T27 Screws T27 Screws Torx Screws Upper Floor Block Off Flap Seal Close Off Panel Seal ...

Page 205: ...ight 2012 Polaris Sales Inc Floor Rocker Panels RZR XP 4 RH Rocker Console Cover LH Rocker Lower Floor Push Rivets U Type Torx Self Tapping Screws Nuts Upper Floor T27 Screw Rear Floor Self Tapping Screws Screws Self Tapping Torx Screws T27 Screw T27 Screw Close Off Panel Block Off Flap Seal Seal ...

Page 206: ...Rear RH Rear Rear LH Rear LH Fender Flair Fender Flair Cargo Box Divider Panel Rear RH Divider Panel Engine Service Panel Heat Shield Tie Down Torx Screw Screws T25 Screws 1 4 Turn Latch Cover Cargo Box Screws Latch Asm Intake Grill Intake Grill Rear Latch Plunger Nut Access Panel Foam Filter Bumper Support Grommet Foam Filter Divider Panel Heat Shield ...

Page 207: ...4 Rear RH Rear Rear LH Rear LH Fender Flair Fender Flair Cargo Box Divider Panel Rear RH Divider Panel Heat Shield Tie Down Torx Screw Screws T25 Screws 1 4 Turn Latch Cover Cargo Box Screws Latch Asm Intake Grill Intake Grill Rear Latch Plunger Nut Access Panel Foam Filter Bumper Support Grommet Foam Filter Divider Panel Heat Shield Engine Service Panel ...

Page 208: ...rvice Manual Copyright 2012 Polaris Sales Inc Chassis Main Frame RZR XP Main Frame Bolt In Brace Skid Plate Rear Bumper Support 40 ft lbs 54 Nm 6 5 ft lbs 8 5 Nm Washer Front Bumper Support 17 ft lbs 23 Nm Screws Screws 17 ft lbs 23 Nm Screws Front Cross Member 40 ft lbs 54 Nm ...

Page 209: ...12 Polaris Sales Inc Chassis Main Frame RZR XP 4 Bolt In Brace Rear Bumper Support 6 5 ft lbs 8 5 Nm Washers Front Bumper Support Screws 17 ft lbs 23 Nm Screws Front Cross Member 40 ft lbs 54 Nm Main Frame Rear 38 ft lbs 52 Nm 17 ft lbs 23 Nm Skid Plate Front Skid Plate 17 ft lbs 23 Nm Screws Front Frame ...

Page 210: ...2 Polaris Sales Inc Front Bumper Rear Bumper Headlight T25 Screws T25 Screw Front Front Bumper Winch Pocket Cover T27 Screw Spring Deflector Side Panel 17 ft lbs 23 Nm Screws Bumper Support Nut Bolt Grill Panel Deflector Panel Tail Light Rear Bumper Speed T27 Screws Nuts Rear Bulb Socket Bumper Support ...

Page 211: ...ar passenger seats 2 Turn both latches 1 4 turn to disengage the panel 3 Lift the panel upward and towards the front of the vehicle to remove it Front Bumper 1 Remove the 2 push rivets from the sides of the front bumper 2 Remove the 8 Torx screws retaining the upper middle and lower portion of the bumper 3 Disconnect the front head lamp connectors and remove the front bumper from the vehicle Rear ...

Page 212: ... Bumper 3 Remove the front portion of the cab frame assembly to allow dash removal Refer to appropriate CAB FRAME Assembly Removal procedure for assembly torque specifications 4 Remove the push rivets and screws that attach the dash assembly to the rocker panels on each side 5 Remove the 2 push rivets that retain the rear portion of the dash assembly 6 Disconnect all electrical dash components not...

Page 213: ...Torx screws B from both the RH and LH side of the vehicle 5 Remove the 2 Torx screws C from both the RH and LH side of the vehicle 6 Remove the 6 Torx screws D from the rear cargo box area 7 Remove the 4 Torx screws E that attach the rear bumper to the vehicle frame 8 Loosen the hose clamp F and disconnect the engine intake hose from the resonator baffle box 9 Remove the 2 Torx screws G from each ...

Page 214: ...me Make note of wire and hose routings for reassembly Rocker Panels Console and Floor Rocker Panel Removal 1 Remove the push rivets and Torx screws retaining the rocker panel and remove panel from the vehicle Console and Lower Floor Removal RZR XP 1 Remove both seats and rocker panels see Rocker Panel Removal 2 Remove the T27 screws retaining the console to the floor 3 Remove shift handle knob and...

Page 215: ...flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged 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 treatin...

Page 216: ...Steering Wheel Cap Pivot Tube Steering Shaft Cotter Pin Gear Box Bearing Bushing Oil Locking Shock Asm Asm 17 ft lbs 23 Nm 17 ft lbs 23 Nm 12 14 ft lbs 16 19 Nm Nut 42 5 ft lbs 58 Nm 42 5 ft lbs 58 Nm 12 14 ft lbs 16 19 Nm 27 33 ft lbs 37 45 Nm 65 ft lbs 88 Nm Apply Red Loctite 271 23 ft lbs 31 Nm 23 ft lbs 31 Nm 7 ft lbs 10 Nm 12 ft lbs 16 Nm Bushing Thick Washer Thin Washer Thick Washers Thin Wa...

Page 217: ...ut and lift the steering wheel off the shaft Steering Shaft Removal Non EPS Models 1 Remove the pinch bolt retaining the lower portion of the steering shaft to the steering gear box assembly 2 Remove the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube 3 Remove the 2 fasteners that retain the pivot tube 4 Remove the steering shaft pivot tube and steering whee...

Page 218: ...ing shaft and press it into the pivot tube by hand NOTE Use care not to allow any of the Loctite to get in the bearing NOTE Bearings will be seated in the pivot housing upon tightening the steering wheel nut in step 14 9 Reinstall the upper washers and spacers in the order in which they were removed 10 Install the steering wheel and hand tighten the nut Apply Loctite 271 11 Reinstall the steering ...

Page 219: ...Bracket 20 24 ft lbs 27 33 Nm Boot Rod End Tie Rod RH Boot LH Boot Spacer Bearing Steering Cap Pivot Tube Cotter Pin Gear Box Bearing Oil Locking Shock Asm Asm 17 ft lbs 23 Nm 17 ft lbs 23 Nm 12 14 ft lbs 16 19 Nm 42 5 ft lbs 58 Nm 42 5 ft lbs 58 Nm 12 14 ft lbs 16 19 Nm 65 ft lbs 88 Nm Apply Red Loctite 271 23 ft lbs 31 Nm 23 ft lbs 31 Nm 7 ft lbs 10 Nm 12 ft lbs 16 Nm Bushing Thick Washer Thin W...

Page 220: ...ng the upper steering shaft to the power steering unit 3 Remove the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube Swing the shock down out of the way 4 Lift the steering wheel up and remove the 2 fasteners that retain the pivot tube 5 Remove the steering shaft pivot tube and steering wheel from the vehicle as an assembly 6 If replacing the upper steering s...

Page 221: ...ft nut to pop the steering wheel off the shaft taper 6 Once the steering wheel pops loose completely remove the nut and lift the steering wheel off the shaft Power Steering Unit Removal 1 Remove the upper steering shaft pivot tube and steering wheel from the vehicle as an assembly Refer to Upper Steering Shaft Removal EPS Models 2 Disconnect the 2 electrical harnesses from the power steering unit ...

Page 222: ...g the power steering unit remove the 4 nuts from the mount bracket 5 Carefully remove the power steering unit and mount bracket from the vehicle as an assembly 6 If replacing the power steering unit remove the 4 bolts that retain the power steering unit to the mount bracket Remove Remove WARNING Electronic Power Steering EPS units are programmed to be vehicle specific and are not interchangeable b...

Page 223: ...ure 4 Remove the pinch bolt retaining the lower steering shaft to the steering gear box assembly 5 Lift up on the shaft and remove it through the floor panel Lower Steering Shaft Installation EPS Models 1 Install the lower steering shaft onto the gear box and align the marks made during step 2 of the Lower Steering Shaft Removal EPS Models procedure 2 Install the pinch bolt that retains the lower ...

Page 224: ... steering stub shaft with the opening in the lower steering shaft 3 Place the power steering mount bracket over the top of the brake pedal mount studs and finger tighten the 4 nuts 4 Position the lower steering shaft on the power steering unit stub shaft and install the pinch bolt Torque to specification 5 Torque the 4 mount bracket nuts to specification 6 Proceed to Upper Steering Shaft Installat...

Page 225: ...er to specification 4 Be sure the front wheels are pointing straight ahead and install the steering wheel and retaining nut Torque the nut to specification and reinstall the plastic wheel cover 5 Install a new upper steering shaft pinch bolt and nut Torque pinch bolt to specification 6 Reconnect both electrical harnesses onto the power steering unit Be sure the connectors snap into place 7 Reinsta...

Page 226: ...carrier and torque bolt to specification 14 Attach shock to A arm with fastener A Torque lower shock bolt to specification 15 INT L Models Attach stabilizer linkage to A arm G with fastener Torque linkage fastener to specification 16 Remove lower ball joint pinch bolt E from bearing carrier 17 Using a soft face hammer tap on bearing carrier to loosen the lower A arm ball joint end while pushing do...

Page 227: ... STEERING SUSPENSION 5 9924096 2013 RANGER RZR XP 900 RZR XP 4 900 Service Manual Copyright 2012 Polaris Sales Inc B E A F C D D G 40 ft lbs 54 Nm 40 ft lbs 54 Nm 45 ft lbs 61 Nm 45 ft lbs 61 Nm 44 ft lbs 60 Nm ...

Page 228: ...joint pinch bolt 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 4 To service the lower ball joint Remove and discard the lower ball joint pinch bolt 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 lower ball jo...

Page 229: ... 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 specification 9 If needed install new brake caliper mounting bolts and torque to specification 10 Install wheel and 4 wheel nuts Torque wheel nuts to specification A arm A D C Ball Joint Installation C A D C...

Page 230: ...ion Torque the linkage fasteners to specification see Exploded View Stabilizer Bar Removal Installation 1 If stabilizer bar linkages are installed remove the bolts that attach the upper portion of the linkages to the stabilizer bar clamps Only remove clamps if replacing stabilizer bar 2 Remove the 2 fasteners on each side of the vehicle retaining the front stabilizer bar to the frame 3 Lift up on ...

Page 231: ...2013 RANGER RZR XP 900 RZR XP 4 900 Service Manual Copyright 2012 Polaris Sales Inc Exploded View Clamp Stabilizer Bushings Grease Linkage Nuts T30 Clamp Upper 40 ft lbs 43 ft lbs Upper A Arm Linkage Screws Bracket Zerk 54 Nm 58 Nm Bar Spacer ...

Page 232: ...rod to the bearing carrier Discard the nuts 5 Remove bolts C and D attaching radius rods to the vehicle frame Discard the nuts 6 Remove radius rods from vehicle 7 Examine radius rod shafts boots and spherical bearings Replace entire radius rod if any excessive wear is evident 8 Reverse this procedure to reinstall the radius rods 9 Torque all fasteners to specification NOTE Use new attaching nuts u...

Page 233: ...ly 4 Remove the lower radius rod mounting bolt nut and washer from the bearing carrier Swing radius rod down Discard the nut 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 Remove the rear wheel hub and brake disk assembly 7 Remove the 5 remaining bolts that attach the rear bearing carrie...

Page 234: ... for wear If bearing requires replacement refer to Trailing Arm Spherical Bearing Replacement 16 Replace trailing arm if physically damaged 17 Reverse this procedure to reinstall rear trailing arm NOTE Use new fastener nuts upon installation of the rear trailing arm and bearing carrier 18 Torque all fasteners to specification Remove Support Trailing Arm T Trailing Arm to Main Frame Bolt Trailing a...

