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Polaris Ranger RZR SW, Service Manual

The Polaris Ranger RZR SW Service Manual is a comprehensive guide that provides users with in-depth information and instructions on maintaining and repairing their vehicle. This essential manual can be downloaded for free from our website, ensuring easy access to reliable and detailed resources for enhancing your off-road experience.

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2011 RANGER RZR SW

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer

 technicians in a properly

equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Publications Question'.

Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.

Publication Printed July 2010 (PN 9922720-CD)

© Copyright 2010 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

Summary of Contents for Ranger RZR SW

Page 1: ...utlined in this Service Manual contact an authorized dealer for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please provide any feedback you may have regarding this manual Authorized dealers can submit feedback using Ask Polaris Click on Ask Polaris and then click on Publications Question Consumers please provide your feed...

Page 2: ...ng instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL Loctite Registered Trademark of the Loctite Corporation Nyogel Trademark of Wm F Nye Co Fluke Registered Trademark of John Fluke Mfg Co Mity Vac Registered Trademark of Neward Enterprises Inc Torx Registe...

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

Page 4: ......

Page 5: ...NGINE SERIAL NUMBER LOCATION 1 2 VEHICLE INFORMATION 1 3 PUBLICATION NUMBERS 1 3 SPECIAL TOOLS 1 3 GENERAL SPECIFICATIONS 1 4 MODEL 2011 RANGER RZR SW 1 4 MODEL 2011 RANGER RZR SW 1 5 MISC SPECIFICATIONS AND CHARTS 1 6 CONVERSION TABLE 1 6 STANDARD TORQUE SPECIFICATIONS 1 7 SAE TAP DRILL SIZES 1 8 METRIC TAP DRILL SIZES 1 8 DECIMAL EQUIVALENTS 1 8 GLOSSARY OF TERMS 1 9 ...

Page 6: ...ed on a portion of the front left frame rail close to the left front wheel see Figure 1 1 The engine model and serial number can be found on a decal applied to the cylinder on the side of the engine see Figure 1 2 Machine Model Number Identification Model Year Designation Basic Chassis Designation Engine Designation Emissions Model Option M 1 1 V E 7 6 A A 4 X A V E 7 6 A B P 0 0 0 0 0 0 1 2 3 4 5...

Page 7: ... be required while servicing this vehicle Some of the tools listed or depicted are mandatory while other tools maybe 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 Mo...

Page 8: ...ight 72 5 in 184 cm Wheel Base 77 in 196 cm Ground Clearance 13 in 33 cm Dry Weight 1112 lbs 504 kg Gross Vehicle Weight 2148 lbs 974 kg Front Storage Capacity 25 lbs 11 3 kg Cargo Box Capacity 500 lbs 227 kg Maximum Weight Capacity Payload 1000 lbs 454 kg Includesrider s cargo accessories and trailer tongue weight Hitch Towing Capacity 1500 lbs 680 kg Hitch Tongue Capacity 150 lbs 68 kg ...

Page 9: ...FI Fan Fuel Pump TURF Blackout Circuit Breaker Fan Motor 20 Amp Fuses Lights 20 Amp Fuel Pump 10 Amp Drive 10 Amp EFI 20 Amp Accessory 20 Amp Drivetrain Transmission Type Polaris Automatic PVT Drive Gear Ratio Front Output Reverse Low High 8 3398 1 7 1474 1 2 8226 1 Drive Gear Ratio Rear Output Reverse Low High 27 0003 1 23 1398 1 9 1381 1 Shift Type In Line Shift H L N R P Front Gearcase Fluid Ty...

Page 10: ...1 6 GENERAL INFORMATION MISC SPECIFICATIONS AND CHARTS Conversion Table C to F 9 5 C 32 F F to C 5 9 F 32 C ...

Page 11: ...he following torque specifications are to be used only as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views or each manual section for torque values of fasteners before using standard torque ...

Page 12: ...1 8 GENERAL INFORMATION SAE Tap Drill Sizes Metric Tap Drill Sizes Decimal Equivalents ...

Page 13: ...he end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In lb 12 in lbs 1 ft lb kg cm Kilograms per square centimeter kg m Kilogram meters Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a rotational direction l or ltr Liter lbs in Pounds per...

Page 14: ...NOTES GENERAL INFORMATION 1 10 ...

Page 15: ...ROTTLE FREEPLAY ADJUSTMENT 2 12 AIR FILTER SERVICE 2 13 ENGINE 2 15 ENGINE OIL LEVEL 2 15 ENGINE OIL AND FILTER SERVICE 2 15 ENGINE BREATHER HOSE INSPECTION 2 17 ENGINE AND TRANSMISSION MOUNTS 2 17 COMPRESSION AND LEAKDOWN TEST 2 17 EXHAUST SPARK ARRESTOR 2 17 TRANSMISSION AND GEARCASES 2 18 TRANSMISSION GEARCASE SPECIFICATION CHART 2 18 TRANSMISSION LUBRICATION 2 18 FRONT GEARCASE LUBRICATION 2 2...

Page 16: ...7 ENGINE TO FRAME GROUND 2 27 STEERING 2 28 STEERING INSPECTION 2 28 STEERING WHEEL FREEPLAY 2 28 TIE ROD END WHEEL HUB INSPECTION 2 28 WHEEL TOE ALIGNMENT INSPECTION 2 29 WHEEL TOE ADJUSTMENT 2 29 SUSPENSION FOX 2 30 SPRING PRELOAD ADJUSTMENT 2 30 SHOCK COMPRESSION ADJUSTMENT 2 31 BRAKE SYSTEM 2 32 BRAKE FLUID INSPECTION 2 32 BRAKE PAD DISC INSPECTION 2 32 BRAKE HOSE AND FITTING INSPECTION 2 32 M...

Page 17: ...egins 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 or the time it takes to use 14 gallons 53 liters of fuel Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Drive ...

Page 18: ... needed Coolant Level Daily Check level daily change coolant every 2 years Head Lamp Tail Lamp Daily Check operation apply dielectric grease if replacing E Air Filter Weekly Inspect replace as needed Brake Pad Wear 10 H Monthly 100 160 Inspect periodically Battery 25 H Monthly 250 400 Check terminals clean test Front Gearcase Oil Demand Drive Plus 25 H Monthly 250 400 Inspect level change yearly R...

Page 19: ...rail and fuel pump Replace lines every two years E Spark Plug 100 H 12 M 600 1000 Inspect replace as needed E Engine Oil Filter Change 100 H 6 M 1000 1600 Perform a break in oil change at 25 hours or one month always replace oil filter when changing engine oil Drive Belt 100 H 12 M 1000 1600 Inspect replace as needed Radiator 100 H 12 M 1000 1600 Inspect clean external surfaces Cooling Hoses 100 H...

Page 20: ... 1st month or first 25 hours of operation 100 hours thereafter Change more often 25 hours in severe duty conditions or short trip cold weather operation 2 Engine Coolant Polaris 60 40 Coolant Maintain coolant level in coolant reservoir bottle Check level daily change coolant every 2 years 3 Brake Fluid Polaris DOT 4 Brake Fluid Maintain fluid level between MAX and MIN lines on the master cylinder ...

Page 21: ...ubricant until it is visible at the fill hole threads Check level every 25 hours change fluid yearly 5 Rear Gearcase Polaris ATV Angle Drive Fluid ADF Add lubricant until it is visible at the fill hole threads Check level every 25 hours change fluid yearly 6 Transmission Polaris AGL Plus Gearcase Lubricant Add lubricant until it is visible at the fill hole threads Check level every 25 hours change...

Page 22: ...ft yoke Apply grease until all traces of water have been purged out at each of these areas Item Recommended Lube Method Frequency Front Propshaft Yoke Polaris Premium U Joint Grease Grease fittings every 500 miles 800 km Grease before long periods of storage and after thoroughly washing or submerging the vehicle A arm Pivot Bushings Stabilizer Bar Bushings ...

Page 23: ...6160 ATV Angle Drive Fluid 8 oz 12 Count 2872276 ATV Angle Drive Fluid 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 oz cartridge 24 Count 2871423 Premium All Season Grease 14 oz cartridge 10 Count 2871460 Starter Drive Grease 12 Count 28...

Page 24: ... Refer to specific fastener torques listed in each chapter Shift Cable Inspection Adjustment Shift cable adjustment may be necessary if symptoms include No AWD or gear position display on instrument cluster Ratcheting noise on deceleration Inability to engage into a gear Excessive gear clash noise Gear selector moving out of desired range 1 Locate the shift cable in the rear LH wheel well area 2 I...

Page 25: ... wear deterioration damage or leakage Replace every two years 2 Be sure vent lines are routed properly and secured with cable ties IMPORTANT Ensure lines are not kinked or pinched WARNING Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where...

Page 26: ...t up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 1 8 1 5 3 mm Adjustment 1 Remove both seats and rear service panel 2 Remove the cargo box as an assembly see Chapter 5 3 Remove the 2 push rivets retaining the air intake box and remove the box from the frame 4 Loosen the hose clamp retaining the PVT intake duct and rem...

Page 27: ...pected using the following procedure Removal 1 The air box is located just above the left rear wheel in the wheel well area 2 Unlatch the 3 clips and remove the air box cap Inspect the seal It should adhere tightly to the cover and seal all the way around 3 Remove the air filter assembly 4 Inspect the air filter element and replace if necessary Do not attempt to clean the air filter with anything ...

Page 28: ... Air Box Air Filter Exploded View Cap Seal Clip 3 Boot Air Box Can Air Intake Duct Breather Seal Fitting Breather Intake Box Air Filter Clamps Front Foam Seal Filter Hose Foil Filter Ring Primary Foam Seal Intake Seal ...

Page 29: ...on the bottom side of the dipstick Proper level indication is determined on the upper surface of the dipstick as it is being removed regardless of the level marks being on top or on bottom see the next illustration NOTE A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full mark chang...

Page 30: ...r and turn by hand until filter gasket contacts the sealing surface then turn an additional 1 2 turn 13 Remove the engine oil dipstick see Engine Oil Level 14 Fill the sump with 2 qts 1 9 l of PS 4 Plus Synthetic Engine Oil 2876244 15 Verify the transmission is still positioned in PARK P 16 Start the engine and let it idle for one to two minutes 17 Stop the engine and inspect for leaks 18 Re check...

Page 31: ...s to perform a cylinder leakage test never use high pressure leakage testers as crankshaft seals may dislodge and leak Exhaust Spark Arrestor Periodically clean spark arrestor to remove accumulated carbon 1 Remove the retaining screw washer and spark arrestor from the end of the silencer 2 Use a non synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm 3 In...

Page 32: ...nd torque to 30 45 in lbs 3 5 Nm 6 Reinstall the fill plug and torque to 40 50 ft lbs 54 68 Nm GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN LEVEL CHECK PLUG TORQUE Transmission Main Gearcase AGL Plus Gearcase Lubricant 24 oz 710 ml 40 50 ft lbs 54 68 Nm 30 45 in lbs 3 5 Nm Transmission Transfer Case AGL Plus Gearcase Lubricant 14 oz 414 ml 40 50 ft lbs 54 68 Nm 30 45 in lbs 3 5 Nm Front Gear...

Page 33: ...Level Check 2 Place a drain pan under the transfer case drain plug 3 Remove the drain plug and allow to drain completely 4 Clean and Reinstall the drain plug with a new O ring Torque to 30 45 in lbs 3 5 Nm 5 Add the recommended fluid through the fill plug hole until it begins to flow out the level plug hole Do not overfill 6 Reinstall the level check plug and torque to 30 45 in lbs 3 5 Nm 7 Reinst...

Page 34: ...uid as needed 4 Reinstall the fill plug and torque to 8 10 ft lbs 11 14 Nm Lubricant Change The drain plug is located on the bottom of the gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug and allow fluid to drain completely 4 Clean the drain plug Inspect the O ring and replace if damaged 5 Reinstall the drain plug torque to 8 10 ft lbs 11 14 Nm 6 Add...

Page 35: ...l plug hole 3 Add the recommended lubricant as needed 4 Reinstall the fill plug and torque to 40 50 ft lbs 54 68 Nm Lubricant Change The drain plug is located on the bottom right side of the rear gearcase 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug and allow the lubricant to drain completely 4 Clean the drain plug 5 Reinstall the drain plug with new O ri...

Page 36: ...the recovery bottle 4 If the coolant level is below the MIN line inspect the coolant level in the radiator NOTE If overheating is evident allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system 5 Remove the pressure cap Using a funnel add coolant to the top of the filler neck 6 Reinstall the pressure cap NOTE Use of a non standard pres...

Page 37: ... a suitable drain pan underneath the radiator fitting on the front RH side of the vehicle 4 Drain the coolant from the radiator by removing the lower coolant hose from the radiator as shown Properly dispose of the coolant 5 Allow coolant to completely drain CAUTION Do not over tighten hose clamps at radiator or radiator fitting may distort causing a restriction to coolant flow Radiator hose clamp ...

Page 38: ...en the hub nut slightly 4 Elevate the appropriate side of the vehicle by placing a suitable stand under the frame 5 Remove the wheel nuts and remove the wheel 6 If hub removal is required remove the hub nut and washers Wheel Installation 1 Verify the transmission is still in PARK P 2 Install the wheel hub washers and hub nut if previously removed 3 Place the wheel in the correct position on the wh...

Page 39: ...eaking grease If the boots exhibit any of these symptoms they should be replaced Refer to Chapter 7 for drive shaft boot replacement CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear On vehicles with tapered rear wheel nuts make sure tapered end of nut goes into taper on wheel WARNING Operating with worn tires will increase the possibility of the vehicle ski...

Page 40: ...ed 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 first 5 Connect and tighten the black negative cable last 6 Verify that cables are properly routed and reinstall the driver s seat WARNING CALIFORNIA PROPOSITION 65 WARNING Batteries battery posts terminals and rela...

Page 41: ...p with a wire gauge Adjust gap if necessary by carefully bending the side electrode 7 If necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark plug is used 8 Apply anti seize compound to the spark plug threads 9 Install spark plugs and torque to specification 10 Install the plug caps to the appropriate cylinder by referencing the MAG and PTO sp...

