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POLARIS RANGER XP 700 4X4 RANGER 6X6 SERVICE MANUAL

Contents

1. r 1 T 2007 RANGER 700 EFI 4X4 6X6 CHASSIS ECU sio 7831 AGNOSTIC BRAKE LAMP SWITCH PAGE 1 2 LOCATED UNDER pes WITH HAND BRAKE APPLIED FRONT COVER i DO 91 RDANI ATV OT RANGER T00 EFI CHASSIS MODEL NO RO7RH68AG 5 ENABLE MODEL NO RO7RH68AD mm Gi FUEL PUMP MD 10 i fre PLUG 98 BN BS MODEL NO ROTRH68AH 4 DIS CIN FUEL TANK SWITCH CONNE LOCATED UNDER NOSE 1 DO g WIRES ARE REPRESENTED BY L Je ERGA PUMP BRANE TONER M PANEL ON DRIVERS SIDE 66 OG WH aq SOLENOID SOLID OR DASHED LINES 0 SE 2 FUEL H B 13 BN WH SIMPLIFY TRACING IN DIAGRAM vu 2 GAUGE r EMPTY 50 0
2. 5 15 MID AXLE A ARM 66 oro Ra RR EE BOR e RI e a AD HR A cR e 5 16 REPLACEMENT ido re tee reete Ve D ter ure d ee Pr ER Ds 5 16 REAR 4X4 oan pgs edi RO E a wal Ge Ra raa 5 17 REPLACEMENT Ae air vh theo t C e ea ec oer 5 17 REAR STABILIZER BAR 4X4 23 err Care Rl ene Et o ea C mee UR aT 5 19 REMOVAL 1 5 19 SWING ARM 656 7 3 06 cd o EDU ENE RON OE 5 20 REMOVAL vein deme but ebd PV eder dien e Ee r eet 5 20 INSTALLATION tdem ee Peto eate Edu pa e 5 20 REAR DRIVE AXLE AND SWINGARM EXPLODED VIEW 6X6 5 21 REAR CARGO BOK vies yas Pee HA Rr he tp Re Oe Reb EEN 5 22 CARGO BOX PANELS ee ende Rx EEN NEEN wie doe 5 22 CARGO BOX TAILGATE BOX SUPPORT 5 23 BOX REMOVAL ati we eta Re EROR TEL acto i ede 5 24 BOX INSTALEATION 5 a leg acd ntn nec t tec c 5 24 STORAGE BOK ed Ee d PAURA 5 25 REMOVAL e RR pe A A REM ue d 5 25 INSTALLATION c e Rome eterne duin ye bI 5 25 e Rene ooa EE RN 5 25 5 1
3. 9 26 CALIPER OVERHEATS BRAKES 9 26 BRAKES LOGK xe tee brodo dere reborn BUSEY rents 9 26 9 1 5 GENERAL SPECIFICATIONS FRONT BRAKE SYSTEM Item Standard Service Limit Front Brake Pad Thickness 298 007 7 56 178 mm 180 4 6 mm Front Brake Disc Thickness 150 165 3 810 4 19mm 140 3 56mm Front Brake Disc Runout 010 254mm REAR BRAKE SYSTEM Park Brake Pad Thickness Outboard 360 9 14 mm Item Standard Service Limit Rear Brake Pad Thickness 298 007 7 56 178 mm 180 4 6 mm Rear Brake Disc Thickness 150 165 3 81 4 19 mm 140 3 56 mm Inboard 304 7 72 mm 240 6 1 mm 310 7 87 mm Park Brake Disc Thickness 0 150 0 164 3 81 4 16 mm 140 3 56 mm Rear Brake Disc Runout 010 254 mm TORQUE SPECIFICATIONS SPECIAL TOOLS Torque Torque Part Number Tool Description ft Ibs Nm 2870975 Mity Vac Pressure Test Tool Front Caliper Mounting Bolts 18 24 Rear Caliper Mounting Bolts 18 24 Parking Brake Mounting Bolts 18 24 Parking Brake Assembly Bolts 25 34 Brake Line Flare 12 15 16 20 Brake Line Banjo Bolts 15 2 Caliper Attachment Brake Line Banjo Bolt 15 20 Master Cylinder Attachment Front Brake Disc to Hub
4. 2 3 PRE RIDE 25 HOUR MAINTENANCE INTERVAL 2 4 50 100 HOUR MAINTENANCE 2 5 100 300 HOUR MAINTENANCE 2 6 GENERAL COMPONENT 6 2 7 RH SIDE AND DASH VIEW 4 4 41 2 7 LH SIDE AND REAR VIEW 4X4 2 8 LH SIDE AND RH SIDE VIEWS 6 6 2 9 SERVICE PRODUCTS AND LUBES NNN re Ree o ey d ae 2 10 POLARIS LUBRICANTS MAINTENANCE AND SERVICE PRODUCTS 2 10 MAINTENANCE REFERENCES 22 26 y mk ox na Rn RR e ER a 2 11 MAINTENANCE REFERENCES 2 12 GENERAL VEHICLE INSPECTION AND 2 13 PRE RIDE DAILY INSPECTION 2 13 FRAME NUTS BOLTS AND FASTENERS 2 13 SHIFT LINKAGE INSPECTION 2 13 FUEL SYSTEM AND AIR INTAKE rernm mmm mme hx y Res 2 14 SYSTEME racio utor lockt tke ce e eec E A e s 2 14 EUEL EINES inem rhe ERIS d peer tte rendi teamed ea anis eid s 2 14 FUEL FII TER dria Ree reete 2 14 Maas
5. 4 7 51 DIFFERENTIAL EXPLODED 2 7 52 REAR AXLE GEARCASE SERVICE 6 6 REAR AXLE REMOVAL 7 53 AXLE TUBE REMOYVAL cer dete Rex Edo atc eet et what wel 7 54 AXLE TUBE BEARING 7 55 GEARCASE DISASSEMBLY INSPECTION 7 55 GEARCASE ASSEMBLY 0 000002 cc eee 7 56 GEARCASE AXLE 5 7 57 GEARCASE EXPLODED 7 60 7 2 FINAL DRIVE SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2872608 Roller Pin Removal Tool 8700226 CV Boot Clamp Pliers TORQUE SPECIFICATIONS Wheel Hub and Spindle Torque Table Black Camo ITEM NUT TYPE SPECIFICATION Aluminum Wheels Cast Lug Nut 1 904 Ibs 122 Nm teel tees Flange Nut 2 35 ft Ibs 47 Nm Front Spindle Nut 70 ft Ibs 95 Nm Rear amp Middle Hub Retaining Nut 110 ft Ibs 150 Nm Aluminum Wheel LE Models 90 ft Ibs 122 Nm Steel Wheel Standard Models 35 ft Ibs 47 Nm FRONT HUB Hub Removal Inspection 1 Elevate front end and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or
6. 9 6 FOOT BRAKE PEDAL wn c eh we steve ole de e 9 6 PEDAL REMOVAL 9 6 BRAKE BLEEDING FLUID 9 7 PARKING BRAKE EE 9 8 EXPEODED VIEW Sr een ee P eer area de dee 9 8 INSPECTION TADIOUSTMENT 2 0 0 0 0 00 c ee eee 9 9 PARKING BRAKE CALIPER SERVICE 9 10 EXPLODED VIEW gt 22 Peck oe ae Wed Ee Go Reti d dn 9 10 CALIPER REMOVAL 9 10 CALIPER DISASSEMBLY 9 11 NEW BRAKE PAD INSTALLATION e RR I n 9 12 CALIPER 1 9 12 PARKING BRAKE DISC SERVIGE omm eww hcec eee AN 9 12 DISC REMOVAL 9 12 FRONT BRAKE PADS ciai usca exakte rape o VY c e die te Red 9 13 PAD REMOVAL DISASSEMBLY 9 13 PAD ASSEMBLY INSTALLATION ADJUSTMENT 9 14 FRONT GALEIPER 5 e EE 9 15 FRONT CALIPER EXPLODED VIEW 9 15 CALIPER REMOVAL 9 15 CALIPER INSPECTION
7. 7 14 B Balance Shaft Gear 3 40 Ball Joint Replacement 5 15 Battery Charging cese eR 2 30 Battery Fluid 2 29 Battery Installation 2 30 Battery Maintenance 2 29 Battery Removal 2 cies erp xs 2 29 Battery Service 10 26 Battery Storage 2 30 Battery Terminal Block 10 26 Battery 10 27 Battery Sealed Low Maintenance 10 30 Body Removal 5 3 Brake Front ed Ee eR eee E 9 18 Brake Disc 9 25 Brake Hose and Fitting Inspection 2 35 Brake Pad Inspection 2 34 Brake beg GAEREN 9 18 Brake Pad Rear 6x6 9 20 Brake Pads Front 9 13 Brake Pedal Installation 9 6 Brake Pedal Removal 9 6 Brake System Inspection 2 34 Brake System Bleeding 9 7 Brake System Exploded View 9 5 Brake System Operation 9 4 Breather Hose Inspection 2 17 C C
8. 3 13 PISTON IDENTIFICATION teer hae te PAG ee e 3 13 COOLING SYSTEM 86 3 13 COOLING SYSTEM PRESSURE 8 3 14 COOLING SYSTEM EXPLODED 1 3 15 COOLING SYSTEM BLEEDING PROCEDURE 3 15 VALVE COVER REMOVAL 6X6 MODELS ENGINE INSTALLED 3 17 ENGINE REMOVAL ekle ene uera RR RR nn A TARTE Rr 3 18 ENGINE INSTALLATION NOTES 3 19 CYLINDER HONE SELECTION AND HONING 3 20 HONING TO DEGEAZE er REIR EM ere opere pas 3 20 CLEANING THE CYLINDER AFTER HONING 3 21 ENGINE LUBRICATION SPECIFICATIONS 3 21 OIL PRESSURE TEST rene be er Rr Ress RR REG PER Ra AE ER 3 21 OIL FLOW CHART teret Ee Rer Rh qe em aci wy ade ge ee es 3 22 ENGINE DISASSEMBLY AND 3 23 CYLINDER HEAD ASSEMBLY EXPLODED 3 23 ROCKER ARMS PUSH 5 3 24 CYLINDER HEAD REMOVAL 3 24 CYLINDER HEAD INSPECTION 3 25 CYLINDER HEAD
9. TURF AND SWITCH SWITCH BACK VIEW OF SWITCH INTERNAL CONNECTIONS Differential Solenoid 4x4 The differential solenoid is located on the rear gear case The solenoid actuates the carrier which locks and unlocks the rear carrier Refer to Chapter 7 for more information on rear carrier operation ELECTRICAL Differential Solenoid Circuit Operation When the switch is pushed to activate Turf mode the White Green wire is connected to ground via the Brown wire at the AWD Diff Lock Switch and signals the ECU to energize the Rear Diff Solenoid Relay Depending on vehicle speed and gear position criteria the ground path is then sent from the ECU to the Rear Diff Solenoid Relay This activates the solenoid and sends 12 volt Key On power from the RD WH wire to the OR WH wire of the Differential Solenoid Rear Differential Solenoid Circuit AWD Diff Lock WH DG DIFFERENTIAL SOLENOID 7 LOCATED ON NOTE POWERED TO UNLOCK DIFFERENTIAL CAUTION DO NOT POWER 12 FOR MORE THAN REAR DIFFERENTIAL LI SECOND 4 ONLY If the rear carrier fails to switch from operational modes Check the connector located under the left rear fender Look for loose wires or bad connections Check for power from the connect
10. 5 4 HOOD DASH 5 5 5 DASH INSTRUMENTS AND CONTROLS ens 5 6 CAB FRAME tob RR Odo els s onc 5 7 ASSEMBLY REMOVAL LE eee e LHP eee 5 7 CHASSIS MAIN FRAME 4X4 i cere xam e ce ea e Ree Re na TR Y CER OR xen 5 8 EXPLODED VIEW e iter pedes eno Cere ere genitus rd rra Pa rie ERO 5 8 CHASSIS MAIN FRAME XB 5 vates n o dh hin ward OE ET EE 5 9 EXPLODED VIEW geeiert da duse as 5 9 SEAT TREAD REST Cite POR tM ion e Ag ON Oe d EH 5 10 SEAT BASE SEAT BACK HEAD REST AGSEMDILY 5 10 STEERING ASSEMBLY E noh m OD AP cR eh e cde Wa E Meo cd 5 11 EXPLODED VIEW tok aether ent eive doctr ce ur ded er y 5 11 STEERING AND SUSPENSION os 1573 x Ere reote R Sie et 5 12 EXPLODED VIEW dra eme ra A Part ee 5 12 FERON RAARM S eto y done 5 13 REPLACEMENT EA he eels das ene id 5 13 FRONT SDR ered a iR UN eon pak ay RU A AE RS 5 14 EXPLODED VIEW eere pel fer ts 5 14 FRONT STRUT CARTRIDGE REPLACEMENT 5 15 BALL JOINT
11. 1 2 26 COOLANT STRENGTH 2 26 COOLING SYSTEM PRESSURE 8 2 26 COOLING SYSTEM HOSES 2 26 RADIATOR te eee ect ace beate ei ore sae gh dodi Eege 2 27 COOLANT DRAIN RADIATOR REMOVAL 2 27 2 1 GENERAL INFORMATION FINAL DRIVE WHEEL AND TIRE BRAKE SYSTEM WHEEL AND SPINDLE TORQUE TABLE 2 27 CV SHAFT BOOT INSPECTION 2 28 WHEEL REMOVAL rev temp tob o 2 28 WHEEL INSTALLATION ed v e ERR geet ale tenet 2 28 TIRE INSPECTION nue LE etcetera 2 28 TIRE PRESSURE eens Dos oe e rer decus duse te dale Patet 2 29 ELECTRICAL AND IGNITION SYSTEM 5 Rr cra CO ex Rm Ree BATTERY MAINTENANCE 2 29 BATTERY FLUID LEVEL CONVENTIONAL BATTERY 2 29 BATTERY REMOVAL oerte aeter eere rng ede dice e ii ad id rg 2 29 BATTERY 2 30 BATTERY STORAGE aae iang ret beri iro Erba ein 2 30 BATTERY CHARGING i uit oar EO tete diet RO n n cct 2 30 SPARK PLUG SERVICE acted relating n eae qoe bee ed and 2 30 ENG
12. 6 5 PVT Troubleshooting 6 23 R Radiator oet kp RI 2 27 Radiator Coolant Level Inspection 2 26 Rear A arm Replacement 5 17 Rear Axle Service 6x6 7 53 Rear Axle Exploded View 5 21 Rear Cargo 5 22 Rear Driveshaft 4x4 CV Joint Boot Replacement 7 40 Rear Driveshaft 4x4 Installation 7 42 Rear Driveshaft 4x4 Removal 7 39 Rear Gearcase 4 4 7 44 Rear Gearcase Lubrication 4x4 2 23 Rear Gearcase Lubrication 6x6 2 24 Rear Propshaft Service 7 43 Rear Spring Adjustment 2 34 Rear Stabilizer Bar 5 19 Rear Suspension 2 33 Rear Suspension Adjustment 4 4 2 34 Relays one aac ec eek oie b EU B 10 21 S Service Interval Indicator 10 9 Shift Lever Removal 8 2 Shift Lever Installation 8 2 Shift Linkage Inspection and Adjustment 2 13 Shift Linkage Adjustment 8 3 Shift Linkage Inspection 8 2 Solenoid Differential 10 4
13. 9 16 CALIPER 1 9 17 FRONT BRAKE DISC rc arn recon Oe o OP os Ta E pee 9 18 DISC INSPECTION REMOVAL 9 18 REAR BRAKE PAD TAKA s P ORE ESL a eee ee RE 9 18 PAD REMOVAL xev here Za e ra pear c 9 18 PAD INSPECTION 9 19 REAR BRAKE PAD 6 6 x prona xi EE 9 20 PADIREMOVAL 1 3e Ee te 9 20 INSPECTION 9 21 REAR GALIPER ua ERG seat SU Rat ER 9 22 REAR CALIPER EXPLODED 9 22 CALIPER REMOVAL 4X4 9 22 CALIPER REMOVAL 6X6 9 23 CALIPER DISASSEMBLY 9 23 CALIPER INSPECTION 9 24 CALIPER INSTALLATION 4X4 6 6 9 25 REAR BRAKE DISC i cis caveat dc ex ck WE Re ae wes ee 9 25 TROUBLESHOOTING EE EEN 9 26 BRAKES SQUEAL POOR BRAKE PERFORMANCE 9 26 PEDAL
14. 2 123 02 J3LIHM QJY 20 dwy 9 H70 IO 3503 Nod 02 3359 11 10 ALIAWD 40123NNO2 01 YOLOINNOD MOHN 390119 40102 122 21871 NOIIVNIWU3I xx xx xx XX 9X9 NO GSN LON SLN HV89HYLOY QV89HYLOY OV89HYLOY SISSVH9 9X9 ON 13000 ON 1300 ON 13000 SISSYH 133 001 439NYU L0 AV 40 39Vd 00 00 11 2 WIRE DIAGRAM RANGER 700 EFI 4 4 6X6 DASH 2007 RANGER 700 4X4 6X6 DASH PAGE
15. 3 30 Cylinder Head Assembly Exploded View 3 23 Cylinder Head Disassembly 3 26 Cylinder Honing To De glaze 3 20 Cylinder Inspection 3 33 D Decal Replacement 5 25 Decimal Equivalent 1 12 Diagnostic Codes Instrument Cluster 10 10 Diagnostics AWD 10 9 Diagnostics Gear Circuit 10 9 Drive Belt Deflection 6 7 Drive Belt Inspection 6 8 Drive Belt Installation 6 9 Drive Belt Removal 6 7 Drive Clutch Assembly 6 18 Drive Clutch Bushing Service 6 16 Drive Clutch Disassembly 6 14 Drive Clutch Exploded View 6 13 Drive Clutch Inspection 6 13 Drive Clutch Operation 6 2 Drive Clutch Service 6 11 Drive Clutch Shift Weights 6 12 Drive Clutch Spider Removal 6 15 Drive Clutch Spring 6 11 Driven Clutch Assembly 6 21 Driven Clutch Disassembly Inspection 6 19 Driven Clutch Exploded View 6 19 Driven Clutc
16. 10 33 W Wheel Alignment 2 32 Wheel Installation 2 28 Wheel 1 2 28 WIRE DIAGRAM RANGER 700 EFI 4X4 6X6 CHASSIS PAGE 1 OF 2
17. 6 Insert valve into guide and tap valve lightly into place a few times 7 Remove valve and check where the Prussian Blue indicates seat contact on the valve face The valve seat should contact the middle of the valve face or slightly above and must be the proper width Tf the indicated seat contact is at the top edge of the valve face and contacts the margin area B itis too high on the valve face Use the 30 cutter to lower the valve seat Tf too low use the 60 cutter to raise the seat When contact area is centered on the valve face measure seat width fthe seat is too wide or uneven use both top and bottom cutters to narrow the seat Tf the seat is too narrow widen using the 45 cutter and re check contact point on the valve face and seat width after each cut NOTE When using an interference angle the seat contact point on the valve will be very narrow and is a normal condition Look for an even and continuous contact point all the way around the valve face A Proper Seat Contact on Valve Face Bottom 60 Seat 45 E n mm Valve Seat Width Intake Std 028 7 mm Limit 055 1 4 mm Exhaust Std 0391 1 0 mm Limit 071 1 8 mm 3 29 8 Clean all filings from the area with hot soapy water rinse and dry with compressed air 9 Lubricate the valve guides with clean engine oil and apply oil or water based lapping c
18. BODY STEERING SUSPENSION CAB FRAME Assembly Removal 1 Assemble the two rear cab frames at the coupler joint and secure with two 3 8 screws and nuts Assemble the front frame in same manner Tighten all 3 8 screws to 25 28 ft Ibs 34 38 Nm 2 Assemble the center cross bracket to the rear cab frame and secure with two 5 16 hex bolts and nuts Tighten all 5 16 bolts to 16 18 ft Ibs 20 24 Nm 3 Assemble the front cab frame to the rear cab frame at both side coupler joints and secure with 3 8 screws and nuts Tighten all 3 8 screws to 25 28 ft lbs 34 38 Nm 4 Place the assembled cab frame onto the vehicle and align the rear mount holes Secure the rear of the frame using the two 2 1 4 bolts on the outer tubes two 3 4 bolts on the inner mounts and nuts Tighten all 5 16 bolts to 16 18 ft Ibs 20 24 Nm NOTE Tighten all nuts finger tight then tighten to specification 5 Secure the front flanges to the vehicle with 5 16 x 3 4 bolts and nuts Tighten all 5 16 bolts to 16 18 ft Ibs 20 24 Nm NOTE Tighten all nuts finger tight then tighten to specification 6 Check all nuts and bolts for proper torque and installation To remove the cab frame reverse the installation instructions 25 28 ft Ibs 34 38 Nm 25 28 ft Ibs 34 38 Nm 22 f p if 16 18 ft lbs Ga 2 lt 1420 24 A s 16 18 ft Ibs Vi 7 20 24 Nm E 25 28 ft Ibs RQ 34 38 Nm ze 16 18 ft
19. e Front Prop Shaft Es Kb 4 A 2 Transmission In al EN Tail Gate Latch 7 2 Hitch Drive Shafts w ica T reem GENERAL INFORMATION LH Side and RH Side Views 6X6 Front Gearcase behind radiator e I a Ear P wr 5 7 ae Mid Gearcase Drive Shafts Front Prop Shaft cna Be Rear Prop Shaft GENERAL INFORMATION SERVICE PRODUCTS AND LUBES Polaris Lubricants Maintenance and Service Products Part No Description Engine Lubricant 2870791 Fogging Cil 12 oz Aerosol 2871098 Premium 2 Cycle Engine Oil Quart 12 Count 2871281 Engine Oil Quart Premium 4 Synthetic OW 40 4 12 Count 2871844 Engine Oil Gallon Premium 4 Synthetic OW 40 4 4 Count 2871567 Engine Oil 16 Gallon Premium 4 Synthetic OW 40 4 Cycle Gearcase Transmission Lubricants 2873602 Premium Synthetic AGL Gearcase Lube 12 oz bottle 12 Count 2873603 Premium Synthetic AGL Gearcase Lube 1 Gal 4 Count 2871653 Premium ATV Angle Drive Fluid 8 oz 12 Count 2872276 Premium ATV Angle Drive Fluid 2 5 Gal 2 Count 2870465 Oil Pump for 1 Gallon Jug 2871654 Premium Demand Drive Hub Fluid 8 oz 12 Count 2872277 Premium Demand Drive Hub Fluid 2 5 gal 2 Count Gr ease Specialized Lubr
20. State of Charge Eed deeg YuMicron 100 Charged 12 60 V 12 70 V 75 Charged 12 40 V 12 50 V 50 Charged 12 10 V 12 20 V 25 Charged 11 90 V 12 0 V P Specific Gravity Test A tool such as a Battery Hydrometer PN 2870836 can be used to measure electrolyte strength or specific gravity As the battery goes through the charge discharge cycle the electrolyte goes from a heavy more acidic state at full charge to a light more water state when discharged The hydrometer can measure state of charge and differences between cells in a multi cell battery Readings of 1 270 or greater should be observed in a fully charged battery Differences of more than 025 between the lowest and highest cell readings indicate a need to replace the battery Battery Hydrometer PN 2870836 110 1 15 1 25 1 30 ELECTRICAL SPECIFIC GRAVITY State of Charge oid YuMicron Type 100 Charged 1 265 1 275 75 Charged 1 210 1 225 5096 Charged 1 160 1 175 25 Charged 1 120 1 135 096 Charged less than 1 100 less than 1 115 At 80 F NOTE Subtract 01 from the specific gravity reading at 40 F Load Test AA CAUTION To prevent shock or component damage remove spark plug high tension leads and connect securely to engine ground before proceeding NOTE This test can only be performed on machines with electric starters This test cannot b
21. FINAL DRIVE Installation FRONT PROPSHAFT REMOVAL 1 Install new spring ring on drive shaft Apply an anti seize compound to splines Align splines of drive shaft with 1 Elevate front end and safely support machine under front gearcase and install by lightly tapping on drive shaft footrest frame area with rubber faced hammer AA CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearings and seals 2 Remove wheel nuts and wheel 3 Remove cotter pin and nut from lower A arm ball joint Remove lower A arm from ball joint See below 2 Install drive shaft in strut 3 Install the lower A arm onto the lower ball joint torque nut to 25 ft Ibs 35 Nm and install new cotter pin 4 Use the Roll Pin Removal Tool PN 2872608 to remove the roll pin from prop shaft at the front housing Slide prop shaft back and away from front housing Pull sharply forward to remove from transmission shaft NOTE The roll pin can also be accessed through the hole in the skid plate shown in the photo below 4 Install hub and tighten spindle nut to 70 ft Ibs 95 Nm Front Spindle Nut Torque 70 ft Ibs 95 Nm Roll Pin Removal Tool PN 2872608 7 11 FINAL DRIVE NOTE Remove the drive shaft floor cover to help 2 Support inner yoke as shown and drive outer yoke down align
22. Front Frame to prevent injury or damage Support E CT e Use the Roll Pin Removal Tool PN 2872608 to remove the roll pin from prop shaft at rear of transmission Za Installation 1 When installing the propshaft ensure that the shaft is touching the rear frame support and reinstall the shaft the same way it was removed with the brake disc over the top of the rear frame support and under the front frame Remove the two bolts that secure the rear parking brake caliper Suspend the brake caliper assembly from the frame with a piece of wire Refer to Chapter 9 for more information on the rear parking brake 2 Slide the shaft onto the rear gearcase input shaft and then slide it onto the transmission shaft 3 Install a new roll pin into the propshaft Install the parking brake caliper and torque mounting bolts to 18 ft Ibs 24 Nm 5 Install cargo box shock mounting pins and pin clips 7 43 FINAL DRIVE REAR GEARCASE 4 4 General Operation The RANGER rear gearcase has three traction operational modes AWD Differential Lock and Differential Unlock Locking the rear differential is beneficial in low traction and rough terrain conditions Unlocking the rear differential makes maneuvering easier and minimizes damage to turf and sensitive terrains Differential Locked Differential Unlocked When the Unlocked option is chosen on the selector the rear differen
23. NOTE If the coolant temperature sensor or circuit malfunctions the radiator fan will default to ONT 10 20 EFI DIAGNOSTICS EFI Component Testing All EFI component information and diagnostic testing procedures are located in Chapter 4 Refer to Chapter 4 Electronic Fuel Injection System EFI when diagnosing an EFI System FUEL SENDER Testing 1 Drain the fuel tank and remove it from the chassis 2 Set the fuel tank on a flat surface 3 Hook up an ohm meter to the fuel sender harness Violet White wire B and Brown wire C 4 With the sender float in the empty position and compare to specification Fuel Sender Empty 5 5 5 Slowly tilt invert the tank so that gravity moves the sender float to the full position and compare to specification Fuel Sender Empty 5 5 Half 57 5 Full 900 5 Fuel Sender Full 90 Q 5 6 Ifthe readings are not to specification or if the reading is erratic or LCD display sticks check the following before replacing the fuel pump assembly Loose float Float contact with tank Bent Float Rod If none of the conditions exists the sender assembly is faulty Fuel pump tank assembly replacement is required ELECTRICAL RELAYS Operation The relays located under the hood assist with component operation like the fan fuel pump and rear differential The differential relay controlled by the AWD switch and ECU op
24. Test starter solenoid coil by connecting an ohmmeter between the solenoid wire and the solenoid mounting plate Resistance should be 3 40 Check Yes solenoid ground path by measuring resistance between mounting plate and Voltage Drop battery negative terminal Testing Reconnect the solenoid Connect the tester black lead No Clean the battery to solenoid cable ends to the battery positive and the red lead to the solenoid gt end of the battery to solenoid wire Depress starter button Reading should be less than 1 V D C Connect the black tester lead to solenoid end of battery to solenoid cable Connect red tester lead No to solenoid end of solenoid to starter cable A Replace the starter solenoid Depress starter button Reading should be less than LV D C or replace the cable Yes Connect the black tester lead to the solenoid end of the solenoid to starter cable Connect the red S Clean the solenoid to starter cable ends or tester lead to the starter end of the same cable bi replace the cable Depress the starter button The reading should be less than 1 V D C Yes If all of these indicate a good condition yet the starter still fails to turn the starter must be removed for static testing and inspection 10 38 ELECTRICAL ELECTRIC BOX LIFT ACTUATOR DIAGNOSIS if equipped
25. YuMicron Type 100 13 0 V 12 70 V 75 Charged 12 80 V 12 50 V 50 Charged 12 50 V 12 20 V 25 Charged 12 20 V 12 0 V 096 Charged less than 12 0 V less than 11 9 V At 80 F NOTE Subtract 01 from the specific gravity reading at 40 F Load Test AA CAUTION To prevent shock or component damage remove spark plug high tension leads and connect securely to engine ground before proceeding NOTE This test can only be performed on machines with electric starters This test cannot be performed with an engine or starting system that is not working properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered To perform this test hook a multitester to the battery in the same manner as was done in the OCV test The reading should be 12 6 volts or greater Engage the starter and observe the battery voltage while cranking the engine Continue the test for 15 seconds During cranking the observed voltage should not drop below 9 5 volts If the beginning voltage is 12 6 volts or higher and the cranking voltage drops below 9 5 volts during the test replace the battery 10 31 ELECTRICAL Off Season Storage To prevent battery damage during ext
26. a Peale SR GE SA ET 25 8 REGULATOR TE FO EE Lh Ga Em Em as si H 2 22 E ae HA a 81 um Ier bz pa ge gel 86 7 8 po DASH p102 RD S us us Me Klee af Eu L ter ES aS oe ae A m 4 e RD WERETIATTAZIASTASTIAST AS TIAZ IST 1 HARNESS H RD n 1 u 3H F F FF El 06 Mierer 7 v63 BN 444 1 Geck if 20 RD WI 5s Sj 106 BN TT i ne n i E EE ea S BNIRD VOLTAGE b d loi il io badiz 2 ue 8 T a 4 s Sei m ee i e REGULATOR i 55 5 s 8 SSSSS amp E i CIRCUIT z SL 1 9 ve i i x 22 gt T 72737 8 BREAKER p EN NOMINAL RESISTANCE SUE SPLICE vr mum SPLICE 1 EE Lat 492 Lull 3 4 ouc SPLICE SUE SPLICE L9 101 RD ES d SPLICE PR M SPACE d DL AT 100 C 0 186 Qut f D i L umi 85 Ext 2 TT RD P qm 2 E 25 Ee E TEMP OH v i T EE z 5 S58 2 SC 69 06 WH SENSOR 1 Lean A eS EE be sd sa E EE ule we 5 7 1 Ld Le He M E D E ES gt G i 22 d DC Ak zk HOLDER 1 n L
27. tte Ate wee eed tee Soa ae ed 2 14 THROTTLE PEDAL 2 14 THROTTLE FREEPLAY ADJUSTMENT 2 15 AIR BIETER SERVIGE teorie Shao caper ae m Ex SEN 2 15 AIR INTAKE 2 16 ENGINE ENEE 2 17 COMPRESSION AND LEAKDOWN 2 17 BREATHER HOSE INSPECTION 2 17 ENGINE OW LEVEL Ee E A atte ne e 2 17 ENGINE OIL AND FILTER 2 18 eo otc eee de ttp e 2 19 TRANSMISSION AND 5 2 20 TRANSMISSION LUBRICATION 2 20 FRONT GEARCASE LUBRICATION 4 4 2 21 MIDDLE GEARCASE LUBRICATION 6X6 2 22 REAR GEARCASE LUBRICATION 4 4 2 23 REAR GEARCASE LUBRICATION 6X6 2 24 COOLING SYSTEM ated Balan ex he ce ee Er SC d 2 25 LIQUID COOLING SYSTEM OVERVIEW 2 25 COOLANT LEVEL 2 25 RADIATOR COOLANT LEVEL
28. 6 Turnsheave and puller barrel together counterclockwise on puller rod until bushing is removed 7 Remove nut from puller rod and set aside 8 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard Moveable Sheave Bushing Installation 1 Place the Main Puller Adapter 8 PN 5020632 onto the puller 2 Apply Loctite 680 PN 2870584 to the back side of new bushing Push bushing into center of sheave on tower side by hand Bushing PN 3576504 Loctite 680 PN 2870584 3 Insert the Clutch Bushing Installation Tool 2 PN 5020628 into center of sheave and with towers pointing away from vise slide sheave onto puller rod CLUTCHING 4 Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed 5 sheave and barrel together counterclockwise until bushing is seated 6 Remove nut from puller rod and set aside 7 Remove sheave from puller 8 Remove installation tool Clutch Cover Bushing Removal 1 Install the Main Puller Adapter 8 PN 5020632 onto the Piston Pin Puller PN 2870386 Piston Pin Puller PN 2870386 Main Puller Adaptor 8 PN 5020632 2 From outside of clutch cover insert the Drive Cover Bushing Remover 3 PN 5020629 into cover bushing 3 With inside of cover toward vise slide cover onto puller Clutch Cover Bushing Installation 1 Install nut onto puller
29. BODY STEERING SUSPENSION TORQUE SPECIFICATIONS SPECIAL TOOLS ITEM TORQUE VALUE TOOL DESCRIPTION PART NUMBER TUIS UNIT Strut and Ball Joint Tool Set 2870871 Front A Arm Attaching Bolt 30 ft Ibs 41 Nm Shock Spanner Wrench 2870872 Front A Arm Ball Joint Stud Nut 30 ft Ibs 41 Nm Shock Spring Compressor Tool 2870623 Rear onoec Bol tuppel US LD Strut Spring Compressor Tool LH 2871573 Real Shor Sol Strut Spring Compressor Tool RH 2871574 Rear Wheel Hub Nut 110 ft Ibs 150 Nm Mid Half Shaft Castle Nut 6x6 110 ft Ibs 150 Nm Wheel Nuts Cast Rims Wheel Nuts Steel Rims 90 ft Ibs 122 Nm 35 ft Ibs 47 Nm Upper Lower Control Arm Mounting Bolt 30 ft Ibs 41 Nm Mid Axle Upper Lower Control Arm Mounting Bolt 6x6 35 ft Ibs 47 Nm Lower Middle Wheel Bearing Carrier Bolt 6x6 35 ft Ibs 47 Nm Lower Rear Wheel Bearing Carrier Bolt 30 ft Ibs 41 Nm Upper Middle Wheel Bearing Carrier Bolt 6x6 35 ft Ibs 47 Nm Upper Rear Wheel Bearing Carrier Bolt 30 ft Ibs 41 Nm Strut Rod Retaining Nut Top 15 ft Ibs 21 Nm Strut Casting Pinch Bolt 15 ft Ibs 21 Nm Tie Rod End Jam Nut 12 14 ft Ibs 17 19 Nm Tie Rod End Castle Nut A0 ft Ibs 54 Nm Seat Belt to Seat Base 40 ft Ibs 54 Nm Steering Wheel to Shaft 25 31 ft Ib
30. Gi P FA ra Rubber Ring Brush Spring Thrust Washer Gear Assembly O Ring Brush Complete O Ring Thrust Washer 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 10 37 ELECTRICAL STARTER SYSTEM TESTING FLOW CHART Condition Starter fails to turn over the engine NOTE Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system A digital multitester must be used for this test With the tester on the VDC position place the tester s black lead on the battery negative and the Remove battery and properly service Install red lead on the battery positive Reading should No fully charged shop battery to continue test be 12 4 V D C or greater Yes lt Disconnect coil engagement wire from the starter Check voltage on both sides of circuit solenoid Connect tester black wire to battery breaker ignition switch engine stop switch ground Connect red tester lead to harness wire at No and starter button The voltage on both sides solenoid Turn on ignition switch and depress the should be the same NOTE The ignition starter button Tester should read battery voltage switch and engine stop switch must be on and the starter button depressed Replace component if failed
31. Install breather reed G into rocker cover H Lightly apply black RTV sealant to the outer edges of the breather reed The reed has a tab and will assemble one way only Torque the breather bolts to specification 20 51 lt 2 5 55 Nm 3 55 e T Breather Bolt Toque 20 5 Ibs 2 5 0 55 Nm NOTE When applying RTV do not get any RTV inside the reed assembly 9 Place a new seal 1 into the bottom of the cover Be sure the seal is seated into the cover properly IMPORTANT Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 10 Install rocker cover Torque bolts to specification 11 Install thermostat J new O ring and thermostat housing Torque to specification K 17 2 ft Ibs 84 8 in Ibs 9 5 0 9 Nm Thermostat Housing Bolt Torque 84 8 in Ibs 9 5 0 9 Nm e T Rocker Cover Bolt Torque 84 8 in Ibs 9 5 0 9 Nm Torque in Sequence 12 Install temperature sender K and torque to specification 3 56 Temperature Sender Torque 17 2 ft lbs 23 3 Nm Oil Pump Priming CAUTION 1 After the engine is completely assembled and ready for installation the engine must be properly primed with AM Polaris 0W 40 Synthetic Oil PN 2871281 Fill the
32. Lift the hood Inspect the foam inserts in the air baffle boxes If the foam inserts are dirty clean the foam with a high flash point solvent followed by hot soapy water Rinse and dry the foam thoroughly Inspect the foam for tears or damage Replace if necessary Reinstall the foam inserts into the air baffle boxes Air Box Engine Intake Duct 2 16 PVT Intake Duct b Lei GENERAL INFORMATION ENGINE Compression and Leakdown Test NOTE This engine does NOT have decompression components Compression readings will vary in proportion to cranking speed during the test Average compression measured is about 150 200 psi during a compression test A smooth idle generally indicates good compression Low engine compression is rarely a factor in running condition problems above idle speed Abnormally high compression can be caused by carbon deposits in the combustion chamber or worn damaged exhaust cam lobes Inspect camshaft and combustion chamber if compression is abnormally high A cylinder leakdown test is the best indication of engine condition Follow manufacturer s instructions to perform a cylinder leakage test Never use high pressure leakage testers as crankshaft seals may dislodge and leak Cylinder Compression Standard 150 200 PSI Cylinder Leakdown Service Limit 15 Inspect for cause if test exceeds 15 Breather Hose Inspection The engine is equipped with a bre
33. Lower Bolt e Hub Disassembly 1 Remove outer snap ring A 2 Fromthe back side tap on the outer bearing race with a drift punch in the reliefs as shown in Figure 7 24 7 24 NOTE Drive bearing out evenly by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed Figure 7 24 3 Inspect the bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged Hub Assembly 1 Support bottom of bearing carrier housing A Bearing Carrier Housing B Bearing C Snap Ring FINAL DRIVE 2 Start bearing B in housing A Hub Installation 1 Install hub carrier to lower A arm Hand tighten lower A arm bolt aft through the hub carrier 2 Slide mid drive sh goi 3 Press bearing into place until outer race bottoms on housing AA CAUTION keen 3 Install upper A arm bolt and torque both upper and lower Use an arbor and press only on the outer race bolts as bearing damage may occur Lower Control
34. 200 AA CAUTION SECs BiueGreen Never shim a drive clutch spring to increase its compression rate This may result in complete stacking of the coils and subsequent clutch cover failure Black 7041002 25 225 2 00 1 75 1 50 1 25 119 COMPRESSED SPRING LENGTH INCHES The drive clutch spring is one of the most critical components of the PVT system Itis also one of the easiest to service Due to the severe relaxation the spring is subject to during operation it should always be inspected for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from the outer coil surfaces as shown Referto 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 fatigue requiring replacement Primary Clutch Springs Secondary Clutch Springs PART WIRE FREE LENGTH PART NUMBER COPE DIAMETER 125 NUMBER BESERUFTIOM 7041021 Plain 157 4 38 7041198 Red 7041022 Black 140 4 25 7041782 Black 5 coil 7041063 Purple 168 4 37 7041501 Gold 6 coil 7041132 White 177 2 92 7041499 Silver 7041168 Green 177 3 05 7041296 Blue 7041157 Blue Green 177 2 53 7041646 Silver Blue 7042202 Blue Gray 187 2 55 7043167 Black Almond 6
35. 6 Install the other output hub B and thrust bearing C into the output cover Apply a small amount of grease onto the thrust bearing 7 Install the armature plate D and spacer washer E into the output cover T i Backlash Plate 72 NOTE Be sure backlash plate is in place 8 Install the retaining ring F into the output cover Be sure the retaining ring is properly seated into the cover 9 Install the ring gear G onto the output hub on the output cover 10 Install the rollers and roll cage into the ring gear Insert the rollers as the roll cage is installed 7 21 FINAL DRIVE main gearcase Backlash Pad Thrust Pad Adjustment 1 Lay the gearcase on the side with the output cover facing up 2 The backlash screw is loctited into place Use a heat gun to lightly heat up the loctite on the screw A 11 Install the output cover assembly onto the 3 Usingahex wrench turn the back lash screw out 3 4 turns Re apply red loctite onto the bottom screw threads Armature plate tabs l fit into roll cage slots EE Armature plate design 2220 71 differ from what is shown NOTE This photo is for reference only the armature plate is actually installed in the output cover 12 Install output cover with new O ring and torque bolts to 17 ft Ibs 23 Nm NOTE Be sure the square O ring is placed flat on 4 Turn the screw in unt
36. 1 Disconnect the wiring harness to the box lift actuator 2 Connect a multimeter across the box lift actuator harness connection 3 Actuate the box lift switch in both directions Verify that there is 12 Volts reaching the box lift actuator Follow the diagram below for diagnosis N YES S Not 12 Volts at actuator YES 12 Volts at actuator Lift the hood Locate the box lift switch Check for 12 Volts between the RED BLACK wire terminal on the back of the switch and the BROWN wire terminal NO YES Not 12 Volts between wires 12 Volts between wires On the main connector behind the dashboard Check the switch Check the measure for 12 Volts between RED BLACK wires between the switch wire terminal and ground and the actuator motor Not 12 Volts between wires 12 Volts between wires _ Test the accessory and wiring circuit Test wiring between the ma breaker located under the seat connector and the circuit Refer to Wiring Schematic breaker Test the wiring between the main connector and the circuit breaker 10 39 Air Filter Service 2 15 Air Intake Inspection 2 16 All Wheel Drive AWD Coil 10 16 AWD Diagnostics 10 9 AWD 7 16 AWD Operation
37. 10 1 ELECTRICAL CHARGING SYSTEM n a em mh Mom La i e RR SK RS CURRENT DRAW KEY 10 22 CHARGING SYSTEM BREAK EVEN 5 10 23 CHARGING SYSTEM ALTERNATOR 5 8 10 23 CHARGING SYSTEM TESTING FLOW 10 25 BATTERY TERMINAL BLOCK Rma y eme AN BATTERY SERVICE 2 2545 da oh tegens OR ER CR uod ug Coe XR on EE BATTERY TERMINALS 5 10 26 BATTERY IDENTIEICATION 00000000 nananana anaana 10 26 CONVENTIONAL 2 tmc nmn ee m BATTERY ACTIVATION s ha 10 27 BATTERY INSPECTION EN uk kd dba NENNEN EEN ee E A 10 27 BATTERY REMOVAL 5 nba esed e rated aet aS aedis 10 28 BATTERY 1 10 28 CONVENTIONAL BATTERY 10 28 OCV OPEN CIRCUIT VOLTAGE 10 28 SPECIFIC GRAVITY TEST eh Ras ee Ae el 10 28 LOAD TR H RE 10 29 OFF SEASON STORAGE 10 29 CHARGING PROCEDURE 10 29 LOW MAINTENANCE BATTERY occa NEE EINEN ner ween e