Page 235: ...sure to only press on outer most surface of bearing race do not press on the center spherical bearing 6 Inspect trailing arm bearing housing for wear or damage Replace trailing arm if damaged 7 Press in new bearing until fully seated into trailing arm casting 8 Install new snap ring new O rings and bushings Rear Suspension Exploded View Radius Rods Shock Stabilizer Bar Link Bearing Carrier Trailin...

Page 236: ...shings and replace if needed Stabilizer Bar Installation 1 Carefully install stabilizer bar through the LH wheel well area NOTE Be sure fuel lines and shift cable are routed ABOVE the stabilizer bar 2 Fully install stabilizer bar bushings bracket and bracket fasteners and stabilizer links Center stabilizer bar in the frame Torque fasteners to specification see below 3 Install stabilizer bar locati...

Page 237: ... 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 IMPORTANT The spring retainer gap should be 180 from the end of the spring upon ...

Page 238: ...Preload Ring Jam Nut 3 1 Body 14 1 Preload Ring 4 1 Eyelet 15 1 Damping Adjust Asm Piston 5 1 Shaft 16 1 Damping Adjust Asm Concentric 6 1 Bearing Cap Asm 17 2 Bearing External 7 1 Bearing Asm 18 1 Bumper 8 1 Valving Asm 19 2 Bearing Spherical 9 1 Lock Nut 20 4 Retaining Ring 10 1 Reservoir 21 2 Retaining Ring 11 1 Piston Asm Floating IFP 22 Shock Oil 2870995 Preload Ring 10 ft lbs 14 Nm 22 ft lbs...

Page 239: ...ck oil and replace seals Front Shock Service Information SHOCK DESIGN DETAILS Travel 6 62 Extended Length 22 87 IFP Location 3 40 86 4 mm Nitrogen Pressure 200 psi 5 Gas Shock Oil 2870995 qt 3 40 IFP Depth SHOCK VALVING COMPRESSION REBOUND 1 600 x 0 008 1 425 x 0 010 1 600 x 0 008 1 425 x 0 010 0 900 x 0 006 1 425 x 0 010 1 600 x 0 008 1 100 x 0 004 1 425 x 0 010 1 425 x 0 010 1 300 x 0 010 1 350 ...

Page 240: ...870995 qt IFP Depth 3 40 SHOCK VALVING COMPRESSION REBOUND 1 600 x 0 008 1 425 x 0 012 1 600 x 0 010 1 425 x 0 010 1 600 x 0 010 1 100 x 0 004 1 250 x 0 004 1 425 x 0 010 1 600 x 0 015 1 350 x 0 010 1 425 x 0 015 1 250 x 0 010 1 425 x 0 015 1 100 x 0 010 1 350 x 0 015 0 950 x 0 010 1 300 x 0 015 1 230 x 082 Top Out 1 250 x 0 015 0 800 x 020 Back Up 1 250 x 0 015 1 100 x 0 015 1 100 x 0 015 1 100 x...

Page 241: ...lding tool PS 45281 A to properly secure the shock body assembly into a vice for service 5 Remove the nylon ball from the reservoir cap using a heavy duty pick Discard nylon ball and replace with new upon assembly 6 Slowly loosen nylon ball retainer from reservoir cap and allow nitrogen to completely escape 7 Remove the nylon ball retainer WARNING FOX shocks contain high pressure nitrogen gas Extr...

Page 242: ...P tool while pulling upward on the shock shaft to remove the shock shaft assembly 16 Remove the center screw and O ring from the IFP 17 Remove the IFP using the Shock IFP Tool 2871351 18 Remove shock body assembly from the vise Drain and properly dispose of shock oil 19 Secure the shock rod in a vice using the shock rod holding tool 2872429 Position the shock rod so the threaded end is facing upwa...

Page 243: ...r reassembly 6 Remove the low speed compression cap using a 10 Torx bit driver 7 Use a 5 8 socket to remove the LSC DSC compression control 8 Replace the O rings on the low speed compression piston 9 Inspect the LSC DSC blow out control with low pressure compressed air and replace O rings 10 Replace the internal and external O rings on the reservoir body Be sure O rings are lubricated with shock o...

Page 244: ...tion onto the shock asm Bearing Cap 1 Use a small pick to remove seal from the bearing cap 2 Lubricate a new seal and fully install into bearing cap 3 Push the Shock Seal Protector Sleeve PU 50939 through the bearing cap seal to insure proper installation 4 Refer to the assembly instructions for component installation onto the shock asm Bearing Assembly 1 Use a small pick to remove the U cup seal ...

Page 245: ...Install the jounce bumper onto the shock rod 3 Install the Shock Seal Protector Sleeve PU 50939 onto the shaft threads 4 Lubricate the shock rod and the Shock Seal Protector Sleeve with new shock oil WARNING FOX shocks contain high pressure nitrogen gas Extreme caution must be used while handling and working with FOX shocks and related high pressure service equipment The pressure must be released ...

Page 246: ...d 12 Remove the shock rod assembly from the vise and place on a clean shop towel 13 Use the appropriate shock body holding tool PS 45281 A to properly secure the shock body assembly into a vice for service 14 Fill the reservoir 3 4 full with the proper shock oil 15 Verify the center screw and O ring are not installed into the IFP 16 Install the IFP into the reservoir Keep top of reservoir covered ...

Page 247: ...ve any air bubbles from the oil 28 Add shock oil to 1 8 3 18 mm below the top of the shock body 29 Wrap a clean shop towel around top of shock body and depress the bearing assembly downward below the retaining ring groove 30 Install the bearing assembly retaining ring and clean excess shock oil Properly dispose of shop towel 31 Add shock oil to reservoir until it is 1 25 4 mm above the top of the ...

Page 248: ...servoir to the recommended pressure 46 Stroke the shock through its travel and adjust the external adjusters to ensure they are functioning properly 47 Use a rubber mallet to fully seat the bearing cap into position 48 Use a dead blow hammer to fully seat a new nylon ball into the reservoir cap 49 Install suspension spring s and reset preload to factory settings 50 Adjust external adjusters to the...

Page 249: ...ng 24 1 Bump Stop 6 1 Seal 25 N A 7 1 Wiper 26 1 Shaft Loop 8 3 O Ring 27 1 Shaft Spacer 1 235 x 1 985 9 1 Piston Clicker 28 2 O Ring 10 2 Clicker Bolt 29 1 Screw 8 32 11 1 Clicker Knob 30 1 O Ring 12 1 Clicker Stud 31 1 O Ring 13 1 Screw 10 32 32 1 Detent Spring 14 1 Piston Asm Floating IFP 33 1 Detent Ball 15 1 Reservoir End Cap 34 1 Shock Body 16 1 Reservoir Body 35 1 Spring Adjustment Nut 17 1...

Page 250: ... 1 Body Cap Asm 30 1 Screw 8 32 9 1 Spring Adjustment Nut 31 1 O Ring 10 1 Piston Asm 32 2 O Ring 11 1 Bridge 33 1 O Ring 12 1 Reservoir Mount 34 1 O Ring 13 1 Lock Nut 35 1 O Ring 14 1 Reservoir End Cap 36 1 Shaft Bushing 0 750 15 1 Check Valve 37 1 Seal 16 1 Clicker Bolt 38 1 Wiper 17 1 Ball 250 39 2 Crimp Nut 7 16 18 1 Reservoir Body 40 1 Snap Ring 19 1 Retention Nut 41 2 O Ring 20 1 Adjuster K...

Page 251: ...00 miles or Annually Change shock oil and replace seals Front Shock Service Information SHOCK DESIGN DETAILS Travel 6 62 Extended Length 22 87 IFP Location 3 375 85 7 mm Nitrogen Pressure 200 psi 5 Gas Shock Oil 2874124 qt 3 375 IFP Depth SHOCK VALVING COMPRESSION REBOUND 0 900 x 0 008 0 800 x 0 015 0 900 x 0 010 1 450 x 0 012 0 900 x 0 010 1 300 x 0 012 1 450 x 0 010 1 200 x 0 012 1 000 x 0 008 1...

Page 252: ...375 IFP Depth SHOCK VALVING COMPRESSION REBOUND 1 550 x 0 008 1 450 x 0 008 1 500 x 0 008 1 200 x 0 010 1 450 x 0 008 1 450 x 0 010 1 300 x 0 008 1 300 x 0 010 1 200 x 0 008 1 200 x 0 010 1 100 x 0 008 1 100 x 0 010 1 000 x 0 008 1 000 x 0 010 0 900 x 0 008 0 900 x 0 012 0 800 x 0 008 0 800 x 0 015 1 500 x 0 015 1 000 x 100 Back Up 1 450 x 0 015 1 300 x 0 015 1 200 x 0 015 1 100 x 0 015 1 000 x 0 ...

Page 253: ...of relief ports will always face the rebound valve stack WARNING Walker Evans shocks contain high pressure nitrogen gas Extreme caution must be used while handling and working with Walker Evans shocks and related high pressure service equipment The pressure must be released from the shock before disassembly It is strongly recommended you wear safety glasses and ear protection during these procedur...

Page 254: ...ervice 4 Remove the valve cap from the valve fitting on the top of the reservoir 5 Carefully depressurize the shock 6 Using a snap ring pliers remove the retaining ring from the reservoir 7 Carefully remove the cap from the reservoir body WARNING Walker Evans shocks contain high pressure nitrogen gas Extreme caution must be used while handling and working with Walker Evans shocks and related high ...

Page 255: ...Internal Floating Piston IFP a few times to purge the shock oil from the reservoir 11 Remove the floating piston from the shock reservoir using the IFP Tool PS 45908 12 Clean and inspect ALL parts and replace as needed IMPORTANT Seal kits are available and should be installed at this time if seals or O rings are damaged or worn 13 Use the appropriate shock rod holding tool and a vise to mount the ...

Page 256: ...appropriate shock body holding tool to properly secure the shock assembly into a vice for service 19 Front Shocks Only Using a 9 16 socket w extension remove the fastener retaining the clicker valve stack Place the valve stack on a clean shop towel in order of removal IMPORTANT Keep the valve stack in the order it was removed If unsure of order refer to Shock Valving under the Shock Service Inform...

Page 257: ...tack IMPORTANT If unsure of the valve stack order refer to Shock Valving under the Shock Service Information provided earlier in this section 8 Place a new lock nut onto the shock rod Torque the new lock nut to specification IMPORTANT Do not over torque the nut or damage to the valve stack can occur NOTE Make sure Top Out washers are orientated as shown 9 Front Shocks Only Assemble the clicker val...

Page 258: ...shock oil 13 Using a 3 32 Allen wrench remove IFP bleed screw 14 Apply a thin film of oil to IFP O ring and wear band Insert IFP into reservoir until completely submerged Allow air to escape as you install the piston 15 Screw IFP Tool PS 45908 onto the floating piston 16 Slowly cycle the IFP up and down Be sure to bottom out piston in the reservoir body Allow time for the bubbles to dissipate Repe...

Page 259: ... This opens the valves on the damping piston You will see the released air bubbles come to the surface of the oil 20 Add oil to the body tube until the surface of the oil is at the top of the shock body threads NOTE During installation some shock oil will over flow Wrap a shop cloth around the shock body to catch any oil overflow 21 Pull the damping piston up until it is just below the surface of ...