Page 42: ...he following components Tie Rod Ends Steering Shaft U Joints Steering Gearbox Tie Rod End Wheel Hub Inspection To check for play in the tie rod end grasp the steering tie rod pull in all directions feeling for movement Replace any worn steering components Steering should move freely through entire range of travel without binding Elevate front end of machine so front wheels are off the ground Check...

Page 43: ...e between measurements A and B is the vehicle toe alignment The recommended vehicle toe tolerance is 1 8 to 1 4 3 to 6 cm toe out This means the measurement at the front of the tire A is 1 8 to 1 4 3 to 6 cm wider than the measurement at the rear B Wheel Toe Adjustment If toe alignment is incorrect measure the distance between vehicle center and each wheel This will tell you which tie rod needs ad...

Page 44: ...conditions or vehicle payloads 1 Raise and safely support the front or rear of the vehicle off the ground to allow the suspension to fully extend 2 Loosen the upper jam nut adjustment ring Turn the lower adjustment ring 1 clockwise to increase preload or counter clockwise to decrease preload T Tie Rod Jam Nut Torque 12 14 ft lbs 16 19 Nm WARNING Uneven adjustment may cause poor handling of the veh...

Page 45: ...t stops the 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 below Shock Spanner Wrench PN 2870803 2 0 Piggyback Increase Preload Decrease Preload 1 Factory Preload Setting 4 8 in 12 2 cm Rea...

Page 46: ...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 wear surface for excessive wear 3 Pads should be changed when t...

Page 47: ...2 33 MAINTENANCE 2 MAINTENANCE LOG Service Date Hours Miles km Service Performed Comments Dealer Technician ...

Page 48: ...NOTES MAINTENANCE 2 34 ...

Page 49: ...HEAD INSPECTION CYLINDER HEAD WARP 3 27 VALVE SEAL SPRING SERVICE ON ENGINE 3 27 CYLINDER HEAD DISASSEMBLY 3 28 VALVE INSPECTION 3 29 COMBUSTION CHAMBER 3 30 VALVE SEAT RECONDITIONING 3 30 CYLINDER HEAD REASSEMBLY 3 32 VALVE SEALING TEST 3 33 CYLINDER REMOVAL VALVE LIFTER REMOVAL INSPECTION 3 33 PISTON REMOVAL 3 34 CYLINDER INSPECTION 3 35 CYLINDER HONE SELECTION AND HONING PROCEDURE 3 36 PISTON T...

Page 50: ...3 2 ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views ...

Page 51: ...3 3 ENGINE 3 Oil Pump Water Pump Engine Cover Exploded View ...

Page 52: ...3 4 ENGINE Stator Cover Starter Water Pump Oil Filter Pressure Relief Exploded View ...

Page 53: ...3 5 ENGINE 3 Cylinder Cylinder Head Piston Exploded View ...

Page 54: ...3 6 ENGINE Engine EFI Sensors Valve Cover General Component Exploded View NOTE See Chapter 4 for more information on the EFI System ...

Page 55: ...3 7 ENGINE 3 Engine Fastener Torque Patterns 22 2 ft lbs 30 3 Nm Crankcase Bolt Tighten Sequence Cylinder Head Bolt Tighten Sequence ...

Page 56: ...eto Cover 6 mm 96 3 10 85 0 35 Oil Baffle Weldment 5 mm 60 6 6 8 0 68 Oil Drain Bolt Crankcase 12 mm 192 24 21 7 2 7 16 21 7 Oil Fill Tube Bolt 5 mm 50 5 5 64 0 56 Oil Filter Pipe Fitting 20 mm 35 4 47 5 5 4 Oil Pick Up 5 mm 60 6 6 8 0 68 Oil Pressure Relief Plug 10 mm 22 2 30 3 Oil Pump Housing Screw 6 mm 84 8 9 50 0 90 Rocker Arm 8 mm 22 2 30 3 Rocker Cover 6 mm 84 8 9 5 0 9 Spark Plug 14 mm 216...

Page 57: ... 005 0 127 mm Cylinder Head Cylinder Head Surface warp limit 0 00394 0 1 mm Cylinder Head Standard height 3 478 88 35 mm Valve Seat Valve Seat Contacting Width Intake 0 0472 0 00787 0 0039 1 20 0 20 0 10 mm Valve Seat Contacting Width Exhaust 0 0591 0 00787 0 0039 1 50 0 20 0 10 mm Valve Seat Angle 45 5 0 255 Valve Guide Valve Guide Inner diameter 0 2367 0 00029 6 012 0 007 mm Valve Guide Protrusi...

Page 58: ...012 0 006 mm Piston Pin Degree of Fit Piston pin must be push fit by hand at 68 F 20 C Piston Connecting Rod Crankshaft Engine Specifications Main Components Piston Connecting Rod RZR800HO 11 PN 1204276 Piston Ring Installed Gap Top Ring Standard 0 0059 0 0138 0 15 0 35 mm Top Ring Limit 15 Leakdown Second Ring Standard 0 0098 0 0197 0 25 0 50 mm Second Ring Limit 15 Leakdown Oil Ring Standard 0 0...

Page 59: ...PPORT BLOCK PU 45497 1 CAM GEAR SPRING INSTALLATION KIT PU 45497 2 CAM GEAR TOOTH ALIGNMENT TOOL PU 45498 CAM SPANNER WRENCH PU 45838 GEAR HOLDER PA 44995 WATER PUMP MECHANICAL SEAL INSTALLER PU 45543 UNIVERSAL DRIVER HANDLE PA 45483 MAIN SEAL INSTALLER PU 45658 CRANKSHAFT MAIN SEAL SAVER PA 45401 WATER PUMP SEAL SAVER 2870975 MITY VAC PRESSURE TEST TOOL PU 45778 OIL SYSTEM PRIMING TOOL ...

Page 60: ... and water pump seals for leakage Pressure Cap Test 1 Remove pressure cap and test cap using a commercially available pressure cap tester 2 The pressure cap relief pressure is 13 psi Replace cap if it does not meet this specification Condition Coolant Temperature F C Room Temperature 68 F 20 C Thermostat Closed 175 F 79 C Thermostat Open 180 F 82 C Fan Off 194 F 90 C Thermostat Full Open Lift 202 ...

Page 61: ...Radiator Pressure Cap Fan Motor Water Pump Cover Thermostat Housing Outlet Hose Inlet Hose Filler Neck To Top Fitting on Filler Neck To Lower Fitting on Filler Neck Bypass Hose To Cylinder Head Coolant Flow Diagram Radiator Recovery Bottle Engine Water Pump Engine Thermostat Housing Filler Neck Engine Cylinder Head Bypass ...

Page 62: ...oosen the bleed screw C on the cylinder head to let air escape If no air is present a steady stream of coolant will stream out If air is present the screw will bubble and sputter as the air escapes 8 Tighten the bleed screw to 70 10 in lbs 8 1 13 Nm on the thermostat housing and properly install the pressure cap 9 Squeeze the coolant lines by hand to help purge the system of air NOTE If there is a...

Page 63: ...nder Piston Rings Rocker Arms Water Pump The following components require engine removal for service Flywheel Alternator Stator Counterbalance Shaft or Bearings Gear Train Components Camshaft Oil Pump Oil Pump Drive Gear Connecting Rod Crankshaft Crankshaft Main Bearings Crankcase Oil Pressure Test 1 Remove blind plug sender from left side of crankcase 2 Insert a 1 8 NPT oil pressure gauge adaptor...

Page 64: ...ement At this point the oil is supplied to the main oil galley through a crankcase passage Oil is then diverted three ways from the main oil galley with the first path entering the camshaft bores onto the rear balance shaft journal and then draining back into the crankcase sump The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump The third ...

Page 65: ...y clean the engine and chassis 4 Drain appropriate lubricant s If servicing the engine drain engine oil If servicing the transmission drain the lubricant from the main gearcase and transfer case If servicing the rear gearcase drain the gearcase lubricant 5 Remove the driver s seat see Chapter 5 6 Disconnect negative battery cable 7 Remove the passenger seat s and remove the rear service panel see ...

Page 66: ...are marked PTO and MAG and should be installed to the corresponding cylinder spark plug and coil post 17 Remove the vent lines from the upper bolt in frame brace and plug vent lines to prevent fluid leakage during removal 18 Remove the 6 fasteners retaining the upper bolt in frame brace and remove it from the vehicle with the ignition coil and PVT duct attached 19 Remove the rear stabilizer bar fr...

Page 67: ...ehicle 26 Mark the fuel injector harnesses to identify MAG and PTO harness connections to aid during reassembly Disconnect the fuel injector harnesses NOTE The fuel injector harness connector and locking spring is bonded to the fuel injectors with an epoxy mix DO NOT attempt to disconnect the connector from the fuel injectors Damage will occur to the injector and or harness if attempting to separa...

Page 68: ...ut and loosen the lower jam nut Pull the shift cable out of the mount NOTE If the upper jam nut is moved shift cable adjustment will be required during engine installation see Chapter 2 Shift Cable Inspection Adjustment 30 Disconnect the transmission gear indicator switch harness 31 Disconnect the CPS harness 32 Disconnect the stator alternator harness Squeeze locking tabs together Push lock outwa...

Page 69: ...cle 37 Pivot the A arms upward and rear hub carriers downward and remove the drive shafts from the hub carriers 38 Grasp the rear drive shafts and pull sharply outward on the shafts to disengage them from the rear gearcase NOTE Clean area around drive shaft orifices on both sides of rear gearcase and cover orifices using duct tape This will prevent the lubricant from leaking out during removal Spe...

Page 70: ...ted in the engine Allow engine coolant to completely drain Properly dispose of the engine coolant antifreeze 43 Remove the positive battery cable from the starter motor terminal and negative battery cable from the starter motor engine mount 44 Remove the outer PVT cover 45 Remove RH engine mount fastener 46 Remove the 2 lower bolts that retain the LH transmission mount to the frame 47 Remove the 2...

Page 71: ...t the front portion of the assembly out first to allow the engine valve cover to clear the vehicle frame 50 Remove propshaft from the transmission output shaft 51 Then move assembly towards the front of the vehicle while lifting it out to allow the rear gearcase to clear the rear portion of the frame 52 Then lift assembly high enough to clear vehicle frame and completely remove it from the vehicle...

Page 72: ...from the assembly 1 Remove the drive belt drive clutch and driven clutch see Chapter 6 2 Remove the 6 fasteners retaining the inner clutch cover to the engine and transmission 3 Remove only the 4 outer fasteners retaining the engine to the transmission bracket 4 Tilt the assembly up and remove the remaining 2 nuts that retain the transmission to the engine 5 Carefully separate the engine and perfo...

Page 73: ...EMBLY AND INSPECTION Cylinder Head Assembly Exploded View Push Rods Hydraulic Lifters Valves Cylinder Head Coolant Bleeder Springs Spring Retainers Rocker Arms Retainer Locks keepers Valve Spring Seats 2 Valve Seals 2 Head Bolts ...

Page 74: ...traightness while they are installed in the engine by rotating them with the valve closed Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness 5 If the push rod A is visibly bent it should be replaced Cylinder Head Removal NOTE The cargo box assembly and the upper frame bolt in brace must be removed to allow enough clearance to remove all th...

Page 75: ... valve cover rocker arms and pushrods align the cylinder to be worked on at top dead center TDC Install the Valve Pressure Hose PU 45652 into the spark plug hole Hook the hose to an air compressor and supply 50 to 100 psi to the hose This will seat the valves during valve spring removal Do not remove air from the hose at anytime until reassembly is completed 2 Using the Valve Spring Compressor PU ...

Page 76: ...ut of specification 4 Remove valve guide seals IMPORTANT It is recommended to replace seals whenever the cylinder head is disassembled Hardened cracked or worn valve seals will cause excessive oil consumption and carbon buildup 5 Mark the valves with a white pen Remove the valves from the cylinder head This will ensure that the valves are properly placed during engine reassembly In mm Valve Spring...

Page 77: ...em with a micrometer in three places then rotate 90 degrees and measure again six measurements total Compare to specifications 5 Measure valve guide C inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer Measure in two directions 6 Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance NOTE The valve guides can...

Page 78: ...nufacturers instructions provided with the valve seat cutters in the commercially available cylinder head reconditioning kit Abrasive stone seat reconditioning equipment can also be used Keep all valves in order with their respective seat NOTE Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the entire circumfer...

Page 79: ... 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 is at the top edge of the valve face and contacts the margin area B it is too high on the valve face Use the 30 cutter to lower the valve seat If too low use the 60 cutter to raise the seat Wh...

Page 80: ...ain proper order 1 Apply engine oil to valve guides and seats 2 Coat valve stem with molybdenum disulfide grease or PS 4 PLUS Synthetic engine oil 3 Install valve carefully with a rotating motion to avoid damaging valve seal 4 Valve seals should be installed after the valves are in the head to avoid valve seal damage Install new valve seals on valve guides 5 Dip valve spring and retainer in clean ...

Page 81: ...PN 2870390 Valve Lifter Removal Inspection 1 Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand 2 Thoroughly clean the lifters in cleaning solvent and wipe them with a clean lint free cloth 3 Mark the lifters with a white pen if using the lifters for reassembly This will ensure that the lifters are properly placed during engine reassem...

Page 82: ...Remove top compression ring Using a piston ring pliers Carefully expand ring and lift it off the piston CAUTION Do not expand the ring more than the amount necessary to remove it from the piston or the ring may break By hand Placing both thumbs as shown spread the ring open and push up on the opposite side Do not scratch the ring lands 4 Repeat procedure for second ring 5 Remove the oil control ri...

Page 83: ... dial bore gauge Measure in two different directions front to back and side to side on three different levels 1 2 down from top in the middle and 1 2 up from bottom Record measurements If cylinder is tapered or out of round beyond 002 the cylinder must be replaced In mm Cylinder Warp 004 0 1 mm Max Measure atdifferent points on surface A B A B C In mm Cylinder Taper Limit 002 050 mm Max Cylinder O...