38. 12 14 ft Ibs 16 19 Nm 30 ft Ibs 40 45 ft Ibs 1 41 Nm 54 61 Nm 20 30 ft Ibs 2 3 5 Nm 25 ft Ibs 35 Nm 5 12 BODY STEERING SUSPENSION FRONT A ARM 8 Attach A arm to hub strut assembly Tighten ball joint nut Um to 25 ft 165 35 Nm If cotter pin holes are not aligned Replacement tighten nut slightly to align Install a new cotter pin with open ends toward rear of machine Bend both ends in 1 Elevate and safely support vehicle with weight removed opposite directions around nut from front wheel s 2 Remove cotter pin from ball joint stud at wheel end of A AA WARNING arm and loosen nut until it is flush with end of stud Upon A arm installation completion test vehicle at low speeds before putting into regular service 3 Using a soft face hammer tap nut to loosen A arm from bolt Remove nut and A arm from hub strut assembly 4 Loosen two bolts on A arm bushing by alternating each about 1 3 of the way until A arm can be removed 5 Examine A arm bushing and A arm shaft Replace if worn A arm Attaching Bolt Torque Discard hardware 6 Insert arm bushings and A arm shaft into new A arm 30 ft Ibs 41 Nm NOTE On AWD models install CV joint shields See Ball Joint Stud Nut Torque Illustration 25 ft Ibs 35 Nm 7 Install new A arm assembly onto vehicle frame Torque new bolts to 30 ft Ibs 41 4 Nm A WARNING The locking features
39. 15 ft Ibs 21 Nm Install the rear wheel and wheel nuts Carefully lower the vehicle REAR BRAKE DISC Disc Inspection 1 2 Visually inspect disc for scoring scratches or gouges Replace the disc if any deep scratches are evident Use a 0 1 micrometer and measure disc thickness at 8 different points around perimeter of disc Replace disc if worn beyond service limit Rear Brake Disc Rear Brake Disc Measure Thickness Front View of Brake Disc Brake Disc Thickness New 150 165 3 81 4 19 mm Service Limit 140 3 56 mm Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements Mount dial indicator and measure disc runout Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 010 254 mm Install brake line and tighten with a flare nut wrench Follow bleeding procedure outlined earlier in this chapter Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when pedal is released If the brake drags re check assembly and installation 9 25 5 TROUBLESHOOTING Brakes Squeal Poor Brake Performance Air in system Water in system brake fluid contaminated Caliper disc misaligned Caliper dirty or damaged Brake line damaged or lining ruptured Worn disc and or friction pads Incor
40. 3 24 Engine Removal Install Procedure 3 18 Engine Rocker Arm Inspection 3 24 Engine Serial Number Location 1 2 Engine Service Specifications 3 11 Engine Speed Display 10 8 Engine Starter Drive Removal 3 35 Engine Starter Removal 3 37 Engine Stator Gear Cover Seal s Installation 3 51 Engine Stator Installation 3 54 Engine Temperature Sensor 4 19 Engine Temperature Sensor Replacement 4 20 Engine Temperature Sensor Test 4 20 Engine Torque Table 3 10 Engine Troubleshooting 3 58 Engine Valve Inspection 3 27 Engine Valve Lifter Removal Inspection 3 31 Engine Valve Seal Spring Service 3 25 Engine Valve Sealing Test 3 31 Engine Valve Seat Reconditioning 3 28 Engine Accessible Components 3 13 IX 2 Exhaust Pipe iii ue giel COPI 2 19 F Fan Control Circuit Bypass Test 10 20 Fan Control Circuit Operation 10 20 Flywheel Stator 3 36 Flywheel Removal 3 36 Front A arm Repnlacement nu ununuununrnna 5 13 Front Driveshaft CV Joint B
41. Lil ZS SENDER FULL 900 Te2 Eel 7 au i WIRE COLOR LEGEND fe ee ao TT 85 RD WH B6 BEIGE TAN EZ ENGINE GROUND m e zT zs al FAN MOTOR EAER D BRAKE Se BLACK SS 2 JAGNOSTI MIT i 80 BLUE gt CHASSIS GROUND H SI 5 MEM Ae 15 FAN 0B DARK BLUE NX 1 redis oo T un n We 88 RELAY SC NC SWITCH NORMALLY CLOSED 1 25 2 9 GREEN NO SWITCH NORMALLY OPEN 2 p i 5 558 K m pe 06 DARK GREEN ze BEL ASS 8 Sp 2 xe zasa I EE SC S CHASSIS HARNESS 241079803 4X4 less ma A 55 8 RD RED 2410854 03 6X6 All is JT E E zz di i ZC VIOLET PURPLE BOX HARNESS 24087702 TURN z Sr l t AE 8 e fo d E S POWER TWO WIRE COLORS ARE SHOWN STIT ZS Es KS mae pet i e SS RELAY WITH MAIN TRACE COLORS mE SS Se We f 1 i 81 RD BK pa EXAMPLE RD YE RED WITH 1 H L de LV di cs d ch Z i _ em K MN den gm 252 F VOLTAGE ae HH a qm REGULATOR i H 1 LL i St E EE Ee E a pa RN HEH 1 1 1 T i 56 0G RD ae n d li ee E n RS E a a A
42. 2 4 4 1 3 25 VALVE SEAL SPRING SERVICE ON 3 25 CYLINDER HEAD DISASSEMBLY 3 26 VALVE INSPECTION ende paie dolce errare Rete Ras 3 27 COMBUSTION 3 28 VALVE SEAT RECONDITIONING 0 0 00 0 2c cece eee 3 28 CYLINDER HEAD 5 3 30 VALVE SEALING TEST soeur EU Rem RUE A EN ep tdi e 3 31 GYEINDER REMOVAL jose ee Roter eer EURO alata a Gal re alate ate ade Eds 3 31 VALVE LIFTER REMOVAL 3 31 PISTON REMOVAL 2 5 ceres Sive er Ee a ete ila dad ntes een i ned cede teda 3 32 CYLINDER 1 42 3 33 PISTON TO CYLINDER CLEARANCE 3 34 PISTON 1 3 34 PISTON RING INSTALLED 3 35 STARTER DRIVE BENDIX REMOVAL 3 35 FLYWHEEL STATOR REMOVAL 3 36 ENGINE CRANKCASE DISASSEMBLY 3 36 CAMSHAFT 1 3 44 ENGINE REASSEMBLY
43. 6 18 Compress spider buttons for each tower and install spider making sure that X or the marks that were made earlier on spider aligns with X or the marks that were made earlier in moveable sheave Torque spider to specification using the holding fixture and spider tool Torque with smooth motion to avoid damage to the stationary sheave Refer to Page 6 2 for torque specification AA 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 SE shift weights using new lock nuts on the bolts Ki e dur Nut on trailing side Reinstall clutch spring Reinstall cover aligning X mark with other marks Torque cover bolts evenly to specification Spider torque 200 ft Ibs 276 Nm Cover Screw Torque 90 in Ibs 10 4 Nm CLUTCHING DRIVEN CLUTCH SERVICE Exploded View DRIVEN CLUTCH Compression Spring Spring Retainer Secondary Stationary Sheave Moveable Inner Sheave Clutch Disassembly Inspection 2 With the snap ring A removed and spring pressure relieved remove the outer retainer B spring C and inner retainer D AA CAUTION Wear eye protection when removing snap ring to prevent serious personal injury Use caution when removing the snap ring pressure
44. 9 Remove the rear transmission to frame bolt 10 Remove front transmission to engine mount bolt 11 Remove transmission from right side of frame 6 Loosenthe jam nuts for the transmission cable Remove the cable from the mounting bracket i Nuts sessiles 8 4 TRANSMISSION Transmission Disassembly NOTE The following disassembly procedure shows the 4x4 transmission disassembly Follow the same procedure for the 6x6 transmission disassembly The transmissions are very similar Refer to the exploded view at the end of this chapter 1 Place the bellcrank in neutral position 2 Remove the nut and washer that secure the bell crank Remove the bellcrank 3 Remove the five bolts that secure the cover and remove the cover from the transmission 5 Mark the detent gear with a white pen Remove the detent gear from the case NOTE It may be helpful to place a mark just above the keyed spline i Detent Gear 6 Mark the lockout disc this will indicate which side of the disc faces outward during assembly Remove the disc NOTE It be helpful to place a mark just above the keyed spline Note the raised edge on the detent 47 vP 7 Remove the shift shaft and detent lever 8 5 TRANSMISSION 8 Note the transmission gear position and mark the two shift NOTE You may have to tap the shift drum from the gears before removing them to aid with reassembly backside
45. Ber all grease fittings pivots cables Shift Linkage 50H 6M Inspect lubricate adjust W Steering 50 H 6M Lubricate gt Front Suspension 50H 6M Lubricate gt Rear Suspension 50H 6M Lubricate Throttle Cable Throttle Inspect adjust lubricate replace if 50 H 6M E Pedal necessary Throttle Body Air Intake E Ducts Flange 50 H 6M Inspect ducts for proper sealing air leaks Drive Belt 50H 6M Inspect adjust replace as needed Cooling System 50H 6M _ Inspect coolant strength seasonally pressure test system yearly Engine Oil Change 100 H 6M Perform break in change at 25 hours E one month Oil Filter Change 100 H 6M Replace with oil change Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 2 5 GENERAL INFORMATION 100 300 Hour Maintenance Interval Maintenance Interval whichever comes first Auxiliary Brake Item Remarks Miles Hours Calendar Km Check for leaks at tank cap fuel lines fuel E Fuel System 100 H 12M pump and fuel rail Replace lines every two years Fuel Filter 100 H 12M Replace yearly Radiator 100 H 12M Inspect clean external surfaces gt Cooling Hoses 100 H 12M Inspect for leaks Engine Mounts 100 12 Inspect Exhaust Muffler Pipe 100 H 12M Ins
46. Brown White AWD Control TURN KEY SWITCH OFF GAIN ACCESS TO FUEL SENDER WIRING CHECK FOR CONTINUITY ON REPAIR GAIN ACCESS TO WIRES AS VIOLET WHITE 2 CAN REQUIRED OA REMAINS 2 CHECK CONNECTION FROM BRN TO GROUND ano i AT GAUGE PIN 12 RETEST ARE WIRES OK DOES FUEL INDICATOR WORK TEST SENDER FOR PROPER OPERATION d CLEAN CONNECTOR TERMINALS REFER TO FUEL SENDER TEST IS IT OK CHECK RELATED WIRING REPLACE FUEL PUMP ASM TEST 6 Shift Indicator Not Working Transmission Switch Operation s e BN RD no The Instrument cluster sends a signal through the White wire os to the resistor module This signal completes it s path on the Brown Red wire through the transmission switch Depending SPEEDOMETER on the transmission switch position the Instrument Cluster _ gen interprets the resistance reading and displays the corresponding shift position on the LCD screen Testing Use the diagram provided to test the continuity loop at each of the shift points with a multi meter NOTE The Instrument cluster contains this diagnostic feature 16 Pin Connector DB RD Red 12V Constant Blue White Engine Overheat Switch Red White 12V Switched Orange Red Park Brake Indicator Grey 7 Mode button Blk White Malfunction Indicator N C V
47. Never remove the pressure cap when the engine is warm or hot Escaping steam can cause severe burns The engine must be cool before removing the pressure cap NOTE Use of a non standard pressure cap will not allow the recovery system to function properly To access the radiator pressure cap raise the front hood The radiator cap is located on the drivers side Coolant Strength Type Test the strength of the coolant using an antifreeze hydrometer Antifreeze Hydrometer 50 50 or 60 40 mixture of antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection Do not use tap water straight antifreeze or straight water in the system Tap water contains minerals and impurities which build up in the system 2 26 Straight water or antifreeze may cause the system to freeze corrode or overheat Polaris 60 40 Anti Freeze Coolant PN 2871323 Cooling System Pressure Test Refer to Chapter 3 for cooling system pressure test procedure Cooling System Hoses 1 Inspect all hoses for cracks deterioration abrasion or leaks Replace if necessary Coolant Lines 2 Check tightness of all hose clamps AA CAUTION Do not over tighten hose clamps at radiator or radiator fitting may distort causing a restriction to coolant flow Radiator hose clamp torque is 36 in lbs 4 Nm GENERAL INFORMATION Radiator 4 Remove t
48. Remove excess fluid from reservoir as required 5 Push upper pad retainer pin inward and slip outer brake pad past edge Remove the pad Pad Inspection 1 Measure the thickness of the pad material Replace pads if worn beyond the service limit Measure s Thickness 9 13 5 4 Slowly pump the brake pedal until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the brake system Front Brake Pad Thickness New 298 7 56 mm 007 178 mm Pad Adjustment Service Limit 1807 4 6 mm i 1 Install the adjuster screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn Pad Assembly Installation counterclockwise 1 Lubricate mounting bracket pins with a light film of Pad Adjuster Screw f Polaris Premium All Season Grease and install rubber i lt dust boots Be sure fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap Master Cylinder Fluid Polaris Premium All Season Grease Up to MAX line inside reservoir PN 2871423 3 Install wheels and torque wheel nuts It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop ting bolts machine Repeat procedure 10 times 2 Compr
49. WARNING Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion Vent should be routed away from frame and body to prevent contact with electrolyte Avoid skin contact with electrolyte as severe burns could result If electrolyte contacts the vehicle frame corrosion will occur 7 Route cables so they are tucked away in front and behind battery LOW MAINTENANCE BATTERY Battery Check NOTE All Low Maintenance batteries are fully charged and tested at the factory before installation Expected shelf life varies upon storage conditions As a general rule before placing the battery into service check the battery condition and charge accordingly 1 Check the date label on the side of the battery to calculate when to check voltage The battery should be checked every 3 months 2 Check the voltage with a voltmeter or multimeter A fully charged battery should be 12 8 V or higher 3 Ifthe voltage is below 12 8 V the battery will need to be recharged STEP 2 Check voltage with voltmeter or multimeter Fully charged Is 12 8 or higher calculate when to check voltage If voltage is below 12 8 volts refresh charge may be reauired Low Maintenance batteries are permanently sealed at the time of manufacture The use of lead calcium and AGM technology instead of lead antimony allows the battery acid to be fully absorbed For this reason a
50. b 1 LO E ecc E 4 26 n ex 8 p d GEAR SWITCH TPS Sane S e 2 UE LOCATED ON RH SIDE e SENSOR BATTERY Dresch 585552 OF MAIN GEARCASE Beaten UNDER BOX HARNESS TTTTTT n ad SEAT BEHIND IRE A THROTTLE BODYO Y REGE Em R 6 GAUGE TO STARTER MOTOR d 01 RD WH 02 RD WH 13 8 15 2 13 8 15 2 a d BLK 6 GAUGE LOCATED ON ENGINE 03 BN 04 BN OHMS OHMS 941 stator MODULE DIODE 3 START SOLENOID 05 06 06 06 2 Eh LOCATED UNDER HOOD 11 1 WIRE DIAGRAM RANGER 700 EFI 4 4 6X6 CHASSIS PAGE 2 OF 2 321145 311 038 Lat 02 830108 3504 91 JLIHM QJY 60 0 118 Y3MOd L n GI 830108 3513 91 JON HO 801 58 138 8104 121145 31IHM 3N 9 HEIGEN 10 401 0115 0 089 0 0 1 1 JOVI vl NMOUG 90 401 0115 48 391145 71 81 90 ihid Sol 401 0115 9 s 121145 71 81 980 ing vol 321145 71 81 8 2 1 1 JOVI 10 038 0 5 321145 71 81 2 1 1 JOVI 10 038 20 0 118 NV 2 1102419 02 91 034 10 310008 40151538 E 6
51. is visible on the bushing Refer to bushing replacement in this chapter 4 Inspectarea on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or damaged 5 Remove and inspect the clutch spring CLUTCHING Spider Removal 1 Install clutch in holding fixture and loosen the spider counterclockwise using spider removal tool Clutch Holding Fixture PN 2871358 Spider Removal Tool PN 2870341 It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly Be sure to note the number and thickness of these washers Moveable Sheave Bushing Inspection 2 Inspect the Teflon coating on the moveable sheave bushing 3 Teflon Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter Roller Pin and Thrust Washer Inspection 1 Inspect all rollers bushings and roller pins by pulling a flat metal rod across the roller Turn roller with your finger If you notice resistance galling or flat spots replace rollers pins and thrust washers in sets of three Also inspect to see if roller and bushing are separating Bushing must fit tightly in roller Use the Roller Pin Tool PN 2870910 to replace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during
52. oases dere et odere fh de 3 45 CRANKCASE REASSEMBLY 1 3 45 FLYWHEEL STATOR INSTALLATION 3 54 CYLINDER HEAD 3 54 OIE PUMP PRIMING te Ree a t icem a 3 57 TROUBLESHOOTING iy 1a xu anis EE Rex REA RR eRe ea ars 3 58 KE LEE 3 58 5 2 m eR dE 3 59 3 1 ENGINE SPECIFICATIONS Crankcase Exploded Views A Journal Bearings B Camshaft Thrust Plate Balance Shaft Woodruff Key Flange Seal Crankshaft Oil Pickup Journal Bearings Baffle Oil Plug Washer O ring Crankcase Crankcase Bolts OZzztU tm amomummun 115 12 in Ibs 8 13 1 35 Nm a 60 6 in lbs S 6 8 68 Nm NOTE If needed heat the oil baffle bolts with a heat gun to remove 5 192 24 in Ibs L 60 6 in Ibs N 6 8 68 Nm s 21 7 2 7 Nm Apply Loctite V 242 to bolt threads EK 1 Apply White Lithium Grease 22 2 ft Ibs 30 3 Nm Apply Moly Lube Grease 3 2 Oil Pump Water Pump Engine Cover Exploded View Split Gear Washer Bolt Oil Rotor Oil Pump Mag Gasket Cover Impeller Washer Nut Counterbalance Gear Washer Bolt O
53. supply for EFI component operation POWER RELAY COLOR FUNCTION Gauge Fused 15 amp constant battery power IN supply for EFI component operation Red White Key On battery power supply switched on by key switch enables power to relay EFI power output Switched by relay when ECU sends a signal on the GRY W wire Red Black closing the relay Supplies 15 amp power for ECU controlled operation of EFI components ECU input to enable relay The ECU Gray White supplies a ground which closes the relay supplying power to run the fuel pump injectors etc 10 21 ELECTRICAL FUSES CIRCUIT BREAKER Operation The fuse panel located under the hood provides component protection for components such as the Instrument Cluster ECU EFI system Chassis Power and Accessories A 20 amp circuit breaker protects the fan motor circuit 20 AM 12V Power to Speedometer CIRCU _BREAKER 12V Power to Fan Relay Accessory Power Terminal Block 12V Power to Key Switch 12V Power to Power Relay 6 Amp Protection for ECU 12V Power from Fusible Link 20 Amp Protection for Key On Power CHARGING SYSTEM Current Draw Key Off Current Draw Inspection CAUTION Do not connect or disconnect the battery cable orammeter with the engine running Damage will occur to electri
54. 1 Reverse Shaft 14 1 Vent Tube 48 1 Needle Cage Bearing 15 1 O Ring 49 1 24 6 Face Sprocket 16 1 Shift Drum 50 1 Washer 17 1 External Retaining Ring 51 2 External Retaining Ring 18 1 6 Pin Switch 52 4 6 Face Engagement Dog 19 1 O ring 53 2 Wave Spring 20 1 Detent Star 54 1 Washer 21 1 Lockout Disc 55 2 Needle Cage Bearing 22 1 16 Sector Gear 56 1 28 6 Face Gear 6x6 23T Gear 23 2 Lock Nut 57 1 51T Mid Output Helical Gear 6x6 47 Gear 24 14 Dowel Pin 58 1 Shift Shaft Rail 25 4 Ball Bearing 59 2 Shift Fork w Pin 26 1 Thrust Washer 61 1 Silent Chain 27 1 Vent Plug 62 1 Input Shaft Assy 28 1 Output Shaft 63 1 LH Main Cover 29 1 Shim 64 1 Dual Lip Seal 30 1 Thrust Button 65 1 Transmission Mount Bracket 31 1 Shim 66 2 Hex Screw 32 1 Output Cover 67 1 33T 6 Face Gear 33 15 Screw 68 1 Washer 34 1 Plain Bearing 69 1 Label 8 17 BRAKES CHAPTER 9 BRAKES GENERAL SPECIFICATIONS TORQUE SPECIFICATIONS SPECIAL TOOLS 9 2 BRAKE SYSTEM SERVICE NOTES Lok A Ew RR ra 9 3 BRAKE NOISE TROUBLESHOOTING 5 Eon Senes 9 3 HYDRAULIC BRAKE SYSTEM 9 4 BRAKE SYSTEM EXPLODED VIEW x vexat eq Ac dR Ee RR oe nc OR Roten 9 5 MASTER CYLINDER e kc c or doc ee eR ot xo late 9 6 REMOVAL
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56. 2 Shield 10 13 Nm 5 23 BODY STEERING SUSPENSION Box Removal 1 Lift the cargo box into the dump position Disconnect the rear wire harness attached to the tail lights 3 Remove the upper clip and pin attaching the shock to the cargo box AA CAUTION Safely support the box during the remainder of the removal process The box is not as stable with the shock removed 4 Remove the screw that secures the hinge pin to the frame on both sides 5 Remove the hinge pin from both sides AA CAUTION Safely support the box during the remainder of the removal process The box is not as stable with the hinge pins removed 5 24 Slide Hinge Pin Out 6 With both hinge pins removed remove the box from the frame Two people maybe needed to remove the box from the frame AA CAUTION Use caution when removing the box It is recommended to have two people carefully remove the box from the frame Box Installation 1 If the shock was replaced install the lower portion of the shock to the frame and secure it with the pin and clip Lower Shock Pin g y A Oe 2 Place the cargo box onto the frame Align the hinges of the box with the bracket on the frame 3 Install the box hinges on both sides Secure the box hinges with the hinge screws on both sides 5 With the hinges installed attach the shock to the cargo box by inserting the pin and clip
57. 5 25 Swing Arm Exploded View 5 21 Swing Arm Installation 5 20 Swing Arm Removal 5 20 Switch AWD Rear Differential 4x4 10 4 Switch Brake 10 5 Switch Headlamp 10 4 Switch Parking Brake 10 6 T Tachometer ps 10 8 Tall Lights i edb how tke 10 18 Tap Drill Sizes ENEE RR 1 12 Temperature Barometric Air Pressure Sensor T Bap 4 16 Throttle Freeplay Adjustment 2 15 Throttle Pedal Inspection 2 14 Throttle Position Sensor 4 17 Throttle Position Sensor Initialization 4 18 Throttle Position Sensor Replacement 4 19 Tie Rod End Inspection 2 31 Timing Gear Mark Alignment 3 37 Tire Inspection e xe Ua epe x 2 28 Tire Pressure Lee ER RR Wes ete eta 2 29 Toe Adjustment ENEE 2 32 Torque Chart eek 1 11 Torque Specifications Body Steering Suspension 5 2 Torque Specifications Brakes 9 2 Torque Specifications Clutching 6 2 Torque Specifications Final Drive 7 3 Torque Specifications Transmission 8 2 Torque Specifications Wheel
58. 6 Check specific gravity of each cell with a hydrometer to assure each has a reading of 1 270 or higher Battery Inspection The battery is located under the hood Inspect the battery fluid level When the battery fluid nears the lower level remove the battery and fill with distilled water only to the upper level line To remove the battery Maintain between upper and lower level marks 10 27 ELECTRICAL Battery Removal 1 Disconnect holder strap and remove covers Disconnect battery negative black cable first followed by the positive red cable AA CAUTION Whenever removing or reinstalling the battery disconnect the negative black cable first and reinstall the negative cable last 3 Remove the battery Remove the filler caps and add distilled water only as needed to bring each cell to the proper level Do not overfill the battery A Refill using only distilled water Tap water contains minerals which are harmful to a battery A Do not allow cleaning solution or tap water inside the battery Battery life may be reduced 5 Reinstall the battery caps Battery Installation 1 Clean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly Route the cables correctly 3 Reinstall battery attaching positive red cable first a
59. 6 Lower the box and secure the latch BODY STEERING SUSPENSION STORAGE BOX Removal 1 Remove the two bottom T 27 torx screws 2 Remove the two top T 27 torx screws 3 Remove the three T 27 torx screws on the front edge oz Torque screws to 4 5 ft Ibs 5 6 Nm IM 4 Lift the storage box towards the rear of the frame for removal Installation 1 Installthe storage box back into the frame assembly Align all screw holes and ensure the storage box is properly fitted to the frame 2 Install all of the T 27 torx screws that were removed Torque screws to 4 5 ft lbs 5 6 Nm DECAL REPLACEMENT Plastic polyethylene material must be flame treated prior to installing a decal to ensure good adhesion The flame treating procedure can often be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged A WARNING The following procedure involves the use of an open flame Perform this procedure in a well ventilated area away from gasoline or other flammable materials Be sure the area to be flame treated is clean and free of gasoline or flammable residue To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly glossy This should occur after just a few seconds of flame treating Do not hold
60. Always wear safety glasses and proper shop clothing when performing the procedures in this manual Failing to do so may lead to possible injury or death Be sure the engine has cooled and there is no pressure built up in the cooling system before removing the radiator cap The coolant may be hot and could cause severe injury or burns AA CAUTION Remove radiator cap A and top off coolant Remove surge tank fill cap B and fill the surge tank to the Use caution when performing these procedures full line Coolant may be hot and may cause Severe injury or burns NOTE If the coolant level is LOW in the radiator or if there are leaks in the system the coolant system will not draw coolant from the reservoir tank NOTE Use this procedure when a unit overheats and no apparent leaks in the cooling system are found 4 Leave the cap off of the radiator to allow any possible air to escape Start the engine and let it idle for 5 10 minutes or until the thermostat opens and allows coolant to flow through the system 5 Slightly loosen the bleed screw C on the thermostat cover 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 Top LH Side of Engine 6 Squeeze the coolant lines by hand to help purge the system of air 7 Add Polaris Premium Antifreeze to the
61. Bore amp Stroke mm 80 x 68 mm Compression Ratio 9 40 1 Compression Pressure 150 170 psi Shift Type In Line Shift H L N R Trans Oil Requirements Polaris AGL Gearcase Lube Belt 3211106 Drive Belt Deflection 1 125 28 57 mm Center Distance 10 254 5 mm Clutch Offset 0 365 9 27 mm Steering Suspension Engine Idle Speed 1150 100 RPM Lubrication Pressurized Wet Sump Oil Requirements 0W 40 Oil Capacity 2qts 1 91 Front Suspension MacPherson Strut Coolant Capacity 3 25 qts 3 11 Front Travel 8in 20cm Rear Suspension Independent Rear Suspension Rear Travel 9 in 23 cm Ground Clearance 11 5 in 29 cm Shock Preload Adjustment Cam Adjustment Front Rear 2 2 Twin Tubes Turning Radius 132 in 335 cm Fuel Capacity Requirement Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style Fuel System Fuel System Type Bosch Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump in tank Fuel Pressure 39 psi Fuel Filters See Chapter 4 9 gal 34 1 87 Octane minimum Electrical Alternator Max Output 500 watts 3000 RPM Lights Main Headlights 2 Dual Beam 35 watts quartz Tail 5 watts x 2 Brake 5 watts x 2 Indicator Panel Lights 1 watt ea Starting System Electric Start Ignition System Bosch EFI ECU Control
62. Do not hang the caliper by the brake line Use wire to hang the caliper to prevent possible damage to the brake line Remove the hub spindle nut Remove hub FINAL DRIVE T Remove cotter pin and nut from lower A arm ball joint Remove lower A arm from ball joint Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly With short sharp jerks remove drive shaft from front gearcase CV Joint Boot Replacement 3 4 5 Remove wheel brake caliper and wheel hub Refer to Front Hub Removal for procedure Remove cotter pin and castle nut from A arm ball joint rk Disconnect A arm from ball joint using a tie rod fo gt gt P Slide strut off end of drive shaft and tie it up out of the way of the shaft Remove clamps from rubber boot using the proper boot clamp pliers Boot Clamp Pliers Earless Type 8700226 7 9 FINAL DRIVE 8 Remove the large end of the boot from the CV joint slide the boot back and separate the wheel spindle and CV joint assembly from the axle shaft by pulling the shaft sharply outward away from the CV joint It may be necessary to tap the CV joint assembly outward with a soft faced hammer Retaining Ring Pull shaft to remove from CV joint Remove small clamp and boot from driveshaft If the vehicle has been operated with a damaged boot the CV joint grease may be conta
63. GEARCASE 7 23 MID DRIVE BEARING CARRIER 6 6 7 23 REMOVAL gee Ed P Ba ety ee ela etel deett Parca t 7 23 DISASSEMBLY Ee ee oa ee RE ee ee 7 24 HUB ASSEMBLY cbe ev el eS E Ss ES 7 24 HUB INSTALLATION ios 2 E NN NEE exuere dx eR 7 25 MID DRIVE EXPLODED VIEW ea eee kage ae don 7 26 MID DISINE SEDAF T 0X0 ee nr ox e ROT bk oe 0 7 21 REMOVAL Ee de E Se 7 27 DISASSEMBLY 1 7 27 INSTALLATION ct e Ct th ae lg er E pet ecu Penta e Tata 7 27 MID JT ROFP SPIAIT 5X60 3 154 2 vr Rote baton Be cto ee EE 7 28 REMOVAL cenae tmi thea wt eia evum pg etim eet dels sov opus dott 7 28 MID DRIVE GEARGASE 6X6 Eege PA a Kop vo Cet em ie ed C XC 7 28 GEARCASE REMOVAL 00 002 cee ee 7 28 GEARCASE 7 29 GEARCASE 5 7 32 GEARCASE 7 34 MID GEARCASE 7 35 REAR DRIVE GE EE EE 7 36 EXPLODED VIEW eh
64. Hub and Spindle 2 27 Torque Specs Engine 3 10 Transmission I D Number Location 1 3 Transmission Lubrication 2 20 Transmission Assembly 8 10 Transmission Disassembly 8 5 Transmission Exploded View 8 16 Transmission Installation 8 14 Transmission Removal 8 3 Trip Meter ENEE eR 10 8 Troubleshooting Brake 9 3 IX 4 Troubleshooting Brake System 9 26 Troubleshooting Clutching 6 22 Troubleshooting No AWD 10 12 Troubleshooting No AWD Hub Safety Limiter 10 14 Troubleshooting No Fuel Gauge Display 10 15 Troubleshooting No Gear Indicator Display 10 15 Troubleshooting No Instrument Display 10 13 Troubleshooting Transmission 8 15 Troubleshooting Wheel Speed Sensor 10 13 V Valve Seal Spring Service 3 25 Valve Sealing Test 3 31 Valve Seat Reconditioning 3 28 Vehicle Dimensions 1 4 Vent Limes CE epe ed 2 14 VIN Identification 1 2 VIN Location errre 3 1 3 Voltage Drop Test
65. Ibs 20 24 Nm 16 18 Ibs AN e WK 20 24 Nm CN H 16 18 ft Ibs ANN 20 24 e J d gt BODY STEERING SUSPENSION CHASSIS MAIN FRAME 4X4 Exploded View Seat Base Frame Extension RH Floor Support 28 32 ft be 38 43 Nm Grills 13 15 ft Ibs 17 20 Nm LH Floor Support T 27 4 6 ft Ibs 6 8 Nm 28 32 ft Ibs 38 43 Nm 5 8 BODY STEERING SUSPENSION CHASSIS MAIN FRAME 6X6 Exploded View Seat Base Frame Extension Front Cab Support 45 ft Ibs 61 Nm 28 32 ft Ibs 38 43 Nm Grills Bumper X 13 15 ft Ibs SE LH Floor Support 1 2 28 32 ft Ibs 4 6 ft Ibs 6 8 Nm 38 43 Nm 5 9 BODY STEERING SUSPENSION SEAT HEAD REST Seat Base Seat Back Head Rest Assembly 1 2 5 10 After attaching the frame to the vehicle install the two headrests onto the frame using T 27 nuts Install the bolts loosely then tighten to 4 6 ft Ibs 5 8 Nm Make sure that the chimney nuts are centered in the mounting hole of the seat back base Place the seat back cover over the seat back base Using the illustrations for reference install the seat back base and seat back cover onto the cab frame NOTE Be sure the indented section of the seat back is positioned upward Insert T 27 nuts through the mounting strap and into the seat back Install all of the T 27 nuts loosely then tighten to 4 6 ft Ibs
66. Measure valve stem in several places Rotate the valve 90 degrees and measure for wear 3 27 Combustion Chamber 1 Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper IMPORTANT Do not use a wire brush metal scraper or abrasive cleaners to clean the bottom of the cylinder head Extensive damage to the cylinder head may result Wear safety glasses during cleaning Valve Seat Reconditioning NOTE Polaris recommends that the work be done by a local machine shop that specializes in this area NOTE The cylinder head valve guides cannot be replaced A WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly Valve Seat Inspection Inspect valve seat in cylinder head for pitting burnt spots roughness and uneven surface If any of the above conditions exist the valve seat must be reconditioned f the valve seat is cracked the cylinder head must be replaced Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Reconditioning Kit PN 2200634 Abrasive stone seat reconditioning equipment can also be used Keep all valves in order with their respective seat 3 28 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
67. Remove the gear split bearing and washer from the reverse shaft 22 Use a press to remove the gear from the shaft 26 Remove the snap ring washer gear and split bearing 8 8 TRANSMISSION 27 Remove bearing and the helical gear 30 Remove the front housing cover shim thrust button and thrust button shim Remove the silent chain from the assembly for shaft inspection Clean all components in a parts washer and inspect for wear Inspect engagement dogs of gears and replace if edges are rounded Inspect gear teeth for wear cracks chips or broken teeth Note the location of the hubs on the gear Note Location of Hubs TRANSMISSION 36 Remove seals from transmission case IMPORTANT New seals should be installed after the transmission is completely assembled 37 Inspect bearings for smooth operation Check for excessive play between inner and outer race Transmission Assembly 1 Reinstall the chain onto the front output shaft and rear output shaft 2 Install front and rear output shafts into the case 8 10 Before installing the cover make sure the sealing surfaces are clean and dry and shafts are fully seated in the transmission case Apply Polaris Crankcase Sealant to the mating surfaces Crankcase Sealant PN 2871557 4 Reinstall the thrust button shim thrust button and other shims into the cover Reinstall cover and torque bolts
68. Spring Retainers Springs e E 27 Seals Valve Spring Seats n 2 mS OSES 5 Hydraulic Lifters D N X e J 8 Valves 3 23 Rocker Arms 5 If the push rod A is visibly bent it should be replaced 1 Mark or tag rocker arms in order of disassembly to keep them in order for reassembly de K Cylinder Head Removal at the valve end of the Inspect th 2 e wear rocker arm for 1 Loosen the six cylinder head bolts evenly 1 8 turn each in indications of scuffing or abnormal wear If the pad is a criss cross pattern until loose grooved replace the rocker arm 2 Remove bolts A and tap cylinder head B lightly with a NOTE Do not attempt to true this surface by soft face hammer until loose CAUTION Tap only in grinding reinforced areas or on thick parts of cylinder head casting to avoid damaging the head or cylinder 3 Check the rocker arm pad and fulcrum seat for excessive 3 Remove cylinder head B and head gasket C from the wear cracks nicks or burrs cylinder D Push Rods 1 Clean push rods A in a suitable solvent Blow dry push rods with compressed air 2 Use compressed air to confirm the oil passage is clear in the center of the push rod A WARNING Always wear safety glasses when working with compressed air to prevent personal injury 3 Check the ends of the push rods A for nicks grooves roughne
69. Use the yellow mode button located under the speedometer to toggle through the mode options Odometer Mode The odometer records the miles traveled by the vehicle Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button until the total changes to 0 NOTE In the Rider Information Display the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Clock Mode The clock displays time in a 12 hour format To reset the clock see Clock Screen in the Diagnostic Display Mode section Diagnostic Display Mode The wrench icon will display when the gauge is in the diagnostic mode To exit the diagnostic mode turn the key switch off and on Any movement of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Lock the parking brake 3 Place the transmission in neutral 4 Hold the mode button and turn the key switch to the ON position Release the mode button as soon as the display is a
70. Wheel Speed Sensor TEST 6 WHEEL SPEED SENSOR Tools Required Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 or equivalent jumper wires To test wheel speed sensor 1 Disconnect 3 Pin connector from speedometer 2 Connect wires from test light to sensor 3 Pin connector as shown at right using the Hall Sensor Probe Harness PN 2460761 or jumper leads Elevate front right side of vehicle until tire is off the ground Slowly turn right front wheel while observing the test light If light flashes sensor is O K Be sure connections Static Timing Light Harness are good and 9 volt battery is in good condition PN 2871745 WHEEL SPEED SENSOR LOCATION RIGHT WHEEL WHEEL SPEED SENSOR 10 13 ELECTRICAL TEST 4 No AWD Hub Safety Limiter NOTE IF THE AWD ICON DOES NOT COME ON OR IF 12 VDC IS NOT REGISTERING AND AWD IS ENGAGING ABOVE 3100 RPM IT MAY BE A MECHANICAL PROBLEM START HERE IS SPEEDO IN NEUTRAL FUNCTIONING CHECK SPEEDO 2 TOGGLE TACHOMETER CORRECTLY SETTING amp REV ENGINE Gp HOLD UNTIL DISPLAY STABILIZES DOES IT APPEAR ACCURATE RESTART ENGINE IDLING TURN KEY SWITCH OFF MEASURE AC VOLTAGE REPLACE SPEEDOMETER BETWEEN PIN 7 AND REMOVE 16 PIN 1 RAISE ATV WHEELS OFF GROUND AND CONNECTOR FROM PIN 8 SUPPORT IN
71. for Install Engine Sensors Valve Cover General Component Exploded View e o NEM 84 8 in 16 9 5 0 9 Nm Screws 20 5 in Ibs C Breather 2 5 0 55 Nm E D O ring Seal 18 2 ft Ibs m Bolts 24 5 2 7 Nm par ugs Apply Dielectric Grease G Intake Boot x ben of dpud Plug H Bolts I Boot Clamp G J Throttle Body 18 P Ibs K Crank Position Sensor 24 5 2 7 Nm qr L Thermistor X d 20 5 in Ibs 2 5 0 55 1 e Bolts wa P Gasket SS Q Exhaust Manifold R Bolts S Thermostat Housing Apply Corrosion 2 Resistant Grease 84 4 in Ibs 9 5 0 9 Nm 17 2 ft lbs 23 3 Nm S e Y Ge 84 8 in lbs Post 18 2 ft Ibs 9 5 0 9 Nm 24 5 2 7 Nm 3 7 EFI Harness Fuel Injection Exploded View A Fuel Injector B Fuel Rail C EFI Harness 18 2 ft Ibs 24 5 2 7 Nm NOTE See Chapter 4 for more information on the EFI system 3 8 Engine Fastener Torque Patterns Crankcase Bolt Tighten Sequence TE 3 3 4 3 8 0 15 2 Q gt Q Oy 22 2 ft lbs 30 3 Nm 2
72. installation 2 Rubber backed buttons can be used in all ATV clutches if the hollow roller pin is changed to the solid roller pin NOTE The rubber side of the button is positioned toward the solid roller pin 6 15 CLUTCHING Bushing Service Clutch Bushing Replacement Tool Kit PN 2871226 Stamp Qty Part Description Part P 90 Drive Driven Clutch 72 Bushing Install Tool SE Drive Clutch Cover Bushing Removal i Installation Tool all 2020029 clutches P 90 Driven Clutch Cover 12 Bushing Removal Tool 3980091 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller 5020633 Adapter Moveable Sheave Bushing Removal 1 Install handle end of the Piston Pin Puller PN 2870386 securely into bench vise and lightly grease puller threads Piston Pin Puller PN 2870386 2 Remove nut from puller rod and set aside 3 Install the Main Puller Adapter 8 PN 5020632 onto the Piston Pin Puller PN 2870386 Piston Pin Puller PN 2870386 Main Puller Adaptor 8 PN 5020632 6 16 4 Insert the Number Two Adapter 10 PN 5020633 into the bushing from belt side as shown With towers pointing toward vise slide sheave and bushing onto puller rod 5 Install the nut removed in Step 2 onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Nut is left hand thread