Page 260: ... fully extended and the reservoir pressure is at 200 psi 35 Reinstall the valve cap 36 Clean all oil residue from the shock and reservoir with solvent and dry with low pressure compressed air in a well ventilated area 37 Check shock for any leaks 38 Reinstall the compression spring and the spring retainer 39 Thread the spring preload adjuster down against the spring and set the preload to the spec...

Page 261: ...RS AND DUCTING COMPONENTS 6 5 PVT DISASSEMBLY 6 5 PVT ASSEMBLY 6 7 DRIVE BELT 6 9 BELT REMOVAL 6 9 BELT INSPECTION 6 9 BELT INSTALLATION 6 10 PVT BREAK IN DRIVE BELT CLUTCHES 6 10 DRIVE CLUTCH SERVICE 6 11 DRIVE CLUTCH EXPLODED VIEW 6 11 DRIVE CLUTCH DISASSEMBLY INSPECTION 6 12 DRIVE CLUTCH SPRING INSPECTION 6 13 NEEDLE BEARING INSPECTION 6 13 SHIFT WEIGHT INSPECTION 6 13 BUTTON TO TOWER CLEARANCE...

Page 262: ...utch Bushing Replacement Tool Kit 2870386 Piston Pin Puller PU 50518 Driven Clutch Compression Tool 2871025 Clutch Bushing Replacement Tool Kit 2877408 Shock Spanner Clutch Spreader RZR XP 2878925 Shock Spanner Clutch Spreader RZR XP 4 SPECIAL SUPPLIES PART NUMBER Loctite 609 and 263 N A RTV Silicone Sealer 8560054 ITEM TORQUE VALUE Drive Clutch Retaining Bolt 96 ft lbs 130 Nm Driven Clutch Retain...

Page 263: ...hifting to maintain optimum engine RPM At full throttle a perfectly matched PVT system should hold engine RPM at the peak of the power curve This RPM should be maintained during clutch upshift 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 upshif...

Page 264: ...fficient engine warm up when exposed to low ambient temperatures Warm engine at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Stuck in mud or snow Shift the transmission to Low ca...

Page 265: ...ut from the left rear shock Discard the nut 6 Swing shock outward toward the front of the vehicle Inner Clutch Outer Cover Outer Outlet Duct Screen Outlet Duct Screws Clutch Cover Clutch Cover Cover Seal Boot Bolt Washer Guard Plates Intake Box Bracket Inner Cover Seal Intake Hose Inlet Duct Clutch Intake Box Seal Filter Cover Drain 17 ft lbs 23 Nm 5 Nm 45 50 in lbs 12 ft lbs 16 6 Nm Push Rivets C...

Page 266: ...l the Drive Clutch Holding Tool 9314177 A on the drive clutch 11 Remove the drive clutch retaining bolt and remove the drive clutch using Drive Clutch Puller 2872085 IMPORTANT Be sure to use the correct Drive Clutch Puller PN 2872085 to prevent damage to crankshaft 12 Remove the 4 push rivets that secure the upper guard plate to the top of the inner PVT cover Make note of the routing of the fuel l...

Page 267: ...7 bolts that retain inner clutch cover to engine and transmission Remove inner clutch cover PVT Assembly 1 Inspect inner clutch cover Replace if cracked or damaged 2 Inspect the seal on the transmission input shaft Replace if damaged 3 Inspect inner clutch cover seal engine side Replace if cracked torn or damaged 4 Install and properly align the inner clutch cover Be sure the fuel line vent line a...

Page 268: ...ll the drive clutch onto the engine 13 Install the Drive Clutch Holding Tool 9314177 A and torque the retaining bolt to specification 14 Install the drive belt noting direction of belt rotation see DRIVE BELT Belt Installation If a new belt is installed install so numbers can be easily read 15 Install a new outer clutch cover seal with the colored stripe facing the inner clutch cover 16 Reinstall ...

Page 269: ... driven clutch as shown tool included with vehicle s tool kit NOTE Make sure the tool is square with the moveable sheave surface of the driven clutch 5 Rotate tool towards the clutch to open the sheaves 6 Walk the belt out of the driven clutch and drive clutch Remove the belt from the vehicle Belt Inspection 1 Inspect belt for hour glassing extreme circular wear in at least one spot and on both si...

Page 270: ...spin the driven clutch and belt approximately 5 7 times to properly seat the belt in the driven clutch 5 Install the outer clutch cover and 8 screws Torque screws to specification PVT Break In Drive Belt Clutches A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and drive belt by operating at slower speeds during the 10 hour bre...

Page 271: ...s Bushing Spring Bushing Clutch Bolt Washer Cover Screws Button Pin Washers Roller Nut Shift Weight Bolt Spacer Spider Needle Bearing Washers Jam Nut Apply 263 Loctite Retaining Ring Washer Limiter Spacer 100 in lbs 12 Nm 96 ft lbs 130 Nm 280 300 ft lbs 379 406 Nm 250 ft lbs 339 Nm 20 in lbs 2 3 Nm Non braking Apply 263 Loctite Moveable Sheave Stationary Sheave Cover ...

Page 272: ...y in a cross pattern and remove cover plate 4 Inspect cover bushing A The outer cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing 5 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or damaged 6 Remove and inspect the clutch spring B Refer to Drive Clutch Spring Inspect...

Page 273: ...ify there is no binding or rough spots If problems are noted continue with disassembly Shift Weight Inspection 1 Remove shift weight bolts and weights Inspect the contact surface of each weight The surface should be smooth and free of dents or gall marks Inspect the weight pivot bore and bolts for wear or galling If weights or bolts are worn or broken replace in sets of three with new bolts and nu...

Page 274: ... cracked Spider Removal 1 Install clutch onto holding fixture 2871358 A and secure in bench vice Loosen and remove the spider jam nut counterclockwise using the Clutch Spider Nut Socket PU 50578 2 Loosen and remove the spider counterclockwise using Clutch Spider Removal Installation Tool PN 2870341 Button to Tower Clearance 000 012 000 304 mm Clutch Spider Nut Socket PU 50578 Clutch Holding Fixtur...

Page 275: ...uttons are not serviceable at the time of this publication Clutch Inspection NOTE Remove cover spring limiter spacer and spider following the instructions for drive clutch disassembly then proceed as follows 1 Remove and inspect the moveable sheave spacer Visually inspect the spacer for damage and replace if necessary 2 Remove the moveable clutch sheave 3 Lift bearing and thrust washers off the sh...

Page 276: ...fication Replace if worn or damaged Moveable Sheave Bushing Inspection Inspect the Teflon coating arrow on the moveable sheave bushing Inspect both sheaves for signs of wear grooving or cracking De glaze sheave surfaces with a 3M Scotch Brite Pad if needed In mm Shaft Diameter Standard 1 3725 1 3712 34 8615 34 8488 mm Service Limit 1 3704 34 8088 mm In mm Thrust Washer Thickness Standard 030 76 mm...

Page 277: ...ler rod 7 Install removal tool Item A B into center of sheave with A side toward sheave EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Tool Description A B 1 5132027 EBS Puller Tool C 1 5132501 EBS Puller Nut D 1 5132029 EBS Main Adapter E 1 5132028 EBS Bushing Removal 1 9915111 Instructions Additional Special Tools Qty Part Tool Description 1 2871226 Clutch Bushing Replacement Tool 1 2870386 P...

Page 278: ... seated 8 Remove nut from puller rod and set aside 9 Remove sheave from puller 10 Remove installation tool Cover Bushing Removal 1 Install main adapter Item 8 on puller 2 Install adapter reducer Item 9 3 From outside of clutch cover insert removal tool Item 3 into cover bushing 4 With inside of cover toward vise slide cover onto puller 5 Install nut onto puller rod and hand tighten Turn puller bar...

Page 279: ...ble sheave slides freely on the spacer 4 Apply Loctite 263 to the spider threads 5 Install the spider assembly onto the shaft threads Be sure all of the alignment marks are in alignment 6 Install clutch onto holding fixture PN 2871358 A and secure in a bench vice Tighten the spider using Clutch Spider Tool PN 2870341 Torque spider to specification 7 Apply Loctite 263 to the threads of the spider j...

Page 280: ... illustrated below are not in alignment upon assembly the clutch will not be in balance and the drive clutch assembly must be replaced 10 Install the limiter spacer A and the clutch spring B 11 Install the drive clutch cover C Be sure all alignment marts are in alignment 12 Install cover bolts and torque in a cross pattern evenly to specification T Spider Jam Nut 250 ft lbs 339 Nm Apply Loctite 26...

Page 281: ...2 It is important to mark the position of the shaft cam cover and sheave before disassembly or use the X s on the components for reference This will aid in assembly and maintains clutch balance 3 Remove the four screws that secure the cam helix assembly using a T25 Torx driver 4 Place the driven clutch into the Universal Clutch Compressor PU 50518 5 Press down on the top of the spider assembly pus...

Page 282: ...late D and spider dampener E Inspect the spider dampener E for wear and replace if needed 8 Remove the E clips F washers G and the clutch rollers H Inspect the rollers for wear replace if worn 9 Remove the clutch assembly from the holding tool 10 Press out the spring pins I in the inner sheave 11 Pull out the clutch roller pins J and rollers K 12 Press the shaft and bearing out of the outer sheave...

Page 283: ...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 Inspect Bushing Inspect Sheave Surface EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Tool Description A B 1 5132027 EBS Puller Tool C 1 5132501 EBS Puller Nut D 1 5132029 EBS Main Adapter E 1 5132028 EBS Bushing Remov...

Page 284: ... removed and sheave comes free 8 Remove nut C left hand thread from puller rod and set aside 9 Remove adapters from puller 10 Remove bushing and removal tool from adapters Discard bushing Clutch Bushing Installation 1 Install puller adapter Item 10 onto puller 2 Install adapter Item 9 onto puller 3 Apply Loctite 609 evenly to bushing bore inside moveable sheave 4 Install sheave face down on puller...

Page 285: ... is fully seated install a new snap ring 2 Install the shaft and bearing assembly into the outer sheave NOTE Press only on the outer race of the bearing during installation to prevent damaging the bearing 3 Line up the X on the moveable sheave with the X on the stationary sheave or use the marks previously used Put the sheaves together 4 Install the roller A onto the roller pin B on both sides Ali...

Page 286: ...the clutch rollers D onto each side of the outside spider Install the washers E and E clips F to secure the rollers The rollers should spin freely 9 Install the spider dampener G inside the outer spider and install the inside spider plate H 10 Install the spider assembly onto the shaft with the retaining ring on top of the spider NOTE Use the marks previously made to align the skip tooth spider or...

Page 287: ...ing 14 Install the cam helix assembly over the shaft Line up the X on the cam X on spider and X on the stationary sheave or use the marks previously made before disassembly NOTE If the cam assembly helix is difficult to install be sure the sheaves are aligned To align the sheaves place the clutch assembly on a flat surface with the cam assembly helix side down Press down on the moveable sheave bel...

Page 288: ...12 Polaris Sales Inc Exploded View Compression Thrust Washer Cam Helix Retaining Ring Roller Pin Slotted Ball E Clips Spring Spider Dampener Outer Spider Spider Insert Stationary Sheave Bearing Spring Pin Moveable Sheave Clutch Shaft Roller Retaining Ring 42 52 in lbs 4 75 5 88 Nm T25 Screws ...

Page 289: ... above specified operating range Incorrect drive clutch spring too high of rate Drive clutch shift weights incorrect for application too light Drive clutch binding Driven clutch binding Converter 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...

Page 290: ...r different terrain as outlined in Owner s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt slippage Belt worn out Water ingestion Belt contaminated with oil or grease Replace belt Inspect and seal PVT syst...