Page 84: ...g If cylinder wear or damage is excessive it will be necessary to replace the cylinder The cylinders are lined with a nicasil coating and are not repairable Hone only enough to de glaze the outer layer of the cylinder bore IMPORTANT Clean the cylinder after honing If cylinder wear or damage is excessive it will be necessary to replace the cylinder The cylinders are lined with a nicasil coating and...

Page 85: ...2 Measure piston pin O D Replace piston and or piston pin if out of specification 3 Measure connecting rod small end ID Piston to Cylinder Clearance See 800 EFI Engine Service Specifications on page 3 9 Piston O D See 800 EFI Engine Service Specifications on page 3 9 Piston Pin Bore See 800 EFI Engine Service Specifications on page 3 9 5 mm Piston Piston Pin Piston Pin O D See 800 EFI Engine Servi...

Page 86: ...gap after re boring a cylinder or when installing new rings A re bored cylinder should always be scrubbed thoroughly with hot soapy water rinsed and dried completely Wipe cylinder bore with oil immediately to remove residue and prevent rust Starter Drive Bendix Removal Inspection 1 Remove stator housing bolts and remove housing 2 Remove the flywheel nut and washer Install Flywheel Puller PN 287104...

Page 87: ...871043 and remove flywheel A 4 Use caution when removing the wire holddown B and the stator assembly D Do not tap or bump the gear stator housing cover or the stator This could cause the seal around the gear stator housing cover and the crankcase to break causing a leak 5 Remove the bendix E if necessary Engine Crankcase Disassembly Inspection 1 Remove the stator cover A and water pump cover B CAU...

Page 88: ...the woodruff key I from the crankshaft The stator does not have to be removed at this point 6 Remove the gear stator housing bolts and remove the gear stator housing cover J and gasket from the crankcase Be sure to catch the excess oil from the crankcase 7 Note the position of the gears in the photo CAUTION Do not thread the puller bolts into the flywheel more than 1 4 or stator coils may be damag...

Page 89: ...o make sure there is spring tension offsetting the teeth between the two gears If there is no tension check the springs inside of the cam gear assembly 11 The cam gear assembly contains three loaded springs To open the cam gear assembly Place the cam gear on a flat surface with the timing mark side facing up While holding both gears together lightly work a small flathead screwdriver between the tw...

Page 90: ...l three tapered pins Do not push the pins too far through or the springs will pop out NOTE Do not remove the tapered pins at this time 17 Note in photograph that the Tapered Pins PU 45497 1 are below flush with end of the springs This helps to align the three gear tabs during the next step 18 Line up the two gears using the timing marks and the three gear tabs that were referenced earlier Push the...

Page 91: ... ease of installing the Cam Gear Alignment Tool PU 45497 2 use a twisting motion when pushing down on the tool 21 To remove the balance shaft gear the flat side of the camshaft P must face the balance shaft gear To rotate the camshaft use the Cam Spanner Wrench PU 45498 to rotate the camshaft so the flat side of the camshaft faces the balance shaft gear NOTE This Cam Spanner Wrench PU 45498 is onl...

Page 92: ...ump gear S so that all four bolts are visible though the gear Remove the four bolts with a hex wrench Pull out the pump 27 Inspect the oil pump rotors for wear Mark the rotors with a white pen to ensure upon reassembly that the correct sides of the rotors are installed and mesh with the same edges as previously installed NOTE If replacing the old rotors new replacement rotors will fit into the ori...

Page 93: ...f the valve is installed incorrectly oil pressure and oil priming problems will occur 31 Carefully press the gear off the assembly while supporting the housing assembly 32 Remove the snap ring from the assembly Place the housing in a support and press out the bearing shaft assembly 33 Place the shaft in a press to remove the bearing T 22 2 ft lbs 30 3 Nm 22 2 ft lbs 30 3 Nm Chamfer End First CAUTI...

Page 94: ...thrust plate U 38 Remove PTO end engine mount Remove crankcase bolts Tap on the reinforced areas on the cases using soft hammer Carefully separate the two crankcase halves NOTE Only remove the oil baffle if the baffle is damaged When removing the oil baffle bolts use a heat gun to heat the bolts and loosen the Loctite This will prevent any possible damage to the bolts or to the crankcase casting P...

Page 95: ...normal wear It is recommended to replace the bearings anytime the engine is disassembled Camshaft Inspection 1 Thoroughly clean the cam shaft 2 Visually inspect each cam lobe for wear chafing or damage 3 Measure height of each cam lobe using a micrometer Compare to specification W V In mm Cam Lobe Height Intake Std 1 357 34 477 mm Exhaust Std 1 342 34 096 mm Cam Lobe Height ...

Page 96: ...cification 2 Install oil baffle weldment B Torque bolts to specification 3 Install the balance shaft Inspect balance shaft clearance C in both gearcase halves Rotate balance shaft to ensure there is clearance between it and the oil baffle weldment In mm Camshaft Journal O D A MAG 1 654 00039 42 010 mm B CTR 1 634 00039 41 50 010 mm C PTO 1 614 00039 41 010 mm In mm Camshaft Journal Bore I D MAG 1 ...

Page 97: ...pply sealant to cam relief hole E 7 Assemble the crankcase halves Apply LocTite 242 PN 2871949 to the threads and pipe sealant to the bolt flanges Torque bolts to specification following torque pattern at beginning of this chapter 8 Lubricate cam lobes and valve lifters with Moly Lube Grease 9 Lubricate lifters with engine oil and install in the original order as removed in disassembly Apply Lubri...

Page 98: ... alignment of the pistons to the connecting rods upon assembly Partially install the piston pins into the pistons NOTE To help align the pistons slide a rod that is close to the same diameter as the wrist pin holes to properly align them in the cylinder 14 Position cylinder and piston assemblies onto the connecting rods and push the piston pins through the piston and connecting rods 15 Install the...

Page 99: ...cation of lubrication aids in priming the oil pump during initial engine start up 19 Align the bolt holes and install oil pump assembly into crankcase Rotate the rotors in the housing during installation as this checks for binding if new rotors are used NOTE For assembly of the gears the cam gear and the crankshaft gear are stamped with This Side Out This indicates the side of the gear that faces ...

Page 100: ...t plate J 23 Use extreme caution when removing the crankshaft gear from the hot plate Use a pair of pliers and leather gloves when handling the crankshaft gear 24 Install the crankshaft gear I onto the crankshaft NOTE For assembly of the gears the cam gear and the crankshaft gear are stamped with This Side Out This indicates the side of the gear that faces outward or away from the case T Oil Pump ...

Page 101: ...TE If the timing mark on the camshaft gear does not align properly remove the camshaft gear and tool Use the Cam Spanner Wrench PU 45498 to rotate the cam to the proper position NOTE Cam Spanner Wrench PU 45498 is only needed to rotate the camshaft when the entire valve train is assembled 27 Reinstall the camshaft gear so the timing marks are properly aligned Install the washer and bolt Torque to ...

Page 102: ...seal lip facing out towards the crankcase Use of a hydraulic press is recommended for this procedure 29 Install a new crankshaft seal P into the gear stator housing cover Use the Universal Driver Handle PU 45543 and the Main Seal Installer PA 45483 to seat the crankshaft seal into place NOTE Install the crankshaft seal P with the seal lip facing out towards the crankcase 30 Once the crankshaft sea...

Page 103: ... to the outside edges of the crankcase halves see arrows where the crankcases mate see the following photos This helps to prevent coolant leakage 35 Install the gear stator housing gasket onto the crankcase 36 Secure the gear stator housing cover to the crankcase with the cover bolts Torque bolts in proper sequence to specification Remove seal protectors from the shaft ends once the cover is secur...

Page 104: ...ue the nut to specification 39 Install water pump cover R with new O ring seal Torque bolts to specification in proper sequence see Page 3 4 40 Sparingly apply Starter Drive Grease PN 2871423 to the starter drive Install the starter bendix NOTE There are thrust washers on both sides of starter drive T Water Pump Impeller Nut Torque 108 6 in lbs 6 8 0 68 Nm P Q T Water Pump Housing Bolt Torque 96 3...

Page 105: ...properly under the wire hold down bracket 3 Install the flywheel washer nut and key Torque flywheel nut to specification 4 Install stator housing with new O ring Torque the bolts to specification and follow proper bolt torque sequence at the beginning of this chapter Cylinder Head Reassembly NOTE Before reassembly clean the bolts and bolt holes with Primer N PN 2874275 to remove any debris This wi...

Page 106: ...bricate rockers E with engine oil 6 Verify pushrods are engaged in lifters 7 Install rockers Be sure that tab of fulcrum F is seated in head stand off Torque bolts to specification T Cylinder Head Bolt Torque 1 Torque to 15 1 5 ft lbs in sequence 2 Back off all head bolts 5 turns in sequence 3 Torque to 35 4 ft lbs in sequence 4 Tighten all head bolts in sequence another 90 or 1 4 turn C T Rocker ...

Page 107: ...t J new O ring and thermostat housing Torque to specification 12 Install 3 8 coolant hose fitting L and torque to specification 13 Install temperature sender K and torque to specification Oil Pump Priming T Breather Bolt Toque 20 5 in lbs 2 5 0 55 Nm T Rocker Cover Bolt Torque 84 8 in lbs 9 5 0 9 Nm G H I 20 5 in lbs 2 5 55 Nm T Thermostat Housing Bolt Torque 84 8 in lbs 9 5 0 9 Nm T Temperature S...

Page 108: ... while setting the engine in place 2 Lightly tighten all fasteners evenly to eliminate any gaps that may be present in the mounting areas 3 Torquefastenerstospecificationusinga twopartsequence Torque fasteners to half of the specified torque value Then torque fasteners to the full specified torque value 4 Install the inner clutch cover drive clutch and driven clutch Torque to specification see Cha...

Page 109: ...mp octane number of 87 R M 2 2 Check oil level indicated on dipstick Add oil if necessary Refer to Chapter 2 Engine Oil Level 3 Drive slowly at first to gradually bring engine up to operating temperature 4 Vary throttle positions Do not operate at sustained idle or sustained high speed 5 Perform regular checks on fluid levels controls and all important bolt torques 6 Pull only light loads during i...

Page 110: ...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 exhaust system Cam worn excessively Engine Has Low Pow...

Page 111: ...lty 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 jacket accident damage Lean mixture vents fuel pump or...

Page 112: ...NOTES ENGINE 3 64 ...

Page 113: ...EL PUMP REPLACEMENT 4 22 FUEL TANK REMOVAL 4 25 FUEL TANK INSTALLATION 4 27 IDLE AIR CONTROL IAC 4 27 IAC TEST 4 27 IAC REPLACEMENT 4 28 THROTTLE POSITION SENSOR TPS 4 28 TPS RESISTANCE TESTS 4 29 TPS TESTER REGULATOR 4 29 TPS REPLACEMENT 4 30 CAMSHAFT PHASE SENSOR 4 32 CAM PHASE SENSOR TEST REPLACEMENT 4 32 ENGINE COOLANT TEMPERATURE SENSOR ECT 4 33 ECT SENSOR TEST REPLACEMENT 4 33 IGNITION COIL ...

Page 114: ...t 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 loss of consciousness and death in a short time Do not smoke or allow open flames or sparks in or near the area where refueling is perfo...

Page 115: ...uipped with a CD drive and serial port connection and is designed to replace multiple shop tools often used to test EFI components It also includes step by step diagnostic procedures to aid technician repair and troubleshooting IMPORTANT If the PC you are using is not equipped with a 9 pin serial port a USB to serial port adaptor will be necessary A USB to serial port adaptor can be purchased thro...

Page 116: ...s can cause significant problems Do not use compressed air if the system is open Cover any parts removed and wrap 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 pr...

Page 117: ...t Position Sensor CPS 4 Fuel Injectors 5 Fuel Filter 6 Fuel Pump Regulator Fuel Level Sender located in fuel tank 7 Fuel Rail 8 Engine Coolant Sensor ECT 9 Throttle Position Sensor TPS 10 Throttle Body 11 Ignition Coil 12 Spark Plugs 1 2 3 4 5 6 7 8 9 10 11 12 13 Spark Plug Wires 14 IAC Motor Idle Air Control Motor 14 15 Camshaft Phase Sensor 15 12 13 ...

Page 118: ...ead 3 Crankshaft Position Sensor CPS Located in the magneto cover between the engine and transmission just in front of the rear gear case 4 Fuel Injectors Fuel Rail Attached to the fuel rail located in the intake track of the cylinder head NOTE Be sure to connect like colored fuel injector connectors for proper engine function Make note of PTO and MAG side injectors before disconnecting them ECU C...

Page 119: ...the right hand side of the throttle body 8 Idle Air Control Motor IAC Located on the right hand top side of the throttle body above the TPS sensor 9 Camshaft Phase Sensor Located in the engine block near the oil filter The sensor can be accessed in the right rear wheel well Fuel Pump Assembly Located in Fuel Tank Fuel Pump Regulator Pump Sending Unit Preliminary Filter Fuel Line Connection Connect...

Page 120: ...T Located in the cylinder head next to the thermostat housing The sensor can be accessed with the driver and passenger seats and rear service panel removed 11 Ignition Coil Located behind the driver s seat and rear service panel just above the PVT cover ECT Ignition Coil ...

Page 121: ...4 9 ELECTRONIC FUEL INJECTION 4 FUEL TANK Exploded View Fuel Flow Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line Fuel Rail Fuel Injectors Pressure Regulator Fuel Tank ...

Page 122: ...t EFI Operation Overview The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions The ignition and injection functions are electronically controlled monitored and continually corrected during operation to maintain peak performance The central component of the system is the Bosch Electronic Control Unit ECU which manages system operati...

Page 123: ...ROL UNIT ECU Operation Overview The ECU is the brain or central processing computer of the entire EFI fuel ignition management system During operation sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECU Signals to the ECU include ignition on off crankshaft position and speed RPM camshaft position MAG PTO throttle position engine coolant tem...