73. m 31 Carefully install the tapered end of the Crankshaft Seal Protection Tool PA 45658 through the paper side of the crankshaft seal Back to Front Leave the seal protector installed in the crankshaft seal Check the crankshaft seal lips to verify they have not been rolled or damaged me 3 51 32 Before installing the gear stator housing cover install the Water Pump Seal Saver PA 45401 onto the water pump shaft PA 4 5401 AU 33 Install a NEW gasket to the gear stator housing cover and crankcase With the tools installed carefully place the gear stator housing cover over the protection tools 34 Apply Crankcase Sealant PN 2871557 to the outside edges of the crankcase halves See arrows where the crankcases mate See photos below This helps to prevent coolant leakage 3 52 36 Gear Stator Housing Gasket 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 secure e T Gear Stator Housing Bolt Torque 96 3 in Ibs 10 85 0 35 Nm Torque in proper sequence NOTE Before assembly clean the bolts and bolt 39 Install water pump cover R with new O ring seal Torque holes with Primer N PN 2870585 to remove any bolts to specification in proper sequence See front of this debris This will
74. on Page 7 3 7 Flange Nuts Washer 5 Install spindle nut and tighten to specification Spindle Nut Torque 70 ft Ibs 95 Nm 6 Install a new cotter pin Tighten nut slightly if necessary to align cotter pin holes 7 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions 8 Install hub cap 9 Rotate hub It should rotate smoothly without binding or rough spots or side play 7 5 FINAL DRIVE Front Hub Exploded View Disc Brake Stud Front Hub 18 ft Ibs 24 Nm Use new bolts with pre applied locking agent Wheel Nut Spec on page 7 3 Dust Cover Washer Slotted Nut 70 ft Ibs 95 Nm Cotter Pin 7 6 FINAL DRIVE DRIVE SHAFT PROPSHAFT Exploded View RANGER Front Driveshaft 30g Grease Packet CV Joint 30g Grease Packet Inner Clamps Plunging Joint Circlip Boots Clamp Clamp RANGER Front Propshaft Joint Kit Grease Zerk O ring Front Yoke RANGER 4X4 amp 6X6 Rear Propshaft Spring Pin O ring Grease Zerk Cross amp Bearing Kit Cross amp Bearing Kit Spring Pin 7 7 FINAL DRIVE DRIVESHAFT CV JOINT HANDLING TIPS Care should be exercised during driveshaft removal or when servicing CV joints Driveshaft components are precision parts Cleanliness and following these instructions is very important to ens
75. the problem is outside the transmission If transmission problem remains disassemble transmission and inspect all gear dogs for wear rounding damage Inspect all bearings circlips thrust washers and shafts for wear 8 15 TRANSMISSION TRANSMISSION EXPLODED VIEW Exploded View 4x4 6x6 7 9 ft Ibs 10 12 Nm A 34 12 18 ft Ibs 16 24 Nm Ze d 8 16 27 34 ft Ibs TN 37 46 Nm im 8X 334 66 45 NAY 44 _ 6 12 ft Ibs 7742 8 16 Nm 1X 33 27 34 ft Ibs 37 46 Nm FOR REASSEMBLY Apply White Lithium Based Grease Apply Polaris Ecc Crankcase Sealant Apply Loctite 262 to the bolt threads TRANSMISSION Exploded View 4x4 6x6 Cont Ref Qty Description Ref Qty Description 1 Asm 4x4 Transmission 35 1 22T Sprocket 1 1 36 1 19 Sprocket 2 1 Shift Drum Bellcrank 37 1 Silent Chain 3 5 Cover Screws 38 1 Front Main Output Shaft 4 1 Sector Cover 39 1 Gear Set 10T 31T 6 1 O ring 40 1 Ball Bearing 7 1 Detent Pawl 41 1 Spacer 8 1 Compression Spring 42 1 Retaining Ring 9 1 Shift Shaft 43 1 Bearing Center Drive Cover 10 1 31T Sector Gear 44 4 Torx Screws 11 2 Hollow Hex Plug 45 1 56T Mid Output Helical Gear 6x6 60T Gear 124 2 Triple Lip Seal 46 4 Ball Bearing 13 1 Gearcase Main 47
76. 0 0027 070mm Limit 0039 10 mm NOTE Replace camshaft if damaged or if any part is worn past the service limit NOTE Replace engine block if camshaft journal bores are damaged or worn excessively ENGINE REASSEMBLY Crankcase Reassembly CAUTION After any reassembly or rebuild the engine must be primed using the Oil Priming Adapter PU 45778 and a 3 4 full oil filter before initial start up Follow Steps 45 46 of this section to prime the engine and to help aid proper break in NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts Install oil pick up A if removed Torque to specification we ul P EN at Torque bolts Install oil baffle weldment B specification Baffle Weldment amp Oil Pick Up Bolt Torque 60 6 in 165 6 8 0 68 Nm 3 Install the balance shaft Inspect balance shaft clearance C in both gearcase halves Rotate balance shaft to ensure that there 1s clearance between it and oil baffle weldment NOTE Always install new balance shaft bearings 3 45 Apply assembly lube to cam journals and balance shaft bearing surfaces of the MAG case halve Install camshaft and balance shaft Assemble the crankcase halves Apply LocTite 242 PN 2871949 to the threads and pipe sealant to
77. 1 Support bottom of bearing carrier housing A Bearing Carrier Housing B Bearing C Snap Ring 3 Press bearing into place until outer race bottoms on housing CAUTION Use an arbor and press only on the outer race as bearing damage may occur 7 38 4 Install snap ring into groove Hub Installation 1 Start the wheel bearing carrier onto the drive shaft 2 Alignthe bottom of carrier housing and lower control arm Slide the lower control arm bushings into place Secure with the lower control arm bolt 3 With the driveshaft placed in the wheel bearing carrier align the carrier with the top control arm Secure with the upper control arm bolt NOTE The lower shock bolt may need to be removed to allow the upper A arm to move more freely FINAL DRIVE 4 Torque the top and bottom A arm bolts as shown in the photo REAR DRIVE SHAFT 4X4 Removal 1 Repeat all of the steps in the Rear Hub Bearing Carrier Hub Removal section 2 Remove upper carrier bolt Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft 5 Install the hub assembly onto the rear drive axle 6 Install the washer with domed side out Install the spindle retainer nut 3 Pull the rear drive shaft straight out of the frame Use short sharp jerks to free the circlip
78. 1 OF 1 ATV 0T RANGER T00 EFI DASH MODEL NO ROTRH68AG MODEL NO ROTRH68AD IONI TION SWITCH MODEL NO ROTRF68AH MODEL NO ROTRF68AF e 1 RES ARE REPRESENTED BY SOLID OR DASHED LINES TO SIMPLIFY TRACING IN DIAGRAM MIDDLE IS POS Ee em y 2 VOLT SPEEDO RECEPTACLE A 1 5 1 1 WIRE COLOR LEGEND l DIAGNOSTIC MOMENTARY 86 BEIGE TAN BK BLACK ENGINE GROUND n i SWITCH BU IGHT BLUE b EHI 5 CHASSIS GROUND ow ww BN BROWN NC SWITCH NORMALLY CLOSED at GY GRAY NO SWITCH NORMALLY OPEN aisteegis 1123 GN LIGHT GREEN DARK GREEN DASH HARNESS 2410799 02 SEE 8 SERE HOOD HARNESS 2410878 01 22S 8555 5 5 RED DEC ES TP ToY VIOLET PURPLE ITE YE YELLOW TWO WIRE COLORS ARE SHOWN WITH MAIN TRACE COLORS i EXAMPLE RD YE RED WITH ee Ss Bi Ex YELLOW TRACE 7 E 2 7 T 1 E 1 5 E 2 E 2 5 z 39 DB 1 D CH ume 38 DG WHEEL SPEED SENSOR 33 BN RD H 28 67106 C 2I RO aam i 5 6 st E 4 f 7 5 e 5 amp G 5 Ed 5 wi TE BLK SC 10 06 80 10 00 80 rev SPEEDOMETE um 12 06 E 3 W 5 32 VIR E z S T gt E i DB WH iE Da _ _ _ _ 32 VT WH 31 DB WH LOCATED ON RIGHT FRONT BRAKE _ 42 0G WH E 2 09 BN mm Ke BE Sp K T Se 1 31 B
79. 11 CLUTCHING Shift Weights Shown below are the shift weights which have been designed for or which may be used in the PVT system These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance clutch balance and shifting pattern 448 2 5630515 5630095 5630509 9 45 gr 58 gr 55 gr PN 5630513 PN 5630709 PN 5630710 PN 5630711 50 5 gr 44 gr 46 gr 47gr PN 5631698 PN 5631700 PN 5631215 20 60 gr 20 62 gr 20 56 gr 6 12 CLUTCHING Exploded View Teflon M coated Drive Clutch brass bushing Spring Teflon coated brass bushing Mark with permanent marker before disassembly Clutch Inspection All PVT system maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual Because of the critical nature and precision balance incorporated into the PVT system it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures DRIVE CLUTCH Shift Weight A WARNING The clutch assembly is a precisely balanced unit Never replace
80. 11 5 6 1 Cylinder Head Bolt Tighten Sequence Lubricate threads and between washer and underside of bolt with engine oil Torque in sequence to spec provided allow the gasket to set for 1 minute then tighten in sequence 90 1 4 turn 35 A ft Ibs 47 5 5 5 Nm 90 1 4 turn GO Oo 9 Gi 9 3 9 Torque Specifications Engine Torque Specifications Fastener Size in Ibs Nm ft Ibs Nm Camshaft Gear 8 mm 22 2 30 3 Camshaft Thrust Plate 6 mm 115 12 13 1 35 9 5 1 13 1 35 Throttle Body Adaptor Bolts 8 mm 216 24 24 5 2 7 18 2 24 5 27 Counterbalance Gear 8mm 22 2 30 3 Crankcase Bolts 8 mm 22 2 30 3 Crankcase Breather 5mm 20 5 2 5 0 55 Cylinder Head Bolts 11 mm 35 4 47 5 5 5 Exhaust Manifold 8mm 216 24 24 5 2 70 18 2 24 5 2 7 Flywheel 14 mm 65 7 88 9 50 Injector Rail 8mm 216 24 24 5 2 70 18 2 24 5 2 7 Magneto Cover 6mm 06 3 10 85 0 35 Oil Baffle Weldment 5mm 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 5mm 50 5 5 64 0 56 Oil Filter Pipe Fitting 20 mm 35 4 47 5 5 4 Oil Pick Up 5mm 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
81. 1500 RPM or lower Leade Chins Heading 8 With the engine running turn the lights on and engage Battery Charge Coil Y1 Y2 or Open Line parking brake lock to keep brake light on to Ground Infinity 9 Repeat test observing ammeter and tachometer With NOTE Any measurement other than Infinity open lights on charging should occur at or below 2000 RPM will indicate a failed or shorted stator leg 10 23 ELECTRICAL TEST 3 Measure AC Voltage Output of Each Stator Leg at Charging RPM 1 Setthe selector dial to measure AC Voltage Start the engine and let it idle 3 While holding the engine at a specified RPM separately measure the voltage across each leg of the stator by connecting the meter leads to the wires leading from the alternator 1 Y2 Y1 Y2 to Y3 4 Refer to the following table for approximate AC Voltage readings according to RPM Test each leg at the specified RPM in the table Example The alternator current output reading should be approximately 18 VAC at 1300 RPM between each leg NOTE If one or more of the stator leg output AC voltage varies significantly from the specified value the stator may need to be replaced RPM Reading AC Voltage VAC Reading 1300 18 VAC x 25 96 3000 42 VAC 25 5000 64 VAC 25 10 24 ELECTRICAL Charging System Testing Flow Chart Whenever charging system problems are su
82. 25 ft 16 35 Nm Bolts Transmission AGL Gearcase Lube 15 2 oz Lubricant Amount 450 ml SHIFT LEVER Removal 1 Disconnect linkage cable from shifter 2 Remove one bolt attaching the gear shift selector mount to machine frame Cover Screw Cable Shifter knob Bearing N Bolt Shifter Grommet Shift Lever Breakdown 8 2 3 Remove the shift lever cover and then remove the screw Pull off the shifter knob Shift Lever Shift Lever Location 4 Luft the gear shift selector out of mounting bracket and away from frame Installation 1 Repeat the steps in reverse order to install the gear shift selector SHIFT LINKAGE Inspection Linkage rod adjustment is necessary when symptoms include e No Wheel Drive light Noise on deceleration nability to engage a gear Excessive gear clash noise Shift selectors moving out of desired range NOTE Remove necessary components to gain access to shift linkage cable ends i e exhaust heat shield exhaust pipe etc Inspect shift linkage cable clevis pins and pivot bushings and replace if worn or damaged 2 Be sure idle speed is adjusted properly TRANSMISSION Adjustment 1 Place gear selector in neutral Make sure the transmission bell _ XS in the neutral position detents With two wrenches loosen the outside jam nut counterclockwise Turn the outside jam nut 1 1 2 turns Perform this procedur
83. 41 Nm Bolt Lock Bracket Loctite 271 BODY STEERING SUSPENSION REAR DRIVE AXLE AND SWINGARM EXPLODED VIEW 6X6 Retaining Ring Wider Axle Tube Screw amp Washer Bearing 60 ft Ibs 81 Nm Screw amp Washer Vehicle Frame 60 ft Ibs 81 Nm Swing Arm Wheel 150 ft Ibs E 203 Nm Bolt Nut amp EON 40 ft Ibs Washer Rear Gearcase U Bolt Assembly Jam Nut Bu Grease Fitting Bolt Lock qo Ze ae Pivot Bushing Swing Arm Bushing Swing Arm Pivot Bolt so ft Ibs 203 Nm 30 ft Ibs 40 Nm Bolt amp Washer EES 60 ft Ibs 81 Nm Skid Plate Apply Loctite 242 5 21 BODY STEERING SUSPENSION REAR CARGO BOX Cargo Box Panels 8 10 in Ibs 9 1 0 Nm Taillight T 20 x 8 10 in Ibs 0 9 1 0 Nm 1 30 T 20 8 10 in Ibs d 0 9 1 0 Front Panel 5 22 Tailgate Support g p 1 27 4 6 ft Ibs 5 8 Nm v 8 10 in Ibs 0 9 1 0 Nm Seal Foam Side Panel 120 8 10 in Ibs 0 9 1 0 Nm BODY STEERING SUSPENSION Cargo Box Tailgate Box Support Tailgate Cap Tailgate E 20 25 Ibs i 1 20 Nm ieu EID 1 d 8 10 lbs zx Ins ee Inner Panel Rod M Outer Panel Tailgate Tube Box Support Box Latch m Shock Eo uem 8 10 ft Ibs
84. 5 8 Nm Install the bolts and nuts that secure the seat belt assemblies to the rear of the seat frame Tighten to 38 42 ft Ibs 51 57 Nm Check all nuts and bolts for proper torque and installation 27 4 6 ft Ibs 5 8 Nm 38 42 ft Ibs 4 Mounting Strap Chimney Nut Seat Back Cushion A Bolt Seat Back Seat Back Cover BODY STEERING SUSPENSION STEERING ASSEMBLY Exploded View Cap E 25 30 ft Ibs 2 34 41 Nm 55 Rod End amp J Nut SE SEN Steering Wheel Bushing ONSE ics Screw amp Lock Washer b el gt 15 22 ft Ibs 20 30 Nm E Screw amp Nut Upper Steering Shaft Bolt be 30 ft bsc Lower Steering Shaft 41Nm 4 Qo 09 Steering Box End Bolt 40 45 ft Ibs 54 61 Nm H Apply Loctite 242 5 11 BODY STEERING SUSPENSION STEERING AND SUSPENSION Exploded View NOTE To avoid damage to the tie rod ends and Always use new other steering components be sure to install tie 2 cotter pins upon rod end bolts in the proper direction The stee reassembly ring post arm bolt B points up the rod end bolts A point down Be sure inner rod ends are placed between the steering post arms 25 30 ft Ibs ry 5 34 41 Nm 1 Always use new bolts upon reassembly A Apply Loctite 242 2715 22 ft Ibs 202030 Nm YA
85. 5631698 7042202 7043167 Feet 1500 3700 20 56 Blu Gray Blk Almd 5000 12000 5631215 7042202 7043167 GENERAL INFORMATION Paint Codes Painted Part Color Description Polaris Number Frame Cab Medium Gloss Black P 067 RANGER XP 4x4 Plastic Hood Dash Black Metallic P 177 RANGER XP 6x6 Plastic Hood Dash Dark Green P 195 RANGER XP 4x4 Plastic Hood Dash Turbo Silver P 402 RANGER XP 4x4 Plastic Hood Dash Mossy Oak P 455 RANGER XP 4x4 Plastic Hood Dash Delta Green P 492 RANGER XP 4x4 Plastic Hood Dash Sunset Red Metallic 520 Replacement Keys Replacement keys can be made from the original key To identify which series the key is take the first two digits on the original key and refer to the chart to the right for the proper part number Series Part Number KEY COVER amp 20 4010278 P N 5533534 gt 21 4010278 22 4010321 23 4010321 j 27 4010321 28 4010321 Key Series 31 4110141 Number 32 4110148 67 4010278 68 4010278 SPECIAL TOOLS Special tools may 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 SP
86. A SAFE MANNER BACK OF OVER 3 VAC INSTRUMENT 2 MONITOR VOLTAGE AT HUB COIL CLUSTER CONNECTOR BETWEEN BROWN WHITE AND GROUND CHECK CHARGING SYSTEM STATOR REGULATOR AND WIRING TURN AWD OFF 16 Pin Connector EU AND HOLD E Blue White Engine Overheat Switch REV AND HOLD THE 1 Red 12V Constant g 2 Red White 12V Switched Park Drake Indicator RN AWB ON NO PROBLEM 3 Grey Orange Mode button White Malfunction Indicator 4 N C Violet White Fuel Gauge DOES FRONT a 5 Green Brown Red Ground DRIVE 6 Blue White Gear Indicator Input 7 Yellow RPM Input N C 8 Brown Red Ground Brown White AWD Control INSPECT HUB COIL WIRING FOR SHORT CIRCUITS ISTHE TO GROUND DISCONNECT REPLACE AWD ICON ON CONNECTOR amp MEASURE BETWEEN HUB COIL SPEEDOMETER BROWN WHT amp GROUND N MECHANICAL PROBLEM REPAIR HUB COIL WIRING 10 14 ELECTRICAL TEST 5 Fuel Gauge Display Not Working 16 Pin Connector START HERE Red 12V Constant Blue White Engine Overheat Switch Red White 12V Switched Orange Red Park Brake Indicator Grey Orange Mode button Blk White Malfunction Indicator N C Violet White Fuel Gauge Green Brown Red Ground Blue White Gear Indicator Input CHECK INSTRUMENT SPEEDOMETER CLUSTER PERFORM TEST 2 7 Yellow RPM Input Brown Red Ground FUNCTION OK
87. AWD SWITCH 2 1 BERENS 15 RED WHITE 18 RED WHITE SPLICE HEADLIGHT SWITCH 5 16 BROWN 8 GNITION SWITCH F HEADLIGHT HARNESS Lil RED WHITE 18 GNITION SWITCH IGNITION SWITCH C 18 BROWN 18 HEADLIGHT SWITCH 1 HEADLIGHT HARNESS H 19 BROWN RED 18 BROWN RED SPLICE SPEEDOMETER 8 pic AWD HOOD HARNESS 20 BROWN I8 AWD SWITCH 1 2V RECEPTACLE SWITCH 21 RED WHITE 18 HEADLIGHT SWITCH 5 HEADLIGHT SWITCH 8 E d as 22 RED WHITE 8 HEADL SWITCH 8 SPEEDOMETER 2 u XE C i 23 WHITE 18 HEADLIGHT SWITCH HEADLIGHT SWITCH 4 31 BI 35 14 OG WH xo BN 24 YELLOW 8 HEADLIGHT SWITCH 6 HEADLIGHT HARNESS 21 aD WH PE 5 23 WH 35 BI TES 72 1 Om 25 GREEN 18 HEADLIGHT SWITCH 3 HEADLIGHT HARNESS Sa 0 rr 26 ORANGE WHITE 18 AWD SWITCH 2 AWD SWITCH 8 23 WE SE HEADLIGHT 21 RED 8 CHASSIS HARNESS Ag SPEEDOMETER 18 B H T3 831 321 AR 20 8N Ty 26 06 WH 28 GRAY ORANGE 20 MOMENTARY SWITCH SPEEDOMETER 3 35 BI 29 BN 29 BROWN 20 MOMENTARY SWITCH AWD SWITC 1 1 30 YELLOW 18 CHASSIS HARNESS SPEEDOMETER 1 06 121 31 BLUE WHITE 18 CHASSIS HARNESS 83 SPEEDOMETER 9 B YE H H SS 32 VIOLET WHITE 1 CHASSIS HARNESS B4 SPEEDOMETER 12 aD WH geg 33 BROWN RED 18 BROWN RED SPLICE SPEEDOMETER 13 BN D n OG WH 34 WHITE 8 CHASSIS HARNESS AT SPEEDOMETER 14 u E 35 BROWN 8 HEADLIGHT SWITCH 1 AWD SWITCH 5 WH DG 8 36 BROWN RED 8
88. 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 Tire Inspection Improper tire inflation may affect vehicle maneuverability When replacing a tire always use original equipment size and type use of non standard size or type tires may affect vehicle handling Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less U Tread Depth 1 8 3 mm 4 GS e DN O oe A WARNING Operating a RANGER with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the tread depth measures 1 8 3 cm or less GENERAL INFORMATION Tire Pressure NOTE Batteries must be fully charged before use or battery life will be reduced by 10 30 of full potential Charge battery for 3 5 hours at a current AA CAUTION equivalent of 1 10 of the battery s rated amp hour capacity Do not use the alternator to charge a new Maintain proper tire pressure battery Refer to Battery Activation and Refer to the warning tire pressure decal Maintenance video PN 9917987 applied to the vehicle Battery Fluid Level Conventional Battery Tire Pressure Inspection PSI Cold A poorly maintained battery
89. CHASSIS HARNESS A8 BROWN RED SPLICE 0 0 ein 8 31 BROWN 20 AWD SWITCH 5 SPEEDO DIAGNOSTIC 38 GREEN 20 SPEEDOMETER 5 SPEEDO DIAGNOSTIC 2 G g 0 B B aN ie g m 39 BLUE 20 SPEEDOMETER 6 SPEEDO DIAGNOSTIC 3 T i 5 SSIS AH SWITCH SWITCH HEADLIGHT 42 ORANGE WHITE 16 CHASSIS HARNESS B2 ORANGE WHITE SPLICE gt 11 3 WIRE DIAGRAM RANGER 700 EFI 4 4 6X6 BREAKOUTS HOI 11938 ZE DA o o w gt HOI 11938 39V L Ou w O gt 08 401 2o25 Ser y20718 BB 0 onnows eaten Com
90. Do notallow grease to come into contact with the piston and seals Damage may occur to the components 4 Follow brake bleeding procedure outlined earlier in this chapter 5 Install wheels and torque wheel nuts to specification Front Wheel Nut Torque 37 ft Ibs 50 Nm NOTE If new brake pads are installed it is 4 Compress the mounting bracket and make sure the dust recommended that a burnishing procedure be seals are fully seated Install the brake pads Clean disc performed to extend pad service life and reduce and pads with brake parts cleaner or denatured alcohol noise Start machine and slowly increase speed to remove any dirt oil or grease 15 mph Gradually apply brakes to stop machine Repeat procedure 10 times Caliper Installation 1 Install caliper on hub strut and torque mounting bolts 2 Apes M 77 t8 ft Ibs 04Nm Ve Front Caliper Mounting Bolt Torque 18 ft Ibs 24 Nm 2 Install brake line and tighten securely with a flare nut wrench 9 17 5 FRONT BRAKE DISC Disc Inspection 1 2 3 9 18 Visually inspect the brake disc for nicks scratches or damage Measure the disc thickness at 8 different points around the pad contact surface using a 0 1 micrometer Replace disc if worn beyond service limit Brake Disc Thickness New 150 165 3 81 4 19 mm Service Limit 140 3 56 mm Brake Disc Thickness Varianc
91. Engine Individual Serial No Emissions Plant No This could be either Powertrain Check Digit a number or a letter Engine Serial Number Location Whenever corresponding about an engine be sure to refer to the engine model number and serial number This information can be found on the sticker applied to the cylinder head on the side of engine 1 2 Unit Serial Number VIN Location The machine model number and serial number are important for vehicle identification The machine serial number A is stamped on the lower LH frame rail close to the front drive wheel The modeland serial number are also located on a sticker under the hood B GENERAL INFORMATION Transmission LD Number Location The transmission 1 0 number is located on the right side when installed in the machine 1 3 GENERAL INFORMATION VEHICLE DIMENSIONS RANGER 4X4 6X6 75 in 190 50 cm 1 4 GENERAL INFORMATION Vehicle Dimensions RANGER 4X4 6X6 120 in 305 cm fi 8 TV 58 in 147 cm 1 5 GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL RANGER XP 4X4 Category Dimension Capacity Length 113 in 287 cm Width 60 in 152 4 cm Height 75 in 190 5 cm Wheel Base 76 in 193 cm Ground Clearance 11 5 in 29 Turning Radius 132 in 335 cm Dry Weight 1185 Ibs 537 kg Gross Vehicle Weight 2750 Ibs 1247
92. Height Intake 1 4638 37 18 mm Exhaust 1 4736 37 43 mm 3 11 Cylinder Piston Engine Specifications Main Components Cylinder Piston Connecting Rod EHO680LE Cylinder Bore Standard 3 1495 80 mm SSES Cylinder Taper Limit 0 00031 0 008 mm Cylinder Out of Round Limit 0 00030 0 0075 mm Cylinder to Piston Clearance 0015 00059 040 015mm Lifter Outer Diameter Standard 0 84245 0 00025 21 39 8 0 00635 mm Lifter Block Bore 0 8438 0 00062 21 4322 0 0157 mm Piston Standard 3 1477 000121 79 954 003mm SE m pn FOLDERS 0 78789 00009 20 0125 0 003 mm Piston Pin Outer Diameter 0 7874 0 7872 20 19 995 mm Piston Pin e standard Clearance Pinton Pratt 0 00 Piston Pin Degree of Fit Piston pin must be a push fit by hand at 68 F 20 C Piston Connecting Rod Crankshaft Engine Specifications Piston Ring Main Components Piston Connecting Rod 068 Ring Standard 0 0059 0 138 0 15 0 35mm Top Ring Limit 1596 Leakdown Installed Second Ring Standard 0 0098 0 197 0 25 0 50mm Gap Second Ring Limit 1596 Leakdown Oil Ring Standard 0 0196 0 00984 0 50 0 25mm Oil Ring Limit 1596 Leakdown Top Ring Standard 0 0024 0 0008 0 060 0 020 mm Ring
93. Joint Grease PN 1350047 Only boot replacement 50g Boot replacement w joint cleaning 75g 10 Remove excess grease from the CV joint s external surfaces and position the boot over the housing making sure the boot is seated in the groove Position clamp over the large boot end and make sure clamp tabs are located in slots NOTE Before tightening boot clamp on inboard joint make sure any air pressure which may have built up in joint boot has been released The air should be released after the plunging joint has been centered properly Tighten boot clamp using boot clamp pliers 11 While pulling out on the CV shaft fully extend the CV joint and slide a straight O ring pick or a small slotted screw driver between the small end of the boot and the shaft This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life Before you remove your instrument be sure the small end of the boot is in its correct location on the axle REAR SHAFT CV Joint Joint Capacity 25 Grams Retaining Ring Large Clamp Grease PN 1350047 Boot Capacity 50 Grams Boot Small Clamp lt Boot Capacity 50 Grams Boot M Grease PN 1350047 Large Clamp Retaining E a Ring Joint Capacity Doi Plunging Joint 50 Grams xis t Spring Ring is Figure 7 31 7 41 FINAL DRIVE Installation 4 Lift bearing carrier into place an
94. Mixture Symptoms Fouls spark plugs black sooty exhaust smoke rough idle poor fuel economy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug TPS setting incorrect Injector failure 4 22 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 incorrectly Symptom Idle Too Low if less than 900 RPM when engine is warm Plugged air filter Leaking injector rich condition Belt dragging Throttle stop screw tampering Symptom Erratic Idle Throttle cable incorrectly adjusted Air Leaks dirty injector TPS damaged or adjusted Tight valves Ignition timing incorrect Belt dragging Dirty air cleaner Engine worn Spark Plug fouled Throttle stop screw set incorrectly out of sync with ECU BODY STEERING SUSPENSION CHAPTER 5 BODY STEERING SUSPENSION TORQUE SPECIFICATIONS 5 d hp deo e e RA PO p RE ed So es 5 2 SPECIAL TOOLS sti s ER one SC EE E te ae 5 2 BODY COMPONENT REMOVAL ENN e Rx ROLE UR RR USER E SCA S 5 3 2 2 1 5 3 LOWER BODY
95. P and input gear R from the output shaft Q Inspect the input gear for abnormal wear broken or chipped teeth 11 Remove the retaining ring and shim P from the rear 14 Inspect the two flange bearings S inside the gearcase output thru shaft Inspect the pinion shaft bushing T for wear that is inside the gearcase 7 31 FINAL DRIVE 2 Install the 26T input gear D shim E and a new retaining ring F onto the output shaft 15 Replace all O ring seals and worn components Replace 2 3 Assemble the pinion shaft assembly if previously disassembled Install the 26T gear G and bearing H onto the pinion shaft T NOTE When replacing the 26T output be sure the step of the gear is facing towards the bearing see below Pinion Shaft Assembly Step Of Gear Gearcase Assembly 1 Install the shim A and a new retaining ring B onto the output end of the output shaft C Install the output thru shaft into the gearcase 4 Install the pinion shaft assembly into the input cover NOTE Alignment of the pinion shaft bearing into the input cover maybe be difficult If needed use the following steps to aid in installation refer to photo on right 7 32 Hold the pinion gear assembly e Use a rubber mallet to lightly tap on the front of the input cover around the bearing cup Tapthe front cover in an X pattern follow the pattern in the photo on the right un
96. Premium Season Grease Conoco Superlube M or Mobilegrease Special Swing Arm Pivot 10 Rear Gearcase 9 Front Prop Shaft Fill Plug pu Yoke TOF 4 8 Rear Prop Shaft 6x6 10 Rear Gearcase GENERAL INFORMATION GENERAL VEHICLE INSPECTION AND MAINTENANCE Pre Ride Daily Inspection Perform the following pre ride inspection daily and when servicing the vehicle at each scheduled maintenance Tires check condition and pressures Fuel and oil tanks fill both tanks to their proper level Do not overfill oil tank All brakes check operation and adjustment includes auxiliary brake Throttle check for free operation and closing Headlight Taillight Brakelight check operation of all indicator lights and switches Engine stop switch check for proper function Wheels check for tightness of wheel nuts and axle nuts check to be sure axle nuts are secured by cotter pins Air cleaner element check for dirt clean or replace Steering check for free operation noting any unusual looseness in any area Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fasteners Engine coolant check for proper level at the recovery bottle Check all rear suspension components for wear or damage Frame Nuts Bolts and Fasteners Periodically inspect the torque of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Re
97. SS HI Ze BEER 7 2 4 Ze DER 4 09 SCH DEM LE bel TL EE oe d dit T i r 1 gt 22 DIFFERENTIAL EXE EREECHEN TI TT x 5 i i i LICE SOLENOID t met 1 Ge ave 11 M 5 a TP Ad Se ir 103 RD ex D LOCATED ON s3 SS SS EE zt E 4 E 16 12 SPLICE O REAR DIFFERENTIAL GEES E E EE SEU rom SML e 8 NOTE POWERED TO UNLOCK 1 ES SS IF Ke Ss m T S 8i DIFFERENTIAL Ee ES EE idee SH D resi nou SS SS xm 1 106 BN CAUTION DO NOT POWER 12 L Sp L Lt Se ap O c FOR MORE THAN Ace SECOND CELEIS 69 0G WH 84 0 4X4 ONLY s KE 25 e i B 52 e P Boz Sa 510 d vss 222 i TERMI 0 m 2 i d TOP VIEW ee LI Yu 4 1 zz pes Nep i 18 06 06 L 5 ER 321 FLUSH ETA i lh 2 90 RD WH SIS my d 57 mw s 5 IGNITION COIL TT E o i LOCATED ABOVE xz Er TALLIGHT 19 GRUND fie LEFT FRONT WHEEL POSITION 122 le SA S ACCESSORY i tle 1f SENSOR
98. WA A A 3 49 25 Install counter balance shaft gear J with new key aligning timing marks with crankshaft gear I Install washer and bolt Use the Gear Holder PU 45838 specification Torque to E T Balance Shaft Gear Bolt Torque 22 2 ft Ibs 30 3 Nm 26 Use the Cam Gear Alignment Tool PU 45497 2 to align the teeth ofthe cam gear M Install the cam gear M with the Cam Gear Alignment Tool still in place onto the camshaft The timing marks on the camshaft gear should align with the keyway on the balance shaft gear P h Ke et NOTE 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 3 50 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 specification NOTE Be sure all of the timing marks are properly aligned Water Pump Gea Timing Marks Counterbalance Gear and Camshaft Gear Bolt Torque 22 2 ft Ibs 30 3 Nm 28 Before installing the gear stator housing replace the seals in the cover Install a new water pump seal N into the gear stator housing Use the Water Pump Mechanical Sea
99. Y1 to and Y2 to Do not run test with high amperage accessories Each test should measure 0 19Q 15 1 Connect a tachometer to the engine Connect Meter Test Ohms Reading Leade 2 Using inductive amperage metering device set to DC amps connect to the negative battery cable Battery Charge Coil 1 to Y2 0 190 15 3 With engine off and the key kill switch and lights the Batter Charge Coil YI to Y3 0 190 15 ON position the ammeter should read negative amps Battery Charge Coil Y2 to Y3 0 19 15 battery discharge Reverse meter lead if a positive reading isimdicated NOTE If there are any significant variations in ohm s readings between the three legs it is an indication that one of the three stator legs maybe weak or failed 4 Shift transmission into neutral with the park brake on and start the engine With the engine running at idle observe meter readings 5 Increase engine RPM while observing ammeter and TEST 2 Resistance Value of Each Stator Leg to Ground tachometer 1 Measure the resistance value of each of the stator legs to ground to Ground Y2 to Ground to Ground 6 Note RPM at which the battery starts to charge ammeter Each test should measure Open Line OL indication is positive 7 With lights and other electrical loads off the break even Connect Meter Ti hms Readin point should occur at approximately
100. a common spring loaded glaze breaker for honing is not advised for nicasil cylinders Polaris recommends using a rigid hone or arbor honing machine Cylinders may be wet or dry honed depending upon the hone manufacturer s recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore Honing To Deglaze A finished cylinder should have a cross hatch pattern to ensure piston ring seating and to aid in the retention of the fuel oil mixture during initial break in Hone cylinder according to hone manufacturer s instructions or these guidelines Honing should be done with a diamond hone Cylinder could be damaged if the hone is not hard enough to scratch the nicasil lining Use a motor speed of approximately 300 500 RPM run the hone in and out of the cylinder rapidly until cutting tension decreases Remember to keep the hone drive shaft centered or cylinder centered on arbor and to bring the stones approximately 1 2 1 3 cm above and below the bore at the end of each stroke Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently de glazed and to check for correct cross hatch NOTE Do not allow cylinder to heat up during honing After honing has been completed inspect cylinder for thinning or peeling If cylinder wear or damage is excessive it will be necessary to replace the cylinder The cylinders are lined wi
101. as needed to maintain a full charge NOTE Battery charge can be maintained by using a Polaris battery tender charger or by charging about once a month to make up for normal self discharge Battery tenders can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging 1 Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific gravity to 1 270 or greater 3 Reinstall the battery 2 30 Spark Plug Service 1 Remove both spark plug high tension leads A Clean plug area so no dirt and debris can fall into engine when plug is removed 2 Remove spark plugs B 3 Inspect electrodes for wear and carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes Inspect electrode for wear and buildup 4 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION wire brush or coated abrasive should not be used 5 Measure gap with a wire gauge Refer to specifications in picture below for proper spark plug type and gap Adjust gap if necessary by bending the side electrode carefully Spark Plug Gap HR Gap 035 0 90 mm 6 If necessary replace spark pl
102. attempt to disassemble the ECU It is sealed to prevent damage to internal components Warranty is void if the case is opened or tampered with in any way operating and control functions within the ECU are pre set No internal servicing or readjustment may be performed If a problem is encountered and you determine the ECU to be faulty contact the Polaris Service Department for specific handling instructions Do not replace the ECU without factory authorization The relationship between the ECU and the throttle position sensor TPS is very critical to proper system operation If the TPS is faulty or the mounting position of the TPS to the throttle body is altered the TPS must be re initialized For the purpose of troubleshooting a known good ECU from another Polaris RANGER XP EFI of the same model may be used without system or engine component damage ECU Replacement 1 Remove the retaining screws 2 holding the ECU With the Ignition turned off disconnect the wire harness from the ECU 3 install reverse the procedures and tighten screws to specification Retaining Screws 10 in Ibs 1 1 Nm FUEL PUMP Operation Overview NOTE All units utilize quick connect lines An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank This assembly includes the fuel pump regulator and fuel gauge sender The pump is rated for a minimum
103. batteries KEEP OUT OF REACH OF CHILDREN A WARNING The gases given off by a battery are explosive Any spark or open flame near a battery can cause an explosion which will spray battery acid on anyone close to it Should there be contact with battery acid wash the affected area with large quantities of cool water and seek immediate medical attention To ensure maximum service life and performance from a new battery perform the following steps NOTE Do not service the battery unless it will be put into regular service within 30 days After initial service add only distilled water to the battery Never add electrolyte after a battery has been in service NOTE New Battery Battery must be fully charged before use or battery life will be significantly reduced 10 30 of the battery s full potential To activate a new battery 1 Remove vent plug from vent fitting Remove cell caps Fill battery with electrolyte to upper level marks on case 3 Set battery aside to allow for acid absorption and stabilization for 30 minutes 4 Add electrolyte to bring level back to upper level mark on case NOTE This is the last time that electrolyte should be added If the level becomes low after this point add only distilled water 5 Charge battery at 1 10 of its amp hour rating Examples 1 10 of 9 amp battery 9 amp 1 10 of 14 amp battery 1 4 amp 1 10 of 18 amp battery 1 8 amp recommended charging rates
104. be performed only by a certified Polaris Master Service Dealer MSD technician who has received the proper training and understands the procedures outlined in this manual Because of the critical nature and precision balance incorporated into the PVT components it is absolutely essential that no disassembly or repair be made without factory authorized special tools and service procedures The Polaris Variable Transmission PVT consists of three major assemblies 1 The Drive Clutch 2 The Driven Clutch 3 The Drive Belt The internal components of the drive clutch and driven clutch control engagement initial vehicle movement clutch upshift and backshift During the development of a Polaris the PVT system is matched first to the engine power curve then to average riding conditions and the vehicle s intended usage Therefore modifications or variations of components at random are never recommended Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning Drive Clutch Operation Drive clutches primarily sense engine RPM The two major components which control its shifting function are the shift weights and the coil spring Whenever engine RPM is increased centrifugal force is created causing the shift weights to push against rollers on the moveable sheave which is held open by coil spring preload When this force becomes higher than the p