Page 291: ...PROPSHAFT INSTALLATION 7 14 SUPPORT BEARING REPLACEMENT 7 15 PROPSHAFT U JOINT SERVICE 7 16 FRONT GEARCASE CENTRALIZED HILLIARD 7 18 CENTRALIZED HILLIARD EXPLODED VIEW 7 18 ALL WHEEL DRIVE OPERATION 7 19 AWD DIAGNOSIS 7 20 FRONT GEARCASE REMOVAL DISASSEMBLY INSPECTION 7 21 FRONT GEARCASE ASSEMBLY 7 24 FRONT GEARCASE INSTALLATION 7 26 REAR BEARING CARRIER 7 27 BEARING CARRIER INSPECTION REMOVAL 7 2...

Page 292: ...ESCRIPTION 2872608 Roll Pin Removal Tool 8700226 CV Boot Clamp Pliers earless type PU 48951 Axle Boot Clamp Tool ITEM SPECIFICATION Wheel Nuts 30 ft lbs 41 Nm 90 1 4 turn Front Hub Castle Nut 80 ft lbs 108 Nm Rear Hub Castle Nut 80 ft lbs 108 Nm Ball Joint Pinch Bolts 44 ft lbs 60 Nm Front Brake Caliper Mounting Bolts 40 ft lbs 54 Nm Tie Rod End Fastener 42 5 ft lbs 58 Nm Propshaft Support Bearing...

Page 293: ... smooth rotation Visually inspect bearing for moisture dirt or corrosion 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 sideways between inner and ou...

Page 294: ...housing clean of any excess compound and install the snap ring Bearing Carrier Installation 1 Install drive shaft axle through the backside of the bearing carrier 2 Install the upper and lower ball joint ends into the front bearing carrier 3 Install new pinch bolts and nuts Torque to specification 4 Apply Anti Seize to drive shaft axle splines 5 Install front wheel hub assembly cone washers and ha...

Page 295: ...ew cotter pin Tighten nut slightly if necessary to align cotter pin holes Bend both ends of cotter pin around end of spindle in different directions 10 Install wheel and 4 wheel nuts Torque wheel nuts to specification 11 Rotate wheel and check for smooth operation CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon ass...

Page 296: ...he brake disc see Chapter 9 CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 5 Remove the front wheel hub assembly 6 Remove and discard the upper and lower ball joint pinch bolts and nuts 7 Using a soft faced hammer lightly tap on the bearing carrier while removing the upper ball joint end 8 Remove the drive shaft from the front bearing...

Page 297: ...to tap on the outboard end of the drive shaft if necessary 3 Install drive shaft into the front bearing carrier 4 Install the upper and lower ball joint ends into the front bearing carrier 5 Install new pinch bolts and nuts Torque to specification 6 Apply Anti Seize to drive shaft axle splines 7 Install front wheel hub assembly cone washers and hand tighten the castle nut Install washers with dome...

Page 298: ...t directions 9 Install new brake caliper mounting bolts and torque to specification 10 Install wheel and 4 wheel nuts Torque wheel nuts to specification 11 Rotate wheel and check for smooth operation T Wheel Hub Castle Nut 80 ft lbs 108 Nm T Front Caliper Mounting Bolts 40 ft lbs 54 Nm CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper m...

Page 299: ... Tool PN 2872608 to remove the roll pin Discard roll pin NOTE Right front wheel can be removed to gain better access to the propshaft roll pin 4 Remove the 4 bolts retaining the front gearcase 5 Carefully move the gearcase forward to remove the front propshaft from the gearcase input shaft 6 Slide the front propshaft off the rear propshaft and remove it from the vehicle 7 Proceed to Front Propshaf...

Page 300: ...the front gearcase 5 Carefully move the gearcase forward to remove the front propshaft from the gearcase input shaft 6 Slide the front propshaft forward to remove it from the rear propshaft 7 Remove the 4 fasteners retaining the front portion of the vehicle skid plate Allow the front portion of the skid plate to hang down for propshaft removal 8 Move the front propshaft towards the rear of the veh...

Page 301: ...ing installation if still visible 5 When installing the front propshaft onto the front gearcase use a new roll pin 6 Reposition the front gearcase and install the 4 bolts that secure the front gearcase to the frame Torque bolts to specification Rear Propshaft Removal RZR XP 1 Remove both seats and engine service panel 2 Remove the gear selector knob and center console 3 Remove the 2 fasteners reta...

Page 302: ... to the frame Remove the support bracket from the vehicle 9 Pull the rear propshaft towards the front of the vehicle and position it as shown 10 Position the rear propshaft yoke between the engine mount tube and rear stabilizer bar to allow the propshaft to be slid further back 11 Remove the rear propshaft assembly from the vehicle through the skid plate IMPORTANT Do not attempt to separate the su...

Page 303: ...ropshaft 6 Once the front and rear propshafts have been separated lift up on the floor and slide the front propshaft underneath the floor as shown 7 Slide the rear propshaft forward to remove it from the transmission output shaft 8 Lift up on the floor and slide the rear propshaft through the floor opening as shown 9 Remove the 4 fasteners retaining the front portion of the vehicle skid plate Allo...

Page 304: ...ll the rear propshaft 2 Lubricate the transmission output shaft splines with Polaris All Purpose Grease 3 Lubricate the front and rear propshaft mid joint with Polaris All Purpose Grease 4 Align the front and rear propshafts as shown below and slide them together NOTE Paint marks are applied to the front and rear propshafts to aid shaft alignment Reference these marks during installation if still ...

Page 305: ...e propshaft IMPORTANT Do not attempt to separate the bearing from the rubber isolated support assembly upon installation 6 Using an appropriate bearing bushing installation sleeve drive the support bearing assembly onto the propshaft until it seats against the shoulder on the shaft IMPORTANT Take care while installing the support bearing assembly Be sure to only drive on the inner race of the bear...

Page 306: ...g installation 2 Support inner yoke as shown and drive outer yoke down bearing cap out with a soft face hammer 3 Support U joint in vise as shown and drive inner yoke down to remove remaining bearing caps 4 Force U joint cross to one side and lift out of inner yoke Assembly 1 Install new bearing caps in yoke by hand Carefully install U joint cross with grease fitting properly positioned inward tow...

Page 307: ...g to contain bearing cap just installed Repeat procedure for other side 5 Install outer yoke aligning marks made at disassembly and repeat Steps 1 3 to install bearing caps on outer yoke 6 Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown 7 When installation is complete yokes must pivot freely in all directions without binding If the joint is st...

Page 308: ...mbly Male 1 5 Ball Bearing 2 22 Rollers 20 6 Ball Bearing Double Row 1 23 Torsion Spring 1 7 Bushing 1 24 H Clip Spring 20 8 Bushing 1 26 Nylon Spacer 2 9 Oil Seal 2 27 Backlash Spacer 1 10 Oil Seal 1 28 Ring Gear Spacer 1 11 Retaining Ring Internal 1 29 Torsion Spring Retainer 1 12 Retaining Ring 1 30 Pinion Gear 1 13 Cover Screws M6 T30 Torx 7 31 Armature Plate 1 14 Cover Plate Assembly 1 32 AWD...

Page 309: ... the roll cage that indexes the rollers inside the ring gear to an engagement position While in the engagement position the front drive will be in an over running condition not engaged until the rear wheels lose traction Once the rear wheels begin to lose traction the front drive will engage by coupling the output hubs to the ring gear via the rollers The front drive will remain engaged until the ...

Page 310: ...s indicated in Step 5 A wear band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation 5 Check to make sure the coil is seated in the U shaped insert that is pressed into the gearcase cover The top of the coil should be seated below the U shaped insert The U shaped insert controls the pole gap If the top of the coil is above the surface of the U shaped i...

Page 311: ... gearcase and remove the harness from the retaining dart 6 Remove the vent line from the front gearcase and plug vent line fitting 7 Remove the 4 bolts securing the front gearcase to the frame 8 Rotate front of gearcase up so the input shaft is facing down Lift and remove the gearcase from the front LH wheel well area and slide it out of the vehicle above the upper A arm Front Gearcase Disassembly...

Page 312: ...viceable and should not be removed 4 Remove and inspect the armature plate Refer to AWD Diagnosis for detailed inspection process 5 Remove the torsion spring retainer and torsion spring from the top of the ring gear 6 Remove the clutch housing ring gear and roll cage assembly from the gearcase housing LH Output Hub LH Output Hub Non serviceable DO NOT Remove Armature Plate Spring Retainer Torsion ...

Page 313: ... and O ring 11 Remove the roll cage assembly and rollers from the clutch housing Use a shop towel to cover the housing in order to retain all the rollers NOTE Rollers are spring loaded Take care not to allow them to fall out or lose them upon removal of the roll cage 12 Thoroughly clean all parts and inspect the rollers A for nicks and scratches The rollers must slide up and down and in and out fr...

Page 314: ... wear or damage Front Gearcase Assembly 1 As mentioned during gearcase disassembly section replace all O rings seals and worn components 2 Install pinion shaft assembly and install internal snap ring NOTE If bearing replacement was required press new bearing onto the pinion shaft and install a new external snap ring 3 Install a new pinion shaft seal into the pinion gear housing Using a universal s...

Page 315: ...tainer dowel pin with ring gear dowel pin and install the retainer on top of the torsion spring 8 Check the action of the torsion spring by rotating in both directions to ensure the spring and retainer are installed properly 9 Install armature plate Be sure all of the armature plate tabs are fully engaged into the roll cage assembly and that it is resting properly on the torsion spring retainer NO...

Page 316: ...o the gearcase housing Install the 7 cover plate screws and torque to specification Front Gearcase Installation 1 Install the gearcase back into the vehicle through the LH wheel well area above the upper A arm 2 Lubricate the front gearcase splines with Anti Seize 3 Install the propshaft onto the front gearcase input shaft Use a NEW spring pin in the front propshaft 4 Install the 4 bolts that secu...

Page 317: ...m of the tire firmly and checking for movement The tire should rotate smoothly without binding or rough spots 3 Remove the 4 wheel nuts and 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 lower radius rod outer mounting bolt nut and washer from the bearing carrier Swing radius rod down Disca...

Page 318: ... trailing arm Discard the nuts 9 Remove the bearing carrier from the rear drive shaft and trailing arm 10 Rotate bearing by hand and check for smooth rotation Visually inspect bearing for moisture dirt or corrosion 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 corr...

Page 319: ... Replace rear bearing carrier if damaged Bearing Installation 5 Thoroughly clean the rear bearing carrier housing and the outer race on the new bearing Be sure that all oil residue has been removed from each surface 6 Support the bottom of the bearing carrier housing 7 Apply Loctite 603 retaining compound to the outer circumference of the new bearing race and carefully press the new bearing into t...

Page 320: ...aring carrier Torque bolts to specification NOTE Use new nuts upon installation of the rear bearing carrier 3 Apply anti seize to drive shaft splines 4 Install rear wheel hub assembly cone washers and hand tighten the castle nut Install washers with domed side out 5 Install the rear brake caliper assembly and new bolts Torque to specification T Bearing Carrier to Trailing Arm Bolts 40 ft lbs 54 Nm...

Page 321: ...ter 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 2 bolts retaining the upper and lower radius rods to the bearing carrier Discard the nuts Let the radius rods swing downward 5 Remove the brake caliper mounting bolts Remove the rear brake caliper assembly CAUTION Do not hang the caliper by the brake line Use wire to han...

Page 322: ...haft in the transmission swing the rear trailing arm assembly outward until it is free from the rear drive shaft 12 Lower the trailing arm 13 With a short sharp jerk remove drive shaft from the transmission splines Drive Shaft Installation 1 Install new spring ring on drive shaft Apply an anti seize compound to the splines 2 Align splines of drive shaft with transmission splines and reinstall the ...