Page 124: ...h the ignition turned off disconnect the wire harness from the ECU 3 To install reverse the procedure and tighten screws to specification TEMP MANIFOLD ABSOLUTE PRESSURE SENSOR T MAP Operation Overview Mounted on the throttle body intake manifold the T MAP sensor performs two functions in one unit Air passing through the intake is measured by the T MAP and relayed to the ECU These signals comprise...

Page 125: ...creates an interrupt input signal corresponding to specific crankshaft position This signal serves as a reference for the control of ignition timing by the ECU Synchronization of the CPS and crankshaft position takes place during the first two revolutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason t...

Page 126: ... under CPS Test IMPORTANT In order to remove the CPS the rear portion of the exhaust system and the mounting bracket between the transmission and rear gearcase will need to be removed 3 Remove the exhaust pipe between the elbow pipe and the exhaust silencer Remove the exhaust silencer 4 Remove the 3 bolts retaining the front portion of the mounting bracket to the transmission Retain the bolts wash...

Page 127: ...ng procedure NOTE Special tool PA 48873 will be required to torque the mounting bracket fasteners when the transmission and rear gearcase are installed in the vehicle 1 Clean bolt threads with solvent and allow them to dry Coat the circumference of the first 4 threads of the bolts with Loctite before installing the bolts Remove Bracket T CPS Retaining Bolt Torque 25 in lbs 2 8 Nm This tool is spec...

Page 128: ...Bolt 5 Remove the special tool and attach an extension to the torque wrench Torque the bottom bolt that attaches the bracket to the rear gearcase through the hole in the frame support Bottom Rear Gearcase Bolt NOTE Special Tool is not required for this torque 6 Using special tool PA 48873 torque the upper 2 bolts retaining the mounting bracket to the rear gearcase Place the torque wrench through t...

Page 129: ...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 the 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 contains a series of calibra...

Page 130: ...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 to fuel delivery Injector clogging is usually caused by a buildup of deposits on the director plate restricting the flow of fuel resulting in a poor spray pattern Some contribu...

Page 131: ...that location Separate the fuel injector from the vehicle harness as shown in the illustration below 6 Thoroughly clean the area around the fuel injectors including the throttle body manifold 7 Using a 6 mm hex wrench loosen the fuel rail mounting screw from the cylinder head Carefully pull the rail away from the injectors and remove the injector s from the cylinder head along with the harness 8 R...

Page 132: ...e 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 not working or if the display reading differs in large ...

Page 133: ...ification replace the fuel pump assembly 6 If the pump did not activate Step 3 disconnect the harness connector from the fuel pump Connect a DC voltmeter across terminals 3 and 4 in the plug on the vehicle harness side 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 ignition switch relay s wiring harness and ...

Page 134: ...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 Apply downward force on the fuel pump flange while removing the fuel pump PFA nut WARNING Always wear safety goggles when working with high pressure or flammable fluids Failure to do so could result in serious injury or complications CAUTION It is possible for pressurized fuel to b...

Page 135: ...ebris 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 10 Remove new fuel pump assembly gasket and PFA nut from packaging Use care not to bend float arm dur...

Page 136: ...pump and fuel tank 17 Torque PFA nut to specification using the Fuel Pump Service Tool PU 50326 and a calibrated torque wrench 18 Verify alignment of fuel pump and tank orientation marks 19 Connect the fuel line to the fuel pump outlet IMPORTANT Be sure to engage the white retainer on fuel line until it snaps into place Pull on fuel line lightly to confirm connection 20 Connect the fuel pump elect...

Page 137: ...ine out of the way for tank removal NOTE A small amount of fuel may come out of the fuel line or tank Properly drain fuel into a suitable container 4 Disconnect the fuel pump electrical harness 5 Remove the fuel tank vent hose clamp with a suitable pliers Remove the vent line from the fuel tank vent fitting 6 Remove the rear seat base assembly from the vehicle by removing the 2 fasteners from the ...

Page 138: ...of the way 10 Remove the 3 Torx fasteners from the rear RH fender well and remove the fender well from the vehicle see chapter 5 11 Remove the 3 shift lever support bracket bolts by and place bracket out of the way of the fuel tank but do not remove or cut the plastic wire harness retainer 12 Remove the 2 tank bracket fasteners that retain the fuel tank in the chassis Swing the tank fastener strap...

Page 139: ...eck for leaks 12 Finally install the rear service panel along with the driver and passenger seats IDLE AIR CONTROL IAC Operation Overview The Idle Air Control IAC is used to stabilize the idle quality of the engine at cold start up and after warm up operations Mounted on the throttle body the IAC contains 1 stepper motor which receives varying voltage signal pulses from the ECU These pulses determ...

Page 140: ...N SENSOR TPS Operation Overview The throttle position sensor TPS is used to indicate throttle plate angle to the ECU Mounted on the throttle body and operated directly off the end of the throttle shaft the TPS works like a rheostat varying the voltage signal to the ECU in direct correlation to the angle of the throttle plate This signal is processed by the ECU and compared to the internal pre prog...

Page 141: ...he Throttle Position Sensor TPS Tester 2201519 A IMPORTANT TPS Tester 2201519 A replaces the existing TPS tester PU 47082 which included the 4010264 regulator If your dealership has PU 47082 and 4010264 you DO NOT need to order 2201519 A as a replacement Set up the TPS Tester Wire Harness PU 47466 and TPS Tester Regulator 547927 according to the instructions that accompanied the tester Make sure t...

Page 142: ...d it must be recalibrated Refer to the TPS Adjustment procedure 1 Remove the seats rear main service panel and the rear cargo box See chapter 5 2 Loosen the hose clamps retaining the throttle body 3 Remove the throttle body from the intake track and plug the intake boots with a clean shop tow 4 Disconnect the vehicle harness from the TPS 5 Remove the 2 Phillips head mounting screws and replace the...

Page 143: ...ation see Figure 4 28 11 Retighten the TPS mounting screws and torque to specification 12 Verify voltage reading did not change If voltage reading is now out of specification repeat steps 2 4 13 Reconnect vehicle harness to the TPS 14 Reinstall the throttle body and securely tighten the hose clamps 15 Reinstall cargo box rear main service cover and seats see Chapter 5 TPS Output Reading 650 750 Vd...

Page 144: ...t must be replaced With the ignition key switch on the sensor should have battery voltage present on the Red Dark Blue wire and ground present on the Brown wire NOTE Use Digital Wrench Diagnostic Software dealer only if you suspect this sensor is faulty Cam Phase Sensor Replacement 1 Disconnect vehicle harness from the sensor 2 Remove the retaining bolt and remove the sensor from the engine 3 Use ...

Page 145: ...nds 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 10 for additional ECT sensor information Polaris dealers can test the sensor by using the Digital Wrench Diagnostic Software dealer only ECT Sensor Replacement 1 Remove the driver and passenger seats 2 Remove the rear service p...

Page 146: ...tion coil harness and remove the high tension leads from the coil 4 Remove the fastener retaining the ignition coil and remove it from the vehicle If replacing the high tension lead s remove the other end of the lead s from the spark plug 5 Install the new ignition coil and or high tension lead s NOTE Be sure to mark note which ignition coil wire goes to which cylinder and ignition coil post The e...

Page 147: ...he 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 in length This number equates to the fault mode FMI 4 If more than one code exists press the MODE button to advance to the next trouble c...

Page 148: ...nded 4 P1693 Fan Relay Driver Circuit Driver Circuit Open Grounded 1071 5 P1481 Driver Circuit Short to B 3 P1482 Driver Circuit Grounded 4 P1483 Ignition Coil Primary Driver 1 MAG Driver Circuit Short to B 1268 3 P1353 Ignition Coil Primary Driver 2 PTO Driver Circuit Short to B 1269 3 P1354 Fuel Pump Driver Circuit Driver Circuit Open Grounded 1347 5 P0230 Driver Circuit Short to B 3 P0232 Drive...

Page 149: ...20230 31 U0131 Idle Air Control Valve IAC M17 IAC Stepper Pin 1 Driver Circuit Open Grounded 520267 5 P1505 Driver Circuit Short to B 3 P1509 Driver Circuit Grounded 4 P1508 Idle Air Control Valve IAC M17 IAC Stepper Pin 3 Driver Circuit Open Grounded 520268 5 P1515 Driver Circuit Short to B 3 P1519 Driver Circuit Grounded 4 P1518 Idle Air Control Valve IAC M17 IAC Stepper Pin 4 Driver Circuit Ope...

Page 150: ...onomy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug TPS setting incorrect Injector failure Poor Idle Symptom Idle Too High If greater than 1300 RPM when engine is warm Throttle stop screw set incorrect Throttle cable sticking improperly adjusted routed incorrectl...

Page 151: ... 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 other electrical sub systems Diagnostic pro...

Page 152: ...roceed 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 are required NOTE Versions and updates are subject to change 1 Open the Digi...

Page 153: ...NT You must already have version 3 1 installed before adding these updates They will not install if you have version 3 0 or older 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 disk and then double click the icon to start the update proces...

Page 154: ...4 42 ELECTRONIC FUEL INJECTION Digital Wrench Feature Map ...

Page 155: ... 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 detection software Virus Scanners Tool Bars ...

Page 156: ...le description by selecting the Change Vehicle Type icon 5 Select the Special Tests icon 6 Select Engine Controller Reprogramming 7 Select the file you want to load into the ECU then click the Continue icon to proceed to the Integrity Check 8 Follow the on screen instructions and connect a 9V battery to the reflash battery connector located off the main diagnostic connector Click the Continue icon...

Page 157: ...ou selected previously while in Digital Wrench Enter the VIN along with the customer s name and address When completed click the Authorize button once to proceed 13 An Authorization Key will appear in the upper left corner of the screen Copy CTRL C this key exactly as it appears 14 Enter or paste CTRL C the Authorization Key in the box located on the Digital Wrench screen Click the Continue button...

Page 158: ...this point the reflash process will begin Do not touch the vehicle or PC during the process 16 Once the ECU reprogramming procedure is complete click the Finish button on the screen Verify the reflash was a success by starting the vehicle ...

Page 159: ...NDER FLAIR AND TIE DOWN REMOVAL 5 12 CARGO BOX ASSEMBLY REMOVAL 5 12 ROCKER PANELS CONSOLE AND FLOOR 5 13 STEERING ASSEMBLY 5 14 EXPLODED VIEW 5 14 STEERING WHEEL REMOVAL 5 15 STEERING SHAFT REMOVAL 5 15 STEERING SHAFT BEARING REPLACEMENT 5 15 FRONT A ARMS 5 16 REMOVAL REPLACEMENT 5 16 EXPLODED VIEW 5 17 BALL JOINT SERVICE 5 18 REMOVAL 5 18 INSTALLATION 5 19 REAR A ARMS 5 19 REMOVAL 5 19 INSTALLAT...

Page 160: ... Nm Shock Mounting Bolts 30 ft lbs 41 Nm Wheel Hub Castle Nuts 80 ft lbs 108 Nm Wheel Nuts Steel Rims 35 ft lbs 47 Nm Tie Rod End Jam Nut 13 ft lbs 18 Nm Seat Belt to Seat Base 40 ft lbs 54 Nm Tilt Shock Upper Fastener 7 ft lbs 10 Nm Tilt Shock Lower Fastener 12 ft lbs 16 Nm Steering Pivot Tube Fasteners 23 ft lbs 31 Nm Steering Wheel to Shaft 28 ft lbs 38 Nm Lower Steering Shaft to Box 30 ft lbs ...

Page 161: ...ket on each side Tighten screws to 15 ft lbs 20 Nm 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 25 28 ft lbs 34 38 Nm 5 Attach side bars to cab frame using M6 screws and nuts on top and M8 screws and nuts on the bottom Tighten to 8 10 ft...

Page 162: ...5 4 BODY STEERING SUSPENSION BODY EXPLODED VIEWS Hood Front Body Work Push Rivets T27 Screws 1 4 Turn Latch Grommet Washer Push Rivet T27 Screws T27 Screws T25 Screws ...

Page 163: ...5 5 BODY STEERING SUSPENSION 5 Front Bumper Rear Bumper Headlight O Ring T25 Screw T27 Screw T30 Screws Bulb RH Tail Light Rear Bumper Speed T25 Screws T27 Screws T27 Screw LH Tail Light Nuts ...

Page 164: ...t 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 Driver 3 Point Seat Belt Rear Seat Base Latch Seat Passenger Seat 3 Point Seat Belt 3 Point Seat Belt Plunger 40 ft lbs 54 Nm 40 ft lbs 54 Nm 40 ft lbs 54 Nm 40 ft lbs 54 Nm 40 ft lbs 54 Nm NOTE Seat Style May Differ Depending on Model Number ...

Page 165: ...oor Rear Front Push Rivets U Type Support Bracket Rear Support Bracket Push Rivets Support Bracket Front Support Bracket Self Tapping Screws Self Tapping Screws Self Tapping Screw T27 Screws T27 Screws Nuts T27 Screws Self Tapping Screw Plastic Dart T27 Screws Torx Screws Upper Floor T27 Screw ...

Page 166: ...5 8 BODY STEERING SUSPENSION Rear Cargo Box Fenders Torx Screws Nut Push Rivets Cargo Box Support T27 Screw 1 4 turn Latch ...

Page 167: ...5 9 BODY STEERING SUSPENSION 5 Chassis Main Frame Main Frame Bolt In Brace Skid Plate Rear Bumper Support 15 ft lbs 20 Nm 15 ft lbs 20 Nm 17 ft lbs 23 Nm 6 8 ft lbs 8 11 Nm Washer ...

Page 168: ...to remove it Front Bumper 1 Remove the 4 push rivets from the sides of the front bumper 2 Remove the 6 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 Bumper 1 Remove the 4 Torx screws retaining the upper portion of the rear bumper to the cargo box 2 Remove the 4 Torx screws retaini...

Page 169: ...RAME Assembly Removal procedure for assembly torque specifications 4 Remove the push rivets that attach the dash assembly to the rocker panels on each side 5 Remove the 2 Torx screws and 2 push rivets that retain the front and rear portions of the dash assembly 6 Disconnect all electrical dash components noting their location and wire routing 7 Remove the dash assembly from the vehicle Front Fende...