105. cable first and reinstall the negative cable last 3 Remove the battery ELECTRICAL Battery Installation Clean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly Route the cables correctly 3 Reinstall battery attaching positive red cable first and then the negative black cable Coat terminals and bolt threads with Nyogel Grease 2871329 4 Reinstall the holder strap 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 Low Maintenance battery to determine its condition OCV Test and a Load Test OCV Open Circuit Voltage Test Battery voltage should be checked with a digital multitester Readings of 12 8 volts or less require further battery testing and charging See charts and Load Test NOTE Lead acid batteries should be kept at or near a full charge as possible If the battery is stored or used in a partially charged condition or with low electrolyte levels hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery NOTE Use a voltmeter or multimeter to test batter voltage OPEN CIRCUIT VOLTAGE State of Charge
106. cause internal damage to the transmission 15 As the engagement dogs are installed onto the shaft place the wave springs into the spring groove Keep the spring in place while the fork is being installed on the shaft and while placing the shafts into the case NOTE Use caution when installing the fork the spring can easily fall out NOTE Installing the shift rail will aid in keeping the shift forks shift dogs and the springs in place 8 11 TRANSMISSION 16 Carefully install the shaft assembly and gear cluster as a unit into their respective bearing case recesses Tap with a soft face hammer to seat shaft assemblies E Y gt 17 Position the shift forks up and so the pins point toward the 9 o clock position before installing the shift drum assembly 18 Replace and grease the O ring s on the shift drum before installation 19 Install the shift drum into the case NOTE Make sure shift shaft pins are properly positioned in the slot on selector arms 8 12 20 21 22 23 24 Lift the shift rail slightly and rotate the rail fork assembly so it meshes with the tracks on the shift drum Be sure the wave springs are properly in place and that the shift rail is seated into the pocket on the backside of the case Install the helical gear and bearing onto the pinion shaft Clean the mating surfaces of the case and cover Apply Crankcase Sealant PN 2871557 to the mating
107. clean and free of burrs nicks or scratches 8 Reinstall drain plug and torque to 192 24 in lbs 21 7 2 7 Nm GENERAL INFORMATION 9 Place shop towels beneath oil filter Using Oil Filter Exhaust Pipe Wrench PV 43527 turn filter counterclockwise to remove A WARNING Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with exhaust components To reduce fire hazard make sure that there are no combustible materials in the area when purging the spark arrestor Wear eye protection Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Do not go under the machine while it is inclined Set the 10 Using a clean dry cloth clean filter sealing surface on hand brake and block the wheels to prevent roll back 11 Lubricate O ring on new filter with a film of fresh engine Failure to heed these warnings could result in serious oil Check to make sure the O ring is in good condition personal injury or death 12 Install new filter and turn by hand until filter gasket contacts the sealing surface then turn an additional 1 2 turn The exhaust pipe must be periodically purged of accumulated 13 Remove dipstick and fill sump with 2 quarts 1 9 1 of carbon as follows P
108. deflection top edges have been trimmed on some drive belts It will be necessary to project the side profiles and measure from corner to corner Place a straight edge on each side of the drive belt Place another straight edge on top of belt Measure the distance where the side straight edges intersect the top Inspect belt for loose cords missing cogs cracks abrasions thin spots or excessive wear Replace if necessary Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt Distance Clutch Center Distance 10 1 05 254 2 5 1 3 mm Belt Outer Circumference New 41 225 104 71 cm Wear Limit 41 413 105 19 cm Measure belt length with a tape measure around the outer circumference of the belt Belts which measure longer than nominal length may require driven shimming or engine adjustment for a longer center distance to obtain proper belt deflection Belts which measure shorter than nominal length may require driven shimming or a shorter center distance Remember proper belt deflection is the desired goal not a specific center distance Replace belt if worn past the wear limit Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic PVT operation See Troubleshooting Chart at the end of this chapter for pos
109. eme o ome Rete DIAGNOSIS IF 10 39 10 2 ELECTRICAL GENERAL INFORMATION Special Tools Part Number Tool Description PV 43568 Fluke 77 Digital Multimeter 2870630 Timing Light 2870836 Battery Hydrometer 2460761 Hall Sensor Probe Harness 2871745 Static Timing Light Harness PU 47063 Digital Wrench Diagnostic Software PU 47471 Digital Wrench SmartLink Module Kit Electrical Service Notes Keep the following notes in mind when diagnosing an electrical problem Refer to wiring diagram for stator and electrical component resistance specifications Under Hood Components A Voltage Regulator Rectifier B Starter Solenoid C Terminal Block D Positive Battery Cable E Negative Battery Cable Battery Starter Motor Positive Lead H Relays When measuring resistance of a component that has a resistance value under 10 Ohms remember to subtract meter lead resistance from the reading Connect the leads together and record the resistance The resistance of the component is equal to tested value minus the lead resistance Become familiar with the operation of your meter Be sure leads are in the proper jack for the test being performed i e 10A jack for current readings Refer to the Owner s manual included with your meter for more information Voltage amperage and resistance values included i
110. end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster Remove clips 2 from air box cover and remove cover Inspect the gasket It should adhere tightly to the cover and seal all the way around 3 Remove air filter assembly Do not clean the main filter Lock Nut the filter should be replaced Adjuster 4 Inspect main element and replace if necessary If the filter 4 Loosen the adjuster lock nut has been soaked with fuel or oil it must be replaced 5 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle pedal Breather Filter NOTE While adjusting lightly flip the throttle pedal up and down 6 Tighten the lock nut 7 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position Installation 1 Reinstall the filter into the air box container Be sure the filter fits tightly in the air box NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 2 15 GENERAL INFORMATION 2 Check air box If oil or water deposits are found drainthem Air Intake Inspection into a suitable container 1 NOTE Service more frequently if vehicle is operated 2 wet conditions or at high throttle openings for extended periods 3 Install air box cover and secure with clips 3 4 Air Baffing Box TEN
111. ensure proper sealing when chapter installing bolts Install the O ring dry no lubricant 37 Install shaft seal with ceramic surface facing inward 4 96 3 in Ibs E dii 10 85 1 35 Nm 38 Install water pump impeller P Secure the impeller with e ST the washer and a new nylok nut Torque the nut to specification Water Pump Housing Bolt Torque 96 3 in Ibs 10 85 0 35 Nm Torque in proper sequence 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 Water Pump Impeller Nut Torque 108 6 in Ibs 6 8 0 68 Nm 3 53 Flywheel Stator Installation NOTE Before assembly clean the bolts and bolt T holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when Flywheel Nut Torque installing bolts 65 7 ft lbs 88 9 50 Nm 1 Install stator assembly S and bolts Torque bolts to 4 Install stator housing with new o rings Torque the bolts to specification specification and follow proper bolt torque sequence at the 2 Installthe wire hold down bracket T Install two new wire beginning of this chapter hold down bolts New bolts contain patch lock Torque bolts to specification following the proper bolt torque sequence Coat the stator wire grommet U
112. from the gearcase The circlip holds the drive shaft in the gearcase 7 Install the wheel washers and wheel nuts Torque wheel nuts to specification See Torque Specifications table on page 7 3 8 Lowerthe vehicle Torque the spindle retaining nut to 110 ft Ibs 149 Nm Install a new cotter key and the hub cap 4 Inspect the axle splines and CV boots for any damage 110 ft Ibs 149 Nm 7 39 FINAL DRIVE CV Joint Boot Replacement 1 Remove clamps from rubber boot s using the CV Boot Clamp Pliers PN 8700226 A CV Boot Clamp Pliers Earless Type 8700226 2 Remove the large end of the boot from the CV joint and slide the boot back NOTE Photo above is shown without shaft for clarity Wipe grease away from recess in CV joint inner hub to locate snap ring 3 Open the snap ring using a snap ring pliers or small needle nose pliers Tap CV housing off shaft with a soft faced hammer while holding snap ring open E 1 Spread ends of snap ring to remove joint from shaft 7 40 NOTE When replacing damaged boot check the grease for contamination by rubbing it between two fingers A gritty feeling indicates contamination If the grease is not contaminated the boot can be replaced without cleaning the CV joint Use the recommended amount of grease for boot replacement only 4 Remove boot from the shaft 5 Thoroughly clean and dry the CV joint and inspect ball tracks and
113. if damaged Bearing Installation 5 Thoroughly clean the hubstrut housing and the outer race on the new bearing Be sure that all oil residue has been removed from each surface 6 Apply Loctite RC 680 to the outer circumference of the Hubstrut Bearing Replacement new bearing race and carefully install the new bearing into the strut housing Bearing Removal 1 Remove outer snap ring g X Apply Loctitee RC 680 NOTE Use care to not allow any of the Loctite compound to get in the bearing 2 Fromthe back side tap on the outer bearing race with a drift 7 Wipe the housing clean of any excess compound and install punch in the reliefs as shown in Step 3 the retaining ring 7 4 FINAL DRIVE Hub Installation 10 Install brake caliper using new bolts Tighten bolts to specified torque 1 Inspect the hubstrut bearing surface for wear or damage 2 Apply grease to drive axle spindle 3 Install spindle through the backside of the hubstrut Install the hub onto the spindle 4 Apply grease to washer and install with domed side out Brake Caliper Bolt Torque 18 ft Ibs 24 Nm AA CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 11 Install wheel washers wheel nuts and tighten evenly in a cross pattern to specified torque Out Refer to Torque Specifications
114. in a criss cross pattern in 3 steps to 27 34 ft Ibs 37 46 Nm NOTE Make sure that the case locating pins knock pipes are in place Front Cover Bolt Torque 277 34 ft Ibs 37 46 Nm Apply grease to the seal lips Apply electricians tape or somehow cover the splines of the shaft to protect the seal lips during installation Install new front and rear output shaft seals Install pinion shaft with bearing Install retainer plate with flat side toward bearing TRANSMISSION 8 Apply Loctite 262 Red PN 2871951 to screw threads 11 Slide the reverse shaft assembly through the silent chain and torque screws to 6 12 ft Ibs 8 16 Nm 12 Install a new needle bearing the low gear the thrust washer and the snap ring Use of a new snap ring is recommended Pinion Retainer Plate Bolt Torque 13 Install the engagement dogs wave springs and bearing 14 Install the ball bearing onto the end of the input shaft 6 12 ft Ibs 8 16 Nm 9 Install a new needle bearing the 24T reverse sprocket washer and a new snap ring Install the shift dogs and wave spring Install the washer a new needle bearing and the high gear Install the press fit gear and ball bearing 10 Install a new snap ring at this time When installing the new snap ring open the snap ring just far enough to go over the shaft to avoid stressing the snap ring If the snap ring is overstressed it could come off the shaft and
115. indicates cylinder taper The cylinder should be measured for excessive taper and out of round 3 If the bottom installed gap measurement exceeds the service limit replace the rings If ring gap is smaller than the specified limit file ring ends until gap is within specified range NOTE Always check piston ring installed 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 2871043 and remove flywheel NOTE Do not thread the puller bolts into the flywheel more than 1 4 or stator coils may be damaged 3 Remove starter bendix assembly A Note the thrust washers located on both sides of the bendix 4 Inspect the thrust washer for wear or damage and replace if necessary 5 After the bendix is removed remove the two bolts retaining the starter Tap on the starter assembly B with a soft faced mallet to loosen the starter from the crankcase 6 Inspectgearteeth on starter drive A Replace starter drive if gear teeth are cracked worn or broken 7 Inspect the bendix bushing C in the mag cover for wear Replace as needed 287104
116. is loaded by the compression spring 1 Apply and hold downward pressure on the outer spring retainer Carefully remove the snap ring Remember the outer spring retainer contains strong spring pressure Remove Snap Ring R CLUTCHING 3 Separate the two clutch sheaves 6 Check the rollers in the stationary sheave for wear If the rollers are worn a new driven clutch assembly may be needed 4 Inspect the helix and inner spring retainer on the moveable sheave 1 5 Remove the inner spring retainer from the inner sheave Inspect for v wear 2 rand replace as needed Moveable Sheave Bearing Inspection Replace the bearing if more brass than Teflon is visible on the bearing 8 Inspect the Teflon coating on the moveable sheave bearings 9 Inspect driven clutch sheave faces for wear or damage 10 Clean and inspect splines on helix and transmission input gt ARS shaft EN th fa she a 11 Lube splines with a light film of grease Do not lubricate the bearings 6 20 CLUTCHING Clutch Assembly 3 Install spring into inner retainer 1 Install moveable inner spring retainer if removed Do not 4 apply oil or grease to the bearings Install outer retainer on top of spring 5 2 Align the X marks on each of the sheaves during reassembly Reassemble Sheaves 6 21 CLUTCHING TROUBLESHOOTING Situation Probable Cause
117. mount to increase the distance at point If a shim is present it can be removed to decrease the distance at point Shim Kit PN 2200126 Clutch Offset IMPORTANT Inspect clutch alignment and center distance before adjusting offset Install clutch alignment tool as shown Offset is correct when rear of tool contacts rear of inner sheave with driven clutch pushed completely inward on shaft and bolt torqued Adjust offset by adding or removing spacer washers between back of driven clutch and spacer as shown Clutch Alignment Tool should contact rear edge of driven clutch sheave Driven Clutch Offset To adjust add or remove washers from behind the driven clutch Spacer Washer PN 7556401 6 10 CLUTCHING DRIVE CLUTCH SERVICE Spring Specifications The drive clutch spring has two primary functions BEA FULL UPSHIFT 1 To control clutch engagement RPM The springs Ha e which have a higher rate when the clutch is in neutral 280 will increase clutch engagement RPM 2 control the rate at which the drive belt moves upward in the drive clutch sheaves This is referred 949 to as drive clutch upshift M AV TRAVEL a 260 FORCE POUNDS 220 There are other components which control upshift but the spring is one of the primary components in insuring optimum performance It is very important that the spring 180 is of the correct design and is in good condition
118. out of each axle tube rear axle assembly safely NOTE Make note of the side each axle was removed 5 Inspect the splines on the axle ends and the splines on rear gearcase for chips or wear Replace as needed 7 54 FINAL DRIVE Axle Tube Bearing Replacement Gearcase Disassembly Inspection 1 1 Drain and properly dispose of used oil 2 Remove the differential housing cover bolts and the gearcase housing cover 2 Remove the bearings from the axle tube with a bearing puller Inspect the bearing contact surfaces in the axle tube 3 4 Removethe output shaft and ring gear from the differential Inspect the ring gear for abnormal wear broken or chipped teeth Inspect the bearings for wear Spin the bearings by hand the bearings should roll smoothly Replace the bearings if needed NOTE The bearing should be properly lubricated before installation 4 Reinstall the retaining ring 7 55 FINAL DRIVE 5 6 7 7 56 Remove the wave spring from the differential assembly 8 Wave Spring Inspect the pinion shaft bushing for wear Remove the four bolts that secure the pinion gear cover to the differential Remove the pinion gear cover and O ring Pinion Gear Cover Gearcase Assembly 1 Replace all O rings seals and worn components Remove the pinion shaft from the differential Inspect for abnormal wear broken or chipped teeth 2 Install the
119. pad are new the thickness is 298 007 7 56 178 mm Brake Pad Measure Thickness Service Limit 180 4 6 mm GENERAL INFORMATION Parking Brake Pad Inspection Measure the thickness of the rear caliper parking brake pads Replace assembly as needed See illustration below for proper readings n Inboard Pad Thickness New 304 7 72 mm Limit 0 24 6 1 mm Inboard Pad Outboard Outboard Pad Thickness New 0 360 9 14 mm Limit 0 31 7 87 mm Installed Disc to Park Brake 0 375 0 953 cm New Rotor Disc Thickness 0 150 0 164 3 81 4 16 mm Brake Hose and Fitting Inspection Check brake system hoses and fittings for cracks deterioration abrasion and leaks Tighten any loose fittings and replace any worn or damaged parts 2 35 3 ENGINE SPECIFICATIONS d 3 2 CRANKCASE EXPLODED VIEWS 3 2 ENGINE FASTENER TORQUE PATTERNS 3 9 TORQUE 8 3 10 700 EFI ENGINE SERVICE SPECIFICATIONS 3 11 SPECIAL TOOLS fis cv wie cette ek Was eet a A EUR R E d 3 13 GENERAL ENGINE SERVICE e eque a KE ERE S aa 3 13 ACCESSIBLE
120. parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Chart Key The following symbols denote potential items to be aware of during maintenance CAUTION Due to the nature of these adjustments it is recommended this service be performed by authorized Polaris dealer SEVERE USE ITEM If vehicle is subjected to severe use decrease interval by 50 Severe Use is defined as frequent vehicle immersion in mud water or sand racing or race style high rpm use prolonged low speed heavy load operation or exten
121. parts with used parts from another clutch assembly 1 Remove shift weight bolts and weights Inspect as shown The contact surface of the weight should be smooth and free of dents or gall marks Inspect the weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or broken replace in sets of three with new bolts Broken 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 6 13 CLUTCHING Button To Tower Clearance Inspection 1 Inspect for any clearance between spider button to tower If clearance exists replace all buttons and inspect surface of towers See Spider Removal Button to Tower Clearance 000 001 2 Inspect sheave surfaces Replace the entire service clutch if worn damaged or cracked Clutch Disassembly 1 Using a permanent marker mark the cover spider moveable and stationary sheaves and steel post to the stationary sheave for reference The X s may not have been in alignment before disassembly X Mark 2 Remove cover bolts evenly in a cross pattern and remove cover plate 6 14 3 Inspect cover bushing A The outer cover bushing is manufactured with a Teflon coating Bushing wear is determined by the amount of Teflon remaining on the bushing Cover Bushing Inspection Replace the cover bushing if more brass than Teflon
122. pressure adapter has an integrated relief valve Connect to the test valve and release the pressure Fuel Pressure Gauge Kit PU 43506 A FUEL INJECTION Digital Wrench Diagnostic Software PU 47063 This dealer only software installs on laptop computers equipped 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 Digital Wrench SmartLink Module Kit PU 47471 This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench diagnostic software Polaris dealers can also order the following separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 This module kit is used on all 8 pin connector based Polaris EFI systems This kit is available to Polaris dealers through our tool supplier SPX 1 800 328 6657 Connect to Vehicle Diagnostic Connector Vehicle Interface PU 47469 SmartLink Module PU 47468 pce pene 1 PU 47470 Connect to Digital Wrench PC Digital Wrench Diagnostic Connector Located under the hood as shown below Throttle Position Sensor Tester PU 47082 This tester allows the use of a digital multi meter to test TPS function as well perform initialization procedures Throttle Body Adjustment Scre
123. result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Use only Polaris Premium 0 40W All Season synthetic oil or equivalent Never substitute or mix oil brands Serious engine damage and voiding of warranty can result Do not operate at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts 1 fuel tank with unleaded or leaded fuel which has a minimum pump octane number of 872 My2 2 Checkoillevel 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 Pull only light loads during initial break in 6 Pull only light loads during initial break in 7 Change oil and oil filter after break in period at 25 hours 3 20 Cylinder Hone Selection And Honing Procedure Cylinders may be wet or dry honed depending upon the hone manufacturer s recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore CAUTION A hone which will straighten as well as remove material from the cylinder is very important Using
124. rod hand tighten Turn puller barrel to increase tension as needed Turn clutch cover counterclockwise on puller rod until bushing is removed Remove nut from puller rod and set aside Remove bushing and bushing removal tool from puller Discard bushing Apply LoctiteTM 680 PN 2870584 to the back side of new bushing Working from inside of cover insert bushing and bushing installation tool into center of clutch cover Bushing PN 3576510 Loctite 680 PN 2870584 With the Main Puller Adapter 8 PN 5020632 on the puller insert cover onto puller rod placing outside of cover toward vise Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 6 17 CLUTCHING 4 Turn clutch cover and barrel together counterclockwise on puller rod until bushing is seated 5 Remove nut from puller rod and take installation tool and clutch cover off the rod Clutch Assembly It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly The Teflon bushings are self lubricating Do not apply oil or grease to the bushings Reassemble the drive clutch in the following sequence Be sure the X or the marks that were made earlier are aligned during each phase of assembly 1 Install moveable sheave onto fixed sheave 2 Install spider spacers Use same quantity and thickness as were removed Spacer washers
125. secure 35 ft Ibs 47 Nm the radiator to the frame 3 Remove the drain plug and drain the coolant from the radiator Drain the coolant into a suitable container and properly dispose of the coolant 2 27 GENERAL INFORMATION CV Shaft Boot Inspection Inspect the CV shaft boots in the front and rear of the RANGER for damage tears wear or leaking grease If the rubber boot exhibits any of these symptoms replace the boot Refer to Chapter 7 for CV boot replacement or have you Polaris dealer replace the boot Front amp Rear Wheel Nuts 4 N Front Hub Nut d 70 ft Ibs 95 Nm _ H a Rear Hub Nut 110 ft Ibs 150 Nm 1 Stop the engine place the transmission in gear and lock the parking brake Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and washers and remove the wheel Wheel Installation 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the washers if applicable and wheel nuts and finger tighten them 3 Lower the vehicle to the ground 2 28 4 Securely tighten the wheel nuts to the proper torque listed in the torque table at the beginning of this section AA
126. sources Inspect and repair as necessary Wrong pad for conditions Change to a softer or harder pad 9 3 BRAKES HYDRAULIC BRAKE SYSTEM OPERATION Typical Hydraulic Brake System Compensating port compensates for temperature changes by allowing fluid back to master cylinder Must be clear to allow proper diaphragm movement Movable Brake Pad The Polaris brake system consists of the following components or assemblies brake pedal master cylinder hydraulic hose brake calipers slave cylinder brake pads and brake discs which are secured to the drive line When the foot activated brake lever A is applied it contacts a piston B within the master cylinder As the master cylinder piston moves inward it closes a small opening compensating port C within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the piston D located in the brake caliper moves outward and applies pressure to the moveable brake pad This pad contacts the brake disc and moves the caliper in its floating bracket pulling the stationary side pad into the brake disc The resulting friction reduces brake disc and vehicle speed As the lever pressure is increased the braking affect is also increased The friction applied to the brake pads will cause the pads to wear As these pads wear the piston within the caliper moves further outward and becomes self adjusting Fluid
127. sure the rubber mount inside the pod is fully installed and that the indexing key on the rubber mount is lined up with the keyway in the dash panel 3 Hold the dash panel securely and insert the instrument cluster into the dash panel Twist the instrument cluster gently in aclockwise motion to properly seat the instrument cluster into the pod assembly Apply pressure on the bezel while pressing down on the instrument cluster 10 11 ELECTRICAL INSTRUMENT CLUSTER TROUBLESHOOTING TESTS Test 1 No All Wheel Drive START HERE CHECK SPEEDOMETER PERFORM TEST 2 KEY SWITCH ON TRANSMISSION IN GEAR AWD SWITCH ON ON HUB COIL CONNECTOR LEAVE IT CONNECTED MEASURE FOR 12V FROM BROWN WHITE TO THE COIL BODY GROUND LEAVE AWD SWITCH ON TURN KEY SWITCH OFF DISCONNECT 16 PIN CONNECTOR FROM CLUSTER TURN KEY SWITCH ON CHECK FOR 12V FROM BRN WHITE TO GROUND TURN KEY SWITCH OFF RECONNECT CLUSTER SHIFT TO LOW OR HIGH LEAVE AWD ON 10 12 Red 12V Constant Red White 12V Switched Grey Orange Mode button N C Green Blue Yellow RPM Input Brown Red Ground WIRING PROBLEM Note If AWD icon comes on instrument cluster is O K Proceed to mechanical tests in Service Manual Check the AWD icon on instrument cluster to verify it s operation The AWD switch is directly powered by switched 12 volts orange white The gear switch only interfac
128. surfaces Be sure the locating pins knock pipes are in place Reinstall cover and torque bolts in a criss cross pattern in 3 steps to 27 34 ft lbs 37 46 Nm Reinstall the mounting bracket if previously removed Front Cover Bolt Torque 27 34 ft Ibs 37 46 Nm Grease the seal lips of the input shaft seal Apply electricians tape or somehow cover the splines of the shaft to protect the seal lips during installation Install new input shaft seal TRANSMISSION 25 Install drain plug with a new sealing washer Torque drain plug to 10 14 ft Ibs 14 19 Nm Transmission Drain Plug 10 14 ft Ibs 14 19 Nm Drain Plug Torque 10 14 ft Ibs 14 19 Nm 26 Place a small amount of grease PN 2871551 into the pocket before installing the sector gear Install the shift gear 16T on the shift drum shaft Install the sector gear in the bushing pocket on the left side Align the timing marks you made on the gears during disassembly IMPORTANT Note the location of the skip tooth on the splines Apply a light coating of grease on the gear teeth 27 Install the shift shaft along with the detent lever 28 29 30 31 Install the lockout disc with the raised edge facing outward Use the white mars that was previously applied for reference Install the detent gear with the raised edge facing outward Note the keyed spline on the end of the shaft Install the detent lever spr
129. 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 1 HN EL Push in Piston Pins e 15 Install the piston pin circlips circlip ends should be installed at the 12 O clock position Piston Pin Cirlcip in 12 O clock position 3 47 NOTE While installing in piston circlips cover all 17 Assemble rotors as marked when disassembled Use a engine passages The clip could fall into the engine cleaner to remove the marks previously made on the rotors during installation Line Up Marks 18 Apply assembly lube or oil to the rotors on the oil pump shaft NOTE The application of lubrication aids in priming the oil pump during initial engine start up 16 Install camshaft thrust plate G with new bolts Torque bolts to specification NOTE New bolts have patch lock on the threads and do not require Loctite 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 e Out This indicates the side of the gear that faces sup outward or away from the case Thrust Plate Scre
130. the tool 3 40 23 Inspect the crankshaft gear Q for broken or worn teeth If 26 Rotate the water oil pump gear S so that all four bolts are the crankshaft gear does not need to be replaced it does not visible though the gear Remove the four bolts with a hex need to be removed If the crankshaft gear is damaged wrench Pull out the pump remove the crankshaft gear with the Flywheel Puller PN 2871043 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 24 Install the two puller bolts R Tighten the puller bolts up so that the bolts are at equal length NOTE If replacing the old rotors new replacement 25 Install the Flywheel Puller PN 2871043 and remove 01015 will fit into the old oil water pump housing 28 Use a feeler gauge to measure the clearance between the two rotors Measure the gap between the two rotor tips as shown below The clearance should not exceed 0 006 0 15 mm I s Max Tip Clearance GEN 0 006 0 15 3 41 29 Remove the oil pressure relief The oil pressure relief 31 Carefully press the gear off the assembly while supporting consists of a bolt washer spring and valve dowel the housing assembly Inspect the valve dowel for signs of possi
131. the vehicle should not roll while parked 3 If the vehicle moves adjustment is necessary Adjust the parking brake where the cable attaches to the lever assembly on the rear brake caliper Adjustment Procedure 1 Place the vehicle in neutral on a flat level surface Carefully lift the rear of the vehicle off the ground and stabilize on jack stands 3 Locate the parking brake cable located under the front hood and under the dash on the driver side Parking Brake Switch NOTE See Chapter 10 for more information on the parking brake switch 4 Use two wrenches to loosen the bottom jam nut C Hold the top jam nut D with one wrench Turn the bottom jam nut C 1 1 2 turns counterclockwise to loosen 5 Now hold the bottom jam nut C and turn the top jam nut D clockwise until the jam nut is tight against the bracket 6 Repeat Step 4 and Step 5 until the proper adjustment is made for the park brake cable To Parking Brake Pedal To Parking Brake Caliper 5 PARKING BRAKE CALIPER SERVICE Exploded View Pad amp Holder Pad amp Holder 18 ft Ibs 24 Nm Hex Head Mount Bolt Thrust Washer Shim Pack 4 Shims Spring Pin Compression Spring Caliper Removal 2 NOTE Do no get grease or fluid on the park brake pads Damage to or contamination of the pads may cause the pads to function improperly 1 Removetheclip pin and pin from the park brake cable
132. to PVT outer cover See Chapter 5 for removal 3 Remove PVT air outlet duct hose Remove outer PVT cover screws 5 Mark the drive belt direction of rotation and remove drive belt See Drive Belt Removal 6 Install the Drive Clutch Holder PN 9314177 A 7 Removedrive clutch retaining bolt and remove drive clutch using the Drive Clutch Puller PN 2870506 B Drive Clutch Puller PN 2870506 Drive Clutch Holder PN 9314177 8 Remove the driven clutch retaining bolt and driven clutch CLUTCHING 9 Use the Driven Clutch Puller PN 2870913 C if Assembly necessary 1 Inspect PVT inner cover to engine seal Replace if cracked or damaged Apply RTV Silicone Here 2 10 Remove driven clutch offset spacers from the transmission input shaft MA Place a new foam seal on transmission input shaft 3 Apply RTV silicone sealant to outside edge of inner cover to engine seal to ensure a water tight fit between the seal and the cover Surfaces must be clean to ensure adhesion of silicone sealant 4 Reinstall cover and tighten rear cover bolts just enough to hold it in place 5 Fit lip of inner cover seal A to engine Install seal retainer plate and tighten screws securely Seal outer edge to cover with RTV silicone sealant 12 Remove inner cover retaining bolts at rear of cover 6 Torque rear inner cover bolts B to specification 13 Remove cover along wit
133. transmission oil drain plug Front Gearcase Specifications area Specified Lubricant Premium Demand Drive Hub Fluid PN 2871654 Capacity 5 0 oz 150 ml 3 Remove drain plug and wipe the magnetic end clean to remove accumulated metallic filings TRANSMISSION ys Fill Plug Torque 8 30 ft lbs 11 41 Nm Drain Plug Torque 10 ft Ibs 14 Nm FRONT GEARCASE Drain Plug Gi Make sure vent is unobstructed 14 ft Ibs 19 Nm 4 After the oil has drained completely install the drain plug Torque to 14 ft Ibs 19 Nm i i 8 30 ft Ibs 5 Add the proper lubricant through the fill plug hole until the Y BL 11 41 Nm oil level is at the bottom of plug threads see figure 7 26 Do not overfill 6 Torque fill plug to 14 ft Ibs 19 Nm Drain Plug 10 ft Ibs 14 Nm 7 Check for leaks Front Gearcase Lubrication To check the lubricant level The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule The front gearcase lubricant level cannot be checked with a dipstick The gearcase must be drained and re filled with the Be sure vehicle is level with parking brake on before proper amount of lubricant or be filled to the bottom of the fill proceeding plug hole threads Refer to procedures Check vent hose to be sure it is routed properly and unobstructed 2 21 GENERAL INFORMATION To change gearcase lubricant
134. will deteriorate rapidly Check the battery fluid level often Maintain the fluid level between the upper and lower level marks Front Rear 8 12 8 12 Upper Level ELECTRICAL AND IGNITION SYSTEM Battery Maintenance Keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Lower Level Be careful not to allow cleaning solution or tap water into the 5 batter Add only distilled water Tap water contains minerals that harmful to a battery WARNING Battery Removal Battery electrolyte is poisonous It contains l Openthe Hood sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases pa Keep sparks flame cigarettes etc away 2 Remove the battery vent tube from the battery Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN D
135. yokes must pivot freely in all directions without binding If the joint is stiff or binding tap the yoke lightly to center the joint until it pivots freely in all directions 7 13 FINAL DRIVE FRONT GEARCASE CENTRALIZED HILLIARD AWD Operation Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains while the front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where the front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest Normal Operation With the AWD switch off the vehicle drives only the rear wheels 2 wheel drive When the AWD switch is activated it engages the Hilliard locking both front axles into All Wheel Drive Roller Cage Output Hub e Armatu re Plate 4X4 Engagement When the AWD switch is activated a 12 VDC current charges the central coil which creates a magnetic field This magnetic field attracts an armature plate keyed to a roller cage that co
136. 0 OPERATION OVERVIEW 4 10 EGU SERVICE zielt Icom RI Ee IRE em RM NM EE RE EE 4 11 ECU REPLACEMENT du iere edet oe oh 4 11 FUEL EI let ue UD NE Nea d iac 4 11 OPERATION OVERVIEW 4 11 amp teu IER EN RI mah 4 12 FUEL PUMP TANK ASSEMBLY REPLACEMENT 4 12 FUEL PRESSURE 4 14 OPERATION OVERVIEW 4 14 FUEL PRESSURE REGULATOR TEST 4 14 FUEL PRESSURE REGULATOR 4 14 FUEL INJECTORS se uote tome erc crei o euer uda DRE DE 4 14 OPERATION OVERVIEW leue uml wrote metre mar A ER DERI GE Pa 4 14 FUEL INJECTOR SERVICE 2 ER rho ERE BOUE ratu 4 15 FUEL INJECTOR 4 15 CRANKSHAFT POSITION SENSOR 8 4 15 OPERATION OVERVIEW 4 15 CRS TEST x rt metet sce ote ww cal fenes Magne ae eae 4 16 GPS REPEAGEMEN Iz 5 3 eene dad leg de ru eset iue 4 16 TEMPERATURE BAROMETRIC AIR PRESSURE SENSOR 4 16 OPERAT