Page 323: ...pecification Install new cotter pin 8 Install the radius rod bolts washers and new nuts Torque fasteners to specification 9 Install the rear brake caliper assembly and new bolts Torque to specification 10 Install wheel and 4 wheel nuts Torque wheel nuts to specification T Lower Shock Bolt to Trailing Arm 70 ft lbs 95 Nm T Stabilizer Bar Linkage 31 34 ft lbs 42 46 Nm T Rear Wheel Hub Castle Nut 80 ...

Page 324: ...s or hot engine and exhaust components The drive shaft is not to be used as a lever arm to position other suspension components Never use a hammer or sharp tools to remove or to install boot clamps Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned Refer to text for grease capacity of CV join...

Page 325: ...he end of the shaft 12 Grease the joint with the special CV joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in the joint s inner race Pack the ball tracks and outer face flush with grease Place any remaining grease into the boot NOTE The amount of grease provided in the boot kit is pre measured Use entire contents of package 13 Slide the join...

Page 326: ...ts correct location on the shaft 20 Install and tighten the small clamp on the boot using the appropriate clamp tool Inner Plunging Joint Boot Replacement 1 Use a side cutters to cut and discard the boot clamps 2 Remove the large end of the boot from the plunging joint and slide the boot down the shaft 3 Clean the grease from the face of the joint and place the drive shaft in a soft jawed vise 4 U...

Page 327: ... balls and the splined hole in the joint s inner race Pack the ball tracks and outer face flush with grease Place any remaining grease into the boot NOTE The amount of grease provided in the boot kit is pre measured Use entire contents of package 13 Fully compress the joint and push the drive shaft firmly into the inner race 14 Align the circlip with the lead in chamfer 15 Use a soft faced hammer ...

Page 328: ...e a straight O ring pick or a small slotted screw driver between the large end of the boot and the joint housing and lift up to equalize the air pressure in the boot 21 Position the boot lip in its groove Install and tighten the large clamp using the appropriate clamp tool Drive Shaft Exploded View Axle Boot Clamp Tool PU 48951 or CV Boot Clamp Pliers 8700226 Axle Boot Clamp Tool PU 48951 or CV Bo...

Page 329: ...Pin Cone Wheel Hub Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Washers 80 ft lbs 108 Nm Ring Carrier Front Rim Aluminum Wheel Nuts 30 ft lbs 41 Nm 90 1 4 turn Studs Wheel Cap Castle Nut Cotter Pin Cone Wheel Hub Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Washers 80 ft lbs 108 Nm Ring Carrier Rear Rim Aluminum Wheel Nuts 30 ft lbs 41 Nm 90 1 4 turn Studs Wheel Cap ...

Page 331: ...N INSTALLATION 8 8 TRANSMISSION SERVICE 8 12 TRANSMISSION DISASSEMBLY 8 12 GEAR SHAFT BEARING INSPECTION 8 16 SNORKEL GEAR BACKLASH PROCEDURE 8 17 TRANSMISSION ASSEMBLY 8 19 TRANSMISSION SERVICE INT L 8 23 DIFFERENTIAL OPERATION 8 23 TRANSMISSION DISASSEMBLY 8 24 PLANETARY DIFFERENTIAL DISASSEMBLY 8 28 PLANETARY DIFFERENTIAL BUSHING REPLACEMENT 8 29 PLANETARY DIFFERENTIAL ASSEMBLY 8 31 GEAR SHAFT ...

Page 332: ...m Snorkel Tube Refer to Snorkel Gear Backlash Procedure Snorkel Tube Locking Screw 8 10 ft lbs 11 14 Nm Support and Shift Cable Bracket Bolts 17 ft lbs 23 Nm Transmission Case Screws 15 20 ft lbs 20 27 Nm Speed Sensor Screw 9 12 ft lbs 12 16 Nm PART NUMBER TOOL DESCRIPTION PA 50231 Snorkel Tool 2871698 Part of 2871702 Kit Rear Output Seal Driver 2871699 Part of 2871702 Kit Rear Driveshaft Seal Gui...

Page 333: ... a T27 and T30 Torx driver Remove the console from the vehicle 3 Remove the clip and washer retaining the shift cable to the shift lever and disconnect the cable end from the lever 4 Remove the retaining ring and slide the shift lever off the mounting bracket and out from the frame 5 Remove both bushings from the shift lever and service as needed Installation 1 Perform the removal steps in reverse...

Page 334: ...dust boot Replace if worn or damaged 3 If adjustment is required loosen the lower jam nut and pull the cable out of the mount to move the upper jam nut 4 Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK 5 Thread the upper or lower jam nut as required to obtain proper cable adjustment NOTE This procedure may require a few attempts to ...

Page 335: ...repair is required drain the transmission lubricant see Chapter 2 9 Remove the lower mounting bolt from the left rear shock Swing shock outward 10 Remove the outer clutch cover drive belt drive clutch driven clutch inner clutch cover and clutch outlet duct see Chapter 6 IMPORTANT Be sure to use the correct Drive Clutch Puller PN 2872085 to prevent damage to crankshaft 11 Loosely install the left r...

Page 336: ...rms up and swing trailing arms outward to remove the drive shafts from the transmission 15 Maneuver the drive shafts out of the vehicle frame Reinstall the lower shock bolts to hold the trailing arms up during the rest of the removal procedure 16 Place a spacer or support between the vehicle frame and engine to hold the engine up in position 17 Remove vent hose from transmission 18 Remove the gear...

Page 337: ...haust springs securing the muffler to the rear transmission mounting bracket 22 Remove the 6 bolts H attaching the rear transmission mount bracket assembly J to the frame Remove the 3 bolts K that attach the 2 rear mounts L to the transmission Remove the mount assemblies from the vehicle 23 Slide transmission towards the rear of the vehicle Lift and rotate the top of the transmission towards the l...

Page 338: ...rings securing the muffler to the rear transmission mounting bracket 5 Install the Clutch Center Distance Tool PU 50658 onto the crankshaft and transmission input shaft to properly position the clutch center distance The pictures below show the tool PU 50658 properly installed 6 Loosen the 2 bolts retaining the transmission coupler bracket to the engine on the right side 7 Align front transmission...

Page 339: ...mbered sequence shown 11 Remove the clutch center distance tool 12 Remove the spacer or support between the vehicle frame and engine 13 Install and properly route the gear position switch connector A speed sensor connector B crankshaft position sensor connector C shift bracket and shift bracket bolts D shift cable clevis pin and washer E onto the transmission 14 Torque the 2 shift cable bracket bo...

Page 340: ...lt and swing the rear trailing arm out and up Align the splines of the drive shaft with the transmission splines Push inward on the trailing arm assembly until the rear drive shafts lock into the transmission splines 21 Install the rear shocks onto the trailing arms and install the lower mounting bolts with new retaining nuts Torque to specification 22 Install the 4 rear radius rods to the bearing...

Page 341: ...he rear bumper and cargo box as an assembly see Chapter 5 28 Connect the negative battery cable 29 Install the engine service panel console cover and seats 30 If transmission lubricant was drained fill the transmission with the specified amount of Polaris AGL Plus see Chapter 2 Transmission Lubrication Recommended Transmission Lubricant AGL Plus PN 2878068 Quart Capacity Standard 44 oz 1300 ml Cap...

Page 342: ...umbs to press in on the shafts while pulling out the cover with your fingers 6 Remove the compression spring H 7 Remove the detent star I Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly 8 Remove the spacer J 9 Remove the shift shaft K detent pawl L and the shift sector gears M and N IMPORTANT Note the timing marks on the shift gears M and N f...

Page 343: ...nderneath the gear or by tapping the shaft from the opposite side 15 Remove the idler gear shaft assembly T and gear cluster assembly U from the transmission housing by pulling both assemblies straight up 16 Place the gear cluster assembly on a clean surface for inspection If disassembly is required refer to Gear Cluster Disassembly 17 Using a 5 mm Allen wrench remove the screws that secure the pi...

Page 344: ...ining ring washer needle bearing and sprocket from the reverse shaft see Figure 8 1 22 Tilt the two shafts towards each other and remove the silent chain from the two shafts 23 If necessary disassemble the other end of the reverse shaft Remove the bearing engagement dog retaining ring washer gear and needle bearing from the reverse shaft see Figure 8 2 24 To disassemble the shift shaft rail remove...

Page 345: ...orkel tube 27 Remove the snorkel tube and shaft assembly from the transmission case 28 Remove the snap ring Y and shim Z from the snorkel shaft 29 Use an arbor press to remove the snorkel tube from the snorkel shaft 30 Remove the snap ring A and shim B retaining the bearing in the snorkel tube CAUTION The pinion shaft must be removed prior to removing the snorkel shaft assembly Failure to remove p...

Page 346: ... the retaining ring to remove the remaining washer bearing and gear from the snorkel shaft Gear Shaft Bearing Inspection Inspect all gear sets and shafts for excessive wear or damage IMPORTANT If gear replacement is required be sure to also replace the corresponding gear or gear shaft Inspect all bearings for signs of wear or damage If replacement is required use a standard bearing puller or an ar...

Page 347: ... press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service 4 Apply a small amount of white lithium grease or Anti Seize on the threads of the snorkel tube 5 Install the snorkel shaft into the gearcase Using the Snorkel Tool PA 50231 tighten the snorkel tube until it is lightly seated in the transmission housing 6 Inspect the ...

Page 348: ...zero backlash position you should still be able to turn the snorkel shaft using your fingers but it will feel rough and may have some tight spots 12 Look down into the transmission housing to see the snorkel locking screw hole opening to reference your starting point NOTE If you have a hard time seeing into the hole insert a small Allen wrench punch or screwdriver into the hole to feel when the no...

Page 349: ...t and pinion shaft must be installed prior to transmission assembly The snorkel shaft cannot be installed after assembling the transmission 1 Clean both transmission case halves thoroughly Inspect case half mating surfaces for damage 2 Assemble the reverse shaft assembly and input shaft assembly if previously disassembled see illustrations T Snorkel Locking Screw 8 10 ft lbs 11 14 Nm 8 10 ft lbs 1...

Page 350: ...o the same side of the rail 6 Install the shift shaft rail D and shift forks into the transmission housing as an assembly Be sure the shift forks are engaged into the engagement dogs NOTE Shift fork pins should be offset towards the input shaft as shown above 7 Inspect the shift drum for any damage or wear Inspect the splines of the shift drum 8 Install the shift drum E into the transmission housi...

Page 351: ...ld be pressed in until it seats flush with the housing The rear output shaft seals H can be installed using a standard bushing installation tool Seals should be installed just past the case lead in chamfer 070 or 1 8 mm from outer face of bore 12 Thoroughly clean the shift shaft housing Be sure the transmission is in High gear prior to reassembly 13 Install the sector gear 16T onto the shift drum ...

Page 352: ...lean the transmission and gear sector cover mating surfaces thoroughly 19 Apply Crankcase Sealant 3 Bond PN 2871557 onto the cover and transmission case mating surface 20 Install the sector cover and align the transmission case dowel with the alignment hole Install and torque the bolts to specification 21 Install the transmission drain plug and torque to specification 22 Install the bellcrank onto...

Page 353: ...ve shafts are now dependent on the differential allowing for tighter turns When Differential Lock is selected power is removed from the electrical solenoid allowing the solenoid plunger to retract Spring tension moves the shift fork back into place and mates the engagement dog to the side gear that is part of the planetary differential assembly This locks the rear differential as a solid rear axle...