Page 170: ...go box and remove from vehicle Cargo Box Assembly Removal 1 Remove the seats and rear panel or cover see Seats and Rear Service Panel 2 Remove the 4 Torx screws retaining the lower portion of the rear bumper to the frame see Rear Bumper 3 Remove the 4 screws from the middle of the cargo box 4 Remove the 4 Torx screws that attach the front portion of the cargo box to the frame 5 Remove the 6 Torx s...

Page 171: ...and Lower Floor Removal 1 Remove both seats and rocker panels see Rocker Panel Removal 2 Remove the T27 screws retaining the console to the floor 3 Remove the shift handle knob and remove the console 4 Remove the Torx screws retaining the upper floor to the lower floor 5 Remove the Torx screws retaining the rear portion of the floor and remove the lower floor from the vehicle Push Rivets Screws ...

Page 172: ...otter 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 25 31 ft lbs 34 42 Nm 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 Washer Thin Washer Spacer ...

Page 173: ...ure for installation Steering Shaft Bearing Replacement 1 Perform the Steering Shaft Removal procedure 2 Remove the steering wheel cap and retaining nut 3 Press steering shaft out of the steering wheel and pivot tube 4 Note the order and location of the washers and spacers between the steering wheel and pivot tube 5 Drive the bearings out of the pivot tube using a drift punch 6 Inspect the pivot t...

Page 174: ...carrier 5 Remove the front bumper to allow A arm bolt removal 6 Loosen and remove the upper A arm through bolt fastener C and remove the upper A arm from the vehicle 7 Examine A arm bushings and pivot tube see Exploded View Replace if worn Discard hardware 8 If not replacing the A arm thoroughly clean the A arm and pivot tube 9 Install new ball joint into A arm Refer to Ball Joint Replacement sect...

Page 175: ... into the bearing carrier Install lower ball joint pinch bolt E into the bearing carrier and torque bolt to specification Exploded View WARNING Upon A arm installation completion test vehicle at low speeds before putting into service T Front Upper Lower A arm Bolts 40 ft lbs 54 Nm T Front Ball Joint Pinch Bolts 22 5 ft lbs 30 5 Nm T Shock Mounting Bolts 30 ft lbs 41 Nm A B C E F Upper A arm Lower ...

Page 176: ...ing process 4 Use a press and correct size driver to remove the ball joint from the A arm NOTE The driver must fit the ball joint housing in the A arm This will allow the ball joint to be properly pressed out of the A arm without damaging the A arm Ball Joint Upper A arm Retaining Ring 1 75 in 1 375 in 3 49 cm 3 in 7 62 cm Driver Dimensions Outside diameter of driver cannot be any larger than 1 75...

Page 177: ...cement on one side of the vehicle Repeat the following steps to remove the A arm s from the opposite side NOTE Use the exploded view in this section as a reference during the procedure see page 5 41 1 Elevate and safely support the rear of the vehicle off the ground 2 Remove the wheel nuts and rear wheel Upper A arm Removal 1 Remove the fastener A attaching the upper A arm to the bearing carrier 2...

Page 178: ...bearing carrier see previous illustration 4 Remove the 2 fasteners J attaching the lower A arm to the frame and remove the lower A arm from the vehicle see previous illustration 5 Examine A arm and bearing carrier bushings and pivot tubes see Exploded View Replace if worn Discard hardware 6 If not replacing the A arm thoroughly clean the A arm and pivot tubes 7 Insert new A arm bushings and pivot ...

Page 179: ...fastener to specification 6 Attach upper A arm to bearing carrier Torque new fastener to specification 7 Install wheel and torque wheel nuts to specification Exploded View WARNING Upon A arm installation completion test vehicle at low speeds before putting into service T Rear Upper Lower A arm Bolts 40 ft lbs 54 Nm T Lower Rear Bearing Carrier Bolts 40 ft lbs 54 Nm T Shock Mounting Bolts 30 ft lbs...

Page 180: ...er bar to the linkage on each side of the vehicle 3 Remove the 4 fasteners retaining the stabilizer bar to the bracket 4 Remove the stabilizer bar from the bracket bracket can remain attached to the frame 5 Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed 6 Reverse the procedure for installation Torque the stabilizer bolts to 18 ft lbs 24 Nm Remove Remove Fast...

Page 181: ...treating Do not hold the torch too close to the surface 2 3 inches from the flame tip is recommended Keep the torch moving to prevent damage 2 Apply the decal on one edge first Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application WARNING The following procedure involves the use of an open flame Perform this procedur...

Page 182: ...37 45 Nm Shock Replacement 1 Using a spring compressor compress the shock spring far enough to remove the spring retainer 2 Remove the spring and adjusting cam from the existing shock and install components onto the new shock 3 Compress the shock spring and install the spring retainer IMPORTANT The spring retainer gap should be 180 from the end of the spring upon installation 4 Reinstall the shock...

Page 183: ...g Cap Asm 21 1 Preload Ring Jam Nut 7 1 Bearing Asm 22 1 Preload Ring 8 1 Spacer 23 1 Damping Adjust Asm Piston 9 1 Plate Top Out 24 1 Damping Adjust Asm Concentric Adjuster 10 1 Valving Asm 25 2 Bearing External 11 1 Piston Damping 26 1 Bumper 12 2 or 3 Plate Back Up 27 2 Bearing Spherical 13 1 Lock Nut 28 4 Retaining Ring 14 1 Reservoir 29 1 Decal 15 1 Piston Asm Floating IFP 30 Shock Oil 287099...

Page 184: ...REBOUND 1 600 x 0 008 1 425 x 0 010 1 425 x 0 010 1 350 x 0 012 1 350 x 0 010 1 250 x 0 012 1 250 x 0 010 1 100 x 0 015 1 100 x 0 010 0 950 x 0 012 0 950 x 0 010 0 800 x 0 010 0 800 x 0 020 0 875 x 100 Back Up 1 570 x 0 128 Top Out 0 875 x 100 Back Up 0 875 x 100 Back Up Piston Orifice 2x 0 070 SHOCK DESIGN DETAILS Travel 6 22 Extended Length 21 34 IFP Location 3 40 Nitrogen Pressure 200 psi Gas S...

Page 185: ...e procedures 1 Safety Glasses 2 Latex Gloves 3 Lint Free Towels 4 Assembly Lube lithium based grease 5 Loctite 271 6 12 Tie Wrap Zip Tie 7 MAPP Gas or Propane Torch 8 1 834 TC Seal Kit 9 5wt Shock Fluid Special Tools Required Body Holding Tool PN 2871071 Charging Needle PN 7052069 A Gas Shock Recharging Kit PN 2200421 FOX Shock IFP Tool PN 2871351 Seal Installation Bullet Tool PN 2201640 PN 220163...

Page 186: ...ock If your shock has polyurethane bushings and sleeves remove them from both ends of the shock Fig 1 5 Note and record the setting on the Compression Adjuster Screw Using the Flat Blade Screwdriver count the clicks as you turn the adjuster clockwise until it stops Fig 2 Once you have written this number down turn the screw all the way counterclockwise until it stops 6 Clean the entire shock assem...

Page 187: ...oir tube using the IFP Depth Setting Tool and place it on a clean lint free towel Remove the shock from the vise and pour shock oil from body and reservoir tubes into a proper disposal container DO NOT RE USE OLD SHOCK OIL 18 Using the 1 8 Hex Tool remove the IFP bleed screw from the IFP 19 Clean the body tube reservoir tube and the IFP using solvent Dry with compressed air in a well ventilated ar...

Page 188: ...a If compressed air is not available dry parts using clean lint free paper towels and let sit in a well ventilated area to allow the remaining solvent to evaporate 3 Use a scribe or dental pick to remove the O ring seal from the IFP 4 Use a scribe or dental pick to remove the O ring seals from the reservoir end cap 5 Install the new well lubricated O rings into the bearing housing Correct placemen...

Page 189: ...Nm using a torque wrench and 9 16 socket Remove shaft assembly from vise and set it aside on a clean lint free paper towel 5 Clamp the body cap of the shock securely in the vise with the open end of the body facing up 6 Using the flat blade screwdriver turn the compression adjuster screw counter clockwise until it stops turning 7 Lubricate the new IFP O ring with an ample amount of assembly lube 8...

Page 190: ...rface of the oil during this process 19 Bring the damping piston up until it is approximately 1 4 below the surface of the oil Using the mallet give 2 3 sharp blows to the eyelet driving the damping piston down into the shock body 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...

Page 191: ...en Safety Needle using a smooth straight motion Keep the reservoir as straight as possible to prevent the safety needle from bending As the safety needle is pulled free from the FOX air valve a popping sound should be heard 35 Install the button head screw into the FOX air valve using a 3 32 hex key 36 Remove the shock from the vise 37 Clean all oil residue from the shock and reservoir with solven...

Page 192: ...NOTES BODY STEERING SUSPENSION 5 34 ...

Page 193: ... 9 BELT REMOVAL 6 9 BELT INSPECTION 6 9 BELT INSTALLATION 6 9 PVT BREAK IN DRIVE BELT CLUTCHES 6 9 DRIVE CLUTCH SERVICE 6 10 SPRING SPECIFICATIONS 6 10 SHIFT WEIGHTS 6 11 NON BRAKING EXPLODED VIEW ALL MODELS 6 11 CLUTCH DISASSEMBLY 6 12 SPIDER REMOVAL 6 12 ROLLER PIN AND THRUST WASHER INSPECTION 6 13 BUTTON TO TOWER CLEARANCE INSPECTION 6 14 SHIFT WEIGHT INSPECTION 6 14 BEARING INSPECTION 6 14 CLU...

Page 194: ...ve belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive belt rotates low in the drive clutch sheaves As engine RPM increases centrifugal force causes the drive belt to be forced upward on drive clutch sheaves TOOL DESCRIPTION PART NUMBER Drive Clutch Puller Short PA 48595 Clutch Holding Wrench 93...

Page 195: ...e 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 hours as recommended see Chapter 3 Engine Break In Period for break in example Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period Maintenance Inspection...

Page 196: ...arm 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 Towing Pushing at low RPM or low ground speed Use Low only Plowing snow dirt etc utility use Use Low only Stuck in mud ...

Page 197: ... screws from the rear of the center console 4 Remove the 2 fasteners from the rear seat base as shown and remove it from the vehicle 5 Loosen the hose clamp on the clutch outlet duct 6 Remove the outer clutch cover screws and remove the clutch cover 7 Mark the drive belt direction of rotation and remove drive belt see DRIVE BELT Belt Removal Inner Clutch Clamps Outer Cover Outer Push Rivets Outlet...

Page 198: ...en the engine and inner clutch cover Both surfaces must be clean to ensure adhesion of silicone sealant 4 Install and properly align the inner clutch cover 5 Install the bolts and washers that retain the cover to the transmission Torque bolts to specification see next page 6 Install the screws that retain the cover to the engine Torque screws to specification see next page Remove any excess silico...

Page 199: ...e speed a clutch offset adjustment is required Washers located behind the driven clutch on the transmission input shaft may need to be added or removed in order to obtain the proper offset Refer to the Clutch Offset Procedure provided below 1 Follow steps 1 6 of the PVT Disassembly procedure 2 Inspect the drive clutch belt to sheave clearance If the belt is contacting either sheave remove the driv...

Page 200: ...sure the belt is tight and riding at the proper height in the clutch The belt should now be resting evenly between the drive clutch stationary and moveable sheaves 7 Inspect the outer clutch cover gasket Replace if damaged 8 Install the outer clutch cover and torque the cover screws to 45 50 in lbs 5 5 6 Nm 9 Install the clutch cover outlet duct and tighten the clamps 10 Sit in the driver s seat a...

Page 201: ...e if necessary 3 Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic PVT operation See the Troubleshooting Chart at the end of this chapter for possible causes Belt Installation NOTE Be sure to position belt in the same position as when removed or so part number is easily read 1 Loop belt over the drive clutch and over top of the driven sheave 2 While pu...

Page 202: ...ld always be inspected for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from the outer coil surfaces as shown Refer to the spring specification chart for specific free length measurements and tolerances Also check to see that spring coils are parallel to one another Distortion of the spring indicates stress fatig...

Page 203: ...t be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance clutch balance and shifting pattern Non Braking Exploded View All Models 7043594 Black 177 2 80 Primary Clutch Springs Washers Bearing Spring Cover Bearing Bushing Lock Washer Bolt Flat Washer Cover Screws Button Pin Washers Roller Nut Shift Weight Bo...

Page 204: ...r 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 See Drive Clutch Spring Specifications for spring inspection Spider Removal 1 Install clutch in holding fixture PN 2871358 and loosen the spider counterclockwise using Clutc...

Page 205: ...s of three Also inspect to see if roller and bushing are separating Bushing must fit tightly in roller Use the Roller Pin Tool PN 2870910 to replace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation 2 Rubber backed buttons can be used in all RANGER clutches if the hollow roller pin is changed to the solid roller pin NOTE The rubber side o...

Page 206: ...surface should be smooth and free of dents or gall marks Inspect the weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or broken replace in sets of three with new bolts NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See Roller Pin and Thrust Washer Inspection Bearing Inspection 1 Rotate the clutch bearing in both c...

Page 207: ...problems were noted 5 Inspect surface of shaft for pitting grooves or damage Measure the outside diameter and compare to specifications Replace the drive clutch assembly if shaft is worn or damaged 6 Visually inspect PTFE thrust washer for damage Measure the thickness and compare to specification Replace if worn or damaged In mm Thrust Washer Thickness Standard 030 76 mm Service Limit 025 64 mm 1 ...

Page 208: ...ection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBSBushingRemovalTool 5132028 1 Instructions 9915111 Additional Special Tools Qty Part Description Part 1 Clutch ...

Page 209: ...pter from puller rod Remove bushing from tool and discard Drive Clutch Bushing Installation 1 Place main adapter Item 8 on puller 2 Apply Loctite 609 evenly to bushing bore inside moveable sheave 3 Set bushing in place on sheave 4 Insert installation puller tool Item A B with A side down into center of bushing NOTE 800 EFI Clutch Use Bushing Tool PA 47336 5 With towers pointing upward slide sheave...