137. 08 1 8 71 1 Rev 6 87 1 5 94 1 Drive Ratio Front 3 818 1 Drive Ratio Mid 3 70 1 Drive Ratio Final 3 70 1 Engine Platform Polaris Domestic Twin Cylinder Liquid Cooled 4 Stroke Engine Model Number EHO068O0LE044 Engine Displacement 683cc Number of Cylinders 2 Bore amp Stroke mm 80 x 68 mm Compression Ratio 9 40 1 Compression Pressure 150 170 psi Shift Type In Line Shift H L N R Trans Oil Requirements Polaris AGL Gearcase Lube Belt 3211106 Drive Belt Deflection 1 125 28 57 mm Center Distance 10 254 5 mm Clutch Offset 0 365 9 27 mm Engine Idle Speed 1150 x 100 RPM Lubrication Pressurized Wet Sump Oil Requirements OW 40 Oil Capacity 2 qts 1 9L Steering Suspension Coolant Capacity 3 25 qts 3 1 L Front Suspension MacPherson Strut Overheat Warning Instrument Cluster Indicator Front Travel 8 in 20 cm Exhaust System 2 to 1 Canister Style Center Suspension Progressive Rate Independent Fuel System Center Travel 5 25 in 13 cm Fuel System Type Bosch Electronic Fuel Injection Rear Suspension Swing Arm w Dual Shocks Rear Travel 6 25 in 16 cm Ground Clearance 7 2 in 18 25 cm Fuel Capacity Requirement Fuel Delivery Electronic Fuel Pump in tank Fuel Pressure 39 psi Fuel Filters See Chapter 4 9 gal 341 87 Octane minimum Sh
138. 1 Remove gearcase drain plug B 11 mm located on the bottom of the gearcase and drain oil The drain plug is accessible through the skid plate Catch and discard used oil properly 2 Clean and reinstall drain plug B using a new sealing washer A Toque to 10 ft Ibs 14 Nm 3 The fill plug can be accessed through the top hood area by removing the storage box or by removing the left side panel in the left wheel well 4 LH Side Panel Ob H aM 2 22 4 Remove fill plug 8 mm hex and check the O ring ei Fa 5 with the recommended fluid amount 5 oz or to the bottom of the fill plug hole threads Plug Threads Fill with 5 oz 6 Install fill plug and check for leaks Middle Gearcase Lubrication 6x6 Middle Gearcase Specifications Specified Lubricant ATV Angle Drive Fluid PN 2871653 Capacity 6 75 oz 200 ml Drain Plug Fill Plug Torque 14 ft Ibs 19 4 Nm The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule sure vehicle is level with parking brake on before proceeding Check vent hose to be sure it is routed properly and unobstructed correct middle gearcase lubricant to use is Angle Drive Fluid GENERAL INFORMATION To check the lubricant level The gearcase must be drained and re filled with the proper amount of lubricant Refer to the procedure below To change middle gea
139. 10 D 11 301V1S Y YOLVINSIY JOVI 10 y 01 0015 29V E L 02 830108 31504 9 11 JONVYO 69 121145 2v 18 03H Y 1303 8 WOW 18 038 19 Y GION3IOS 4410 18 138 GIONFIOS 3310 4938 8 JLIHM JONVYO 99 g GION3IOS 4410 391145 NMOWB 9 NMOUG 59 6 191145 LW SSANUVH HSV 9 79 401 0115 0 089 2 2 YOLVINDIY 39Vl 10A kl NMOUG 9 1064 HOLIMS Wed 121145 31 034 9 Jl IHN O3U 49 321145 311 038 Y SSINYYH HSY 91 NEIER 19 321145 3LIHM Q3U 1062 814138 AU0S 322V 81 3LIHM Q3Y 95 1054 814118 18055122 1981 9 3LIHM QdY LG 1054 HOLIMS J4VU8B WuVd 8 8 SSiNUVH HSV 8 33 JONVUO 96 S HOLIMS 18055144 i vud 1081 30010 9219715 9 JONVYO 55 YOLOW NY4 9v SSjNUVH HSV 91 NMOUG v6 321145 NMOUG 2 14101 8 NMOUG 6 0115 8 121145 21 91 071 ing 25 321145 NMOUG 081 81 NMOUG 1G 9 v SSANUWH HSV gt 121145 3U NMOU8 81 05 5 321145 088 801 0115 089 91 NMOSG 6b 401 0115 0 089 0 801715 kl NMOUG 97 081 E HOLIMS 38055184 INVES 9 JONVYO Lb 2 JINGOW 40151538 d HOLIMS 8719 8 13101A 9y 541 321145 11101 102 13101A Sy 805815 4 8 1 E 321145 11101 102 13101A vy 1109 NOILINOI 101145 02 AV40 038 r Y YOLIINNOD 21150 9 10 121145 02 S131 1HM 38 27 1109 NOILLINOI c 101145 02 0111HS 1 2 391145 21150 0 10 2 101145 02 13195 0 2 101145
140. 121145 81 3L LHM 001 E 321145 NMOSG S8 AVvii8 QIONJIOS 4410 uvis 8 NMOSG 86 gt 121145 311HM Q3H 0t 138 1083105 3310 uvis 8 3LIHM QdY L6 18 SSANUVH HSV 081 01 1019384 JOVI 10 8 96 121145 2IISONDVIQ 0 21150 9 10 0c NMOUG 56 401 0115 0 089 FEZA QNfOND JAVUJ NMONUG 76 vit 391195 E 2 391198 02 7 0131 5 6 0115 00 9 9 552 HSY 91 NMOYS 26 391145 3H NMOUG 801 0015 GNAOYS 91 16 1083105 18 15 y Vv SSiN VH HSVQ 8 3LIHM QdY 06 v SSjNU YH HSV 1102 8fH 9 68 18 NYJ 9 YOLOW NY J 9 32V 18 199740 98 1109 8H 9 SSiNUVH HSV 8 jl IHM NMONSG 18 98 SSINYYH HSV L n 02 3504 9 98 S 321145 311 03 5 AVI3U 9 311 038 5 401 0015 22 28 552 5 0 9 11 39NYUO 78 121145 138 088 2 HOLIMS 8719 9 Q39 NMOUG 8 3181513 02 81010 35013 2 039 48 S 121145 42v18 03H 18 AWAAY 81004 9 WOW 18 038 8 8 1303 v8 SSjNUVH HSV 8 JL1HM 13101A 08 S 321145 NMOUG E HOLIMS 384055184 eg 8 NMONUG 61 QION310S 18 15 WO 30010 8318 15 9 N3389 19 0 91 HIH 111959 dWV 02 2 L 02 830108 3504 9 KEF LL HOLIMS 8 39 1 JINGOW 80151534 9 138 3118 91 8 HOLIMS 8 39 i JINGOW 80151538 9 3t 18 31 SL 0 H LIMS 8 39 d JINGOW 80151534 9 il IHM N3189 D I SSjNUVH HSV 02 3503 9 JONVYO eL YOLVIS 2 1 801710914 19 110 V MOTI3A el YOLWIS 8 1 YOLVINDIY 10 1
141. 19 CLUTCH DISASSEMBLY INSPECTION 6 19 CLUTCHIASSEMBLY A Ge LA ra a ees 6 21 TROUBLESHOOTING e Xe OR Ae Ae CR DS 6 22 6 1 CLUTCHING SPECIAL TOOLS AND SUPPLIES TOOL DESCRIPTION PART NUMBER Clutch Puller 2870506 Clutch Holding Wrench 9314177 Clutch Holding Fixture 2871358 Spider Nut Socket 2870338 Drive de and 2870341 Driven Clutch Puller 2870913 Roller Pin Tool 2870910 Clutch Bushing Replacement Tool Kit 2871226 Piston Pin Puller 2870386 Clutch Compression Tool 8700220 Clutch Bushing Replacement Tool Kit 2871025 Standard Clutch Alignment Tool PA 47346 SPECIAL SUPPLIES PART NUMBER Loctite 680 2870584 RTV Silicone Sealer 2870661 Loctite Gasket Remover 2870601 TORQUE SPECIFICATIONS PVT System Fastener Torques TORQUE VALUE ft Ibs Nm Drive Clutch Retaining Bolt 40 ft Ibs 54 Nm Driven Clutch Retaining Bolt 17 ft Ibs 23 Nm PVT Inner Cover Bolts 12 ft Ibs 16 Nm PVT Outer Cover Bolts 45 50 in Ibs 5 5 6 Nm Drive Clutch Spider 200 ft Ibs 271 Nm Drive Clutch Spider Lock Nut Plastic 15 ft Ibs 20 3 Nm Drive Clutch Cover Plate 90 in Ibs 10 Nm 6 2 PVT SYSTEM OVERVIEW General Operation A WARNING All PVT maintenance or repairs should
142. 3 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 Flywheel Stator Removal Inspection 1 Remove stator housing bolts and remove housing t Remove Stator 5 Remove the bendix E if necessary Engine Crankcase Disassembly Inspection 1 Remove the stator cover and water pump cover B 2 Remove flywheel nut and washer 3 Install Flywheel Puller PN 2871043 and remove flywheel A AA CAUTION 15 Ss e W Do not thread puller bolts into the flywheel more than 1 4 or stator coils may be damaged ae Va us 5 7 Sr S 3 36 Remove the nylok nut C washer D and water pump 5 Remove the starter bendix G wire holddown plate H impeller E Remove part of the water pump seal behind and the woodruff key I from the crankshaft The stator the impeller does not have to be removed at this point 6 Remove the gear stator housing bolts and remove the gear Remove flywheel nut and washer stator housing cover J and gasket from the crankcase Be Install Flywheel Puller PN 2871043 and remove flywheel sure to catch the excess oil from the crankcase F AA CAUTION Do not thread the puller bolts into the flywheel more t
143. 30 3 Rocker Cover 6mm 84 8 9 5 0 9 Spark Plug 14 mm 216 24 24 5 2 7 18 2 24 5 2 7 Starter Motor 6mm 84 8 9 5 0 9 Stator Assembly 6mm 96 3 10 85 0 35 Stator Housing 6mm 96 3 10 85 0 35 Temperature Switch 3 8 NPT 17 2 23 3 Thermostat Housing 6mm 84 8 9 5 0 9 Timing Plug 3 4 16 7 9 10 12 Trigger Coil Stator Wire Holddown 5mm 96 3 10 85 0 35 Water Pump Housing Cover 6mm 96 3 10 85 0 35 Water Pump Impeller Nut 8mm 108 3 12 0 35 NOTE See exploded views for notes or torque sequences 3 10 700 EFI Engine Service Specifications ENGINE Cylinder Head Engine Specifications Main Component Cylinder Head EHO680LE Camshaft Cam Lobe Height Intake Exhaust 1 3334 33 8674 mm Camshaft Journal Outer Diameter Mag 1 654 0 00039 42 0 010 mm Camshaft Journal Outer Diameter Center 1 634 0 00039 41 50 0 010 mm Camshaft Journal Outer Diameter PTO 1 614 0 00039 41 0 010 mm Camshaft Journal Bore Inner Diameter Mag 1 656 0 00039 42 07 0 010 mm Camshaft Journal Bore Inner Diameter Center 1 637 0 00039 41 58 0 010 mm Camshaft Journal Bore Inner Diameter PTO 1 617 0 00039 41 07 0 010 mm Camshaft Oil Clearance 0 00276 0 00079 0 07 0 02 mm Camshaft End Play 0 0167 0 0098 0 425 0 25 m
144. 69 7 16 REG 30 40 ree er hr 50 69 70 97 7 16 35 048 ri eost eism Der 55 76 tette 80 110 12 UE EE SOGI wainnaa ee nna 75 104 110 152 12 20 64 e gie TER en gege ge 90 124 soins 120 166 Metric 6 x 1 0 72 78 In Ibs 8x 1 25 14 18 ft Ibs 10x 1 25 26 30 ft Ibs To convert ft Ibs to Nm multiply foot pounds by 1 382 To convert Nm to ft Ibs multiply Nm by 7376 SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section GENERAL INFORMATION SAE Tap Drill Sizes uad 1 12 7 8 14 1 8 1 12 1 1 8 7 1 1 8 12 1 1 4 7 1 1 4 12 1 1 2 6 1 1 2 12 1 3 4 5 1 3 4 12 2 4 1 2 2 12 2 1 4 4 1 2 2 1 2 4 2 3 4 4 3 4 Decimal Equiva lent 27 64 29 64 31 64 33 64 17 32 37 64 21 32 11 16 49 64 13 16 7 8 59 64 63 64 1 3 64 1 7 64 1 11 64 1 11 32 1 27 64 19 16 1 43 64 1 25 32 1 59 64 2 1 32 2 1 4 2 1 2 2 3 4 Nearest Fraction Decimal Equivalents e mms 2mme 3mm 4mm 5MM mms amp 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 0394 0787 11181 1575 1969 2362 2756 3150 3543 393
145. 7 4331 4724 5118 5512 5906 6299 6693 7087 7480 7874 8268 8661 9055 9449 9843 GENERAL INFORMATION Glossary of Terms ABDC After bottom dead center Alternating current voltage Alternator Electrical generator producing voltage alternating current ATDC After top dead center BBDC Before bottom dead center BDC Bottom dead center BTDC Before top dead center CC Cubic centimeters Center Distance Distance between center of crankshaft and center of driven clutch shaft Chain Pitch Distance between chain link pins No 35 3 8 or 1 cm Polaris measures chain length in number of pitches CI Cubic inches Clutch Buttons Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch Clutch Offset Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face Clutch Weights Three levers in the drive clutch which relative to their weight profile and engine RPM cause the drive clutch to close and grip the drive belt Crankshaft Run Out Run out or bend of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase Measure at various points especially at PTO DCV Direct current voltage CVT Centrifugal Variable Transmission Drive Clutch System DCV Direct current voltage Dial Bore Gauge A cylinder measuring i
146. 8 Nm 24 We 25 35 ft Ibs 34 48 Nm 30 40 ft Ibs 41 52 Nm 28 REF DESCRIPTION QTY REF DESCRIPTION QTY 1 Pinion Oil Seal 1 20 Flanged Hex Nut 3 2 Pinion Nut 1 21 Flanged Hex Bolt 3 3 Pinion Bearing Cone 2 22 Vent Tube 1 4 Bearing Cup 2 23 Differential Case Half Cover 1 5 24 Hlanged Hex Bolt 6 6 Pinion Bearing Spacer 1 25 Gear 1 7 Drain Plug 1 26 Shift Yoke 1 8 Oil Seal Shaft 1 27 Shift Spring Lever 1 9 O Ring 1 28 Shift Lever 1 10 Half Cover 1 29 Shift Return Spring 2 11 Fill Check Plug 1 30 Diff Lock Solenoid 1 12 Gear Side Differential 2 31 Hex Bolt 8 13 Gear Pinion Mate Differential 2 32 Differential Case Half 1 14 Differential Case Half Cover 1 33 Differential Cross Dm 1 15 Differential Bearing Spacer AR 34 Differential Roll Pin 1 16 Tapered Roller Bearing 1 35 Spacer 17 O Ring Housing Halves 1 36 Differential Bearing Spacer AR 18 Shift Yoke Pivot Shaft 1 37 Differential Bearing Cup 1 19 Set Screw 1 38 Differential Bearing Cone 1 FINAL DRIVE REAR AXLE GEARCASE SERVICE 6X6 Rear Axle Removal 1 Jack up vehicle and support on frame and swing arm AA CAUTION Serious injury could occur if machine tips or falls 2 Removerear wheels 3 Removethe brake calipers Suspen
147. 8 ft Ibs 21 25 Nm 16 18 ft Ibs 21 25 Nm Stabilizer Assembly Inspect Bushings 5 19 BODY STEERING SUSPENSION SWING ARM 6X6 Removal 1 Support machine on a level surface 2 Remove rear wheels NOTE The rear axle may be removed to ease the removal of the swing arm Refer to Chapter 7 REAR AXLE HOUSING REMOVAL INSPECTION 3 Support swing arm remove rear axle shocks 4 Drive spring pin out of rear propshaft at middle angle drive guns the Roll Pin Removal ET PLE 2872608 NOTE Use jacks and jackstands to help remove the swing arm assembly 5 Remove the pivot bolt lock brackets A swing arm pivot bolts B bolts swing arm bushings lower swing arm and rear axle Bushings A 5 20 Installation Raiseswing arm assembly and align the drive shaft to the rear gearcase splined shaft lube splines 2 Insert new bushings check pivot bolts for wear replace if necessary torque bolts to 150 ft lbs 75 9 Nm Install bolt lock brackets and bolts torque to 30 ft Ibs 41 Nm 3 Install rear coil over shocks onto swing arm torque bolts to 30 ft Ibs 41 Nm Install rear wheels lower machine 5 Insert new spring pin on rear propshaft Pivot Bolt and Nut Torque 150 ft Ibs 75 9 Nm Rear Shock Mount Bolt Torque 30 ft Ibs 41 Nm Swing arm U Bolt Shock Coil 30 ft Ibs 41 Nm Pivot Bolt ER ds zb 203 30 ft Ibs
148. 82 turn the air flow adjustment screw until the voltmeter reads 710 01 volts The throttle body is now adjusted to the correct flow value Turn Air Flow Screw In TPS Tester Adapter Harness PU 47082 Should Read 710 V 2710 Black Probg RedProbe A Reconnect TPS harness lead Reinstall throttle cable on throttle cam and install cover Adjust cable freeplay TPS Replacement The correct position of the TPS is established and set at the factory If the TPS is repositioned replaced or loosened it must be re calibrated 1 Remove the seat base to gain access to the throttle body 2 Disconnect sensor from the harness 3 Loosenand rotate the throttle body B to gain access to the retaining screw 4 Remove the retaining screw and replace the sensor 5 Refer to TPS Initialization for setting the TPS voltage ENGINE COOLANT TEMPERATURE SENSOR ECT Operation Overview Mounted on the cylinder head the engine temperature sensor measures coolant temperature The engine temperature sensor is a Negative Temperature Coefficient NTC type sensor as the temperature increases the resistance decreases Coolant passes through the cylinder and by the sensor probe varying a resistance reading which is relayed to the ECU This signal is processed by the ECU and compared to it s programming for determining the fuel and ignition requirements during operation The ECU also us
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150. After any reassembly or rebuild the engine filter three quarters full with Polaris OW 40 Synthetic Oil PN 2871281 Let the oil soak into the filter for 8 10 minutes Install the filter onto the engine must be primed using the Oil Priming Adapter PU 45778 and a 3 4 full oil filter before initial start up Follow the steps in this section to properly prime the engine and aid proper engine break in Failure to perform this procedure may cause internal engine damage on initial start up 2 Remove primer plug from the engine Install Oil System Priming Adapter PU 45778 into the oil plug hole Push 3 5 oz approx of Polaris OW 40 into the adapter or until resistance is felt Remove the adapter Apply sealant to the plug threads Install the plug and torque to specification ey T Primer Plug Torque 18 2 fi lbs 24 4 2 71 Nm 3 57 TROUBLESHOOTING Engine Spark Plug Fouling Spark plug cap loose or faulty Incorrect spark plug heat range or gap PVT system calibrated incorrectly components worn or mis adjusted Fuel quality poor old or octane too high Low compression Restricted exhaust Weak ignition loose coil ground faulty coil stator or ETC switch ETC switch mis adjusted Restricted air filter main or pre cleaner or breather system Improperly assembled air intake system Restricted engine breather system Oil contaminated with fuel Engine
151. Arm Bolt Torque 35 ft Ibs 47 Nm Upper Control Arm Bolt Torque 35 ft Ibs 47 Nm 7 4 Pull drive shaft outward and install hub onto driveshaft splines Apply Anti Seize compound to the axle splines 5 Install the flat washer and cone washer B with domed side facing outward Refer to next photo 4 Install snap ring into groove Washer 7 25 FINAL DRIVE 6 Install the castle nut C wheel and wheel nuts 7 Remove jackstand and torque mid hub nut to 110 ft Ibs 149 Nm and wheel nuts to 35 ft Ibs 47 Nm Mid Hub Nut Torque 110 ft Ibs 149 Nm Mid Wheel Nut Torque 35 ft Ibs 47 Nm 8 Install a new cotter pin Tighten nut slightly to align holes if required 9 Install hub cap Mid Drive Exploded View 35 ft Ibs 2 47 Nm 07 BUSHING S D 9 A SHAFT e MID UPPER A ARM e e 35 ft Ibs MID DRIVE s LN Ji M b 7 BEARING CARRIER 35 ft Ibs i 47 Nm SHAFT LG e BUSHING MID LOWER A ARM 7 26 FINAL DRIVE MID DRIVE SHAFT 6X6 Removal 1 Repeat Steps 1 7 in the Mid Drive Hub Bearing Carrier Removal section 2 Slide the middle axle out of the bearing carrier by pulling the bearing carrier assembly outward and down NT o 4 UU IS AE 3 Pull the middle axle straight out from
152. B Oil Fill Tube C Dipstick D O ring E Hex Plug F Oil Filter Nipple G Oil Filter H Dowel 1 GalleyPlugAsm J Screw K Relief Spring 50 5 in Ibs 5 65 0 56 Nm 22 2 ft lbs Si 30 3 Nm pK e E 18 2 ft lbs 24 4 2 71 Nm 3 5 4 ft Ibs 4 e 7 5 5 4 Nm 50 5 in lbs 5 65 0 56 Nm 3 5 Cylinder Cylinder Head Piston Exploded View 3 6 D Lubricate threads amp between washers and underside of bolt heads with engine oil Torque in sequence provided Apply Moly Lube grease to valve tips Q Gasket free of oil Verify tabs are visible Apply thin film of OW 40 to 25 55 mm of cylinder bore Apply 0W 40 to piston pin or pin bore 6 Apply OW 40 to lifters Do Not install expansion plug more than 1 5 mm inward E 1 5 mm Side View Head Bolts Rocker Arms Head Assembly Gasket Pushrods Bushing Expansion Plug Cylinder PistonAssembly Circlip Gasket Hydraulic Lifter gt Apply Polaris OW 40 pu Apply Moly Lube Grease lt i Initial 35 4 ft Ibs 47 5 5 5 Nm in sequence Finalize sequence o tightening an additional 90 Apply each 1 4 turn Bolt Threads AS 22 2 ft Ibs 2 30 3 Nm e o e 6 00 Head Bolt Tighten Sequence Circlip UP
153. Bolts 18 24 Brake Switch 12 15 16 21 Master Cylinder Clevis Nut 9 13 12 18 9 2 5 BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight low maintenance and perform well in the conditions ATVs routinely encounter There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life Do not over fill the master cylinder fluid reservoir Adjust stop pin on front caliper after pad service Make sure atmospheric vent on reservoir is unobstructed products BRAKE NOISE TROUBLESHOOTING Optional pads are available to suit conditions in your area Select a pad to fit riding style and environment Make sure the brake lever and pedal returns freely and completely Check and adjust master cylinder reservoir fluid level after pad service Test for brake drag after any brake system service and investigate cause if brake drag is evident Make sure caliper moves freely on guide pins where applicable Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely Perform a brake burnishing procedure after installing new pads to maximize service life DO NOT lubricate or clean the brake components with aerosol or petroleum products Use only approved brake cleaning Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise s
154. Carrier Bolt Loosen two bolts that secure the A arm to frame by alternating each about 1 3 of the way until A arm can be removed Perform this procedure on the upper A arm See exploded view next page Examine the A arm bushing and A arm shaft Replace if worn Discard hardware To remove the lower control arm the wheel bearing carrier needs to be removed Remove the upper and lower wheel carrier bolts and slide the rear drive shaft from the carrier See Chapter 7 for more details 5 17 BODY STEERING SUSPENSION 11 Remove the bottom stabilizer bar nut px gt Stabilizer lt 12 Loosen two bolts that secure the A arm bushing to frame by alternating each about 1 3 of the way until the A arm can be removed The lower A arm should now be free to remove A Arm Installation 13 Insert new A arm bushings and new A arm shaft into new A arm 30 ft Ibs 41 Nm Nuts 8 G Ce Bushings 4 E 9 e e A arm Bolts Shaft D 2 Shock Bushings 14 Install new A arm assembly onto vehicle frame Torque new bolts to 30 ft 165 41 Nm A WARNING The locking features on the existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 15 Attach A arm to wheel bearing carrier Torque upper and lower carrier bolts a
155. Condition Bad Condition Wear from coil on armature plate Check to make sure the coil is seated in the U shaped insert that is pressed into the gearcase cover The top of the coil should be seated below the U shaped insert The U shaped insert controls the pole gap If the top of the coil is above the surface of the U shaped insert it raises the armature plate thereby increasing pole gap If the pole gap increases the coil will not be strong enough to engage the AWD system If this is the cause order a new Plate Cover Assembly Gearcase Cover f NM let U shaped insert Side cutaway view of Centralized Hilliard cover FINAL DRIVE 5 Inspect the rollers for nics and scratches The rollers must 8 slide up and down and in and out freely within the roll cage sliding surfaces Rollers Gearcase Removal 1 Stop engine place machine in gear set parking brake Loosen right front wheel nuts slightly Elevate and support machine under footrest frame area Serious injury may result if machine tips or falls AA CAUTION Be sure machine is secure before beginning this Service procedure Wear eye protection when removing and installing bearings and seals Remove right wheel nuts and wheel 10 Remove cotter pin lower ball joint nut and A arm from ball joint 11 Repeat Step 1 through Step 5 on the opposite side Pull each axle out from the front gearcase refer
156. Drive at higher speed or use Low The use of Low is highly recommended at approximately 3 7 MPH for cooler PVT operating temperatures and longer component life Insufficient warm up of Utility Task Warm engine at least 5 min then with transmission in neutral advance Vehicles exposed to low ambient throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will temperatures become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Towing Pushing at low RPM low ground Use Low only speed Plowing snow dirt etc utility use Use Low only Shift the transmission to Low carefully use fast aggressive throttle Stuck in mud or snow application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Shift the transmission to Low carefully use fast aggressive brief throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Shiftthe transmission to neutral Using the throttle vary the engine rpm from Belt slippage from water or snow idle to full throttle Repeat several times as required During this procedure ingestion into the PVT system the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking occurs Forinspection of clutch components please contact your Polaris de
157. Following Components can be serviced or removed with the the information below to identify pistons and rings engine installed See Page 3 17 for 6x6 Valve Cover R amp R Accessible Components Engine Model Piston Diameter Flywheel EHO068OLE 80 mm Alternator Stator Starter Motor Drive Cylinder Head 6x6 See Page 3 17 Cooling System Specifications Cylinder 6x6 See Page 3 17 Condition Specification Piston Rings 6x6 See Page 3 17 Thermostat Open 180 F 82 C Camshaft 6x6 See Page 3 17 Thermostat Full Open Lift 6 mm at 203 F 95 C Rocker Arms 6x6 See Page 3 17 Thermostat Closed 171 F 77 C Oil pump Water Pump Oil Pump Drive Gear System Capacity 3 25 Quarts 2 13L Gear Train Components Radiator Cap Pressure Relief 13 PSI Following Components Require Engine Removal for service Counterbalance Shaft or Bearings Polaris Premium Antifreeze 2871534 Quart Connecting Rod Crankshaft 2871323 Gallon Crankshaft Main Bearings Crankcase 3 13 Recommended Coolant Use only high quality antifreeze coolant mixed with distilled water in a 50 50 or 60 40 ratio depending on freeze protection required in your area CAUTION Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation resulting in possible engine damage Po
158. HEADLIGHT 10 17 HEADLAMP BULB 10 17 HEADLAMP HOUSING 10 17 HEADLAMP HOUSING 10 18 TAIL LIGHT BRAKE EIGHT vsti Re Rem eae ne 10 18 LAMP REPLACEMENT Eri iak wees esate RUE gen de Bla e ats 10 18 COOLING SYS DENM s x xc neice racc Pan Race ad eam 10 19 COOLING SYSTEM BREAK OUT 10 19 FAN CONTROL CIRCUIT OPERATION 10 20 FAN CONTROL CIRCUIT BYPASS 8 10 20 COOLANT TEMPERATURE SENSOR 10 20 EFIDIAGNOSTICS EE cab oed Bee 10 20 EFI COMPONENT 10 20 RUEE SENDER cda de lh ird Eu 10 20 TESTING et a REL D ERE ERN oes ea 10 20 BEbAY S scis ate veka ne ely POP AURORA S CR dod ia 10 21 OPERATION NEE b Rue Reden med bao a RA QR 10 21 FUSES CIRCUIT BREAKER 1 345 053 REPRE EA 10 22 OPERATION umen RR Rea ER Re URS A X RU ER 10 22
159. INE TO FRAME 2 31 STEERING AND SUSPENSION toe nc Rm n ic RR e reg STEERING EE 2 31 TIE END STEERING INSPECTION 2 31 CAMBER AND CASTER 2 31 WHEEL TOE ALIGNMENT 2 32 TOE ADJUSTMENG Pit oct he eel d DA ed dad 2 32 FRONT SUSPENSION s ssi ena kk ra ee ee E 2 33 dune AE ee ett a ke et ety pape da 2 33 REAR SUSPENSION ADJUSTMENT 4X4 2 33 REAR SPRING ADIUSGTMENT ren 2 34 BRAKE SYSTEM 2 34 BRAKE PAD INSPECTION 2 34 PARKING BRAKE PAD 2 35 BRAKE HOSE AND FITTING 2 35 2 2 GENERAL INFORMATION PERIODIC MAINTENANCE CHART Periodic Maintenance Overview Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement
160. INSTALLATION 51 EE Ee Pared 7 5 FRONT HUB EXPLODED VIEW 7 6 DRIVE SHAFT PROPSHAFT ot e oc pe e ep For dees 7 7 EXPLODED VIEW iiA nee EE a GOMA RR RARE aie he hela 7 7 DRIVESHAFT CV JOINT HANDLING TIPS 7 8 FRONT DRIVESHAFT theirs ope TEE ECH 7 8 REMOVAL t Papae A n PA an en a aE dues torte A 7 8 CV JOINT BOOT REPLACEMENT 7 9 INSTALLATIONS inet ee ro ERA EE cod der Meg d ter Eee one Se ERE Ie 7 11 FRONT PIROPSHAITTSEMQNVAL 51522 EE 7 11 PROPSFHAFT U JOINT SERVICE mm kn E 7 12 DISASSEMBLY 5 gt b exea RE ee ee DE CE 7 12 ASSEMBLY esr Pared Uer eh fere eee eth nC 7 13 FRONT GEARCASE CENTRALIZED HILLIARD 7 14 AWD OPERATION acta e E unte age Sa aa ES ont 7 14 CENTRALIZED HILLIARD EXPLODED 2 2 7 15 AWD DIAGNOSIS kie un RR IRR 7 16 GEARCASE REMOVAL 00002 cee 7 17 GEARCASE DISASSEMBLY 7 18 GEARCASE REASSEMBLY 7 20 BACKLASH PAD THRUST PAD 7 22
161. ION OVERVIEW rera Sek ey erative Seats Be De ges 4 16 TEBAL NEE oP dase oh i o E 4 16 2 25 rnm Be onde want See aes 4 16 THROTTLE POSITION SENSOR 8 4 17 OPERATION OVERVIEW REENEN ey RE im PA 4 17 IPS WES Tis ks tex llr dendi ole ci ee cs ol Vrae 4 17 TPS INITIALIZATION 1 ier tco e AE AN dese Send 4 18 TPS 4 19 ENGINE COOLANT TEMPERATURE SENSOR 4 19 OPERATION OVERVIEW 4 19 5 i ded iae e eate eue dh v 4 20 ECT SENSOR 4 20 GENERAL 4 21 DIAGNOSTIC BLINK 5 4 21 EFI 4 22 4 1 FUEL INJECTION GENERAL INFORMATION A WARNING under certain conditions EFI components are under high pressure Verify system pressure has been relieved before disassembly Never drain the fuel system when the engine is hot Severe burns may result Do not overfill the tank The tank is at full capacity wh
162. Low Maintenance battery case is dark and the cell caps are not removable since there is no need to check electrolyte level 10 30 NOTE New Batteries Batteries must be fully charged before use or battery life will be reduced by 10 30 of full potential Charge battery for 3 5 hours at a current equivalent of 1 10 of the battery s rated amp hour capacity Do not use the alternator to charge a new battery Refer to Battery Activation and Maintenance video PN 9917987 NEVER attempt to add electrolyte or water to a Low Maintenance battery Doing so will damage the case and shorten the life of the battery Refer to the Battery Maintenance Video PN 9917987 for proper instruction on servicing Low Maintenance batteries To service a Low Maintenance battery 1 Remove battery from the vehicle Test battery with a voltage meter or load tester to determine battery condition This will determine the length of time required to charge the battery to full capacity Refer to capacity table 3 Charge battery using a variable rate charger Battery Inspection The battery is located under the front hood Low Maintenance Battery shown but not used on current RANGER Models Battery Removal 1 Remove the seat and remove battery holder strap 2 Disconnect battery negative black cable first followed by the positive red cable AA CAUTION Whenever removing or reinstalling the battery disconnect the negative black
163. N 3 Remove wheel nuts and wheel Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearings and seals 7 36 FINAL DRIVE Remove the two brake caliper attaching bolts 7 Removetheupper and lower control arm bolts from the rear CAUTION Do not hang the caliper by the brake line Use wire to hang the caliper to prevent possible damage to the brake line hub bearing carrier 8 Remove the bearing carrier Inspect the bearing again for smoothness and side to side movement replace as needed Hub Disassembly 1 Remove outer snap ring 2 Fromthe back side tap on the outer bearing race with a drift punch in the reliefs as shown NOTE Drive bearing out evenly by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 7 37 FINAL DRIVE 3 Inspect the bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement sideways between inner and outer race 4 Inspect bearing housing for scratches wear or damage Replace housing if damaged Hub Assembly
164. N 3 2 5 e eret tt ety pre A ens te nte tt SE d 6 9 CLUTCH ALIGNMENT f OFFSET utere oae d awed ead eae eG te m Rs 6 9 GlUTCH AEIGNMENT hereto trot cn t tnde Rech c Rs Deu nc adea 6 9 CLUTCH OFFSET mr RE qva s tt ben ons 6 10 DRIVE CLUTCH SERVICE 1 iam a uox x EE 6 11 SPRING 5 2 6 11 SHIFT WEIGHTS ao ter ur oed ire Bb Een 6 12 EXPLODED VIEW Do Ed Re dI br re ia 6 13 CLUTCH INSPECTION zu eer ict rc e er diete qoe dem o De hc RS ds 6 13 CLUTCH DISASSEMBLY RR er Rh ru eR e RR ee 6 14 SPIDER REMOVAL sn te eR EA eor de edo ted atero te gard et aps 6 15 ROLLER PIN AND THRUST WASHER 6 15 BUSHING SERVICE ENT RR a SER ache ate tees 6 16 MOVEABLE SHEAVE BUSHING REMOVAL 6 16 MOVEABLE SHEAVE BUSHING INSTALLATION 6 16 CLUTCH COVER BUSHING 6 17 CLUTCH COVER BUSHING 6 17 GF TCH ASSEMBEY x ee i 6 18 DRIVEN CLUTCH SERVICE sat beat Wawa biked RO e RI eee 6 19 EXPLODED VIEW eech aia de tal a ated dade AEN 6
165. NOTE Be sure the park brake is not engaged 9 10 Plain Washer Stationary Actuator Steel Balls 3 Figure 9 10 If replacing the brake pads slightly loosen the caliper assembly bolts before removing the complete caliper assembly This will ease the caliper disassembly procedure later 4x4 Model Shown 5 3 Loosen the two brake caliper mount bolts B in equal 6 Slide the brake pads and springs from the assembly increments NOTE Retain the lever and ball bearings for reassembly 7 Inspect the brake pads linings for excessive wear Replace as needed 8 Check the three steel balls for any signs of cracking Replace as needed 9 Check ball seats in lever and stationary actuator If excessively worn replace parts as needed 10 Measure the thickness of the rear caliper parking brake pads Replace assembly or pads as needed See illustration below for proper readings 4 Remove the bolts from the frame and lift park brake assembly out Inboard pad thickness New 304 7 72 mm Limit 0 24 6 1 mm Inboard Outboard Pad Pad Outboard Pad Thickness New 0 360 9 14 mm Limit 0 31 7 87 mm Installed Disc to Park Brake 0 375 0 953 cm Caliper Disassembly Inspection New Rotor Disc Thickness NOTE The rear park brake caliper assembly is 0 150 0 164 8 81 4 16 mm _ replaced as an assembly Refer to your parts book pe for information 5 Remove the
166. Ohm The unit of electrical resistance opposing current flow 7 Ounce ounces Piston Clearance Total distance between piston and cylinder wall psi Pounds per square inch PTO Power take off PVT Polaris Variable Transmission Drive Clutch system 46 Quart quarts Regulator Voltage regulator Regulates battery charging system output at approx 14 5 DCV as engine RPM increases Reservoir Tank The fill tank in the liquid cooling system Resistance In the mechanical sense friction or load In the electrical sense ohms resulting in energy conversion to heat RPM Revolutions per minute Seized Piston Galling of the sides of a piston Usually there is a transfer of aluminum from the piston onto the cylinder wall Possible causes 1 improper lubrication 2 excessive temperatures 3 insufficient piston clearance 4 stuck piston rings Stator Plate The plate mounted under the flywheel supporting the battery charging coils TDC Top dead center Piston s most outward travel from crankshaft Volt The unit of measure for electrical pressure of electromotive force Measured by a voltmeter in parallel with the circuit Watt Unit of electrical power Watts amperes x volts WOT Wide open throttle 1 13 GENERAL INFORMATION CHAPTER 2 GENERAL INFORMATION PERIODIC MAINTENANCE CHART rer eR RR ERR RI EE NR 2 3 PERIODIC MAINTENANCE OVERVIEW 1 2 3 MAINTENANCE CHART KEY
167. POLARIS RANGER XP 700 4 4 RANGER 6X6 SERVICE MANUAL GENERAL INFORMATION MAINTENANCE ENGINE FUEL INJECTION BODY STEERING SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL E RH RR RM RH IE POLARIS RANGER XP 700 4 4 RANGER 6X6 SERVICE MANUAL GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION MODEL INFORMATION d RR ieee eae REGII Oe 1 2 MODEL 1 2 ENGINE DESIGNATION NUMBER 1 2 VIN IDENTIFICATION ENNEN kart bekam E hod Ra e a 1 2 ENGINE SERIAL NUMBER LOCATION 1 2 UNIT SERIAL NUMBER VIN LOCATION 1 3 TRANSMISSION I D NUMBER LOCATION 1 3 VEHICLE DIMENSIONS c ds wa de Co WS RO RC 1 4 VEHICLE DIMENSIONS RANGER 4X4 6X6 1 5 GENERAE SPEGIFIGATIONS sa rn e C Pn aad E RGR aw ICE cen 1 6 MODEL RANGER XP 4 4 1 6 MODEL RANGER XP 6 6 1 6 MODEL RANGER XP 4 4 1 7 MODEL RANGER XP 6 6 1 8 VEHICLE INFORMATION hine eR mt hte Rc hnc et m
168. Remedy Engine RPM below specified operating range although engine is properly tuned Wrong or broken drive clutch spring Drive clutch shift weight too heavy Driven clutch spring broken or installed in wrong helix location Replace with recommended spring Install correct shift weight kit to match engine application Replace spring refer to proper installation location Erratic engine operating RPM during acceleration or load variations Drive clutch binding Belt worn unevenly thin burnt spots Driven clutch malfunction Sheave face grooved Disassemble drive clutch inspect shift weights for wear and free operation B Clean and polish stationary shaft hub reassemble clutch without spring to determine problem area Replace belt A Replace ramp buttons B Inspect movable sheave for excessive bushing clearance Replace the clutch Engine RPM above specified operating range Incorrect drive clutch spring too high spring rate Drive clutch shift weights incorrect for application too light Drive clutch binding Driven clutch binding Converter sheaves greasy belt slipage Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassemble c
169. Spark Plug Service 2 30 Special Tool Cam Gear Installation Kit 3 39 Special Tools eee REIR S 1 9 Special Tools Body Steering Suspension 5 2 Special Tools Brakes 9 2 Special Tools Clutching 6 2 Special Tools Electrical 10 3 Special Tools Engine 3 13 Special Tools Final 7 3 Specification Balance Shaft Gear Bolt Torque 3 50 Specification Cam Lobe Height 3 44 Specification Cam Thrust Plate Fastener Torque 3 48 Specification Camshaft Gear Bolt Torque 3 50 Specification Coolant Sensor Resistance 10 20 Specification Cylinder Head Warp 3 25 Specification Cylinder Taper Limit 3 33 Specification Cylinder Warp Limit 3 33 Specification Oil Pump Bolt Torque 3 49 Specification Oil Pump Rotor Clearance 3 41 Specification Timing Gear Alignment 3 37 Specification Valve Seat Contact Width 3 29 Specification Valve Spring Free Length 3 26 Specification Valve Stem Diameter 3 27 Specification Valve Stem Guide LD 3 27 Specification Wheel 2 32 Specifications Cam Shaft 3 44 Spec
170. TE You may need to support the engine during this step by using a jack or by using wooden blocks between the engine and frame 10 R M T S d Lower Mount Loosen Front Mount Move the engine to allow the valve cover to be removed through the dog house cover hole To reinstall reverse steps 1 9 Torque all bolts to specification as listed earlier in this chapter NOTE It may be necessary to use a pry bar to get the bolts back in during reassembly 3 17 Engine Removal E re 10 11 3 18 Always wear safety glasses and proper shop A WARNING clothing when performing the procedures in this manual Failing to do so may lead to possible injury or death Clean work area Thoroughly clean the engine and chassis Disconnect battery negative cable Remove the following parts as required Seat Storage unit under driver seat Refer to chapter 5 Remove middle dog house cover and remove exhaust pipe bolts Remove springs from exhaust pipe and remove pipe Refer to PVT System in Chapter 6 to remove outer clutch cover drive belt drive clutch driven clutch and inner cover Drain coolant and engine oil Remove the air breather line A Remove PVT exhaust duct B Remove the exhaust shield C 12 13 14 Remove the spark D Disconnect the air intake hose D from the air box and remove the ai