Page 354: ... with your fingers 6 Remove the compression spring H 7 Remove the detent star I Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly 8 Remove the spacer J 9 Remove the shift shaft K detent pawl L and the shift sector gears M and N IMPORTANT Note the timing marks on the shift gears M and N for reassembly purposes 10 Remove the O rings P from each s...

Page 355: ...S by lifting underneath the gear or by tapping the shaft from the opposite side If use of a pry bar is necessary take care not to pry on sealing surfaces of case 16 Remove the idler gear shaft assembly T and gear cluster assembly U from the transmission housing by pulling both assemblies straight up 17 Place the idler gear shaft assembly T and gear cluster assembly U on a clean surface for inspect...

Page 356: ... bearing off the reverse shaft see Figure 8 1 23 Remove the retaining ring and engagement dog from the reverse shaft see Figure 8 1 24 Remove the retaining ring washer needle bearing and sprocket from the reverse shaft see Figure 8 1 25 Tilt the two shafts towards each other and remove the silent chain from the two shafts 26 If necessary disassemble the other end of the reverse shaft Remove the be...

Page 357: ...orkel tube 30 Remove the snorkel tube and shaft assembly from the transmission case 31 Remove the snap ring Y and shim Z from the snorkel shaft 32 Use an arbor press to remove the snorkel tube from the snorkel shaft 33 Remove the snap ring A and shim B retaining the bearing in the snorkel tube CAUTION The pinion shaft must be removed prior to removing the snorkel shaft assembly Failure to remove p...

Page 358: ...ng washer bearing and gear from the snorkel shaft Planetary Differential Disassembly NOTE If the gearcase is completely assembled perform the Gearcase Disassembly and Inspection procedure 1 Use a scribe to mark the differential cover and ring gear prior to disassembly 2 Remove the 6 screws retaining the differential cover and remove the cover 3 Remove the 6 planet gears and each side gear assembly...

Page 359: ...erform the Planetary Differential Disassembly procedure Ring Gear Bushing Replacement 1 Press the old bushing out of the ring gear 2 Thoroughly clean the bore of the ring gear and check for any unwanted burs 3 Press the new bushing into the ring gear housing 4 Install the bushing to the specified depth as shown Planet Gear Bushing Replacement 1 Press the old bushing out of the planet gear 2 Thorou...

Page 360: ...rs 3 Press the new bushing into the differential cover 4 Install the bushing to the specified depth as shown Female Side Gear Bushing Replacement 1 Locate the bushing split Using a small chisel or flat blade screwdriver peel back and remove the old bushing from the side gear being careful not to damage the side gear 2 Thoroughly clean the bore of the side gear and check for any unwanted burs 3 Pre...

Page 361: ...ously made scribe marks 4 Apply Loctite 2760 to cover screws 5 Install screws hand tight Place assembly in soft jaw vise and torque to specification Gear Shaft Bearing Inspection Planet Gears Side Gears T Differential Cover Screws 18 22 ft lbs 24 30 Nm Inspect all gear sets and shafts for excessive wear or damage IMPORTANT If gear replacement is required be sure to also replace the corresponding g...

Page 362: ...press the gear back against the washer and retaining ring will lead to a gear backlash change after vehicle is placed into service 4 Apply a small amount of white lithium grease or Anti Seize on the threads of the snorkel tube 5 Install the snorkel shaft into the gearcase Using the Snorkel Tool PA 50231 tighten the snorkel tube until it is lightly seated in the transmission housing 6 Inspect the p...

Page 363: ... zero backlash position you should still be able to turn the snorkel shaft using your fingers but it will feel rough and may have some tight spots 12 Look down into the transmission housing to see the snorkel locking screw hole opening to reference your starting point NOTE If you have a hard time seeing into the hole insert a small Allen wrench punch or screwdriver into the hole to feel when the n...

Page 364: ...sembling the transmission 1 Clean both transmission case halves thoroughly Inspect case half mating surfaces for damage 2 Install shift fork S and torsion spring into transmission housing as an assembly Load spring as shown in image below 3 Apply Loctite 242 to 2 screws T and install with retaining plates over shift fork Torque to specification 4 Slide engagement dog U onto retaining pins of shift...

Page 365: ... A and gear cluster assembly B into the transmission housing all at the same time 7 Install the rear output shaft assembly C Rotate output shaft assembly to align slots with engagement dog Ensure bearing is fully seated upon assembly 8 Assemble shift shaft rail if previously disassembled NOTE Both shift forks need to be orientated the same way so that the shift fork pins are both offset to the sam...

Page 366: ... housing Lift up on the shift shaft rail D and move the rail assembly towards the shift drum to allow the shift fork ends to be installed into the shift drum E 12 Apply a continuous bead of Crankcase 3 Bond Sealant PN 2871557 to the left hand transmission mating surface 13 Install the transmission case cover and retaining bolts Torque bolts to specification 14 Install new seals into the transmissi...

Page 367: ...n shaft Install the washer and apply Loctite 262 or 2760 to the mounting bolt threads Torque the bolt to specification 16 Thoroughly clean the shift shaft housing Be sure the transmission is in High gear prior to reassembly 17 Install the sector gear 16T onto the shift drum shaft Install the shift shaft assembly and sector gear 11T into the bushing pocket on the left side Align the timing marks on...

Page 368: ...lean the transmission and gear sector cover mating surfaces thoroughly 23 Apply Crankcase Sealant 3 Bond PN 2871557 onto the cover and transmission case mating surface 24 Install the sector cover and align the transmission case dowel with the alignment hole Install and torque the bolts to specification 25 Install the transmission drain plug and torque to specification 26 Install the bellcrank onto...

Page 369: ...s or pivot arm bushings Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting the shift cable end from the transmission bellcrank Manually select each gear range at the transmission bellcrank and test ride vehicle If it functions p...

Page 370: ...W FOR REASSEMBLY Apply White Lithium Based Grease Apply Polaris Crankcase Sealant Apply Loctite to the bolt threads 12 18 ft lbs 16 24 Nm 10 14 ft lbs 14 19 Nm 8 10 ft lbs 11 14 Nm 242 242 Refer to Snorkel Gear Backlash Procedure 10 14 ft lbs 14 19 Nm 8 10 ft lbs 11 14 Nm 15 20 ft lbs 20 27 Nm 15 20 ft lbs 20 27 Nm 9 12 ft lbs 12 16 Nm ...

Page 371: ...ing Ring External 61 1 Sprocket 48T 6 Face 19 1 Retaining Ring Internal 62 1 Gear Low 67T 20 2 Retaining Ring External 63 1 Engagement Dog 6 Face 21 2 Retaining Ring External 64 1 Gear 53T 22 3 Retaining Ring External 65 1 Shaft Pinion 11T 23 1 Retaining Ring External 66 1 Gear 46T 24 2 Washer Thrust 67 1 Gear Snorkel 13T 25 1 Washer Thrust 68 1 Shaft Shift 26 1 Shim 69 1 Weldment Rear Mount Brack...

Page 372: ...um Based Grease Apply Polaris Crankcase Sealant Apply Loctite to the bolt threads 12 18 ft lbs 16 24 Nm 10 14 ft lbs 14 19 Nm 8 10 ft lbs 11 14 Nm 242 242 Refer to Snorkel Gear Backlash Procedure 10 14 ft lbs 14 19 Nm 8 10 ft lbs 11 14 Nm 15 20 ft lbs 20 27 Nm 15 20 ft lbs 20 27 Nm 9 12 ft lbs 12 16 Nm 18 22 ft lbs 24 30 Nm 7 10 ft lbs 10 14 Nm 18 22 ft lbs 24 30 Nm 262 2760 ...

Page 373: ... Ring External 75 1 Gear 46T 24 2 Retaining Ring External 76 1 Gear Snorkel 13T 25 3 Retaining Ring External 77 1 Shaft Shift 26 1 Retaining Ring External 78 1 Weldment Rear Mount Bracket 27 2 Washer Thrust 80 2 Retainer Fork 28 1 Washer Thrust 81 1 Bracket Rear Mount 29 1 Shim 82 1 Cover Bearing Center Drive 30 1 Shim 83 1 Spacer 31 2 Bearing Needle Cage 84 1 Chain Silent 32 2 Bearing Ball 85 1 S...

Page 375: ... PARKING BRAKE DISC INT L MODEL 9 14 FRONT BRAKE PADS 9 15 PAD REMOVAL INSPECTION 9 15 PAD ASSEMBLY INSTALLATION 9 16 BRAKE BURNISHING PROCEDURE 9 16 FRONT CALIPER SERVICE 9 17 CALIPER REMOVAL 9 17 CALIPER DISASSEMBLY 9 18 CALIPER INSPECTION ASSEMBLY 9 19 CALIPER INSTALLATION 9 20 FRONT BRAKE DISC 9 21 REAR BRAKE PADS RZR XP 9 23 PAD REMOVAL 9 23 PAD INSPECTION ASSEMBLY INSTALLATION 9 24 BRAKE BUR...

Page 376: ...AKE SYSTEM INT L MODEL Item Standard Service Limit Park Brake Pad Thickness Inboard 0 300 7 62 mm 0 240 6 10 mm Outboard 0 250 6 35 mm 0 190 4 83 mm Park Brake Disc Thickness 0 175 0 185 4 44 4 70 mm 0 150 3 81 mm Item Torque ft lbs Torque Nm Front Caliper Mounting Bolts 40 54 Rear Caliper Mounting Bolts 40 54 Brake Line Flare 12 15 16 20 Brake Line Banjo Bolts Caliper Attachment 15 20 Brake Line ...

Page 377: ...TROUBLESHOOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise Permatex Disc Brake Quiet can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust Brake...

Page 378: ...r outward and becomes self adjusting Fluid from the reservoir fills the additional area created when the caliper piston moves outward Brake fluid level is critical to proper system operation Too little fluid will allow air to enter the system and cause the brakes to feel spongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating p...

Page 379: ...iper Banjo Style Fittings 15 ft lbs 20 Nm All Caliper Bleed Screws 47 in lbs 5 3 Nm Master Cylinder Side View Cross MC Rear Brake Line RH Rear Line RH Front Brake Line Front Calipers Brake Master Cylinder LH Front Rear Calipers Brake Line LH Rear Line 1 2 1 1 2 2 1 3 All Flare Style Fittings 12 15 ft lbs 16 20 Nm 3 1 1 2 2 3 Fitting Switch 1 ...

Page 380: ...anjo Style Fittings 15 ft lbs 20 Nm All Caliper Bleed Screws 47 in lbs 5 3 Nm Cross Fitting MC Rear Brake Line RH Rear Line LH Front Brake Line Front Caliper Brake Master Cylinder RH Front Rear Caliper Brake Line LH Rear Line 1 2 1 2 3 All Flare Style Fittings 12 15 ft lbs 16 20 Nm 3 1 1 3 Switch Seals Seals Seals 2 Seals ...

Page 381: ...at secure the master cylinder to the frame Installation 1 Reverse Steps 1 5 for master cylinder installation Refer to the torque specifications in the illustration 2 After installing the foot brake check pedal freeplay Pedal freeplay should not exceed 090 2 286 mm BRAKE PEDAL LEVER Pedal Removal 1 Locate the brake pedal lever L and remove the clip A and master cylinder clevis pin B 2 Remove the E ...

Page 382: ...ssure builds and holds 6 Hold brake pedal down to maintain pedal pressure and open bleeder screw Close bleeder screw and release pedal NOTE Do not release foot pedal before bleeder screw is tight or air may be drawn into master cylinder 7 Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir 8 Tighten bleeder sc...