Page 210: ...er toward vise 4 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 5 Turn clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and clutch cover off rod Clutch Assembly NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly The Teflon...

Page 211: ...h spring 7 Reinstall cover aligning X mark with other marks 8 Torque cover bolts evenly to specification T Spider Torque 200 ft lbs 271 Nm CAUTION Be sure the spider spacer washers are fully seated in the recessed area in the spider Any misalignment will alter clutch balance Inverting the clutch while initially tightening the spider will help position the washers T Cover Screw Torque 90 in lbs 10 ...

Page 212: ...on Extensions PN PS 45909 apply and hold downward pressure on the outer spring retainer Carefully remove the snap ring Remember the outer spring retainer contains strong spring pressure NOTE Spring is compression only and has no torsional wind Stationary Moveable Inner Compression Spring Outer Retaining Spring Retainer Ring Spacer Spring Retainer Secondary Sheave Secondary Sheave CAUTION Wear eye ...

Page 213: ...g retainer from the inner sheave Inspect for wear and replace as needed 8 Check the rollers in the stationary sheave for wear If rollers are worn a new driven clutch assembly may be needed 9 Inspect the bearings inside the moveable sheave A B C E D C E B D Inspect for Abnormal Wear Moveable Sheave Bearing Inspection Replace the clutch assembly if more brass than Teflon is visible on the bearing In...

Page 214: ...er if removed Do not apply oil or grease to the bearings 2 Align the X marks on each of the sheaves during reassembly 3 Install the spring into the inner retainer 4 Install the spacer over the shaft 5 Install the outer retainer on top of the spring 6 Place the clutch into Clutch Compression Tool PN 8700220 Using Compression Extensions PN PS 45909 apply and hold downward pressure on the outer sprin...

Page 215: ...clutch spring too high spring rate Driveclutchshiftweights incorrectfor 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 move sheaves through entire range to further det...

Page 216: ... Maintenance Manual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt slippage Belt worn out Water ingestion Belt contaminated with oil or grease Replace belt Inspect and seal PVT system Inspect and clean PVT noise Belt worn or separated...

Page 217: ... OPERATION 7 15 AWD DIAGNOSIS 7 16 GEARCASE REMOVAL 7 17 GEARCASE DISASSEMBLY INSPECTION 7 17 GEARCASE ASSEMBLY INSPECTION 7 20 GEARCASE INSTALLATION 7 22 REAR BEARING CARRIER 7 23 BEARING CARRIER INSPECTION REMOVAL 7 23 BEARING REPLACEMENT 7 24 BEARING CARRIER BUSHING REPLACEMENT 7 25 BEARING CARRIER INSTALLATION 7 25 REAR DRIVE SHAFT 7 27 DRIVE SHAFT REMOVAL 7 27 OUTER CV JOINT BOOT REPLACEMENT ...

Page 218: ...ront wheel hub assembly 5 Remove the fastener retaining the steering tie rod end to the front bearing carrier PART NUMBER TOOL DESCRIPTION 2872608 Roll Pin Removal Tool 8700226 CV Boot Clamp Pliers earless type PU 48951 Axle Boot Clamp Tool ITEM NUT TYPE SPECIFICATION AluminumWheels Cast Lug Nut 1 30 ft lbs 90 1 4 turn Steel Wheels Flange Nut 2 35 ft lbs 47 Nm Front Hub Castle Nut 80 ft lbs 108 Nm...

Page 219: ...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 outer race 12 Replace bearing if moisture dirt corrosion or roughness is evident Bearing Replacement Be...

Page 220: ...he bearing carrier 2 Install the upper and lower ball joint ends into the front bearing carrier 3 Install pinch bolts and torque to specification 4 Apply grease to drive shaft axle splines 5 Install front wheel hub assembly cone washers and hand tighten the castle nut Install washers with domed side out 6 Install brake caliper mounting bolts and torque to specification 7 Install the steering tie r...

Page 221: ...heel nuts and remove the front wheel 3 Remove the cotter pin and loosen the front wheel hub castle nut Remove the nut and 2 cone washers from the front wheel hub assembly 4 Remove the two front brake caliper mounting bolts and remove the caliper from the 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 T Tie Rod...

Page 222: ...ed during handling to avoid damage Do not allow boots to come into contact with sharp edges or hot engine and exhaust components The drive shaft is not to be used as a lever arm to position other suspension components Never use a hammer or sharp tools to remove or to install boot clamps Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint b...

Page 223: ...It is very important to use the correct type and quantity of grease by using the grease contained in the boot kit DO NOT use a substitute grease and DO NOT overfill or under fill the CV joint 11 Slide the joint onto the drive shaft splines and align the circlip with the lead in chamfer on the inner race 12 Use a soft faced hammer to tap the CV joint into the splines of the axle Pull on the joint t...

Page 224: ...int 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 that s provided is pre measured so use all the grease 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 to tap the joint onto the drive shaft until it locks in...

Page 225: ...2 Align splines of drive shaft with front gearcase and reinstall the drive shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 3 Install drive shaft into the front bearing carrier 4 Install the upper ball joint end into the front bearing carrier CV Boot Clamp Pliers Earless Type 8700226 FRONT DRIVE SHAFT Grease Capacity 80 Grams Grease Capacity 80 Grams Plunging Jo...

Page 226: ...ication 10 Install wheel and 4 wheel nuts Torque wheel nuts to specification 11 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions T Pinch Bolts 22 5 ft lbs 30 5 Nm 22 5 ft lbs 30 5 Nm Out Cone Washers Wheel Hub 80 ft lbs NEW Cotter Pin 108 Nm T Wheel Hub Castle Nut 80 ft lbs 108 Nm T Front Caliper Mounting Bolts 31 34 ft lbs 42 4...

Page 227: ...haft 4 Slide prop shaft back far enough to remove it from the front gearcase input shaft 5 Pull sharply forward to remove it from transmission shaft NOTE You may have to loosen the front gearcase mounting bolts to allow for propshaft removal 6 Remove the fasteners retaining the plastic skid plate and remove the skid plate from the vehicle 7 Remove the propshaft from the vehicle 8 Reverse removal s...

Page 228: ...nd 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 toward center of shaft Take care not to dislodge ...

Page 229: ... 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 stiff or binding tap the yoke lightly to center ...

Page 230: ...7 14 FINAL DRIVE FRONT GEARCASE CENTRALIZED HILLIARD Centralized Hilliard Exploded View 8 10 ft lbs 11 14 Nm 7 11 ft lbs 10 15 Nm 8 10 ft lbs 11 14 Nm ...

Page 231: ...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 torque requirement goes away i e rear wheels regain traction AWD...

Page 232: ...rrupted wear mark may indicate a warped plate which may cause intermittent operation See the following illustrations 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 insert it raise...

Page 233: ...e the vent line from the front gearcase 6 Remove the 4 bolts securing the front gearcase to frame 7 Remove the gearcase from the front LH wheel well area and slide it between the upper and lower A arm Gearcase Disassembly Inspection 1 Drain and properly dispose of gearcase fluid Remove any metal particles from the drain plug magnet 2 Remove the 7 cover screws and remove the cover plate 3 Remove an...

Page 234: ...tput hub assembly from the gearcase housing 8 Remove pinion seal The pinion seal must be replaced every time it is removed Take out the internal snap ring Remove pinion bearing assembly from the gearcase housing by pulling and rocking the pinion shaft strait out Inspect and clean the gearcase housing and replace ALL oil seals 9 Clean and inspect all parts Check for excessive wear or damage Armatur...

Page 235: ... the roll cage 13 Thoroughly clean all parts and inspect the rollers A for nicks and scratches The rollers must slide up and down and in and out freely within the roll cage sliding surfaces and H springs IMPORTANT Refer to the Electronic Parts Catalog for individual part availability Most parts are to be replaced as an assembly or as a complete kit 14 Inspect the roll cage assembly B sliding surfa...

Page 236: ...g the assembly into the clutch housing NOTE Install the roll cage so that the ring gear grooves line up with the roll cage slots see below IMPORTANT To ensure gearcase is assembled properly assemble the gearcase components starting with the cover plate and build upward 6 Install a new O ring on the cover plate assembly NOTE Be sure the square O ring is placed flat on the cover surface If the O rin...

Page 237: ...he ring gear NOTE Verify armature plate tabs are in the slots on the roll cage and are resting in the ring gear grooves 13 While holding the clutch housing and the armature plate in the roll cage flip the clutch housing assembly over and set it on the cover plate NOTE Be sure to hold armature plate in place until the housing is completely resting on the cover plate 14 Install the RH output hub int...

Page 238: ...the vehicle through the LH wheel well area between the upper and lower A arms 2 Install the propshaft onto the front gearcase input shaft Use a NEW spring pin in the front propshaft 3 Install the 4 bolts that secure the front gearcase to the frame and torque to 30 ft lbs 41 Nm 4 Install the vent line T Cover Plate Screws 7 11 ft lbs 10 15 Nm Torque All Cover Plate Screws T Front Gearcase Mounting ...

Page 239: ...e tire should rotate smoothly without binding or rough spots 3 Remove the 4 wheel nuts and remove the rear wheel 4 Remove the cotter pin and loosen the rear wheel hub castle nut Remove the nut and 2 cone washers from the rear wheel hub assembly 5 Remove the two brake caliper mounting bolts CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake lin...

Page 240: ...ation or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 10 Replace bearing if moisture dirt corrosion or roughness is evident Bearing Replacement Bearing Removal 1 Remove outer snap ring 2 From the back side of the bearing carrier tap on the outer bearing race with a drift punch in the relie...

Page 241: ...ushings and pivot tubes for excessive wear or damage If replacement is required slide pivot tubes out and remove bushings with a drift punch Install new bushings by pressing them into the bearing carrier Bearing Carrier Installation 1 Install drive shaft axle through the backside of the bearing carrier Be sure bushings and pivot tubes are installed 2 Install the fasteners that attach the rear bear...

Page 242: ...d 4 wheel nuts Torque wheel nuts to specification 8 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions T Rear Caliper Mounting Bolts 18 ft lbs 24 Nm CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly Out Cone Washers Wheel Hub 18 ft lbs 24 Nm...

Page 243: ...g caliper to prevent damage to the brake line 5 Remove the rear wheel hub assembly 6 Remove the bolt that attaches the rear bearing carrier to the upper A arm 7 Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft 8 Grasp the rear drive shaft and pull sharply outward on the shaft to disengage it from the rear ...

Page 244: ...e Using a soft faced hammer or brass drift strike the inner race of the joint to drive the joint off the drive shaft Be sure to tap evenly around the joint to avoid binding IMPORTANT Tap on inner race only 5 Make sure the circlip is on the shaft and not left in the joint 6 Remove the CV boot from the shaft CAUTION Complete disassembly of the CV joint is NOT recommended The internal components are ...

Page 245: ...rclip on the 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 that s provided is pre measured so use all the grease 13 Slide the joint onto t...

Page 246: ...the air pressure to equalize in the CV boot in the position that the joint will spend most of its life Before you remove your instrument be sure the small end of the boot is in its correct location on the shaft 20 Install and tighten the small clamp on the boot using the Axle Boot Clamp Tool PU 48951 Inner Plunging Joint Boot Replacement 1 Using a side cutters cut away and discard the boot clamps ...

Page 247: ... Replace if needed 10 Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly 11 Slide the small boot clamp and boot small end first onto the drive shaft and position the boot in its groove machined in the shaft 12 Install a NEW circlip on the end of the shaft 13 Grease the joint with the special joint grease provided in the boot replacement kit Fill the cavi...

Page 248: ...ull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 20 Install and tighten the small clamp using the Axle Boot Clamp Tool PU 48951 21 Pull out on the drive shaft to center the joint in the housing Slide a straight O ring pick or a small slotted screw driver between the large end of the boot and the jo...

Page 249: ... shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary NOTE Take care when installing the drive shaft to prevent damaging the seal 3 Slide the rear drive shaft into the rear bearing carrier REAR SHAFT CV Joint Plunging Spring Ring Gear Side Boot Kit Wheel Side Boot Kit Joint Spring Ring Large Clamp Grease Pack Small Clamp Spring Ring Large Clamp Grease Pack Apply Ant...

Page 250: ...o 80 ft lbs 108 Nm and install a NEW cotter pin Tighten nut slightly if necessary to align cotter pin holes 9 Install wheel and 4 wheel nuts Torque wheel nuts to specification T Upper Rear Bearing Carrier Bolt 40 ft lbs 54 Nm Out Cone Washers Wheel Hub 18 ft lbs 24 Nm T Rear Caliper Mounting Bolts 18 ft lbs 24 Nm CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Al...

Page 251: ...t are attached to the differential gear assembly This unlocks the rear differential When Differential Lock is selected on the switch power is removed from the electrical solenoid allowing the solenoid plunger to retract Spring tension moves the shift yoke back into place and engages the clutch gear into the engagement dogs that are attached to the differential gear assembly locking the rear differ...

Page 252: ...T on page 7 28 2 Remove the exhaust pipe and exhaust silencer to allow for gearcase removal 3 Remove the 4 bolts retaining the rear rack cab frame to the rear suspension plate Remove the upper A arm bolts lower rear A arm bolts and plate 4 Remove the 2 rear gearcase mount bracket fasteners and mount bolt and remove bracket from vehicle Differential Clutch Gear IRS Axle Clutch Gear Unlocked Locked ...

Page 253: ...er to disengage it 9 Remove the vent line and lift the rear gearcase upward and on its side to remove it from the vehicle Gearcase Disassembly IMPORTANT The pinion gear assembly is NOT intended to be disassembled from the case as it requires special OEM tooling in order to properly reassemble If there is any damage to the pinion gear bearings or case the entire gearcase assembly must be replaced P...

Page 254: ... differential assembly Inspect the bearing for smoothness and wear 6 Remove the shim s from the differential assembly Be sure to keep the shims together for reassembly 7 Remove the bearing from the lower portion of the differential assembly Inspect the bearing for smoothness and wear 8 Remove the shim s from the differential assembly Be sure to keep the shims together for reassembly Inspect Teeth ...