171. Torque the rear shock bolts to 25 ft Ibs 35 Nm 18 ft Ibs 24 8 Nm 25 ft Ibs 35 Nm 14 Install the tire and four wheel nuts Torque the castle nut and the wheel nuts to specifications Rear Coil Over Shock Bolt Torque 25 ft Ibs 35 Nm 11 Reinstall the vent hose and clamp to the rear gearcase housing 12 Apply anti seize to the splines of the axle Reinstall the hub Rear Hub Nut Torque onto the axle Reinstall the domed washer and spindle nut 110 ft Ibs 149 Nm onto the axle Rear Wheel Nut Torque 35 ft Ibs 47 Nm 15 Install a new cotter pin Tighten nut slightly to align holes if required Install the hub cap 7 59 FINAL DRIVE Gearcase Exploded View DESCRIPTION DESCRIPTION QTY 1 Seal Triple Lip 1 12 O Ring 1 2 Screw 5 16 18 x 1 0 12 13 Spring Wave 1 3 Cover Input 1 14 Ball 1 4 O Ring 1 15 Shaft Output 1 5 Bearing Ball 1 16 Gear Ring 37T 1 6 Pinion 10T 1 17 Ball 1 7 Bearing Plain 1 18 Shim 1 8 Plug Square Socket 2 19 Plug Expansion 1 9 Seal Dual Lip 2 20 Tube Vent 1 4 Hose 1 10 Rear Housing 1 2 Cover Output 1 11 Knock 1 7 60 TRANSMISSION CHAPTER 8 TRANSMISSION TORQUE SPECIFICATIONS duci ia b er tae et ew e CC Eno e Oe 8 2 SIP TPE BRE isp ees
172. Turns Over But Fails To Start No fuel Dirt in fuel line or filter Fuel will not pass through fuel valve Fuel pump inoperative restricted Tank vent plugged or pinched Engine flooded Low compression high cylinder leakage No spark Spark plug fouled ignition component failure Engine Does Not Turn Over Dead battery Starter motor does not turn Engine seized rusted or mechanical failure Engine Runs But Will Not Idle Restricted carburetor pilot system Low compression Crankcase breather restricted 3 58 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 or restricted carburetor jetting ETC switch limiting speed Reverse speed limiter limiting speed Incorrect ignition timing Restricted exhaust system Cam worn excessively Engine Has Low Power Spark plug fouled Cylinder piston ring or valve wear or damage check compression PVT not operating properly Restricted exhaust muffler Cam worn excessively Piston Failure Scoring Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup Excessive piston to cylinder clearance Wet sumping Worn rings piston or cylinder Worn valve guides or seals Restricted breather Air filter dirty or contaminated Piston Fai
173. U WH 21 RD CHASSIS i 10 OG RD 22 RD WH HARNESS BN RD 1 19 BN RD rj 05 BK WH 034 28 GY 0G WIRE ENTRY VIEW SPLICE 33 BN RD 32 VI WH 04 33 BN RD 0528 38 DG E L 2 5 34 WH os H 39 DB 40 RD WR 150 01 30 YE ooo SPEEDOMETER 09 BN WH ttie 9 BN RD 05 BK WH TER 7 L 1 3 E i WIRE ENTRY VIEW 34 WHH 4 F FAD 36 BN RD e WIRE TERMINATION TABLE DEI COLOR GAUGE FROM CONNECTOR CAVITY TO CONNECTOR CAVITY 3 7 M n 3 01 RED WHITE 16 RED WHITE SPLICE IGNITION SWITCH C 02 WHITE GREEN 18 CHASSIS HARNESS A2 AWD SWITCH 4 eo 03 GRAY 18 CHASSIS HARNESS A3 AWD SWITC 3 04 WHITE RED 8 CHASSIS HARNESS M IGNITION SWITCH dio Tub 05 BLACK WHITE 18 CHASSIS HARNESS 5 SPEEDOMETER E zo 06 BROWN 16 BROWN SPLICE 12V RECEPTACLE 8 85 SS SES 07 ORANGE WHITE 16 ORANGE WHITE SPLICE 12V RECEPTACLE 1 Y firm 1T 08 2 au BN RD WH 09 BROWN WHI TE 8 CHASSIS HARNESS BI SPEEDOMETER 16 SPLICE SPLICE SPLICE 10 ORANGE RED 8 CHASSIS HARNESS 88 SPEEDOMETER 10 EE jue rm cma BLACK 18 CHASSIS HARNESS 85 IGNITION SWITCH BSESSY SESS SSS858 585 12 ORANGE 16 CHASSIS HARNESS 86 IGNITION SWITCH D 2255 EE BROWN 8 BROWN SPLICE IGNITION SWITCH F N NI any 14 ORANGE WHITE 18 ORANGE WHITE SPLICE
174. X Corporation 1 800 328 6657 1 9 GENERAL INFORMATION MISC SPECIFICATIONS AND CHARTS Conversion Table 1 10 Unikot Measure Gomese ede DEEL e imm BE quam pm mie EC _ 22046 Dec imperial quarts imp qi Liers 0 imperia quarts mp US quarts 05 9 US quaris US 4 Liers 0 Kilopascals kPa C to F 9 40 5 40 F F to F 40 9 40 GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used only as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views or each manual section for torque values of fasteners before using standard torque Q Q Q Bolt Size Threads in Grade 2 Grade 5 Grade 8 Torque in Ibs Nm 10 de SU ise es 60 6 9 10 lt 931 9 0 ke Ce vce NNN 49 5 6 68 7 8 Torque ft Ibs Nm 1 4 20 05 12 16 14 28 102 225555265222 10 14 14 19 516 ul TI 5 colis e483 vt vers 17 23 25 35 5 16 D ee 2016 19 26 29 40 3 8 16525 12226 20 07 25 5 55 30 40 45 62 3 8 d AE EEES 2348255 35 48 uelis 50
175. ab Frame Assembly Removal 5 7 Caliper Front ER 9 15 Caliper EE 9 22 Cam Gear 3 39 Cam Gear Removal 3 38 Cargo Box Installation 5 24 Cargo Box Removal 5 24 Centralized Hilliard Exploded View 7 15 Charging System 10 22 Circuit Breaker Mop teats 10 22 Clocks Seting e ey apis aire arte NEE 10 8 Clutch Alignment 6 9 Cl tch Offset 6 10 Combustion Chamber 3 28 Compression Test 2 17 Conversion Chart 1 10 Coolant Level Inspection 2 25 Coolant Strength and Type 2 26 Cooling System Bleeding Procedure 3 15 Cooling System Hoses 2 26 Cooling System Pressure 2 26 Cooling System Specifications 3 13 Cooling System Pressure Test 3 14 Crankshaft Gear Removal 3 40 Crankshaft Position Sensor 4 15 CV Shaft Boot Inspection 2 28 Cylinder Head Assembly
176. alculated by the ECU 4 9 FUEL INJECTION Initial Priming Starting Procedure NOTE The Injection system must be purged of all air prior to the initial start up and or any time the system has been disassembled If the EFI system is completely empty of fuel or has been disassembled and repaired 1 Cycle the key switch from OFF to 6 times waiting for approximately 3 seconds at each cycle to allow the fuel pump to cycle and shut down 2 Once step 1 is completed turn the key switch to START until the engine starts or 5 seconds has passed 3 If the engine failed to start repeat step 1 for 2 more cycles and attempt to start the engine If the engine fails to start a problem may still exist and should be diagnosed NOTE Accurate testing of EFI recommended utilizing the Digital Diagnostic Software dealer only components is Wrench 4 10 ELECTRONIC CONTROL 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 throttle position engine coolant temperature air temperature intake manifold air pressure and battery voltage The ECU compares the input signals to the programmed maps in its m
177. aler Shift transmission to Low during loading of the vehicle to prevent belt burning Fouled plugs foreign material in gas tank fuel lines or carburetor Contact you dealer for further service information Low Heavy pulling basic operational speeds less than 7 MPH riding through rough terrain swamps mountains ect low ground speeds High High ground speeds speeds above 7 MPH Climbing over large objects from a stopped position Clutch malfunction Poor engine performance GENERAL RANGE OPERATION GUIDELINES Operating in Low Gear Low is the primary driving gear Low should be used in ALL driving applications except for driving on hard packed level surfaces with light loads In this circumstance High may be used IMPORTANT Using High for heavy loads hilly terrain or in wet muddy conditions will increase the chance of drive belt burning RANGER 4X4 1 6X6 1 Use Low as the primary driving gear H for all RANGERs 2 Use High only on hard packed level surfaces with light loads L N R CLUTCHING PVT SYSTEM SERVICE PVT Sealing Guard and Ducting Components SEALING AND DUCTING COMPONENTS Inner Cover Inner Cover Seal Retainer Outer Cover Seal Disassembly Some fasteners and procedures will vary Refer to the appropriate parts manual for proper fasteners and fastener placement 1 Remove seat Remove the LH storage box to gain access
178. ality Riding with poor lighting can result in severe injury or death Headlamp Bulb Replacement 1 Open the hood 2 Unplug the headlamp bulb A from the wiring harness Be sure to pull on the connector not on the wiring 3 Turn the lamp counterclockwise to remove it 4 Insert new bulb Reinstall the harness assembly into the headlight assembly NOTE Make sure the tab on the lamp locates properly in the housing Headlamp Housing Removal 1 Open the hood 2 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 10 17 ELECTRICAL 3 Remove the O ring from the headlamp brackets both sides 4 After the O rings are removed from the headlamp Remove the adjustment screw B and pull the headlamp from the brackets Headlamp Housing Installation 1 To install the headlamp housing press the headlamp tabs back into the brackets 2 Secure the headlamp housing with the rubber O rings on each side A Install the adjustment screw B 2 fe P 3 Reconnect wire harness or re insert bulb if previously removed 4 Adjust headlights using the High Beam Headlight Adjustment procedure on the previous page 10 18 TAIL LIGHT BRAKE LIGHT Lamp Replacement Before replacing the tail light use a digital multi meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present If the tail ligh
179. and transmission vent lines for signs of wear deterioration damage or leakage Replace every two years 2 Be sure vent lines are routed properly and secured with cable ties CAUTION Make sure lines are not kinked or pinched Throttle Pedal Inspection Throttle Pedal If the throttle pedal has excessive play due to cable stretch or cable misadjustment it will cause a delay in throttle speed Also the throttle may not open fully If the throttle pedal has no play the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart and adjust the play if necessary GENERAL INFORMATION Throttle Freeplay Adjustment Air Filter Service Inspection Itis recommended that the air filter be replaced annually When riding in extremely dusty conditions replacement will be 1 Apply the parking brake required more often 2 Putthe gear shift lever in the N Neutral position 3 Start the engine and warm it up thoroughly The filter should be inspected periodically before each ride 4 Measure the distance the throttle pedal moves before Using the following procedure engine begins to pick up speed Free play should be 1 16 1 Lift the box to access the filter box cover 1 8 1 5 3 mm ix Air Box Location P Adjustment 1 Remove the seat 2 Locate the throttle cable adjuster 3 Squeeze the
180. asurement B NOTE It is important that the height of both marks be equally positioned in order to get an accurate measurement 4 Measure the distance between the marks and record the measurement Call this measurement 5 Rotate the tires 180 by moving vehicle forward or backward Position chalk marks facing rearward even with the hub axle centerline 6 Again measure the distance between the marks and record Call this measurement Subtract measurement from measurement A difference 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 Aer Sa In mm Wheel Toe Out A B 1 8 1 4 3 to 6 cm 2 32 Toe Adjustment If toe alignment is incorrect measure the distance between vehicle center and each wheel This will tell you which tie rod needs adjusting NOTE Be sure steering wheel is straight ahead before determining which tie rod s need adjustment AA CAUTION During tie rod adjustment itis very important that the following precautions be taken when tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not pivot and may break To adjust toe alignment Hold t
181. at the factory 10 9 ELECTRICAL To enable or disable the service interval Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the mode button for about seven 7 seconds until either ON or OFF appears in the Rider Information Display depending on your preference To reset the service interval Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the mode button for 2 3 seconds until the wrench icon flashes Release the button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly NOTE If you scroll past the intended number press and hold the button until the hours cycle back to zero 5 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers Toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement Enter the diagnostic mode 2 Toggle to the screen that displays either kilometers KM or miles MP 3 Press and hold the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set 10 10 Viewing Diagnostic Codes Use the following procedure to view diagnostic blink codes failure codes from the EFI
182. ather hose A Inspect the breather hose for possible kinks or wear The hose is form fit ted for a proper fit Follow the breather hose from the side of the airbox to the engine valve cover NOTE Make sure lines are not kinked or pinched Engine Oil Level The twin cylinder engine is a wet sump engine meaning the oil is contained in the bottom of the crankcase To check the oil level follow the procedure listed below Dipstick 1 Setmachine on a level surface and set the parking brake 2 Besurethe machine has sat for awhile before removing the dipstick IMPORTANT Do not run the machine and then check the dipstick 3 Stop engine and unlock the lever lock Remove dipstick Lever Lock Dipstick sarEQ ADD8 02 2 17 GENERAL INFORMATION 4 Reinstall dipstick and push it into place Do not lock the dipstick NOTE Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of dipstick consistent When reinstalling the dipstick make certain to seat the lever lock 5 Remove dipstick and check to see that the oil level is in the normal range Add oil as indicated by the level on the dipstick Do not overfill See NOTE below NOTE Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Proper level indication is determined on the upper surface of the dipstick as it is being removed regardl
183. aused by bad failed connections and grounds 10 16 GEAR POSITION INDICATOR SWITCH Test Diagram NOTE Alsosee INSTRUMENT CLUSTER TROUBLESHOOTING for switch circuit TRANSMISSION SWITCH High Low Neutral Reverse Switch High Range Low Range Neutral Reverse Green White Violet Brown Red White Blue i NEU REV LOW H ELECTRICAL HEAD LIGHTS High Beam 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 the center of the headlight and make a mark on the wall at the same height LA With the machine in Neutral and park brake applied start the engine and turn the headlight switch to high beam 4 most intense part of the headlight beam should be aimed 8 in 20 cm below the mark placed on the wall in Step 2 NOTE Rider weight must be included in the seat while performing this procedure 5 Adjust the beam to the desired position by loosening the adjustment screw A and moving the lamp to the appropriate height 6 Adjustthe beam to desired position Repeat the procedure to adjust the other headlight A WARNING Due to the nature of light utility vehicles and where they are operated headlight lenses become dirty Frequent washing is necessary to maintain lighting qu
184. bearings or case the assembly must be replaced 3 Remove the four bolts that secure the rear differential Pinion and ring gear shimming information is NOT brackets to the frame provided due to OEM manufacturing requirements 1 Drain and properly dispose of used gearcase fluid 2 If necessary remove the rear differential mount brackets from the rear differential 4 Carefully pull the rear differential case assembly from the frame Let the rear propshaft slide off of the rear differential 3 Remove the bolts that secure the carrier cover A bolts to the carrier housing B 7 46 FINAL DRIVE 4 Remove the differential assembly C from the housing 6 Remove the differential lock solenoid F from the carrier Inspect the bevel gear teeth for chipped worn or broken teeth housing by turning the solenoid counterclockwise VO 7 Inspectthe tip of the solenoid F for wear If the tip of the solenoid is flat the solenoid may need to be replaced 5 Removethe bearings from each side of the carrier assembly C Inspect the bearings D for smoothness and wear Be sure to keep the shims E together for reassembly 8 Remove the clutch gear G from the carrier cover B and shift yoke H 7 47 FINAL DRIVE 9 Inspect the shift yoke H shift lever J and shift lever 12 Thread the bolt into the shift yoke pivot shaft L return spring K 7 52 13 Carefully pull th
185. ble obstructions Use compressed air to blow out any debris AA CAUTION 30 Reinstall the valve dowel chamfered end first Install the spring washer and bolt Torque to specification Wear appropriate safety gear during this procedure Protective gloves clothing and eye 22 2ft Ibs s wear are required 30 3 Nm 32 Remove the snap ring from the assembly Place the housing in a support and press out the bearing shaft assembly Press out shaft and bearing assembly 22 2 ft Ibs 30 3 Nm NOTE Be sure to place the tapered end of the valve dowel in first If the valve is installed incorrectly oil pressure and oil priming problems will occur Retaining Ring 33 Place the shaft in a press to remove the bearing 3 42 34 Press shaft into the new bearing 37 Remove thrust plate U 35 Press the bearing shaft assembly using the bearing s outer race Do not use the shaft to press the assembly into the 38 Remove PTO end engine mount Remove crankcase bolts housing as bearing damage may result Install retaining on the reinforced areas on the cases using soft hammer ring Carefully separate the two crankcase halves Press Bearing Shaft Separate Assembly using Crankcase Halves outer race only 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 an
186. cages for wear cracks or other damage NOTE Shiny areas in ball tracks and on the cage spheres are normal Do not replace CV joints because parts have polished surfaces Replace CV joint only if components are cracked broken worn or otherwise unserviceable 6 Place a new snap ring in the groove of the CV joint inner hub with tabs facing the shaft as shown 7 Before you assemble the CV joint slide the new boot small end first and clamp over the splined shaft FINAL DRIVE 8 Refit CV joint on the shaft by tapping with a plastic hammer on the joint housing Take care not to damage threads on the outboard CV joint The joint is fully assembled when the snap ring is located in the groove on the shaft Tap joint onto shaft NOTE It is very important to use the correct type and quantity of grease by using the grease contained in the boot kit DO NOT use a substitute grease and DO NOT overfill or underfill the CV joint 9 the CV joint and or boot with the recommended type and amount of grease Rear drive shaft inner or outer boot replacement requires 50g of grease if the CV joints were not disassembled NOTE If the joints were disassembled and cleaned refer to the call out below or Figure 7 31 for the correct amount of grease required Boot Replacement Grease Requirement Inner Plunging Joint Grease PN 1350047 Only boot replacement 50g Boot replacement w joint cleaning 100g Outer CV
187. cal components Connect an ammeter in series with the negative battery cable Check for current draw with the key off If the draw is excessive loads should be disconnected from the system one by one until the draw is eliminated Check component wiring as well as the component for partial shorts to ground to eliminate the draw Current Draw Key Off Maximum of 01 DCA 10 mA 10 22 ELECTRICAL Charging System Break Even Test Charging System Alternator Tests Three tests can be performed using a multimeter to determine A CAUTION the condition of the stator alternator Do not allow the battery cables to become disconnected with the engine running Follow the steps below as outlined to reduce the chance of 1 Y2 damage to electrical components The break even point of the charging system is the point at which the alternator overcomes all system loads lights etc and begins to charge the battery Depending on battery condition and system load the break even point may vary slightly The battery should be fully charged before performing this test A WARNING Never start the engine with an ammeter TEST 1 Resistance Value of Each Stator Leg connected in series Damage to the meter or meter fuse will result 1 Measure the resistance value of each of the three stator Do not run test for extended period of time legs to Y2
188. ct offset voltage is reached once the correct throttle body flow is set Throttle Plate Must Be Closed Remove cover and disconnect throttle cable from throttle cam 4 18 With engine off back out air flow screw until it no longer is in contact with throttle plate cam The throttle plate should seal off throttle bore completely Back Air Flow Screw Out Until No Contact is Made Open and close throttle plate a couple of times to ensure full throttle closing Do not snap closed as this could cause unnecessary throttle plate to throttle body interference and or damage Set up the TPS Test Adapter Harness PU 47082 according to the instructions Verify that the 9 volt battery is new See illustration below TPS Tester Adapter Harness PU 47082 Should Read 528 V Red Using a voltmeter attached to the TPS Tester Harness PU 47082 check the voltage output of the TPS It should read 528 01 volts If it does not read 528 01 volts loosen the screw holding the TPS to the throttle body Rotate TPS until voltmeter reads 528 01 volts Retighten TPS mounting screw and verify the voltage did not change If changed repeat the previous steps FUEL INJECTION STEP 2 Establishing correct flow Now that the zero offset voltage has been set you can now set the throttle body to the correct air flow value 6 With voltmeter still attached to the TPS Test Adapter Harness PU 470
189. ctivated 5 Use the mode button to toggle through the diagnostic screens 10 8 Clock Screen To reset the clock 1 Enter the diagnostic mode Toggle to the clock screen Press and hold the mode button until the hour display flashes Release the button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly 5 When the desired hour is displayed wait approximately four seconds until the minute display flashes 6 When the display stops flashing the mode has been set 7 Use the same procedure to reset the minutes Battery Voltage Screen View this screen to check battery voltage level Tachometer Screen View the tachometer to check engine speed ELECTRICAL AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil NOTE A 10 2096 variance from these readings is within normal parameters Programmable Service Interval Gear Circuit Diagnostic Screen When the hours of engine operation equal the programmed This screen displays the resistance value in ohms being read 31 service interval setting the wrench icon will flash for 5 seconds the gear switch input of the gauge each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance NOTE The service interval is programmed at 50 hours
190. d Rx ene eh e Rb er pai 7 36 7 1 FINAL DRIVE REAR BEARING CARRIER 4 4 H B INSPEGTION oe xb eme TEE We aee EH 7 36 HUB REMOVAL tu vetat tuc etf Oia A e 7 36 HUB DISASSEMBLY eene net dae eeh oe eee eie seen ere 7 37 HUB ASSEMBLY acu IESU EE Ree AR RR S m 7 38 INSTALLATION idem ea mre i le almi I Ia EN EN Rx ER Rs 7 38 REAR DRIVE SHAFT 4X4 gag RUE EU e asain eR An db pom AO RR UR Rs REMOVAL EE 7 39 CV JOINT BOOT REPLACEMENT 7 40 INSTALLATION ea DEO noes 7 42 REAR PROPSHAFT 4X4 1 435 3 4 2 3 x a RC EAR RR eee Pe aae et REMOVAL i RESO RT due Rue dd aea de Rie A A 7 43 INSTALLATION enge ele E Ae 7 43 REAR GEARCASE 454 eres Bot BORNE GENERAL OPERATION tette eh a 7 44 OPERATION MODES dE S kn dex ee 7 45 DIFFERENTIAL REMOVAL E E eee 7 46 DIFFERENTIAL 7 46 DIFFERENTIAL 7 49 DIFFERENTIAL
191. d den ue ca M IRR AC iH Sp etd cse tides GE M ap d up e doa 8 2 REMOVAL iraa Siti it ba Weed na nc it eo D PCR Eeer 8 2 INSTALLATION 3 20 EE Re iod ewm aree d 8 2 SHIFIEINISAGE e ESI e X RU 8 2 INSPECTION varen e tuere A EENS d dee EE 8 2 ADJUSTMENT eir rete Reste te Pad eR Pr ne er ge 8 3 TRANSMISSION SERVICE v3 rte ars o Arona dol e e D Rae Re BEEP dA Oe gat 8 3 TRANSMISSION REMOVAL 1 8 3 TRANSMISSION DISASSEMBLY 8 5 TRANSMISSION ASSEMBLY 8 10 TRANSMISSION 8 14 TROUBLESHOOTING Hila Bx RC REOR wees ced x ROUTE 8 15 TROUBLESHOOTING CHECKLIST 8 8 8 15 TRANSMISSION EXPLODED VIEW oie cee ead NEEN E EE E ERE 8 16 EXPLODED VIEW 4X4 6 6 1 8 16 8 1 TRANSMISSION TORQUE SPECIFICATIONS ITEM TORQUE VALUE 10 14 ft Ibs Transmission Fill Plug 14 19 Nm 10 14 ft Ibs Transmission Drain Plug 14 19 Nm m 27 34 ft Ibs Transmission Case Bolts 37 46 Nm 12 18 ft Ibs Bell Crank Nut 16 24 Nm 7 9 ft Ibs Bell Crank Gear Cover 10 12 Nm Transmission Mounting
192. d install the bolt into the upper control arm Torque bolt to 30 ft Ibs 41 Nm 1 Slidethe rear drive axle into the bearing carrier hub NOT 5 Install hub domed washer domed side out and nut 2 Install a new circlip onto the rear drive shaft Apply Anti Torque rear spindle nutto 110 ft Ibs 149 Nm Install new Seize Compound onto the rear driveshaft splines both cotter pin and hub cap ends Rear Hub Nut Torque 3 Reinstall the rear driveshaft into the rear gearcase Be sure the circlip is securely fitinto the rear gearcase Use a rubber 110 ft Ibs 149 Nm mallet to tap on the outboard end of the driveshaft if necessary 6 Install rear wheel and torque washers and wheel nuts to specification See Torque Specifications on page 7 3 110 ft Ibs 149 Nm Flat washer ol Wheel Nut 4 outside 7 42 FINAL DRIVE REAR PROPSHAFT 4X4 4 Slide the propshaft off the transmission shaft and rear gearcase input shaft Orientate the shaft so that it s parallel with the frame supports as shown below Removal 1 Remove the pin clips from upper and lower cargo box shock pins and remove shock Carefully allow cargo box to rest in the dump position as you remove the propshaft 5 Remove the shaft by placing the brake disc over the top of the rear frame support and under the front frame support A WARNING Support the cargo box while the shock is removed
193. d loosen the Loctite This will prevent any possible damage to the bolts or to the crankcase casting 36 Press gear onto shaft while supporting the housing 39 Remove and clean oil pick up V and oil baffle weldment W 3 43 40 Remove balance shaft and crankshaft 41 Remove and inspect crankshaft main journal bearings for abnormal wear It is recommended to replace the bearings anytime the engine is disassembled 3 44 Camshaft Inspection Thoroughly clean the cam shaft Visually inspect each cam lobe for wear chafing or damage Ne 3 Measure height of each cam lobe using a micrometer Compare to specification Y RE es In mm Cam Lobe Height Intake amp Exhaust Std 1 3334 33 8674 mm 4 Measure camshaft journal outside diameters O D Y Bes 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 x 010 mm 5 Measure ID of camshaft journal bores l d t In mm Camshaft Journal Bore I D Mag 1 656 0 00039 42 07x0 010 mm Ctr 1 637 x 0 00039 41 58 0 010 mm PTO 1 617 0 00039 41 07 0 010 mm 6 Calculate oil clearance by subtracting journal O D s from journal bore I D s Compare to specification d ee In mm Calculated Camshaft Oil Clearance Std
194. d the brake calipers from the frame with wire both sides 4 Remove the hub cover cotter pin spindle nut and washer both sides 5 Pull the hub off of the axle 6 Remove the hose clamp from the rear gearcase breather hose Remove the breather hose 7 Remove the bottom shock bolts and shocks both sides _ 28 x 8 Remove the two bolts that secure the rear axle housing to the frame 9 Mark the positions of the four U bolts that secure the axle to the frame This will aid with proper U bolt and axle placement during reassembly EI Mark U bolt Positions 7 53 FINAL DRIVE 10 Loosen the four U bolts Loosen each U bolt nut afew turns Axle Tube Removal at a time this will reduce stress on all of the U bolts during U bolt removal 1 Place the rear axle assembly a clean surface 2 Remove the bolts that secure the rear gearcase to the axle tubes and remove the rear gearcase skid plate Loosen U bolts SS _ 27 e e 11 With the U bolts removed carefully lower the rear axle assembly from the frame Pull the axle assembly out from em the frame NOTE The drive shaft yolk A slides off of the rear 3 Remove the axle and axle tube s from the rear gearcase gearcase Note the placement of the axle spacer seals for placement during reassembly NOTE Use caution when removing the rear axle assembly Extra jacks maybe needed to lower the 4 Slide the axles
195. dc test the battery ignition switch wiring harness and ECU 5 If voltage at the plug was good and there was continuity across the pump terminals reconnect the plug to the pump making sure you have good clean connections Turn on the key switch and listen for the pump to activate NOTE If the pump starts repeat steps 1 and 2 to verify correct pressure NOTE If the pump still does not operate check for correct ECU operation by plugging in a known good ECU of the same model NOTE If the pump still does not operate replace the pump tank assembly Fuel Pump Tank Assembly Replacement NOTE All EFI units utilize quick connect fuel lines A WARNING Always wear safety goggles when working with high pressure or flammable fluids Failure to do so could result in serious injury or complications NOTE The fuel pump cannot be replaced as an individual part the entire fuel pump and fuel tank is replaced as an assembly Refer to your parts book for the proper part number FUEL INJECTION 1 Disconnect the negative battery cable 6 Remove the RH rear fender and fuel cap 2 Remove the seat 3 Disconnect the fuel line from the fuel pump 7 Remove the two inner bolts that hold the fuel tank to the 8 Remove the two outer lower bolts that hold the fuel tank to the frame 5 Remove the fuel tank vent hose NOTE A small amount of fuel may come out of the fuel line or tank Pl
196. ded idle More preventative maintenance is required under these conditions Fluid changes cable chain and chassis lubrication are required more frequently For engine oil short trip cold weather riding also constitutes severe use Pay special attention to oil level A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil imme diately and monitor level If oil level begins to rise discontinue use and determine cause Emission Control System Service California NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts A WARNING Improperly performing the procedures marked with could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 2 3 GENERAL INFORMATION Pre Ride 25 Hour Maintenance Interval Maintenance Interval whichever comes first Item Remarks Hours Calendar mias KM W Steering Pre Ride gt Front Suspension Pre Ride Rear Suspension Pre Ride Tires Pre Ride gt Brake Fluid Level Pre Rid de 7 Make adjustments as needed Brake Pedal Travel Pre Ride See Pre Ride Checklist on Page 2 13 Brake Systems Pre Ride Wheels Fasteners Pre Ride Frame Fasteners Pre Ride d Engine Oil Leve
197. der 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 45257 compress the valve spring and remove the valve keepers NOTE A small parts magnet A can aid in the removal of the retainers B PU 45257 NOTE To prevent damage to the valve seals do not compress the valve spring more than is needed to remove the valve keepers 3 Remove spring retainer and spring 4 valve seals are now serviceable 3 25 Cylinder Head Disassembly 4 Remove valve guide seals 1 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 Carefully remove the cylinder components 5 Markthe valves with a white pen Remove the valves from the cylinder head This will ensure that the valves are properly placed during engine reassembly 2 Place the hydraulic lifters C pushrods D and rocker arms E in a safe clean area 3 Measure free length of spring with a Vernier caliper Compare to specifications Replace spring if measurement is out of specification Valv
198. drive and driven clutches are continually shifting to maintain optimum engine RPM At full throttle a perfectly matched system should hold engine RPM at the peak of the power curve This RPM should be maintained during clutch upshift and backshift In this respect the PVT system is similar to a power governor Rather than vary throttle position as a conventional governor does the PVT system changes engine load requirements by either upshifting or backshifting Maintenance Inspection Under normal operation the PVT system will provide years of trouble free operation Periodic inspection and maintenance is required to keep the system operating at peak performance The following list of items should be inspected and maintained to ensure maximum performance and service life of PVT components Refer to the troubleshooting checklist at the end of this chapter for more information 1 Belt Tension Drive to Driven Clutch Offset Belt Width See these sections later in chapter for each model 2 Drive and Driven Clutch Buttons and Bushings Drive Clutch Shift Weights and Pins Drive Clutch Spider Rollers and Roller Pins Drive and Driven Clutch Springs See these sections later in chapter 3 Sheave Faces Clean and inspect for wear 4 PVT System Sealing Refer to appropriate illustration on the following pages The PVT system is air cooled by fins on the drive clutch stationary sheave The fins create a low pressure area in the c
199. e Service Limit 002 051 mm difference between measurements Mount dial indicator as shown to measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 010 254 mm Disc Removal Replacement 1 Remove bolts and disc Clean mating surface of disc and hub Install disc on hub Install new bolts and tighten to 18 ft Ibs 24 Nm AA CAUTION Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal REAR BRAKE PAD 4X4 Pad Removal 1 Elevate and support rear of machine AA CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls Remove the rear wheel Loosen pad adjuster screw 2 3 5 3 Clean caliper area before removal Pad Inspection 4 Remove caliper mounting bolts and lift caliper off of disc 1 Clean the caliper with brake cleaner or alcohol 2 Measure the thickness of the pad material Replace pads if NOTE When removing caliper be careful not to worn beyond the service limit damage brake line Support caliper so as not to kink or bend brake line zi Measure Dr Thickness Remove Caliper Bolts 5 Push caliper piston into caliper bore slowly with pads Rear Brake Pad Thickness N
200. e 6x6 7 28 Middle Gearcase Lubrication 2 22 Miles to Kilometers Toggle 10 10 Model Identification 1 2 Odometer CR UR 10 8 Oil Pump Disassembly 3 41 Oil Pump Reassembly 3 42 Oil Pump Removal 3 41 P Paint Codes ex rep LO PU ep 1 9 Parking Brake Caliper Service 9 10 Parking Brake 9 12 Parking Brake Pad Inspection 2 35 Parking Brake 9 9 Parking Brake Exploded View 9 8 Parking Brake Inspection 9 9 Periodic Maintenance 2 3 Piston Ring Installed Gap 3 35 Piston to Cylinder Clearance 3 34 Piston to Rod Inspection 3 34 Pre Ride Daily Inspection 2 13 Programmable Service Interval 10 9 Propshaft Mid Drive 6x6 7 28 Publication Numbers 1 9 PVT System Assembly 6 6 PVT System Disassembly 6 5 PVT System Maintenance 6 3 PVT System Overview 6 2 PVT System Service
201. e RN SNAM ES 10 22 G Gear Stator Housing Seal Replacement 3 51 Gear Circuit Diagnostics 10 9 Gear Position Indicator Switch Test 10 16 General Specifications Brakes 9 2 H Head Pee 10 17 Hour REN 10 8 Hub Bearing Carrier Mid Drive 6x6 7 23 Hub Bearing Carrier Rear 4x4 7 36 I Indicator Service Interval 10 9 Instrument Cluster 10 7 K Keys Replacement 1 9 Kilometers to Miles Toggle 10 10 Maintenance Brake System 2 34 Maintenance Cooling System 2 25 Maintenance Electrical and Ignition 2 29 Maintenance Engine 2 17 Maintenance Final Drive 2 27 Maintenance Fuel System 2 14 Maintenance General Vehicle Inspection 2 13 Maintenance References 2 11 Maintenance Service Products and Lubricants 2 10 Maintenance Steering and Suspension 2 31 Maintenance Transmission and Gearcases 2 20 Master Cylinder Installation 9 6 Master Cylinder Removal 9 6 Mid Axle A arm Replacement 5 16 Mid Drive Gearcas
202. e Spring Free Length A SE n mm Valve Spring Free Length Std 1 735 44 069 mm 3 26 Valve Inspection 1 Remove all carbon from valves with a soft wire wheel or n mm brush 2 Check valve face for runout pitting and burnt spots check for bent valve stems mount valve in a drill or use Valve Stem Diameter blocks and a dial indicator Intake 0 2356 0 00039 5 985 0 01 mm Exhaust 0 2351 0 00039 5 972 0 01 mm 6 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 3 Check end of valve stem for flaring pitting wear or damage A mm 4 Inspect split keeper groove for wear or flaring of the keeper Valve Guide I D seat area B 0 23672 0 000295 NOTE The valves can be re faced or end ground if 6 0617 0 0075 mm necessary They must be replaced if extensively worn burnt bent or damaged 7 Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance NOTE 5 Measure diameter of valve stem with a micrometer in three The valve guides cannot be replaced Be sure to measure places then rotate 90 degrees and measure again six each guide and valve combination individually measurements total Compare to specifications