Page 383: ... Manual Copyright 2012 Polaris Sales Inc 12 Field test machine at low speed before putting into service Check for proper braking action and pedal reserve With pedal firmly applied pedal reserve should be no less than 1 2 1 3 cm 13 Check brake system for fluid leaks ...

Page 384: ...RAKE INT L MODEL Exploded View Parking Brake Lever Nuts Clip Cable Parking Brake Caliper Parking Brake Caliper Shift Cable Bolts Clevis Pin Mounting Assembly 16 ft lbs 22 Nm 14 ft lbs 19 Nm 37 ft lbs 50 Nm Tie Strap Bolts Spacer Clip Clevis Pin Parking Brake Lever Mount Bracket Mount Bracket 50 Nm 37 ft lbs Bolts ...

Page 385: ...switch electrical connector Reconnect the connector as soon as practicable and adjust the parking brake cable to proper tension 1 Pull back on parking brake lever located in the dash 2 After 3 to 4 clicks BRAKE should display on the instrument cluster and the wheels should not rotate when turning by hand After 8 full clicks of lever travel the vehicle should not roll while parked 3 If the vehicle ...

Page 386: ...perly 1 Remove the clip pin and pin A from the parking brake cable NOTE Be sure the parking brake is not engaged 2 Remove the two fasteners B retaining the parking brake caliper mount shift cable bracket 3 Lift the parking brake caliper off the brake disc and remove it from the vehicle Sleeve Thrust Washer Shim Pack 4 Shims Apply Anti Seize Lubricant Pad Holder Lever Assembly Steel Balls 3 Station...

Page 387: ...or brake pad specifications New Brake Pad Installation 1 Install new pads and assemble the caliper with one shim For shim location see Figure 9 1 on page 9 11 2 Measure gap for the brake disc and compare to gap specification Disassemble and add shim s between thrust washer and the inside brake pad as needed to close the gap to 207 217 in 5 25 5 51 mm 3 Once you have determined the correct amount o...

Page 388: ...c Inspection 1 Measure the brake disc with a micrometer If the thickness of the disc is less than specified replace the brake disc see Disc Replacement Disc Replacement 1 Remove the parking brake caliper from the disc see Caliper Removal 2 Using a 1 2 socket and ratchet remove the brake disc retaining bolt and flat washer 3 Remove the disc from the transmission shaft 4 Install the new brake disc I...

Page 389: ...wly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 6 Push the mounting bracket inward and slip the outer brake pad out between the bracket and caliper body 7 Remove the inner pad from the bracket and caliper Pad...

Page 390: ...clockwise 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap 7 Install wheel and torque wheel nuts to specification Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop...

Page 391: ...a before removal 4 Place a container below the caliper to catch brake fluid when removing the line Remove brake line from caliper A B C D 47 in lbs 5 3 Nm A SocketSetScrew B Bleeder Screw C Caliper Assy D Boots E Square O rings F Pistons G CaliperMount H Brake Pads I Brake Scraper J Bolts F G H Apply Silicone Grease Apply Polaris DOT 4 Brake Fluid to Components D I E J CAUTION Use care when suppor...

Page 392: ...ee FRONT BRAKE PADS Pad Removal 2 Remove mount bracket assembly and dust boots 3 Thoroughly clean the caliper before disassembly and prepare a clean work area for disassembly 4 Use a commercially available caliper piston pliers to extract the pistons from the caliper IMPORTANT Do not remove the caliper pistons with a standard pliers The piston sealing surfaces will become damaged if a standard pli...

Page 393: ...r Measure piston diameter and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads as outlined in this chapter Caliper Assembly 1 Install new O rings in the caliper body Be sure the grooves are clean and free of residue or brakes may drag upon assembly 2 Coat pistons with clean Polaris DOT 4 Brake Fluid Install pistons with a twisting motion while pushing inward Piston...

Page 394: ...ved reinstall it upon caliper installation 3 Torque the banjo bolt to the proper torque specification 4 Install the adjustment set screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise 5 Perform brake bleeding procedure as outlined earlier in this chapter 6 Install wheel and torque wheel nuts to specification 7 Field test unit for proper braking action...

Page 395: ...thickness at eight different points around the pad contact surface Replace disc if worn beyond service limit Disc Replacement 1 Remove the front brake caliper see FRONT CALIPER SERVICE 2 Remove wheel hub cotter pin castle nut and washers 3 Remove the wheel hub assembly from the vehicle and remove the 4 bolts retaining the disc to the hub 4 Clean the wheel hub mating surface and install new disc on...

Page 396: ... FRONT CALIPER SERVICE 8 Follow bleeding procedure outlined earlier in this chapter 9 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when pedal is released If the brake drags re check assembly and installation T New Bolts 30 ft lbs 41 Nm CAUTION Always use new brake disc mounting bolts The bolts have...

Page 397: ... caliper mounting bolts and lift caliper off the brake disc NOTE When removing caliper be careful not to damage brake line Support caliper to avoid kinking or bending brake line 6 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed ...

Page 398: ...ssembly Installation 1 Lubricate mounting bracket pins with a light film of silicone grease and install rubber dust boots 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other 3 Install the caliper and torque the new mounting bolts to specification Rear Brake Pad Thickness 298 007 7 57 mm 178 mm Service Limit 180 4 6 mm Measure ...

Page 399: ...to the MAX line inside reservoir and install reservoir cap 8 Install wheel and torque wheel nuts to specification Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool sufficien...

Page 400: ... caliper mounting bolts and lift caliper off the brake disc NOTE When removing caliper be careful not to damage brake line Support caliper to avoid kinking or bending brake line 6 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed ...

Page 401: ...ubricate mounting bracket pins with a light film of silicone grease and install rubber dust boots 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other 3 Install the caliper and torque the new mounting bolts to specification Front Brake Pad Thickness New 298 007 7 56 178 mm Service Limit 180 4 6 mm Measure Thickness WARNING If b...

Page 402: ... MAX line inside reservoir and install reservoir cap 8 Install wheel and torque wheel nuts to specification Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool sufficiently du...

Page 403: ...before removal 3 Place a container below the caliper to catch the brake fluid when removing the line Remove brake line from caliper A B C D E F G H I K Apply Polaris DOT 4 Brake Fluid to Component Apply Silicone Grease 47 in lbs 5 3 Nm A Brake Pad B Mount Bracket C Piston D Caliper Assy E Square Ring thick F Square Ring thin G Boot Pin Bushing H Boot Pin Seal I Bleeder Screw K Set Screw CAUTION Us...

Page 404: ... mounting bolts and remove the caliper Caliper Disassembly 1 Remove brake pad adjustment set screw K 2 Push upper pad retainer pin inward and slip brake pads past the edge and remove from the caliper 3 Remove mount bracket B and dust boots G and H 4 Using a hammer and a small punch remove the piston C from the caliper body D Remove the square O rings E and F from the caliper body D 5 Clean the cal...

Page 405: ...re groove is clean and free of residue or brakes may drag upon assembly 2 Coat piston with clean Polaris DOT 4 Brake Fluid PN 2872189 Install piston D with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounting bracket pins with silicone grease and install the rubber dust seal boots 4 Compress the mounting bracket and m...

Page 406: ...d bolt washer and new nut Torque to specification 4 Install the pad adjustment screw and turn until stationary pad contacts disc then back off 1 2 turn 5 Follow bleeding procedure outlined earlier in this chapter 6 Install wheel and torque wheel nuts to specification NOTE If new pads are installed refer to REAR BRAKE PADS Brake Burnishing Procedure T Rear Caliper Mount Bolt 40 ft lbs 54 Nm 40 ft l...

Page 407: ...n caliper area before removal 4 Place a container below the caliper to catch brake fluid Remove brake line from caliper A B C D E F G H Apply Silicone Grease Apply Polaris DOT 4 Brake Fluid to Component 47 in lbs 5 3 Nm I A Socket Set Screw B Bleeder Screw C Caliper Asm D Boot E Square O rings large F Square O rings small G Piston H Caliper Mount I Brake Pads CAUTION Use care when supporting vehic...

Page 408: ... the two caliper mounting bolts and remove the caliper Caliper Disassembly 1 Remove both brake pads from the caliper Refer to REAR BRAKE PADS RZR XP 4 2 Remove mount bracket assembly and dust boots from caliper Thoroughly clean caliper before disassembly and prepare a clean work area for disassembly 3 Use a commercially available caliper piston pliers to extract the pistons from the caliper IMPORT...

Page 409: ... the seal grooves in caliper body Caliper Inspection 1 Inspect caliper body for nicks scratches pitting or wear Measure bore size and compare to specifications Replace if damaged or worn beyond service limit 2 Inspect piston for nicks scratches pitting or wear Measure piston diameter and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads as outlined in this chapter C...

Page 410: ...ubricate the mounting bracket pins with silicone grease and install the rubber dust seal boots 4 Compress the mounting bracket and make sure the dust seal boots are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease Caliper Installation 1 Install the rear caliper with new mounting bolts Torque mounting bolts to...

Page 411: ...2 turn 4 Install lower radius rod bolt washer and new nut Torque to specification 5 Follow brake bleeding procedure outlined earlier in this chapter 6 Install wheel and torque wheel nuts to specification NOTE If new pads are installed refer to REAR BRAKE PADS Brake Burnishing Procedure T Radius Rod to Bearing Carrier Bolt 45 ft lbs 61 Nm T Wheel Nuts 30 ft lbs 41 Nm 90 1 4 turn Pad Adjuster 1 2 Tu...

Page 412: ... 1 Remove rear brake caliper see REAR CALIPER SERVICE 2 Remove wheel hub cotter pin castle nut and washers 3 Remove the hub assembly from the vehicle and remove the 4 bolts retaining the disc to the hub 4 Clean the wheel hub mating surface and install new disc on wheel hub 5 Install new bolts and torque to specification Brake Disc Thickness New 188 4 78 mm Service Limit 170 4 32 mm Brake Disc Thic...

Page 413: ... brake fluid contaminated Caliper or disc misaligned Caliper dirty or damaged Brake line damaged or lining ruptured Worn disc and or friction pads Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Damaged break pad noise insulator Brake pads dragging Brake caliper dragging Pedal Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Cali...

Page 415: ...ION GEAR POSITION SWITCH 10 14 PARKING BRAKE SWITCH INT L MODEL 10 15 THROTTLE RELEASE SWITCH TRS 10 16 REAR DIFF SOLENOID INT L 10 18 VEHICLE SPEED SENSOR 10 19 ALL WHEEL DRIVE COIL 10 19 HEAD LIGHTS 10 20 HEADLIGHT ADJUSTMENT 10 20 HEADLAMP REPLACEMENT 10 20 HEADLAMP INSTALLATION 10 21 TAIL BRAKE LIGHTS 10 21 BULB REPLACEMENT 10 21 COOLING SYSTEM 10 22 COOLING SYSTEM BREAK OUT DIAGRAM 10 22 FAN ...

Page 416: ...5 VOLTAGE DROP TEST 10 35 STARTER MOTOR REMOVAL INSTALLATION 10 35 STARTER SOLENOID BENCH TEST OPERATION 10 36 STARTING SYSTEM TESTING FLOW CHART 10 37 ELECTRONIC POWER STEERING EPS 10 38 EPS OPERATION 10 38 PROPER EPS SYSTEM DIAGNOSING 10 38 EPS SYSTEM BREAKOUT 10 39 EPS TROUBLESHOOTING EPS NON FUNCTIONAL WITH MIL ON 10 40 EPS TROUBLESHOOTING EPS NON FUNCTIONAL WITH MIL OFF 10 41 EPS TROUBLESHOOT...

Page 417: ...d with your meter for more information Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is used when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc and the position of the decimal point For resistance readings isolate the com...