Page 255: ...ng while checking for any looseness or roughness Inspect the pinion gear for chipped worn or broken teeth If damaged replace the gearcase assembly NOTE In the event damage to the gears pinion bearings or housing requires replacement the entire assembly must be replaced 13 Remove the differential solenoid from the gearcase if servicing the solenoid shift lever shift lever spring or shift yoke If no...

Page 256: ...m the gearcase housing 18 Carefully remove the shift yoke assembly from the gearcase cover 19 Inspect the shift lever A shift lever spring B shift return springs C shift yoke D and lock pin bushing E Inspect the components for excessive wear or damage and replace as needed NOTE The pinion shaft assembly is NOT intended to be disassembled from the case as it requires special OEM tooling in order to...

Page 257: ...l cover 3 Remove the upper differential gear 4 Use a scribe to mark the ring gear and differential case Remove the 8 bolts that secure the ring gear to the differential and allow the ring gear to slide down and off 5 Place the differential assembly upright Use a roll pin punch to remove the roll pin from the differential case 6 With the roll pin removed slide the cross pin out and remove the remai...

Page 258: ...d thrust washers and slide the cross pin into position with the hole side facing the hole in the differential case 4 Install a new roll pin 5 Install the upper differential gear and differential cover Apply Loctite 271 to the cover screws and torque the screws to specification 6 Install the ring gear and torque the retaining bolts to specification Thrust Gear Gears Washers Thrust Washer Differenti...

Page 259: ...r other suitable method 4 Install a new O ring in the gearcase cover 5 Install a new pinion shaft seal using a standard seal installer or other suitable method 6 Install the original shim s previously removed onto the appropriate sides of the differential assembly Install the bearings by hand as they are a slip fit 7 If previously removed assembly the shift lever A shift lever spring B shift retur...

Page 260: ...all the differential assembly into the gearcase housing and install a new lightly greased O ring onto the cover 12 Assemble the gearcase halves and install the bolts that secure the cover to the housing Torque the bolts in a criss cross pattern to 23 27 ft lbs 31 37 Nm 13 If previously removed install the differential solenoid Torque the solenoid to 30 40 ft lbs 41 54 Nm C O Ring 23 27 ft lbs 31 3...

Page 261: ...ge 4 14 NOTE Special tool PA 48873 will be required to torque the mounting bracket fasteners when the transmission and rear gearcase are installed in the vehicle Refer to the Installation procedure listed on page 4 14 2 Add Polaris ATV Angle Drive Fluid to rear gearcase Refer to maintenance information in Chapter 2 for more details Torque drain and fill plugs to specification Rear Gearcase Capacit...

Page 262: ...r 1 10 Bearing Ball 2 29 Screw Flange Head 10 11 Plug Drain 1 30 Case Diff Cover Half 1 12 Shim Kit 2 31 Thrust Washer Pinion 2 13 Gear Clutch 1 32 Gear Diff Pinion Mate 2 14 Yoke Shift 1 33 Gear Diff Side 2 15 O Ring 1 34 Thrust Washer Side Gear 1 16 Cover Asm Rear 1 35 Case Diff Half 1 17 Screw 2 36 Pin Diff Cross 1 18 Seal Oil 2 37 Pin Spring 1 19 Screw Flanged 4 1 2 3 4 5 6 7 9 10 13 14 15 16 ...

Page 263: ...eel Hub Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Front Tire Washers 35 ft lbs 47 Nm 80 ft lbs 108 Nm Ring Carrier Steel Studs Rear Rim Castle Nut Cotter Pin Cone Wheel Hub Brake Disc Bolts Retaining Sealed Ball Bearing Bearing Rear Tire Washers 80 ft lbs 108 Nm Ring Carrier Steel Studs Wheel Nuts 35 ft lbs 47 Nm ...

Page 264: ...NOTES FINAL DRIVE 7 48 ...

Page 265: ...TMENT 8 3 TRANSMISSION SERVICE 8 4 TRANSMISSION REMOVAL SERVICE NOTES 8 4 TRANSFER CASE DISASSEMBLY 8 4 TRANSFER CASE REASSEMBLY 8 7 TRANSMISSION SHIFT HOUSING DISASSEMBLY 8 9 TRANSMISSION SHIFT HOUSING REASSEMBLY 8 13 TROUBLESHOOTING 8 18 TROUBLESHOOTING CHECKLIST 8 18 TRANSMISSION EXPLODED VIEW 8 19 SHIFT HOUSING TRANSFER CASE EXPLODED VIEW 8 19 ...

Page 266: ...nut to specification ITEM TORQUE VALUE Transmission Fill Plugs 40 50 ft lbs 54 67 Nm Transmission Drain Level Plugs 30 45 in lbs 0 2 0 3 Nm Transmission Case Screws 23 27 ft lbs 31 36 Nm Shift Cable Lever Screw 15 20 ft lbs 20 27 Nm Detent Sleeve Assembly 40 45 ft lbs 54 61 Nm Outer Detent Screw 23 27 ft lbs 31 37 Nm Drain Plugs Check Plug 30 45 in lbs 0 2 0 3 Nm Ground Speed Sensor Screw 130 155 ...

Page 267: ... the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH H gear and PARK P 5 Thread the upper or lower jam nut as required to obtain proper cable adjustment NOTE This procedure may require a few attempts to obtain the proper adjustment 6 Once the proper adjustment is obtained place the shift cable and upper jam nut into the mount Tighten the lowe...

Page 268: ...embly NOTE Exploded views are located at the end of this chapter for additional information 1 Place the transmission in the neutral position 2 Drain both the transfer case and transmission case halves 3 Remove the 7 fasteners retaining the transmission to rear gearcase mount bracket 4 Remove the connector tube bolts securing the rear gear case and transmission transfer case 5 Inspect the driveshaf...

Page 269: ...iscard removed bearings as they become damaged by the removal process 10 Remove the intermediate pinion shaft assembly from the housing Check bearings and gear teeth for wear or damage and replace as needed The shaft can be disassembled as shown using a press and standard bearing removal tools 11 Disassemble the output pinion shaft assembly by removing the retaining screws on the bearing cup brack...

Page 270: ...mbled as shown using a press and standard bearing removal tools 14 Remove the upper snap ring from the top side of the 21T main pinion gear and remove the gear 15 Remove the lower snap ring from under the gear 16 Remove the intermediate shaft seal using a seal puller or other suitable method ...

Page 271: ... shaft assembly NOTE Bearing is pressed onto the shaft 3 Install the shims bearing cup and alignment dowels into the retaining bracket 4 Install a new output shaft seal flush with the case Install the output pinion shaft assembly and bearing cup bracket assembly as shown Verify the alignment dowels are seated Torque the bracket screws evenly to specification T Output Pinion Shaft Bracket Screws 23...

Page 272: ...ces Apply lubricant to the seal lip 7 Install the transfer case cover Align the dowels 1 7 and insert the cover screws note position of the longest screw 4 Torque the screws evenly to specification in sequence as shown 8 Reinstall the transmission to rear gearcase mount bracket Hand tighten all fasteners first then torque fasteners to specification Apply Sealant PN 2871557 To Case Mating Surfaces ...

Page 273: ...d 2 from the backside as shown NOTE Shift cable bracket removal is required 2 Place the transmission shift housing onto a flat surface as shown Lift the transmission case half straight up and remove NOTE Shaft components may catch during transmission case half disassembly Work slowly and deliberately to avoid component loss or damage 3 Remove the retaining ring and retaining plate 4 Remove the rev...

Page 274: ...amages the bearing 7 Remove the reverse idler snap ring upper washer gear needle bearing and lower washer from the idler shaft NOTE The reverse idler shaft is a non serviceable item and should not be pressed out of the housing 8 Remove the input shaft seal and clutch intermediate shaft seal using a seal puller or punch 9 Remove the 2 screws that attach the gear position sensor to the shift housing...

Page 275: ...haft 13 Pull back fully on gear selector arm to bring shift collar up and disengage the shift collar from the clutch yoke Lifting on the clutch shaft may aid in shift collar removal 14 Inspect the inner and outer gear teeth and splines on both ends of the shift collar for excessive wear or damage 15 Remove the retaining rings from each end of the shift collar 16 Remove the wave spring and ball bea...

Page 276: ...taining the pivot pin 22 Locate the retaining ring on the shifter assembly and move the retaining ring out of the groove to allow the shifter assembly to slide out 23 Use a needle nose pliers to grab the pivot pin and slide the pin out of the case 24 Remove the clutch yoke from the shifter assembly and out from the transmission housing 25 Remove the transmission input shaft from the housing Inspec...

Page 277: ...ss damages the bearing Transmission Shift Housing Reassembly 1 Install a new shift cable lever seal and press it flush with the case Apply lubricant to the seal lip 2 Lubricate the shaft of the shifter assembly and install the assembly into the housing with a new retaining ring and washer Install the shift cable lever X facing out and torque the retaining screw to specification 3 Assemble the inpu...

Page 278: ... Install the pivot pin set screw and torque to specification 7 Assemble the clutch shaft with new needle bearings Press a new ball bearing onto the end of the shaft and install a new retaining ring 8 Install the clutch shaft into the transmission housing 9 Install the sliding shoes onto the clutch yoke Pivot Pin Shifter Assembly Clutch Yoke T Pivot Pin Set Screw 100 125 in lbs 11 14 Nm ...

Page 279: ...pecification TURN THE OUTER DETENT SCREW ONLY UNTIL LIGHT SHIFTING RESISTANCE IS FELT AT THIS TIME PLACE THE TRANSMISSION IN NEUTRAL 12 With the transmission in neutral lubricate and install the thrust washer drum gear plate springs contact pins and the gear position sensor O ring assembly Verify the contact pins are aligned as shown with the transmission in neutral Torque the retaining screws to ...

Page 280: ...rque the 5 screws to specification 17 Install the reverse clutch assembly onto the park flange Note the orientation of the needle bearing 18 Install the retaining plate and a new retaining ring 19 Install the input shaft seal and verify it is fully seated Install the intermediate shaft seal circled flush or slightly below the case Apply lubricant to both seal lips T Park Flange Screws 130 155 in l...

Page 281: ...faces 21 Install the shift cable bracket 7 shift housing case screws to the front of the transmission Torque to specification 22 Install the 2 shift housing case screws to the backside as shown Torque to specification NOTE Shift cable bracket installation is required 23 Proceed with transfer case reassembly See Transfer Case Reassembly on page 8 7 Apply Sealant PN 2871557 to Case Mating Surfaces T...

Page 282: ...t and rod end positioning Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty is caused by an internal transmission problem isolate the transmission by disconnecting the shifter from transmission bellcrank Verify the engine RPM is set to specification Manually select each gear range at the transmission bellcrank and test ride ...

Page 283: ...8 19 TRANSMISSION 8 TRANSMISSION EXPLODED VIEW Shift Housing Transfer Case Exploded View Transfer Case Shift Housing ...

Page 284: ...NOTES TRANSMISSION 8 20 ...

Page 285: ...0 CALIPER EXPLODED VIEW 9 10 CALIPER REMOVAL 9 10 CALIPER DISASSEMBLY 9 11 CALIPER INSPECTION 9 12 CALIPER ASSEMBLY 9 12 CALIPER INSTALLATION 9 13 FRONT BRAKE DISC 9 14 DISC RUNOUT 9 14 DISC INSPECTION 9 14 DISC REPLACEMENT 9 14 REAR BRAKE PADS 9 15 PAD REMOVAL 9 15 PAD INSPECTION 9 16 PAD ASSEMBLY INSTALLATION 9 16 BRAKE BURNISHING PROCEDURE 9 17 REAR CALIPER SERVICE 9 18 CALIPER EXPLODED VIEW 9 ...

Page 286: ... mm Rear Brake Disc Thickness 188 4 78 mm 170 4 32 mm Rear Brake Disc Runout 010 254 mm Item Torque ft lbs Torque Nm Front Caliper Mounting Bolts 31 34 42 46 Rear Caliper Mounting Bolts 18 24 Brake Line Flare 12 15 16 20 Brake Line Banjo Bolts Caliper Attachment 15 20 Brake Line Banjo Bolt Master Cylinder Attachment 15 20 Front Brake Disc to Hub Bolts 18 24 Rear Brake Disc to Hub Bolts 28 38 Brake...

Page 287: ...r 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 Noise Troubleshooting...

Page 288: ...m 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 port which is opened and closed by the master c...

Page 289: ... 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 15 ft lbs 20 Nm 3 Fitting Switch ...

Page 290: ...stallation 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 master cylinder clevis pin B and clip A 2 Remove the E ring E from the pedal mount and remove the br...

Page 291: ...eat 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 screw securely and remove bleeder hose Torque bleeder screw to 47 in lbs 5 3 Nm 9 Repeat procedure Steps 5 8 for the remaining calipers 10 Add brake fluid to MAX level inside reservoir 11 Install master cylinder reservoir cover 12 Field test ma...

Page 292: ... 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 the slip outer brake pad out between the bracket and caliper body 7 Remove the inner pad from the bracket and caliper Pad Inspection 1 Measure the thickness of the...

Page 293: ...servoir 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 machine Allow pads and disc to cool...

Page 294: ...low 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 Socket Set Screw B Bleeder Screw C Caliper Assy D Boots E Square O rings F Pistons G CaliperMount H Brake Pads F G H Apply Polaris All Purpose Grease Apply Polaris DOT 4 Brake Fluid to Components D E CAUTION Use care when supporting vehicle so that it does not tip or fall Severe in...

Page 295: ...t 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 pliers is used 5 Once the pistons are removed us...

Page 296: ...d 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 should slide in and out of bore smoothly with ...

Page 297: ...ification 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 before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is ...

Page 298: ... 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 wheel hub 5 Install new bolts and torque to 18 ft lbs 24 Nm Brake Disc Ru...

Page 299: ...sed If the brake drags re check assembly and installation REAR BRAKE PADS Pad Removal 1 Elevate and support rear of vehicle 2 Remove the rear wheel 3 Loosen pad adjuster screw 2 3 turns 4 Remove the two caliper mounting bolts and lift caliper off the brake disc NOTE When removing caliper be careful not to damage brake line Support caliper so as not to kink or bend brake line CAUTION Always use new...