203. e new O rings Lubricate O rings lightly with oil to aid installation Torque the fuel rail mounting screw to specification e T Fuel Rail Mount Screws 16 20 ft Ibs 22 6 27 Nm CRANKSHAFT POSITION SENSOR CPS Operation Overview The engine speed sensor is essential to engine operation constantly monitoring the rotational speed RPM and position of the crankshaft A ferromagnetic 60 tooth ring gear with two consecutive teeth missing is mounted on the flywheel The inductive speed sensor is mounted 1 0 0 26 mm 0 059 0 010 in away from the ring gear During rotation an AC pulse is created within the sensor for each passing tooth The ECU calculates engine speed from the time interval between the consecutive pulses The two tooth gap creates an interrupt input signal corresponding to specific crankshaft position for PTO cylinder This signal serves as a reference for the control of ignition timing by the ECU Synchronization of the CPS and crankshaft position takes place during the first two revolutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will quit running 4 15 FUEL INJECTION CPS Test The crankshaft position sensor is a sealed non serviceable assembly If fault code diagnosis indicates a problem within this area test and correct as follows 1 Disconnect main harne
204. e on the shift lever end also Inside Jam Nut UT Outside Jam Nut After turning the outside jam nut 1 1 2 turns Hold the outside jam nut with a wrench and tighten the inside jam nut clockwise until it is tight against the bracket Repeat Step 4 and Step 5 until the proper adjustment is made for the transmission cable Use this procedure to loosen or tighten the shift linkage cable as needed Inside Jam Nut Outside Jam Nut Cou nterclockwise TRANSMISSION SERVICE Transmission Removal Remove the PVT system from the left side of the transmission 2 Drive roll pin from rear driveshaft yoke NOTE On the 4x4 amp 6x6 transmission the front output shaft yolk slides off during the transmission removal Roll Pin Removal Tool PN 2872608 Remove the air intake hose from the air box that is located above the transmission Place the hose to the side this eases the transmission removal Remove the vent hose from the top of the transmission EE Vent Tube amp Air Intake Hose 8 3 TRANSMISSION 4 Disconnect the transmission switch 7 Remove the mounting bolts from the transmission 5 A mounting on both sides of the transmission General Transmission Mounting Transmission Switch 5 Remove the cotter pin from the shift linkage rod Remove the shift linkage rod and a washer from the bellcrank 8 Remove four bottom transmission to frame bolts
205. e performed with an engine or starting system that is not working properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered To perform this test hook a multitester to the battery in the same manner as was done in the OCV test The reading should be 12 6 volts or greater Engage the starter and observe the battery voltage while cranking the engine Continue the test for 15 seconds During cranking the observed voltage should not drop below 9 5 volts If the beginning voltage is 12 6 volts or higher and the cranking voltage drops below 9 5 volts during the test replace the battery Off Season Storage To prevent battery damage during extended periods of non use the following basic battery maintenance items must be performed Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water Rinse with lots of fresh water after cleaning NOTE Do not get any of the baking soda into the battery or the acid will be neutralized Using a wire brush or knife remove any corrosion from the cables and terminals Make sure that the electrolyte is at the proper level Add distilled water if necessary Charge at a rate no grea
206. e shift yoke pivot shaft L out of the carrier cover 14 Remove the shift lever M and springs N from the shift yoke H Inspect the components for wear and replace as 11 Remove the shift yoke pivot shaft L Use a 1 4 in 20 needed coarse thread bolt approximately 3 in long to thread into the pivot shaft 7 48 FINAL DRIVE 15 Remove the pinion shaft seal P using a seal puller 2 Install the original shims A onto the differential assembly B on both sides Install the bearings C replace with new bearings if needed 16 SPECIAL NOTE The Pinion assembly is NOT intended to be disassembled as it requires special OEM tooling in order to properly assemble the pinion assembly If there is any damage to the pinion gear bearings or case the assembly must be replaced Differential Assembly Replace all O rings seals and worn components Replace the O ring and oil seal on the carrier housing NOTE Grease all seals and O rings with Polaris All Season Grease PN 2871322 upon assembly 4 Install the spring lever and shift yoke into the carrier cover if previously removed 7 49 FINAL DRIVE KE 7 7 50 Assemble the shift yoke D shift lever spring lever 8 Install the new lightly greased O ring K onto the carrier F and return spring E cover H carier Use the bolt that was used to remove the shift yoke pivot shaft H to reinse
207. ecifications Replace if damage is evident or if worn beyond service limit Rear Caliper Piston Bore I D Std 1 2550 3 227 mm Service Limit 1 256 31 902 mm Inspect piston for nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit Rear Caliper piston O D Std 1 250 31 75 mm Service Limit 1 2495 31 737 mm Inspect the brake disc and pads as outlined for brake pad replacement in this chapter Caliper Assembly Install new square O rings A in the caliper body Be sure that the grooves are clean and free of residue or brakes may drag Coat the piston with clean Polaris DOT 4 Brake Fluid P N 2872189 Install piston B with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance Lubricate the mounting bracket pins with Polaris Premium All Season Grease and install the rubber dust seal boots Polaris Premium All Season Grease PN 2871423 Compress the mounting bracket and make sure the dust seals are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease 5 Caliper Installation 4 4 6x6 1 2 3 Install the rear caliper with the mounting bolts Torque mounting bolts to 18 ft Ibs 24 Nm Install brake line banjo bolt Torque banjo bolt to 15 ft Ibs 21 Nm
208. ed into the driven sheave 1 Place a straight edge on top of the belt between drive and driven clutch Push down on drive belt until it is lightly tensioned 3 Measure belt deflection as shown in photo If belt deflection is out of specification adjust by removing or adding shims between the driven clutch sheaves Remove shims to decrease belt deflection Add shims to increase belt deflection See Driven Clutch Service At least one shim must remain between the inner and outer sheave of the driven clutch If proper belt deflection cannot be obtained measure drive belt width length and center distance of drive and driven clutch outlined in this section all have an effect on belt deflection Belt Removal 1 Remove outer PVT cover as described in PVT Disassembly 2 Mark the drive belt direction of rotation so that it can be installed in the same direction 6 7 CLUTCHING NOTE Belt is normally positioned so that part 1 numbers are easily read 3 Toremove drive belt put transmission in gear apply brake pull upward and rearward on belt to open driven clutch 3 sheaves pull out and down on belt to slip over the driven clutch outer sheave Belt Inspection Belt width Belt Width New 1 188 3 02 cm Wear Limit 1 157 2 94 cm Measure belt width and replace if worn severely Generally belt should be replaced if clutches can no longer be adjusted to provide proper belt
209. edure below To change rear gearcase lubricant 1 With the vehicle on a level surface remove the fill plug and check the lubricant level Lubricant should be kept at the specified level according to the proper gearcase specifications listed 2 Support the vehicle securely with a jack stand and remove the front tire on the driver s side 3 Remove gearcase drain plug located on the bottom of the gearcase and drain oil The drain plug is accessible through the skid plate Catch and discard used oil properly 4 Clean and reinstall drain plug using a new sealing washer REAR GEARCASE 6X6 Make sure vent is unobstructed GENERAL INFORMATION 5 Remove fill plug 6 Fill with 10 oz 300 ml or fill to the bottom of the threads of the fill plug hole 7 Install fill plug and torque to 14 ft Ibs 19 Nm Check for leaks COOLING SYSTEM Liquid Cooling System Overview The engine coolant level is controlled or maintained by the recovery system recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on
210. ee ew eee BATTERY CHECK enit p da eee 10 30 BATTERY INSPECTION 10 30 BATTERY REMOVAL 5 eae a abd Extr P ete Coca 10 30 BATTERY 1 10 31 BATTERY TESTING steed warts att A ead pes hye toe PE Seek ge 10 31 OCV OPEN CIRCUIT VOLTAGE 10 31 Bel WEE 10 31 OFF SEASON 8 10 32 BATTERY CHARGING shes o tee ete E Mk 10 32 STARTER SYSTEM Seatac asian adole a dee ice I CR QR CR TROUBLESHOOTING x rte trece on etta etur car VITE ae 10 33 VOLTAGE DROP TEST e RR Rb RD a 10 33 STARTER MOTOR REMOVAL DISASSEMBLY 10 33 BRUSH INSPECTION REPLACEMENT 10 34 ARMATURE 10 35 STARTER REASSEMBLY 10 35 STARTER SOLENOID BENCH 8 10 36 STARTER DRIVE tha aeter ero ritratto mee oops Ee ERR e 10 36 STARTER EXPLODED VIEW issus lii ke RE RERO ea 10 37 STARTER SYSTEM TESTING FLOW ELECTRIC BOX LIFT ACTUATOR ac eto e me xh Re mre
211. emory and determines the appropriate fuel and spark requirements for the immediate operating conditions The ECU then sends output signals to set the injector duration and ignition timing During operation the ECU continually performs a diagnostic check of itself each of the sensors and system performance If a fault is detected the ECU turns on the Check Engine light in the speedometer and stores the fault code in its fault memory Depending on the significance or severity of the fault normal operation may continue or Fail Safe operation slowed speed richer running may be initiated A technician can determine the cause of the Check Engine light by initiating the Blink Code sequence or by using Digital WrenchTM The ECU requires a minimum of 7 0 volts to operate The memory in the ECU is operational the moment the battery cables are connected To prevent engine over speed and possible failure a rev limiting feature is programmed into the ECU If the maximum RPM limit 6200 is exceeded the ECU suppresses the injection signals cutting off the fuel flow This process repeats it self in rapid succession limiting operation to the preset maximum FUEL INJECTION RANGER 700 EFI RPM Limit Hard Limit Injector suppression occurs High 6200 Low 6200 Neutral 6200 Reverse 6200 Soft Limit Timing suppression occurs High None Low 5900 Neutral 5900 Reverse 5900 ECU Service Never
212. en the fuel reaches the bottom of the filler neck Leave room for expansion of fuel Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored If you get gasoline in your eyes or if you should swallowgasoline seekmedicalattentionimmediately f you spill gasoline on your skin or clothing immediately wash with soap and water and change clothing Always stop the engine and refuel outdoors or in a well ventilated area Gasoline is extremely flammable and explosive Special Tools PART NUMBER TOOL DESCRIPTION PU 43506 A Fuel Pressure Gauge Kit PU 47063 Digital Wrench Diagnostic Software Digital WrenchTM PU 47471 SmartLink Module Kit PU 47470 PU 47469 PU 47468 PU 47470 Digital WrenchTM PC Interface Cable PU 47469 Digital Wrench Vehicle Interface Cable PU 47468 Digital Wrench SmartLink Module 2201519 Throttle Position Sensor Tester PU 47315 Throttle Body Adjustment Screwdriver small D shape 4 2 Fuel Pressure Gauge Kit PU43506 A IMPORTANT The EFI fuel system remains under high pressure even when the engine is not running Before attempting to service any part of the fuel system the pressure must be relieved The
213. ence of the seat and the seat must be the proper width all the way around f the seat is uneven compression leakage will result If the seat is too wide seat pressure is reduced causing carbon accumulation and possible compression loss If the seat is too narrow heat transfer from valve to seat is reduced The valve may overheat and warp resulting in burnt valves Good Narrow Too Uneven Wide 1 Install pilot into valve guide 2 Apply cutting oil to valve seat and cutter Place 46 cutter on the pilot and make a light cut 4 Inspect the cut area of the seat fthe contact area is less than 75 of the circumference of the seat rotate the pilot 180 and make another light cut fthecutter now contacts the uncut portion of the seat check the pilot Look for burrs nicks or runout If the pilot is bent it must be replaced fthe contact area of the cutter is in the same place the valve guide is distorted from improper installation f the contact area of the initial cut is greater than 75 continue to cut the seat until all pits are removed and a new seat surface is evident NOTE Remove only the amount of material necessary to repair the seat surface 5 Tocheckthe contact area ofthe seat on the valve face apply a thin coating of Prussian Blue paste to the valve seat If using an interference angle 46 apply black permanent marker to the entire valve face A
214. ended periods of non use the following basic battery maintenance items must be performed Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water Rinse with lots of fresh water after cleaning Using a wire brush or knife remove any corrosion from the cables and terminals Charge at a rate no greater than 1 10 of the battery s amp hr capacity Store the battery either in the machine with the cables disconnected or store in a cool place NOTE Stored batteries lose their charge at the rate of 196 per day Recharge to full capacity every 30 to 60 days during a non use period If the battery is stored during the winter months electrolyte will freeze higher temperatures as the battery discharges The chart below indicates freezing points by specific gravity Electrolyte Freezing Points E Beane Freezing Point 1 265 75 F 1 225 35 F 1 200 17 F 1 150 45 F 1 100 418 F 1 050 27 F 10 32 Battery Charging If battery voltage is 12 8 V or less the battery may need recharging When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging NOTE Always verify battery condition before and 1 2 hours after the end of charging A WARNING An overheated battery could explode causing severe i
215. er 3 oz tube 12 Count 2871958 Black RTV Silicone Sealer 11 oz cartridge 12 Count 2870990 DOT 3 Brake Fluid 12 Count 2871557 Crankcase Sealant 3 Bond 1215 5 2 2872893 Engine Degreaser 120z 12 Count NOTE The number count indicated by each part number in the table above indicates the number of units that are shipped with each order GENERAL INFORMATION MAINTENANCE REFERENCES Item Lube Rec Method Frequency Change after 1st month 25 hrs 6 months Polaris 0W 40 or 100 hours thereafter Change more often 1 Engine Oil Add oil to proper level Synthetic 2871281 in extremely dirty conditions or short trip cold weather operation Fill reservoir between MAX 2 Brake Fluid DOT 3 PN 2870990 or Dot 4 and Min lines As required Change fluid every 2 years 3 Transmission Polaris AGL Gearcase Add lube to bottom of fill plug Change annually Change more often if Lubricant PN 2873602 threads used in severe conditions Polaris Demand Drive Hub Draincompletely Add lube to mun Pront Gearcase c Sd BN 2871654 specified quantity SE Angle Drive Fluid Drain completely Add lube to 3 CR 5 Middle Gearcase PN 2871653 specified quantity Semi annually More often under severe use such as operated in water or under severe loads Semi annually or 50 hours of operation refer to Maintenance Schedule for add
216. erates the differential solenoid The fan relay controlled by the ECU and Temp Sensor operates the fan The power relay controlled by the ECU turns on power for components such as the fuel pump injectors etc Key On 12V Power RD WI Ground BN Rear Diff Power Ouput 06 WH ECU Input BN W Key On 12V Power RD WH Fan Power Output 6 8 n Y BLK SS ECU Input 20 Amp Power Supply RD 15 Amp Power Supply Key On Power Input Das 1 48 Key On Power Output RD 8K 0 ECU Input GY WH REAR DIFF SOLENOID RELAY COLOR FUNCTION Red White Key On battery power supply switched on by key switch enables power to relay Brown Ground path for relay Key On power supply switched by relay provides power to Rear Diff Solenoid Brown White ECU ground input to connect relay Key On power to Rear Diff Solenoid output FAN RELAY COLOR FUNCTION Red White Key On battery power supply switched on by key switch enables power to relay Orange Black Fused 20 Amp power switched by relay provides power to Fan Motor Yellow Black ECU input to connect relay Fused 20 Amp power to Fan Motor output Fused 20 Amp constant battery power IN Red
217. ern 18 23 ft Ibs 24 31 Nm 4 Install a new roll pins into the mid and rear prop shafts and middle gearcase input and rear output shafts 12 Remove the fill plug P and fill the mid gearcase with 6 75 5 oz 200 ml of Polaris ATV Angle Drive Fluid PN 2871653 Torque the fill plug to 14 ft Ibs 19 Nm 6 Install the vent tube A and clamp Install the mid drive shafts D onto the mid gearcase B 7 Lift bearing carrier into place and install bolt to upper control arm Torque bolt to 35 ft Ibs 47 Nm Refer to the MID DRIVE SHAFT INSTALLATION section for more details 8 Install hub flat washer domed washer domed side out and nut Torque center nut to 110 ft Ibs 149 Nm Install new cotter pin and hub cap 9 Install rear wheel and torque wheel nuts to specification 10 Install the parking brake caliper C refer to Chapter 9 Parking Brake Caliper Service Caliper Installation 7 34 FINAL DRIVE Mid Gearcase Exploded 18 23 ft Ibs 24 31 Nm 18 23 ft Ibs 24 31 Nm REF DESCRIPTION QTY REF DESCRIPTION QTY 1 Screw 5 16 18 x 1 0 12 16 Washer Thrust 2 2 Plug Square Socket 3 17 Bearing Plain Flanged 2 3 Seal Dual Lip 2 18 Gearcase 1 4 Tube Vent 1 4 Hose 1 19 1 5 Cover Output 1 20 Pinion 10T 1 6 Shim 1 21 Gear 26T Output 1 7 Bearing Ball 1 22 Ball 1 8 Gear Rin
218. es that the transmission is tight against the lower frame and helps to properly align the transmission NOTE Align clutches as outlined in Chapter 6 7 Align the front input shaft to the front propshaft yoke on the vehicle 8 Align rear output shaft to rear propshaft yoke and roll pin hole 9 Slide rear output shaft and into propshaft yoke Drive the roll pin into the driveshaft yolk x 0 10 Reinstall the shift linkage rod the air intake hose the vent hose on top of the transmission AGL Gearcase Lube 15 2 oz 450 ml 8 14 TRANSMISSION TROUBLESHOOTING Troubleshooting Checklist Check the following items when shifting difficulty is encountered dle speed adjustment PVT alignment Transmission oil type quality Transmission torque stop adjustment where applicable Engine torque stop adjustment where applicable Drive belt deflection Loose fasteners on rod ends Loose fasteners on selector box Worn rod ends clevis pins or pivot arm bushings Linkage rod adjustment and rod end positioning Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting linkage rod from transmission bellcrank Manually select each gear range at the transmission bellcrank and test ride vehicle If it functions properly
219. es this signal to determine when to activate the fan during operation If for any reason the engine temperature sensor circuit is interrupted the fan will default to ONT 4 19 FUEL INJECTION ECT Sensor Test Engine Temperature Sensor To quickly rule out other components and wiring related to the ETS disconnect the harness from the ETS The fan should turn on and should indicate on the instrument cluster This indicates all other components are working properly Referto Chapter 10 for ECT testing Polaris dealers can also test the sensor by using the Digital Wrench Diagnostic Software dealer only Refer to the Digital Wrench User Guide for more information ECT Sensor Resistance Readings Temperature Resistance 68 F 20 C 2 5 6 212 F 100 C 0 186 kO 2 ECT Sensor Replacement Drain coolant to level below sensor 2 Disconnect sensor from engine harness 3 Using a wrench remove and replace the sensor applying a light coating of thread sealant to aid installation 4 Torque the sensor to 17 ft Ibs 23 Nm ey T ECT Retaining Bolt Torque 17 ft Ibs 23 Nm 4 20 FUEL INJECTION GENERAL TROUBLESHOOTING 3 Any blink codes stored in the ECU will display a numerical blink code one at a time in numerical order Diagnostic Blink Codes NOTE The EFI diagnostic mode is intended to quickly view
220. es with the instrument cluster To enable AWD the cluster must be displaying low high or reverse gear 16 Pin Connector Blue White Engine Overheat Switch Orange Red Park Brake Indicator BIk White Malfunction Indicator Violet White Fuel Gauge Brown Red Ground White Gear Indicator Input NIC Brown White AWD Control NOT AN INSTRUMENT N CLUSTER PROBLEM CHECK AWD SWITCH AND WIRING Note Reversing polarity when connecting the battery or other DC power source backwards will fail the AWD control and the instrument cluster If the key switch and the AWD switch are turned on REPLACE INSTRUMENT CLUSTER PROCEED TO MECHANICAL AWD N COMPONENTS IF AWD PROBLEM P RSISTS ELECTRICAL TEST 2 No Display Note Before starting diagnosis turn off speedometer and wait 10 seconds 9 then turn on again to see if problem clears CHECK FOR MINIMUM Seen START HERE 3 Pin Connector PINC REPLACE KEY SWITCH ON SPEEDO A D C Power B Signal MEASURE C Ground G BACK OF Y REPLACE CHECK WHEEL SPEEDO POINTER ll SPEED BACK OF SPEEDO MOVE SENSOR CHECK FOR 10 12 SPEEDO SEE TEST 3 VDC ON PIN A TO PIN C ON THE 3 PIN Y CONNECTOR 16 PIN MEA N SURE 12VDC REPAIR ON PINS 1 amp WIRING N 8 AND 2 amp 8 REPLACE SPEEDO REPLACE N Y TEST ODOMETER DRIVE ODOMETER Y SOINTER Y SPEEDO DISPLAY VEHICLE CHANGE MOVE OK SPEEDO TEST 3
221. ess mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other Be sure pads and disc are free of dirt or grease Install caliper on hub strut and torque moun e E Front Wheel Nut Torque 37 ft Ibs 50 Nm y Y T en re Front Caliper Mounting Bolts Torque 18 ft Ibs 24 Nm 9 14 5 FRONT CALIPER Front Caliper Exploded View DURING ASSEMBLY a APPLY POLARIS DOT 4 BRAKE FLUID TO COMPONENT f r APPLY POLARIS ALL Bleeder Screw PURPOSE GREASE 30 60 in Ibs Dust Boots 3 4 6 8 Nm aL N FRONT CALIPER EXPLODED VIEW Adjuster Screw Finger Tight Caliper Body Caliper Mount Caliper Removal Caliper Disassembly 1 Elevate and support front of machine 1 Remove brake pad adjuster screw A A CAUTION 2 Push upper pad retainer pin inward and slip brake pads past edge if pads are still installed Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 3 Remove mounting bracket B and dust boot C Remove the front wheel 3 Remove brake line from the caliper Place a container under caliper to catch fluid draining from brake line 1 U Y HA Figure 9 15 Ve 4 Remove brake caliper mounting bolts and caliper 9 15 5 4 Remove piston D and square O rings E f
222. ess of the level marks being on top or on bottom See the next illustration E Dipstick K Always read top side of dipstick to properly check oil level in crankcase EE ec 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 change the oil immediately 2 18 Engine Oil and Filter Change A WARNING Personal injury can occur when handling used oil Hot oil can cause burns or skin damage Recommended Engine Oil Polaris Premium Synthetic OW 40 PN 2871281 Quart Ambient Temperature Range 40 F to 120 F Place vehicle on a level surface ease access to the oil filter try to access the oil filter from the front engine cover or remove the storage container located under the driver side seat refer to Chapter 5 for front engine cover and storage removal Ne 3 Run engine two to three minutes until warm Stop engine Clean area around drain plug at bottom of oil engine Drain plug is accessible through the skid plate AA CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result 5 Place a drain pan beneath crankcase and remove drain plug Drain Plug 6 Allow oil to drain completely 7 Replace the sealing washer on drain plug NOTE The sealing surface on the drain plug should be
223. et eo 10 7 OVERVIEW EE LOU wah Un 10 7 RIDER INFORMATION DISPLAY 10 7 STANDARD DISPLAY MODES 10 8 DIAGNOSTIC DISPLAY 10 8 VIEWING DIAGNOSTIC 5 10 10 INSTRUMENT CLUSTER REMOVAL 10 11 INSTRUMENT CLUSTER INSTALLATION 10 11 INSTRUMENT CLUSTER TROUBLESHOOTING 5 5 10 12 TEST 1 NO ALL WHEEL DRIVE 00 0 0 ccc eee 10 12 TEST 2 NO DISPLAY occ cc etek ek bee Re A Ae don 10 13 TEST 3 WHEEL SPEED SENSOR 10 13 TEST 4 NO AWD HUB SAFETY LIMITER 00 0 0 00 00000000 10 14 TEST 5 FUEL GAUGE DISPLAY NOT WORKING 10 15 TEST 6 SHIFT INDICATOR NOT WORKING TRANSMISSION SWITCH 10 15 ALL WHEEL DRIVE AWD NN 10 16 OPERATION OVERVIEW 4 4 10 16 DIAGNOSING SYSTEM FAILURES 0 10 16 GEAR POSITION INDICATOR 10 16 TEST DIAGRAM b e VER ae due en Baa 10 16 HEADLIGHTS 5 acide LA Geese Re eae 10 17 HIGH BEAM
224. ew 298 007 7 56 178 mm installed Service Limit 180 4 6 mm NOTE Brake fluid will be forced through compensating port into master cylinder fluid Installation reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 1 Install new pads in caliper body 6 Remove the brake pads 18 ft Ibs 24 Nm 9 19 5 Rear Brake Caliper Mounting Bolt Torque 18 ft Ibs 24 Nm 3 Turnadjuster screw back in finger tight using a hex wrench Slowly pump the brake pedal until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the master cylinder Pump the Brake Pedal REAR BRAKE PAD 6X6 Pad Removal 1 Elevate and support rear of machine CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 2 Remove the rear wheel Loosen pad adjuster screw 2 3 turns Adjuster Screw 9 20 3 Clean caliper area before removal 4 Remove caliper mounting bolts and lift caliper off of disc NOTE When removing caliper be careful not to damage brake line Support caliper so as not to kink or bend brake line 5 Push caliper piston into caliper bore slowly with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoi
225. falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearings and seals Check bearings for side play by grasping the tire wheel firmly and checking for movement Grasp the top and bottom of the tire The tire should rotate smoothly without binding or rough spots Remove wheel nuts washers and wheel Remove the two brake caliper attaching bolts CAUTION Do not hang the caliper by the brake line Use wire to hang the caliper to prevent possible damage to the brake line 7 3 FINAL DRIVE 5 Remove hub cap cotter pin front spindle nut and washer 3 Drive bearing out evenly by tapping on outer race only b vpr Once bearing is at bottom of casting support casting on outer edges so bearing can be removed d uwt 6 Rotate each bearing by hand and check for smooth rotation Visually inspect bearing for moisture dirt or corrosion Replace bearing if moisture dirt corrosion or roughness NOTE Due to extremely close tolerances and is evident 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 4 Inspect bearing hubstrut housing for scratches wear or damage Replace hubstrut housing
226. fer to specific fastener torques listed in each chapter Shift Linkage Inspection Adjustment Linkage rod adjustment is necessary when symptoms include e No Wheel Drive light Noise on deceleration nability to engage a gear Excessive gear clash noise Shift selectors moving out of desired range NOTE Remove necessary components to gain access to shift linkage cable ends i e exhaust heat shield exhaust pipe etc SS 1 Inspect shift linkage cable clevis pins and pivot bushings and replace if worn or damaged 2 Besure idle speed is adjusted properly 3 Place gear selector in neutral Make sure the transmission bell crank is engaged in the neutral position detents 4 With two wrenches loosen the outside jam nut counterclockwise Turn the outside jam nut 1 1 2 turns Perform this procedure on the shift lever end also a EP j D Bi Inside Jam Nut Outside Jam Nut EEDA LJ Shift Cable Adjustment 5 After turning the outside jam nut 1 1 2 turns Hold the outside jam nut with a wrench and tighten the inside jam nut clockwise until it is tight against the bracket 6 Repeat Step 4 and Step 5 until the proper adjustment is made for the transmission cable 2 13 GENERAL INFORMATION 7 Use this procedure to loosen or tighten the shift linkage cable as needed Inside Jam Nut Counterclockwise Outside Jam Nut FUEL SYSTEM AND AIR INTAKE Fuel System A WARNING Gaso
227. ferential mounting will have to be loosened to allow the propshaft to slide off of the transmission output shaft MID DRIVE GEARCASE 6X6 Gearcase Removal MID DRIVE GEARCASE REAR DRIVE SHAFT PIN e e d MID DRIVE SHAFT TRANSMISSION COUPLER SS 1 MOUNTING BOLTS amp WASHERS 7 28 FINAL DRIVE NOTE To ease the removal of the middle axle gearcase remove the box from the frame Refer to the Box Removal Procedure in Chapter 5 1 Remove the vent line clamp vent line A from the top of the mid drive gearcase B Remove the mid drive shafts D Repeat steps 1 3 in the Mid Drive Shaft Removal section Remove the parking brake caliper C refer to Chapter 9 Parking Brake Caliper Service Caliper Removal Use the Roll Pin Removal Tool PN 2872608 to remove the roll pins that secure the rear prop shaft and middle prop shaft to the mid drive gearcase Roll Pin Removal Tool 2872608 NOTE If the rear drive shaft does not slide off the mid gearcase output shaft compress the rear suspension and the rear driveshaft will move back 5 Remove the four bolts and washers that secure the gearcase to the frame The bolts are accessible through the skid plate on the bottom of the frame With the drive shafts removed from the mid gearcase lift the gearcase out of the frame Gearcase Disassembly Drain the oil from the mid drive gearcase Properly di
228. for more information on fan functions AA CAUTION Keep hands away from fan blades during operation Serious personal injury could result NOTE The fan may not function or operation may be delayed if coolant level is low or if air is trapped in the cooling system Be sure cooling system is full and purged of air Refer to Maintenance Chapter 2 for cooling system information Fan Control Circuit Bypass Test 1 Disconnect harness from coolant temperature sensor on engine 2 Withthe parking brake on turn the ignition key and engine stop switch ON The fan should start running 3 If the fan does not run or runs slowly check the fan motor wiring ground motor condition and mechanical relay for proper operation Repair or replace as necessary If the fan runs with the sensor harness disconnected but will not turn on when the engine is hot check the coolant temperature sensor and connector terminals Coolant Temperature Sensor The coolant temperature sensor can be tested using an ohmmeter or voltmeter 1 With the engine and temperature sensor at room temperature 68 F 20 disconnect the harness connector 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 TEMPERATURE F C RESISTANCE 68 F 20 C 2 5kQ 6 0 186 A 2 212 F 100 C
229. from the reservoir fills the additional area created when the caliper piston moves outward Brake fluid level is critical to proper system operation Too little fluid will allow air to enter the system and cause the brakes to feel spongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the lever is released and the master cylinder piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion heated fluid or contraction cooled fluid During system service be sure this portis open Dueto the high temperatures created within the system during heavy braking itis very important that the master cylinder reservoir have adequate space to allow for fluid expansion Never overfill the reservoir Do not fill the reservoir past the MAX LEVEL line This system also incorporates a diaphragm E as part of the cover gasket and a vent port F located between the gasket and the cover The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts Make sure the vent is open and allowed to function If the reservoir is over filled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system leading to brake failure When servicing Polaris brake systems
230. g calipers 11 Add brake fluid to MAX level inside reservoir Master Cylinder Fluid Level Between the MIN and MAX line shown on the reservoir 12 Install master cylinder reservoir cover 13 Field test machine at low speed before putting into service Check for proper braking action and pedal reserve With pedal firmly applied pedal reserve should be no less than 1 2 1 3 cm 14 Check brake system for fluid leaks 9 7 5 PARKING BRAKE Exploded View Park Brake Handle Lever Mount Cotter Pin Washer Spring e Washer ei mi 2 fa i i N Bushings Park Brake Sensor Switch Spring Handle Nut DN Pin Clip Grommet Washer Pin 2 gt 4 Clip Pin dm Pin Park Brake mmm Caliper Assembly ATN go gt S Rear Prop Shaft Park Brake Disc Mount Bolt 9 8 5 Inspection l Inspectthe springs and bushings on the parking brake lever assembly 2 Inspect the parking brake cable and brake pads on the caliper assembly located on the rear propshaft See Parking Brake Caliper Service for brake pad replacement information Front p 3 Outboard Pad p Adjustment 1 Push the parking brake A down with your foot 2 After2to3clicks the wheels should not rotate when turning by hand After 10 full clicks of lever travel
231. g 37 1 23 Shaft Output Thru 1 9 Shaft Output 1 24 Gear 26T Input 1 10 Bearing Ball 1 25 Cover Input 1 11 Spring Wave 1 26 Seal Triple Lip 1 12 1 30 Bolt 5 16 18 x 1 25 3 13 Pipe Knock 4 31 Bracket Caliper Mount 1 14 Seal Triple Lip 1 32 Hog 2 15 Ring Retaining 2 7 35 FINAL DRIVE REAR DRIVE 4X4 Exploded View Rear Gearcase A arm bolts amp Shaft Bushings A pper A arm A Bushings Rear Drive Axle d 1 Ec zx VT gt 82 en Nm Em 2 Caliper dt E Tmn 18 ft Ibs A arm bolts DN 24 A J 9 Se i Nuts i Gack 5 pe E 2 We Bearing lt gt X Bushings Lower A arm Ta d Ar OK AG KN Carrier Bolt 30 ft lbs V 22 Shaft Snap Ring C e Bushings REAR HUB BEARING CARRIER 4X4 Hub Inspection Hub Removal 1 Support machine securely with rear wheels elevated 1 Elevate rear end and safely support machine under main frame area 2 Grasp wheel hub and check for movement Check bearings for side play by grasping the tire wheel firmly and checking for movement Grasp the top and bottom of the tire The tire should rotate smoothly without binding or rough spots 3 If movement is detected inspect hub hub nut torque and bearing condition and correct as necessary AA CAUTIO
232. h Operation 6 3 Driven Clutch Service 6 19 Driveshaft CV Joint Handling Tips 7 8 Driveshaft Propshaft Exploded View 757 Driveshaft Mid Drive 6x6 7 27 E EFI Operation Overview 4 9 EFI Priming Starting Procedure 4 10 EFI Troubleshooting 4 22 Electric Box Lift 10 39 Electrical Cooling System Breakout Diagram 10 19 Electronic Control Unit ECU 4 10 Engine Balance Shaft 3 44 Engine Camshaft Inspection 3 44 Engine Camshaft Installation 3 46 Engine Cooling System 3 13 3 14 Engine Cooling System Troubleshooting 3 59 Engine Crankcase Assembly 3 45 Engine Crankshaft Gear Removal 3 41 IX 1 Engine Crankshaft Installation 3 46 Engine Cylinder Head Assembly 3 30 Engine Cylinder Head Inspection 3 25 Engine Cylinder Head Removal 324 Engine Cylinder Head Warp 3 25 Engine Cylinder Honing 3 20 Engine Cylinder Inspection 3 33 Engine Cylinder Installation 3 47 Engine Cyl
233. h foam seal on back of cover or 1 shaft Install clutch offset spacers on transmission input shaft Offset Spacer s P K Y 6 6 CLUTCHING 10 11 12 13 14 15 16 Clean splines inside driven clutch and on the transmission input shaft Apply a light film of grease to the splines on the shaft Install the driven clutch washer lock washer and retaining bolt Torque to specification Clean end of taper on crankshaft and the taper bore inside drive clutch Install drive clutch and torque retaining bolt to specification Reinstall drive belt noting direction of rotation If anew belt is installed install so numbers can be easily read Toward outer cover L PVT Cover Gasket Replace PVT outer cover rubber gasket with the narrow side out C Reinstall PVT outer cover and secure with screws Torque to 45 50 in Ibs 5 5 6 Nm Install the PVT cover outlet duct and tighten the clamps Inner Cover Bolt Torque Rear 12 ft Ibs 16 6 Nm Outer Cover Bolt Torque 45 50 in lbs 5 5 6 Nm Driven Clutch Retaining Bolt Torque 17 ft Ibs 23 5 Nm Drive Clutch Retaining Bolt Torque 40 ft Ibs 55 Nm DRIVE BELT Belt Deflection Tension Straight Edge Deflection Measurement See Spec Below Belt Deflection Tension 1 1 8 2 9 cm 1 1 4 3 2 Pinch the sheaves lightly together with clamp to prevent the belt from being push
234. han 1 4 or stator coils may be damaged 2871043 rank Ce E y 1 A T Counterbalance Gear 3 37 8 Useawhite pen to accent the timing marks on the following gears camshaft gear K crankshaft gear M or counterbalance gear N This will ensure proper gear alignment and timing during reassembly of the gears NOTE If replacing one of the gears it is recommended that all of the gears be replaced A gear kit is available in the parts book 9 Use the Cam Gear Tooth Alignment Tool PU 45497 2 O to align the cam split gear assembly With the split gear aligned remove the bolt and cam gear assembly NOTE Install the Cam Gear Tooth Alignment Tool PU 45497 2 into the assembly hole counter clockwise from the timing mark as shown 10 Inspect the cam gear teeth and check to 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 E Loaded Springs 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 two gears Remove the top gear The springs should stay in place 3 38 AA CAUTION Wear safety glasses at all times Use caution when working with