Page 418: ...ptions NOTE Some features are not applicable to all models IMPORTANT The use of a high pressure washer may damage the instrument cluster Wash the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the instrument cluster lens Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Imm...

Page 419: ... 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 9 Check Engine MIL Illuminated when the ECM has detected a Diagnostic Trouble Code in the engine management system 10 AWD Indicator Illuminated when the AWD TURF switch is...

Page 420: ...otal hours can not be reset Programmed Service Interval The initial factory service interval setting is 50 hours Each time the engine is started the engine hours are subtracted from the service interval hours When the service interval reaches 0 the LCD wrench icon will flash for approximately 10 seconds each time the engine is started To change the hour setting or reset the function follow these s...

Page 421: ...hes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode Units of Measurement To change between Standard and Metric units of measurement follow these steps 1 Turn the key to the OFF position 2 Press and hold the MODE button while turning the key to the ON position 3 Whe...

Page 422: ...f Park Brake Indicator INT L Model Only This warning is used to notify the operator that the park brake lever is engaged When the park brake is fully engaged BRAKE appears in the rider information display Engine speed is limited to 1500 RPM in all gears except neutral If throttle is applied this limiting feature prevents operation which protects the park brake pads from excessive wear Diagnostic M...

Page 423: ... This number equates to the fault mode FMI 4 Use the trouble code reference table in the EFI Chapter for a description of each code see Chapter 4 5 If more than one code exists press the MODE button to advance to the next trouble code 6 To exit the diagnostic mode press and hold the MODE button or turn the ignition key OFF once the codes are recorded NOTE If there is a diagnostic problem with the ...

Page 424: ...l is a snap on assembly and is a serviceable part Instrument Cluster Installation 1 Spray a soap and water mixture onto the outer surface area of the instrument cluster This will help the instrument cluster slide into the rubber mount more easily 2 Be sure the rubber mount inside the dash is fully installed and that the indexing key on the rubber mount is lined up with the keyway in the dash 3 Hol...

Page 425: ...r than 0 5 ohms clean the switch terminals Re test and replace switch if necessary 4 For switch replacement refer to Chapter 9 Brakes Headlamp Switch 1 Disconnect the headlamp switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 3 sets of outputs OFF LOW HIGH If any of the tests fail replace headlamp switch assembly Move the swi...

Page 426: ...d D Turn the ignition key to START There should be continuity between switch pins A and B C and D Ignition Key Switch INT L 1 Disconnect the key switch harness by lifting the connector lock and pulling on the connector Do not pull on the wiring 2 Test between the 4 sets of outputs OFF ON LIGHTS ON START If any of the tests fail replace ignition switch assembly Turn the ignition key to ON LIGHTS Th...

Page 427: ...tween switch pins 2 and 3 Move the switch to 2WD NONE OFF There should be no continuity between any pins AWD 2WD TURF Switch INT L 1 Disconnect the AWD 2WD TURF switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 3 sets of outputs AWD 2WD TURF If any of the tests fail replace the switch assembly Move the switch to AWD There sho...

Page 428: ...embly Move switch to ON There should be continuity between switch pins 2 and 3 Move switch to NONE OFF There should be no continuity between switch pins Transmission Gear Position Switch 1 The transmission gear position switch is located on the RH side of the transmission and can be accessed through the RH wheel well area 2 Disconnect the transmission switch harness by lifting the connector lock a...

Page 429: ... is released This feature has been added to prevent drive away with the parking brake applied Testing The Parking Brake Switch 1 Disconnect the harness connector at the parking brake switch Orange Red and Red Blue wires 2 Place the ohmmeter leads onto the switch terminals The reading should be infinite OL 3 Apply the parking brake Continuity should now exist between the switch terminals If no cont...

Page 430: ...s located in the drivers foot control area mounted on the top of the throttle pedal assembly TRS Testing The TRS is a serviceable item and can be tested using Digital Wrench or an Ohm meter 1 Disconnect the TRS harness connection located by the fuse box 2 With the throttle pedal at rest connect an ohmmeter between the TRS pin terminals A resistance value of 2 15k Ohms 5 at room temperature should ...

Page 431: ...dal assembly and loosely install the 2 fasteners 2 The TRS mounting holes are oblonged to allow for switch alignment Visually center the TRS slot with the throttle pedal blade C It may be necessary to manually cycle the throttle pedal to verity the center alignment 3 Torque the 2 mounting bolts to specification and connect the TRS harness connection 4 Manually cycle the throttle pedal to verify th...

Page 432: ...l When the switch is pushed to activate TURF a ground signal is provided to the ECU from the AWD 2WD TURF Switch Depending on engine speed and gear position criteria the ECU energizes the Rear Diff Solenoid Relay allowing it to enable the differential solenoid If the rear diff fails to switch from operational modes Check the solenoid and relay connectors Look for loose wires or bad connections Che...

Page 433: ...e hub coil When the AWD switch is ON and if the criteria is met the Engine Controller provides a ground path brown white wire When this occurs the AWD icon should display in the instrument cluster The AWD system must be grounded to operate Diagnosing System Failures Verify the AWD switch is functional and that a minimum of 11 volts is present at the hub coil Verify the AWD hub coil is functional T...

Page 434: ... position by loosening or tightening the 3 T 25 adjustment screws and moving the lamp to the appropriate height 6 Adjust the beam to desired position Repeat the procedure to adjust the other headlight Headlamp Replacement IMPORTANT If an LED headlamp has fogging or moisture inside disconnect the wire harness from the headlamp s for a few days to allow the moisture to clear out 1 Disconnect wire ha...

Page 435: ...ll the front bumper as shown in Chapter 5 if previously removed 6 Connect headlamp electrical connector to the headlamp assembly 7 Perform the Headlight Adjustment procedure as shown in this chapter TAIL BRAKE LIGHTS Bulb Replacement Before replacing the bulb s use a digital multi meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present If a tail light b...

Page 437: ...an ohmmeter or voltmeter 1 With the engine and temperature sensor at room temperature 68 F 20 C disconnect the harness 2 With the meter in the ohms mode place the meter leads onto the sensor contacts 3 Use the table Temperature Resistance table to determine if the sensor needs to be replaced NOTE If the coolant temperature sensor or circuit malfunctions the radiator fan will default to ON while th...

Page 438: ...tection for wiring and components such as the instrument cluster ECU EFI system main harness lights accessories and power steering The relays assist with component operation like the cooling fan fuel pump EFI system drive system and electronic power steering A separate 20 amp circuit breaker protects the fan motor circuit Two separate relays located under the dash operate the headlights and the fl...

Page 439: ...96 2013 RANGER RZR XP 900 RZR XP 4 900 Service Manual Copyright 2012 Polaris Sales Inc Fuse Box Detail IMPORTANT All relays PN 4011283 located in fuse box are the same and can be swapped out to help diagnose electrical problems ...

Page 440: ... Power Steering Unit Color Function Red 30 Amp fuse protected 12 Vdc constant battery voltage Brown Relay coil ground Orange 12 Vdc power input from key switch to enable relay White Provides 12 Vdc power for lights drive and accessory circuits Color Function Red White 20 Amp fuse protected 12 Vdc constant battery voltage Dark Green Yellow ECU ground input to enable relay Red White 20 Amp fuse prot...

Page 441: ...relay Brown Relay coil ground Red Relay switched power to operate the Rear Diff Solenoid Blue Ground to energize the Rear Diff Solenoid Color Function Red Yellow 20 Amp fuse protected 12 Vdc battery voltage White Red Key switch input to enable relay Brown Relay coil ground Yellow Dark Green Relay switched power to operate the Headlights Color Function Dark Green 12 Vdc switched power from headligh...

Page 442: ... amps battery discharge 3 Shift transmission into park and start the engine With the engine running at idle observe meter readings 4 Increase engine RPM while observing ammeter and tachometer Note the RPM at which the battery starts to charge ammeter indication is positive 5 With lights and other electrical loads off the break even point should occur at approximately 1500 RPM or lower 6 With the e...

Page 443: ...idle 3 While holding the engine at a specified RPM separately measure the voltage across each leg of the stator by connecting the meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to Y3 4 Refer to the following table for approximate AC Voltage readings according to RPM Test each leg at the specified RPM in the table Example The alternator current output reading should be ap...

Page 444: ...nt of the left rear shock It is mounted under the LH panel divider NOTE If the regulator rectifier case temperature exceeds 230 F or 110 C the unit will turn itself off to cool down The unit will turn on again after it has cooled down to at least 212 F or 100 C If it turns off verify the cooling fins are clean free from debris and that adequate airflow is present A Battery Stator Lead Leads Fusibl...

Page 445: ...harge if operated below the Break Even RPM Con tinued problems would call for battery inspection Yes Inspect the wiring harness between the regulator and the stator for remove the stator cover Inspect the flywheel magnets stator coils and stator wires for damage No Check battery and battery connections Also check wire connections and wire condition Repair or replace faulty wiring or components No ...

Page 446: ... Procedure Type Polaris Deka ETX30L Sealed Maintenance Free Voltage 12 Vdc Nominal Capacity 10 HR Rate 30 AH CCA 365 Nominal Open Circuit Voltage 12 8 Vdc or more Recommended Charging Rate 1 8A 5 10 HR or 6 0A 1 HR WARNING CALIFORNIA PROPOSITION 65 WARNING Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the State of California ...

Page 447: ...Battery voltage should be checked with a digital multitester Readings of 12 6 volts or less require further battery testing and charging See the following chart and Load Test NOTE Maintenance Free batteries should be kept at a high state of charge during storage If the battery is stored or used at a low state of charge hard crystal sulfation will form on the plates reducing the efficiency and serv...

Page 448: ...battery NOTE Charge the battery using an automatic charger that will not exceed 14 6 Vdc An automatic charger will signal when charging is complete NOTE Allow the battery to stand disconnected for at least 1 2 hours after being properly charged If the voltage drops below 12 6 volts charging was ineffective or the battery needs to be replaced NOTE Follow the charger instructions supplied by the man...

Page 449: ...nection or component To perform the test place the meter on DC volts and place the meter leads across the connection to be tested Refer to the voltage drop tests on the starter system in this chapter Starter Motor Removal 1 Remove driver side seat and disconnect the battery 2 Raise and support rear of vehicle 3 Remove the RH rear wheel 4 Remove positive wire from starter motor terminal 5 From the ...

Page 450: ...ment is out of specification replace the starter solenoid Starter Solenoid Operation To energize the Starter Solenoid the following must occur The brake must be applied to provide a ground path via the Orange wire The key switch must be turned to the start position to provide 12V power via the Green White wire Once the pull in coil is energized the solenoid provides a current path for 12V power to...

Page 451: ...ith the solenoid energized resistance should read about 0 5 10 between the two terminals If resistance measurement is out of specification replace the starter solenoid see Starter Solenoid Bench Test Reconnect the solenoid Connect the tester black lead to the battery positive and the red lead to the solenoid end of the battery to solenoid wire Apply the brake and turn the ignition key to the start...

Page 452: ... power steering operation NOTE To conserve battery power the EPS unit will shut down 5 minutes after the engine has stopped if the key remains in the ON position At this point the EPS Malfunction Indicator Light will illuminate to indicate the EPS has shut down and will set a fault code in Digital Wrench The Power Steering 30A Fuse If the fuse fails the Power Steering Malfunction Indicator Light M...

Page 456: ...RZR XP 900 RZR XP 4 900 Service Manual Copyright 2012 Polaris Sales Inc EPS Troubleshooting Using Digital Wrench These Error Codes must have multiple occurrences or you must be able to duplicate the condition before replacing the EPS unit ...

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