Page 300: ... 1 Clean the caliper with brake cleaner or alcohol 2 Measure the thickness of the pad material Replace pads if worn beyond the service limit Pad Assembly Installation 1 Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease PN 2871423 and install rubber dust boots 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction materi...

Page 301: ... 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 machine Allow pads and disc to cool sufficiently during the procedure Do not allow pads or disc to ...

Page 302: ...e pad adjustment set screw to allow brake pad removal after the caliper is removed 6 Remove the two caliper mounting bolts and remove the caliper 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 A B C D E F G H I K Apply Polaris DOT 4 Brake Fluid to Component Apply Polaris All Purpose Grease 47...

Page 303: ...er or alcohol NOTE Be sure to clean seal grooves in caliper body Caliper Inspection 1 Inspect caliper body for nicks scratches or wear Measure bore size and compare to specifications Replace if damage is evident or if worn beyond service limit 2 Inspect piston for nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads a...

Page 304: ...an 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 the mounting bolts Torque mounting bolts to specification 2 Install brake line banjo bolt and torque to specification 3 Install the pad adjustment screw and turn until stationary pad contacts disc then back off 1 2 turn 4 Follow bleeding procedure...

Page 305: ...install new disc on wheel hub 5 Install new bolts and torque to 28 ft lbs 38 Nm 6 Install wheel hub assembly washers and castle nut Torque castle nut to 80 ft lbs 108 Nm and install a new cotter pin 7 Install rear caliper see REAR CALIPER SERVICE Follow bleeding procedure outlined earlier in this chapter 8 Field test unit for proper braking action before putting into service Inspect for fluid leak...

Page 306: ...ster cylinder or components Damaged break pad noise insulator Brake pads dragging Brake caliper dragging Pedal Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port plugged Pad clearance set incorrectly Brake pedal binding or unable to return fully Residue build up under caliper seals Operator riding brakes Brakes Lock A...

Page 307: ...ON DISPLAY 10 10 INFORMATION DISPLAY AREA 10 10 DIAGNOSTIC MODE 10 13 INSTRUMENT CLUSTER PINOUTS 10 14 INSTRUMENT CLUSTER REMOVAL 10 14 INSTRUMENT CLUSTER INSTALLATION 10 14 ALL WHEEL DRIVE COIL 10 15 OPERATION OVERVIEW 10 15 DIAGNOSING SYSTEM FAILURES 10 15 HEAD LIGHTS 10 15 HEADLIGHT ADJUSTMENT 10 15 HEADLAMP BULB REPLACEMENT 10 16 HEADLAMP HOUSING REMOVAL 10 16 HEADLAMP HOUSING INSTALLATION 10 ...

Page 308: ...0 26 BATTERY OFF SEASON STORAGE 10 26 BATTERY TESTING 10 26 OCV OPEN CIRCUIT VOLTAGE TEST 10 27 LOAD TEST 10 27 BATTERY CONDUCTANCE ANALYZER 10 27 CHARGING PROCEDURE 10 28 STARTING SYSTEM 10 28 TROUBLESHOOTING 10 28 VOLTAGE DROP TEST 10 29 STARTER MOTOR REMOVAL DISASSEMBLY 10 29 BRUSH INSPECTION REPLACEMENT 10 29 ARMATURE TESTING 10 30 STARTER REASSEMBLY INSTALLATION 10 31 STARTER DRIVE 10 32 STAR...

Page 309: ...imal point For resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply Under Dash Components The following switches and components can be accessed underneath the instrument dash panel Speedometer Speedometer Mode Switch Digital Wrench Diagnostic Connector Digital Wrench ECU Reflash 9 Vdc Battery Plug AWD Switch Headlamp Switch 12 Vdc Accessory P...

Page 310: ... switch pins 2 and 3 4 and 5 Move the switch to OFF There should be continuity between switch pins 1 and 2 4 and 5 NOTE Pins 7 and 8 provide power and ground to light the switch lamp Ignition Key Switch 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 3 sets of outputs OFF ON START If any of the tests fail r...

Page 311: ...o continuity between any pins Move the switch to TURF There should be continuity between switch pins 1 and 2 Blackout Switch 1 Disconnect the blackout switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 2 sets of outputs OFF ON If any of the tests fail replace the blackout switch assembly Move the switch to ON POS 1 There shoul...

Page 312: ...nd 3 Move the switch to OFF POS 3 There should be no continuity between any pins NOTE Pins 7 and 8 provide power and ground to light the switch lamp Winch Switch 1 Disconnect the winch switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring 2 Test between the 2 sets of outputs OUT IN If any of the tests fail replace the winch switch assembly Move the...

Page 313: ...heel well area Speed Sensor Testing Special Tools Required Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 1 Disconnect the 3 wire harness from the speed sensor and remove the sensor from the transmission 2 Connect the wires from the Static Timing Light Harness to the sensor 3 pin connector using the Hall Sensor Probe Harness PN 2460761 3 Pass a screwdriver back and for...

Page 314: ... 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 differential fails to switch from operational modes Check the solenoid and relay connectors Look for loose wires or bad connections Check for power from the relay connector ...

Page 315: ... 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 Immediately clean off any gasoline that splashe...

Page 316: ...justable 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 in...

Page 317: ...d 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 steps 1 Toggle the MODE button until t...

Page 318: ... 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 When the display flashes the distance setting tap ...

Page 319: ...MIL has been activated Use the following procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to illuminate Diagnostic trouble codes will remain stored in the gauge even if MIL turns off until the key is turned off 1 If the trouble code s are not displayed use the MODE button to toggle until CK ENG displays on the information display area ...

Page 320: ...not remove the rubber mount from the dash panel Only remove the rubber mount if necessary The bezel 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 ins...

Page 321: ...nd wiring connections have been tested properly with a known good volt ohm meter before suspecting a component failure 80 of all electrical issues are caused by bad failed connections and grounds HEAD LIGHTS Headlight Adjustment The headlight beam is adjustable 1 Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to t...

Page 322: ...he O rings A from the headlamp brackets on both sides of the headlamp 3 Remove the adjustment screw B from the bracket 4 Carefully remove the headlamp from the front bumper Headlamp Housing Installation 1 Install the headlamp housing back into the front bumper 2 Secure the headlamp housing with the rubber O rings A on both sides of the headlamp and install the adjustment screw B 3 Reconnect wire h...

Page 323: ...iving 12 volts and that a ground path is present If a tail light or brake light does not work the bulb may need to be replaced 1 Remove bulb by turning the rubber base 1 4 turn and pulling the bulb out Replace it with recommended bulb Apply Dielectric Grease PN 2871329 2 Test the tail light and brake light to verify it is working properly Tail Brake Light ...

Page 324: ...10 18 ELECTRICAL COOLING SYSTEM SCHEMATIC Cooling System Break Out Diagram ...

Page 325: ... 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 EFI DIAGNOSTICS EFI Component Test...

Page 326: ...e dash the fuses provide overload protection for wiring and components such as the instrument cluster ECU EFI system chassis power lights and accessories The relays assist with component operation like the cooling fan fuel pump and EFI system A separate 20 amp circuit breaker protects the fan motor circuit ...

Page 327: ...lay coil ground Orange ECU 12 Vdc power input to enable relay White Provides12Vdc powerforlights drive and accessory circuits EFI RELAY 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 protected 12 Vdc constant battery voltage Red Dark Blue Provides 12 Vdc power for EFI system circuits FAN RELAY ...

Page 328: ... battery condition and system load the break even point may vary slightly The battery should be fully charged before performing this test BLACKOUT RELAY COLOR FUNCTION White Ground input from Blackout Switch to enable open relay Red Yellow BUS Bar 10 Amp fuse protected 12 Vdc battery voltage Red Yellow 10 Amp fuse protected 12 Vdc battery voltage Red Yellow Provides 12 Vdc power for all light circ...

Page 329: ... 1 Measure the resistance value of each of the stator legs to ground Y1 to Ground Y2 to Ground Y3 to Ground Each test should measure Open Line OL NOTE Any measurement other than Infinity open will indicate a failed or shorted stator leg TEST 3 Measure AC Voltage Output of Each Stator Leg at Charging RPM 1 Set the selector dial to measure AC Voltage 2 Start the engine and let it idle 3 While holdin...

Page 330: ... 2 wire connector Open Circuit BLACK Ground 2 wire connector RED Battery 2 wire connector 2300mV to 2400mV BLACK Ground 2 wire connector Regulator Rectifier Case Closed Circuit continuity BLACK Ground 2 wire connector Any Phase Open Circuit AC 1 3 wire connector BLACK Ground 2 wire connector Open Circuit AC 2 3 wire connector BLACK Ground 2 wire connector 2200mV to 2300mV AC 3 3 wire connector BLA...

Page 331: ...ts The battery will continually discharge if operated below the Break Even RPM Con tinued problems would call for battery inspection Yes Inspect the wiring harness between the panel and the stator for remove the recoil and flywheel Inspect the flywheel magnets stator coils and stator wires for damage No Check stator regulator ground battery and battery connections Also check wire connections and w...

Page 332: ...onth to make up for normal self discharge Battery tenders can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Testing Whenever a service complaint is related to either the starting or charging systems the battery should be checked first Following are two tests which can easily be made on a sealed Mainte...

Page 333: ...sting device that has an adjustable load Apply a load of three times the ampere hour rating At 14 seconds into the test check battery voltage A good 12V battery will have at least 10 5 volts If the reading is low charge the battery and retest Battery Conductance Analyzer Conductance describes the ability of a battery to conduct current A conductance tester functions by sending a low frequency AC s...

Page 334: ... loose disconnected or corroded Poor ground connections at battery cable starter motor or starter solenoid see Voltage Drop Tests Faulty key switch Faulty starter solenoid or starter motor Engine problem seized or binding can engine be rotated easily Starter Motor Turns Over Slowly Battery discharged Excessive circuit resistance poor connections see Voltage Drop Test Engine problem seized or bindi...

Page 335: ...er to clean starter motor parts Some solvents may leave a residue or damage internal parts and insulation 1 Remove the starter from the engine 2 Remove the two bolts washers and sealing O Rings Inspect O Rings and replace if damaged NOTE Note the alignment marks on both ends of the starter motor casing These marks must align during reassembly 3 Remove the front bracket assembly and the rear bracke...

Page 336: ...ely in their holders Brush Replacement 1 Remove terminal nut with lock washer flat washer large phenolic washer the small phenolic spacers and sealing O ring Inspect O ring and replace if damaged 2 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Armature Testing 1 Remove armature from starter casing Note order of shims on drive end for reassembly 2 ...

Page 337: ...ce 4 Slide armature into field magnet housing Release brushes 5 Lightly grease the drive roller bearing and reinstall drive end frame on armature Inspect seal for wear or damage Replace drive end cap if necessary 6 Be sure wire insulation is in place around positive brush wire and pushed completely into slot on phenolic plate 7 Using Dielectric Grease PN 2871329 lubricate brush end bushing and ins...

Page 338: ... overrun clutch off the end of the pinion shaft Remove the old spring and install a new one Lightly grease the pinion shaft and reinstall the clutch spring retainers end washer and lock ring in the reverse order Make sure the end washer is positioned properly so that it will hold the lock ring in its groove Starter Solenoid Bench Test Test the start solenoid by powering the solenoid using battery ...

Page 339: ... 3 Thrust Washer 4 Gear Assembly 5 O Ring 6 Brush Complete 7 O Ring 8 Thrust Washer 9 Shaft Complete 10 Gear Assembly 11 Through Bolt 12 Cover 13 Stopper 14 Snap Ring 15 Washer 16 Flange Bolt 17 Thrust Washer 18 Flange Bushing Indicates Do not reuse Replace with new parts ...

Page 340: ...d 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 Turn the ignition key to the start position Reading should be less th...

Page 341: ...tion Problems Digital Wrench 4 39 Compression Test 2 17 Console and Floor Panel Removal 5 13 Conversion Table 1 6 Coolant Level Inspection 2 22 Coolant Strength and Type 2 22 Cooling System Bleeding Procedure 3 14 Cooling System Hoses 2 23 Cooling System Specifications 3 12 Cooling System Pressure Test 3 12 Crankshaft Gear Removal 3 43 Crankshaft Position Sensor CPS 4 13 Cylinder Head Assembly 3 3...

Page 342: ...gine Piston Removal Inspection 3 34 Engine Piston Ring Installed Gap 3 38 Engine Piston to Cylinder Clearance 3 37 Engine Piston to Rod Clearance 3 37 Engine Push Rod Inspection 3 26 Engine Rocker Arm Inspection 3 26 Engine Starter Drive Removal 3 38 Engine Stator Gear Cover Seal s Installation 3 54 Engine Stator Installation 3 57 Engine Troubleshooting 3 62 Engine Valve Inspection 3 29 Engine Val...

Page 343: ...wer Clearance 6 14 PVT Drive Clutch Bushing Service 6 16 PVT Drive Clutch Cover Bushing 6 17 PVT Drive Clutch Disassembly 6 12 PVT Drive Clutch Spider Removal 6 12 PVT Moveable Sheave Inspection 6 16 R Radiator 2 23 Radiator Removal 2 23 Rear A arm Replacement 5 19 Rear Bearing Carrier 7 24 Rear Bumper 5 5 5 10 Rear Cargo Box 5 8 Rear Drive Shaft CV Joint Boot Replacement 7 29 Rear Drive Shaft Plu...

Page 344: ...10 39 Starter System Troubleshooting 10 32 Stator Removal 3 39 Steering Shaft Bearing Replacement 5 15 Steering Shaft Removal Non EPS 5 15 Steering Wheel Freeplay 2 28 Steering Wheel Removal Non EPS 5 15 Steering Exploded View 5 14 Steering Inspection 2 28 Suspension FOX 2 30 Suspension Compression Adjustment FOX 2 31 Suspension Spring Preload Adjustment FOX 2 30 Switch AWD 2WD TURF 10 5 Switch Bl...

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