235. he outlet radiator hose inlet radiator hose surge tank hose and overflow hose from the radiator 1 Check radiator A air passages for restrictions or damage 5 Remove the xadiator Inlet Radiator Hose Outlet Radiator Hose Carefully straighten any bent radiator fins 3 Remove any obstructions with compressed air or low pressure water Coolant Drain Radiator Removal 1 Remove the front bumper Remove three bolts that secure FINAL DRIVE WHEEL AND TIRE the bumper to the bottom of the frame Remove six screws both sides that secure the wheel well panel to the frame Wheel Hub and Spindle Torque Table Remove two bolts that secure the top bumper to the frame Remove the darts that attach the plastic to the bumper Item Nut Type Specification Je gent BOdE The 122 Cast Steel Wheels Black Flange Nut 2 35 ft Ibs 47 Nm Front Spindle Nut 70 Ft Lbs 95 Nm Rear amp Center Hub 110 Ft Lbs 150 Nm Retaining Nut 2 Removetwo mounting screws that secure the top of the radiator to the frame Remove the radiator cap Pull the radiator out of the frame at an angle NOTE If you have trouble reaching the top radiator Sa bolts remove four screws from the top front of the Aluminum Wheel Steel Wheel hood liner Prop the front of the hood up 1 5 inches LE Models Standard Models 38 10 mm to help remove the top bolts that
236. he side pull brushes out of 6 their guides and remove brush plate AA CAUTION Some cleaning solvents may damage the insulation in the starter Care should be exercised when selecting an appropriate solvent If the commutator needs cleaning use only electrical contact cleaner Armature Testing Place armature in a growler Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1 8 3 cm above armature coil laminates Rotate armature 360 If hacksaw blade is drawn to armature on any pole the armature is shorted and must be replaced Use care when handling starter housing Do not AA CAUTION drop or strike the housing as magnet damage is possible If magnets are damaged starter must be replaced 1 Remove armature from starter casing Note order of shims Starter Reassembly Installation on drive end for reassembly Inspect surface of commutator worn or damaged Replace if excessively 3 Using a digital multitester measure the resistance between 2 each of the commutator segments reading should be 3 ohms or less 3 4 Measure the resistance between each commutator segment and the armature shaft The reading should be infinite no 4 continuity 5 5 Check commutator bars for discoloration Bars discolored in pairs indicate shorted coils requiring replacement of the starter motor 6 1 Install brush plate to field magnet housing alig
237. he tank 4 14 Fuel Pressure Regulator Test Refer to the FUEL PUMP TEST procedure See Fuel Pump Test on page 4 12 Fuel Pressure Regulator Replacement The regulator is a sealed non serviceable assembly If it is faulty the pump assembly must be replaced Refer to the Fuel Pump Tank Assembly Replacement procedure FUEL INJECTORS Operation Overview NOTE All EFI units utilize quick connect fuel lines The fuel injectors mount into the intake manifold and the fuel rail attaches to them at the top end Replaceable O rings on both ends of the injector prevent external fuel leaks and also insulate it from heat and vibration When the key switch is on the fuel rail is pressurized and voltage is present at the injector At the proper instant the ECU completes the ground circuit energizing the injector 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 see inset contains a series of calibrated openings which directs the fuel into the intake port in a cone shaped spray pattern The injector is opened and closed once for each crankshaft revolution however only one half the total amount of fuel needed for one firing is injected during each opening The amount of fuel injected is controlled by ECU and determined by the length of time the valve needle is held open also referred to a
238. hite zip tie to measure the depth of the fluid in the rear gearcase If level is low add ATV Angle Drive Fluid PN 2871653 Measuring Instrument Reinstall fill plug Tighten to 40 ft Ibs 54 Nm Check for leaks 2 23 GENERAL INFORMATION To change the lubricant 1 Remove gearcase drain plug located on the bottom and drain the oil Catch and discard used oil properly Under Side View Drain Plug 30 45 Ibs 3 5 Nm 2 Cleanandreinstall the drain plug with a new sealing washer and tighten to 30 45 in Ibs 3 5 Nm 3 Remove fill plug Fill Plug 40 ft Ibs 54 Nm 4 Add 18 oz 532 ml of ATV Angle Drive Fluid PN 2871653 5 Reinstall fill plug Tighten to 40 ft Ibs 54 Nm 6 Check for leaks 2 24 Rear Gearcase Lubrication 6x6 Rear Gearcase Specifications Specified Lubricant ATV Angle Drive Fluid PN 2871653 Capacity 10 Oz 300 ml Drain Plug Fill Plug Torque 14 ft Ibs 19 4 Nm The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule e Be sure vehicle is level before proceeding with parking brake on Check vent hose to be sure it is routed properly and unobstructed correct rear gearcase lubricant to use is Polaris ATV Angle Drive Fluid To check the lubricant level The gearcase must be drained and re filled with the proper amount of lubricant Refer to the proc
239. ic Lifter NOTE Lifters that are scored worn or if the bottom is not smooth should be replaced with new lifters and cam as an assembly If replacing the lifters the camshaft should also be replaced 3 31 Piston Removal 1 Remove circlip A Mark the piston with a white pen to ensure proper orientation if reused during assembly NOTE If the pistons are to be reused reassemble the pistons in the same cylinder and direction from which they were removed NOTE New pistons are non directional and can be placed in either cylinder 2 Remove piston circlip and push piston pin out of piston If necessary heat the crown of the piston slightly with a propane torch CAUTION Do not apply heat to the piston rings The ring may lose radial tension 3 Remove top compression ring Using a piston ring pliers Carefully expand ring and lift it off the piston CAUTION Do not expand the ring more than the amount necessary to remove it from the piston or the ring may break By hand Placing both thumbs as shown spread the ring open and push up on the opposite side Do not scratch the ring lands i 7 4 Repeat procedure for second ring 5 Remove the oil control ring 3 32 The oil control ring is a three piece design consisting of atop and bottom steel rail and a center expander section The top rail has a locating tab on the end which fits into a notch B in the upper oil ring land
240. icants 2871322 Premium Season Grease 3 oz cartridge 24 Count 2871423 Premium All Season Grease 14 oz cartridge 10 Count 2871460 Starter Drive Grease 12 Count 2871515 Premium U Joint Lube 3 oz 24 Count 2871551 Premium U Joint Lube 14 oz 10 Count 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogel Coolant 2871323 60 40 Coolant Gallon 6 Count 2871534 60 40 Coolant Quart 12 Count 2 10 NOTE Each item can be purchased separately at your local Polaris dealer Part No Description Additives Sealants Thread Locking Agents Misc 2870585 Loctite Primer Aerosol 25 g 2871956 Loctite Thread Sealant 565 50 ml 6 Count 2871949 Loctite Threadlock 242 50 ml 10 Count 2871950 Loctite Threadlock 242 6 ml 12 Count 2871951 Loctite Threadlock 262 50 ml 10 Count 2871952 Loctite Threadlock 262 6 ml 12 Count 2871953 Loctite Threadlock 271 6 ml 12 Count 2871954 Loctite Threadlock 271 36 ml 6 Count 2870584 Loctite 680 Retaining Compound 10 ml 2870587 Loctite 518 Gasket Eliminator Flange Sealant 50 ml 10 Count 2871326 Premium Carbon Clean 12 oz 12 Count 2870652 Fuel Stabilizer 16 oz 12 Count 2871957 Black RTV Silicone Seal
241. id will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces This procedure should be used to change fluid or bleed brakes during regular maintenance Clean reservoir cover thoroughly Remove cover from reservoir If changing fluid remove old fluid from reservoir with a Mity Vac pump or similar tool Mity Vac PN 2870975 Add brake fluid to the indicated MAX level of reservoir Polaris DOT 4 Brake Fluid P N 2872189 Begin bleeding procedure with the caliper that is farthest from the master cylinder Install a box end wrench on caliper bleeder screw Attach a clean clear hose to fitting and place the other end in a clean container Be sure the hose fits tightly on fitting Slowly pump foot pedal until pressure builds and holds 7 8 Hold brake pedal on to maintain pedal pressure and open bleeder screw Close bleeder screw and release foot pedal NOTE Do not release foot pedal before bleeder screw is tight or air may be drawn into master cylinder Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir A CAUTION the reservoir to prevent air from entering the master cylinder Maintain at least 1 2 1 27 cm of brake fluid in Tighten bleeder screw securely and remove bleeder hose 10 Repeat procedure Step 5 through Step 9 for the remainin
242. ie rod end to keep it from rotating Loosen jam nuts at both end of the tie rod Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in Wheel Toe Alignment IMPORTANT When tightening the tie rod end jam nuts the rod ends must be held parallel to prevent rod end damage and premature wear Damage may not be immediately apparent if done incorrectly Hold RodEnd di c3 key D A Correctly Tightened Jam Nut Incorrectly Tightened Jam Nut After alignment is complete torque jam nuts to 12 14 ft Ibs 16 19 Nm ey T Tie Rod Jam Nut Torque 12 14 ft Ibs 16 19 Nm GENERAL INFORMATION Front Suspension Rear Suspension Compress and release front suspension Damping should be smooth throughout the range of travel Check all front suspension components and fasteners for wear or damage nspect front strut cartridges for leakage 0 5 POLARIS Bolt Torque 15 ft Ibs 20 Nm RANGER4X4 Independent Rear Suspension Inspect for leaks RANGER 6X6 Rear Swingarm Suspension Compress and release rear suspension Damping should be smooth throughout the range of travel Check all rear suspension components for wear or damage Inspect shock for leakage 2 33 GENERAL INFORMATION Rear Suspension Adjustment 4x4 The rear suspensi
243. ifications Cooling System 3 13 Specifications Crankcase Fastener Torque 3 46 Specifications Engine 3 2 Specifications Engine Lubrication 3 21 Specifications Engine Oil Pressure 3 21 Specifications General 1 6 Specifications Oil Baffle Bolt Torque 3 45 Specifications Oil Pick up Bolt Torque 3 45 Speedonieter led metal care eod 10 7 Speedometer Installation 10 11 Speedometer 1 10 11 Speedometer Troubleshooting Tests 10 12 Starter Armature Testing 10 35 Starter Assembly Exploded View 10 37 Starter Brush Inspection Replacement 10 34 Starter d sos se RUE ROPA 10 36 Starter Drive 1 3 35 Starter Motor 1 10 33 Starter Reassembly Installation 10 35 Starter System Flow Chart 10 38 Starter System Troubleshooting 10 33 Stator Removal 3 36 Steering oe PUDE REP PEE das 2 31 Steering Exploded View 5 11 Storage Box Installation 5 25 Storage Box 1
244. il Pump Bolts Engine Cover Wire Hold down Stator Housing Bolts ozg mi cocmommonsm 22 2 ft Ibs 30 3 Nm _ 84 8 in 165 9 5 90 Nm kb off bo 2 No Grease on this M DU U 1 Portion of the Gasket 108 12 in Ibs i LI p gt 6 8 68 Nm Apply corrosion resistant 9 grease to stator grommet area 96 3 in lbs Woe GU S E EE 10 85 0 35 Nm Oil Pump Bolt Tighten Sequence ane e mm mm mm zm mm Mag Cover Bolt Tighten Sequence Apply Polaris OW 40 oil to component GEAR TIMING AT TDC Apply White Lithium Grease 3 3 Stator Cover Starter Water Pump Exploded View Apply Polari ei EE Water Pump Cover Starter Grease S Bolt Tighten Sequence 2 Apply Polaris OW 40 E oll to seal Loctite Pipe Sealant PN 2871956 A 84 8 ft lbs 9 5 0 9 Nm L Tighten Top Bolt First 96 12 in lbs 10 85 1 35 Nm M 65 7 ft 165 88 9 5 Nm Bolts Starter Washer Nut Positive Cable Se Negative Cable 5 Gasket 96 12 in Ibs 10 85 1 35 Nm Clamp Stator Cover Bolt Bolts Tighten Sequence Gasket WaterPump Cover Bolts Crank Nut Washer Flywheel e redii pi Z Oil Filter Pressure Relief Dipstick Assembly Exploded View A Clamp
245. il it is lightly seated then turn the the cover surface f the O ring is twisted fluid screw out 1 4 turn leakage may occur 5 Setthe gearcase upright Rotate the pinion shaft at least 4 4 times This ensures the ring gear completes full rotation Cover Bolts Torque 17 ft Ibs 23 Nm 7 22 FINAL DRIVE If a tight spot is felt during rotation loosen the backlash screw another 1 8 turn Perform the previous step again Repeat this procedure until the pinion shaft rotates smoothly 4 times 1 revolution of ring gear Gearcase Installation 1 install gearcase reverse removal procedure Use new spring pin in front prop shaft 2 Torque mounting bolts to 30 ft lbs 41 Nm 3 4 Bolts 30 ft Ibs 41 Nm Front Housing Mount Bolt Toque 30 ft Ibs 41 Nm Add the proper lubricant to the front gearcase Check drain plug for proper torque Refer to Chapter 2 for fluid fill and change information Premium Front Drive Hub Fluid PN 2871654 Front Housing Capacity 5 fl oz 148 ml MID DRIVE HUB BEARING CARRIER 6X6 Removal 1 Lock the emergency parking brake Safely raise the center of the machine with a floor jack Raise the machine just enough to remove the middle wheel 2 Remove the four wheel nuts and wheel 3 Remove the hub cap and cotter pin ADEM Hub Nut amp Washers 5 Remove the hub from the axle shaft 7 23 FINAL DRIVE ss dm
246. in line fuel filter The in tank fuel pressure regulator maintains a system operating pressure of 39 psi and returns any excess fuel to the tank At the engine fuel is fed through the fuel rail and into the injectors which inject into the intake ports The ECU controls the amount of fuel by varying the length of time that the injectors are on This can range from 1 5 8 0 milliseconds depending on fuel requirements The controlled injection of the fuel occurs each crankshaft revolution or twice for each 4 stroke cycle One half the total amount of fuel needed for one firing of a cylinder is injected during each injection When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for air temperature barometric air pressure engine temperature speed RPM and throttle position load These primary signals are compared to the programming in the ECU computer chip and the ECU adjusts the fuel delivery and ignition timing to match the values During operation the ECU has the ability to re adjust temporarily providing compensation for changes in overall engine condition and operating environment so it will be able to maintain the ideal air fuel ratio During certain operating periods such as cold starts warm up acceleration etc a richer air fuel ratio is automatically c
247. inder Removal 3 31 Engine Designation Number 1 2 Engine Diagnostic Codes 4 21 Engine Exploded Views 3 2 3 3 3 4 3 5 3 7 3 8 Engine Fastener Torques 3 9 Engine Flywheel Stator Installation 3 54 Engine Flywheel Stator Removal 3 36 Engine Flywheel Removal 3 37 Engine Removal 3 37 Engine Gears Installation 3 49 Engine Head Assembly 3 54 Engine Installation Notes 3 19 Engine Lubrication 3 21 Engine Oil and Filter Change 2 18 Engine Oil Flow Chart 3 22 Engine Oil Level cse cto Rer ee E e688 2 17 Engine Oil Pressure 3 21 Engine Oil Priming 3 57 Engine Oil Pump Installation 3 48 Engine Oil Pump Removal 3 41 Engine Piston Identification 3 13 Engine Piston Installation 3 47 Engine Piston Removal Inspection 3 32 Engine Piston Ring Installed Gap 3 35 Engine Piston to Cylinder Clearance 3 34 Engine Piston to Rod Clearance 3 34 Engine Pushrod Inspection
248. ing Install a new o ring onto the shift shaft after the detent lever is assembled to the shaft Place a small amount of grease on the small O ring on the shift shaft and on the detent gear Grease the o ring on the end of the shift drum Detent Gear N f Detent er a CS lt m Install the cover and hand tighten all of the bolts Tighten the bolt indicated in the picture below first and torque the bolt to 7 9 ft 165 10 12 Nm This helps to align the cover and shaft to ensure smoother shifting THLE Tighten This Bolt First TRANSMISSION 32 Torque the remaining bolts to 7 9 ft lbs 10 12 Nm Transmission Installation 1 Install transmission from right side of vehicle Cover Bolt Torque 2 Position transmission in frame 7 9 ft Ibs 10 12 Nm 3 Loosely install the front transmission to frame bolts 33 Install a new bellcrank onto the shift shaft Note the keyed 4 Loosely install the rear transmission to frame bolt spline on the bellcrank and shaft Install the washer and nut 5 Loosely install the three bottom transmission to frame bolts 6 Tighten mounting fasteners in order A D as shown Bellcrank Nut Torque 12 18 ft Ibs 16 24 Nm Transmission Mounting Bolts Torque 34 Install transmission and add Polaris AGL Gearcase 25 ft Ibs 34 5 Nm Lubricant PN 2872602 NOTE Be sure to tighten the lower transmission bolts first this ensur
249. installation 18 ft Ibs gege 4x4 Model Shown Torque the two mounting bolts to 18 ft Ibs 24 Nm e T Parking Brake Caliper Mounting Bolts 18 ft Ibs 24 Nm Install the cable pin and clip pin Test the park brake for proper function PARKING BRAKE DISC SERVICE Disc Removal Inspection 1 Measure the park brake disc with micrometer The minimum allowable thickness of the disc should be 161 4 00 mm If the thickness of the disc is less than specified replace the rear propshaft disc assembly Follow the Rear Prop Shaft Removal 4 4 amp 6x6 procedure in Chapter 7 to remove the rear prop shaft disc assembly 4x4 Shaft Shown Remove Bolts Minimum Disc Thickness 0 140 3 56 mm New Disc 0 150 0 164 3 81 4 16 mm 5 FRONT BRAKE PADS Pad Removal Disassembly 1 Elevate and support front of machine AA CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls Remove the front wheel Loosen pad adjuster screw 2 3 turns b Pad SI SE Remove the two caliper bolts and caliper from mounting bracket 4 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper
250. iolet White Fuel Gauge Green Brown Red Ground Blue White Gear Indicator Input N C Yellow RPM Input R Brown Red Ground Brown White AWD Control WH DB JO Ob gt ELECTRICAL ALL WHEEL DRIVE AWD COIL Operation Overview When the AWD switch is ON 12 VDC power is present at the hub coil If the criteria is met the instrument cluster provides a ground path at pin 16 When this occurs the AWD icon should display in the instrument cluster AWD system must be grounded to operate Diagnosing System Failures Verify the AWD switch is functional and that a minimum of 11 volts is present at the hub coil Verify the AWD hub coil is functional Test the AWD hub coil using an ohm meter See specifications below 11 VOLTS MINIMUM REQUIRED TO POWER HUB COIL HUB COIL Test Resistance Readings should be GY to BN WH 24 Ohms GY to Ground No Connection AWD Coil Resistance 4 0 x 540 Verify the wiring harness wiring connectors connector pins and grounds are undamaged clean and connect properly Verify continuity of wire connections with a known good volt ohm meter IMPORTANT Verify all wires and wiring connections have been tested properly with a known good volt ohm meter before suspecting a component failure 8096 of all electrical issues are c
251. isconnect the black negative battery cable Bo Disconnect the red positive battery cable 2 29 GENERAL INFORMATION 5 Lift the battery out of the vehicle being careful not to tip it sideways and spill any electrolyte CAUTION To reduce the chance of sparks Whenever removing the battery disconnect the negative black cable first When reinstalling the battery install the negative cable last Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging procedure before installing the battery Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 Install the battery vent tube NOTE The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte 4 Coattheterminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables are properly routed Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge
252. itional information Annually or 100 hours of operation refer to Maintenance Schedule for additional information 1 Engine 2 Brake Master Cylinder Dipstick Fill Tube Fill Plug Fill Plug Drain Plug E Drain Plug 2 11 GENERAL INFORMATION Maintenance References Continued Item Lube Rec Method Frequency 6 Hubstrut Assembly Both Sides Polaris All Season Grease PN 2871423 Locate grease fitting on the underside of the hubstrut assembly and grease with grease gun Semi annually 7 Swing Arm Pivot Polaris All Season Grease PN 2871423 Locate grease fitting on inside of the swing arm pivot Semi annually 8 Rear Prop Shaft Yoke Polaris Premium U Joint Lube PN 2871551 Locate fittings and grease with grease gun Semi annually 9 Front Prop Shaft Yoke Polaris Premium U Joint Lube PN 2871551 Locate fittings and grease with grease gun Semi annually 10 Rear Gearcase ATV Angle Drive Fluid PN 2871653 Drain completely Add lube to specified quantity Change annually More often under severe use such as operated in water or under severe loads Semi annually or 50 hours of operation refer to Maintenance Schedule for additional information Annually or 100 hours of operation refer to Maintenance Schedule for additional information Grease conforming to NLGI No 2 such as Polaris
253. kg Cargo Box Capacity 1000 Ibs 454 kg Cargo Box Dimensions 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Vehicle Payload 1500 Ibs 681 kg Includes driver and two passengers 500 Ibs 227kg Hitch Towing Capacity 1500 Ibs 681 kg Hitch Tongue Capacity 150 Ibs 68 kg MODEL RANGER XP 6X6 Category Dimension Capacity Length 120 in 305 cm Width 60 in 152 4 Height 75 in 190 5 cm Wheel Base 90 in 229 cm Ground Clearance 7 2 in 18 25 cm Turning Radius 180 in 457 cm Dry Weight 1410 Ibs 640 kg Gross Vehicle Weight 2900 Ibs 1315 kg Cargo Box Capacity 1250 Ibs 567 kg Cargo Box Dimensions 58 x 48 x 10 in 147 x 122 x 25 4 cm Vehicle Payload 1750 Ibs 794 kg Includes driver and two passengers 500 Ibs 227kg Hitch Towing Capacity 1750 Ibs 794 kg Hitch Tongue Capacity 150 Ibs 68 kg 1 6 GENERAL INFORMATION MODEL RANGER XP 4X4 Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio Front Rear High 3 34 1 2 89 1 Low 8 67 1 7 49 1 Rev 5 92 1 5 11 1 Drive Ratio Front 3 818 1 Drive Ratio Final 3 70 1 Engine Polaris Domestic Twin Cylinder Liquid Cooled DC Engine Model Number EHO680LE044 Engine Displacement 683 Number of Cylinders 2
254. ks must align during reassembly 10 33 ELECTRICAL 3 Remove the front bracket assembly and the rear bracket assembly Remove the shims from the armature shaft and inspect the O rings located on the armature housing NOTE The reassembly shims will be replaced during BRUSH INSPECTION REPLACEMENT 1 Measure resistance between starter input terminal and insulated brushes The reading should be 3 ohms or less Remember to subtract meter lead resistance am on 6 Measure resistance between insulated brush and starter housing Reading should be infinite OL Inspect insulation on brush wires for damage and repair or replace as necessary 3 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Slide brush end frame off end of starter NOTE The electrical input post must stay with the field coil housing 4 Measure resistance between ground brush and brush plate Resistance should be 3 ohms or less Brush Inspection 1 Measure length of each carbon brush Replace brush assembly when worn to 5 16 8 mm orless The brushes must slide freely in their holders Brush Length Limit 5 16 8 mm 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 ELECTRICAL 2 Slide positive brush springs to t
255. l Pre Ride Air Filter Pre Filter Daily Inspect clean often Air Box Sediment Tube Daily Drain deposits when visible Coolant Level Daily _ Check level daily change coolant every 2 years Head Lamp Tail Lamp S Daily _ operation apply dielectric grease if replacing gt Air Filter E Main Element Weekly Inspect replace as needed gt Brake Pad Wear Inspect NT m Parking Brake Pads 10 H Monthly Inspect periodically Battery 20 H Monthly Check terminals clean test Front Gearcase Oil if equipped 25H Monthly Inspect level change yearly Middle Gearcase Oil if equipped 25H Monthly Inspect level change yearly Rear Gearcase Oil S if equipped 25H Monthly Inspect level change yearly Transmission Oil 25H Monthly Inspect level change yearly Engine Breather E Filter if equipped 25 H Monthly Inspect replace if necessary gt Engine Oil Change nme E Break In Period 25H 1M Perform a break in oil change at one month Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California Have an authorized Polaris dealer perform these services 2 4 GENERAL INFORMATION 50 100 Hour Maintenance Interval Maintenance Interval whichever comes first Item Remarks Hours Calendar Miles KM b General Lubrication 50H 3M
256. l Installer PA 44995 to properly install the seal to the correct depth in the cover IMPORTANT Due to seal design and construction seals MUST be installed DRY no lubricant during assembly Use of lubricants oil soapy water etc will not allow the seal to wear in and seal properly Do not touch seal surface or allow seal surface to come in contact with contaminates during installation Thoroughly clean parts tools and hands before installation NOTE To remove the water pump seal the gear stator housing must be removed The water pump seal cannot be removed or installed with the gear stator housing attached to the engine Shaft damage will occur NOTE Install the water pump seal N with the seal lip facing out towards the crankcase Use of a hydraulic press is recommended for this procedure 29 Install anew 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 Seel NOTE Install the crankshaft seal P with the seal lip facing out towards the crankcase lt Seal lip goes towards the crankcase 30 Once the crankshaft seal is installed into the gear stator housing cover set the direction of the paper lip by sliding the Main Crankshaft Seal Saver PA 45658 into the crankshaft seal from the rubber lipped side to the paper lip side Back to Front Remove the tool
257. laris Premium 60 40 Antifreeze Coolant is recommended for use in all cooling systems and comes pre mixed ready to use FLOW Thermostat Cylinder Cooling System Pressure Test 1 Open front hood 2 Remove surge tank hose from coolant filler neck 3 Connect a Mity Vac PN 2870975 to the filler neck nipple and pressurize system to 10 psi The system must retain 10 psi for five minutes or longer If pressure loss is evident within five minutes check the radiator hoses clamps and water pump seals for leakage Coolant Flow Diagram Radiator Cap Pressure Test A WARNING Never remove radiator cap when engine is warm or hot The cooling system is under pressure and serious burns may result Allow the engine and cooling system to cool before servicing 1 Remove radiator cap and test cap using a commercially available cap tester 2 radiator cap relief pressure is 13 psi Replace cap if it does not meet this specification Radiator Cap Surge Tank 28 gt From Thermostat Housing 3 14 Radiator Cooling System Exploded View Radiator Inlet Hose Engine Outlet Hose D d d 4 Za c Engine Inlet Hose Radiator Outlet Hose Surge Tank Radiator Shroud Drain Plug Cooling System Bleeding Procedure PROCEDURE 1 1 Park machine on a flat surface Place the vehicle in Neutral WARNING and set the parking brake AA CAUTION
258. le to the ECU low verify the 9 volt battery is good or try a new 9 volt battery 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 programmed maps to determine the required fuel and ignition settings for the amount of engine load NOTE The correct position of the TPS is established and set at the factory Do not loosen the TPS or alter the mounting position If the TPS is repositioned replaced or loosened it must be re calibrated TPS Test The throttle position sensor TPS is a non serviceable item If it is faulty it must be replaced It can be tested using the following method NOTE Before proceeding with any of the following measurements or tests it s extremely important to verify the throttle body bore is clean of any carbon build up Remove the intake boot and inspect the throttle body bore If required remove the throttle body and clean the bore Setup the TPS Test Adapter Harness PU 47082 according to the instructions that accompanied the tester Make sure that the 9 volt battery is new Test Procedure 1 PU 47082 TPS Test 2 Adapter Harness Plug the TPS test adaptor harness in the TPS harness Connect the red test probe in yellow test port and black test Use NEW probe in
259. lean and inspect driven clutch noting worn sheave bushing and ramp buttons and helix spring location Clean sheaves with denatured alcohol or brake cleaner install new belt Harsh drive clutch engagement Drive belt worn too narrow Excessive belt sheave clearance with new belt Replace belt Perform belt sheave clearance adjustment with shim washers beneath spider Drive belt turns over Wrong belt for application Clutch alignment out of spec Engine mount broken or loose Replace with correct belt Adjust alignment offset Inspect adjust or replace Belt burnt thin spots Abuse continued throttle application when vehicle is stationary excess load Dragging brake Slow easy clutch engagement Caution operator to operate machine within guidelines Vehicle operated with park brake on Inspect brake system Fast effective use of throttle for efficient engagement 6 22 CLUTCHING Troubleshooting Continued Situation Probable Cause Remedy PVT cover overheating melting Plugged air intake or outlet Belt slippage due to water oil grease etc rubbing on cover Clutches or weight being applied to cover while in operation High vs low range Clear obstruction Inspect system Clean repair or replace as necessary Seal PVT system ducts Remove weight Inform operator Instruct operator on guide
260. led Ignition Timing 7 BTDC 1200 RPM Toe Out 1 8 1 4 in 3 6 35 mm Wheels Brakes 3 12x 6 10 gauge EE Model AW 14 x 7 12x 8 10 gauge Rear hee L E Model AW 14 x 8 Front Tj Carlisle PXT 26 x 8 R12 Ge nes Bu is L E Model AW Kenda Radial Bounty Hunter 26 x 10 R14 Rear Tire Carlisle PXT 26 x 11 R12 Model AW Kenda Radial E Bounty Hunter 26 x 12 R14 Tire Air Pressure 8 12 psi Front 8 12 psi Rear Spark plug Gap Champion RC7YC3 035 in 0 9 mm Brake Front Rear Foot Actuated 4 Wheel Hydraulic Disc Battery Model Amp Hr Yuasa YB30L B 30 Amp Hr 12 Volt Parking Brake Foot Actuated Mechanical Brake Fluid DOT 3 or DOT 4 Instrument Type Multifunction Speedometer DC Outlet Standard Circuit Breakers Fan 20 Amp Dash Harness 20 Amp Accessory Terminal 20 Amp Power Relay 15 Amp ECU Battery Supply 6 Amp CLUTCH CHART z 2 Driven Altitude Shift Weight Drive Spring Spring 0 1500 20 60 Blu Gray Blk Almd Meters 0 5000 5631698 7042202 7043167 Feet 1500 3700 20 56 Blu Gray Blk Almd 5000 12000 5631215 7042202 7043167 1 7 GENERAL INFORMATION MODEL RANGER XP 6X6 Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio Front Rear High 3 89 1 3 36 1 Low 10
261. line 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 refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If you get gasoline in your eyes or if you swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time Never drain the fuel when the engine is hot Severe burns may result Fuel Lines 1 Check fuel lines for signs of wear deterioration damage orleakage Replace if necessary 2 Be sure fuel lines are routed properly and secured with cable ties CAUTION Make sure lines are not kinked or pinched 3 Replace all fuel lines every two years 2 14 Fuel Filter The RANGER XP 4x4 and 6x6 EFI engines use a non serviceable high volume high pressure 60 micron internal fuel pump filter and an internal 10 micron filter located before the pump regulator Neither filter is servicable gei Fuel filter in tank is not serviceable NOTE For all other information related to the EFI fuel system refer to Chapter 4 Vent Lines 1 Check fuel tank
262. lines for operation in proper driving range for differentterrain as outlined in Owner s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt worn out Replace belt Belt slippage Water ingestion Inspect and seal PVT system Belt contaminated with oil or grease Inspect and clean Belt worn or separated thin spots loose belt Replace belt PVE DOSS Broken or worn clutch components cover hitting Inspect and repair as necessary clutches Thin spots on belt worn belt Replace belt Refer to belt burnt troubleshooting and Engagement instruct operator erratic or stabby Drive clutch bushings stick Inspect and repair clutches 6 23 FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIAL TOOLS Vox db a aac E ok ORO a ae Paes oU c 7 3 TORQUE SPECIFICATIONS i ENEE iS cre a RR oh x CR ORC RR 7 3 WHEEL AND SPINDLE TORQUE 7 3 FROIN EIB 5025 lt er Dee P Dig e Jb d e Re A 7 3 HUB REMOVAL 7 3 HUBSTRUT BEARING 1 7 4 HUB
263. lure Scoring Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup Excessive piston to cylinder clearance Wet sumping due to over full crankcase Worn rings piston or cylinder Worn valve guides or seals Restricted breather Air filter dirty or contaminated Low Compression Cylinder head gasket leak No valve clearance cam wear Cylinder or piston worn Piston rings worn leaking broken or sticking Bent valve or stuck valve Valve spring broken or weak Valve not seating properly bent or carbon accumulated on sealing surface Rocker arm sticking Backfiring ETC or speed limiter system malfunction Fouled spark plug or incorrect plug or plug gap Exhaust system air leaks Exhaust system air leaks Ignition system faulty Spark plug cap cracked broken Ignition coil faulty Ignition or kill switch circuit faulty Poor connections in ignition system Ignition timing incorrect Sheared flywheel key Valve sticking 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 restricted jets vents fuel pump or fuel valve Fuel pump output
264. m Counter Balance Counter Balance End Play 0 005 0 127 mm Cylinder Head Surface warp limit 0 00394 0 1 mm Valve Seat Contacting Width Exhaust Cylinder Head Cylinder Head Standard height 3 478 88 35 mm Valve Seat Contacting Width Intake 0 0472 0 00787 0 0039 1 20 0 20 0 10mm Valve Seat 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 Protrusion Above Head 0 807 0 0039 20 50 0 01 mm Valve Valve Margin Thickness Intake Standard 0 79 20 06 mm Max 0 98 24 89 mm Min 0 59 14 98 mm Valve Margin Thickness Exhaust Standard 0 80 20 32 mm Max 1 0 25 4 mm Min 0 60 15 24 mm Valve Stem Diameter Intake 0 2356 0 00039 5 985 0 01 mm Valve Stem Diameter Exhaust 0 2351 0 00039 5 972 0 01 mm Valve Stem Oil Clearance Intake 0 00228 0 00098 0 058 0 025 mm Valve Stem Oil Clearance Exhaust 0 00275 0 00098 0 0870 0 025mm Valve Stem Overall Length Intake 4 51 0 01476 114 5550 0 375 mm Valve Stem Overall Length Exhaust 4 5453 01496 115 45 0 38 mm Valve Spring Valve Spring Overall Length Free Length 1 735 46 069 mm Valve Spring Overall Length Installed
265. mains in the open position when the park brake lever is not applied 3 Apply the parking brake There should be continuity between the switch terminals If no continuity exists when the park brake is applied try to clean the switch terminals and re test Replace switch if necessary Park Brake Indicator Parking Brake Not Applied X S aS TAS e GC E uU 000000000000 The switch makes contact when the park brake is applied and sends voltage to the ECU and Speedometer to illuminate the Park Brake Indicator near the top center of the instrument cluster i WIRE ENTRY VIEW HARNESS WIRE ENTRY VIEW 10 6 ELECTRICAL INSTRUMENT CLUSTER Overview The RANGER instrument cluster senses vehicle speed from the right front wheel The instrument cluster measures distance in miles as well as time hours of operation and engine RPM ParkBrake Indicator Speedometer Speedometer Needle Rider Information Display PELAHRBRIS NOTE In addition to showing vehicle speed the speedometer needle flashes when a low fuel condition exists NOTE Use the Mode Button shown below to toggle between Instrument Cluster display screens Instrument Cluster Ignition S witch Rider Information Display The rider information display is located in the instrument cluster All segments will light up for 2 5 seconds at s
266. minal bolts See Battery Installation on Page 10 28 10 26 Battery Identification IMPORTANT Identify what type of battery you have installed in your RANGER Different types of batteries require different service procedures Proper servicing and upkeep of your battery is very important for maintaining long battery life Your RANGER may have a Conventional Battery or a Sealed Low Maintenance Battery To identify which type of battery your RANGER has refer to the illustration below and follow the correct service and charging procedures that follow in the manual CONVENTIONAL BATTERY Removable Caps Top View Electrolyte Level GP POLARIS Side View SEALED LOW MAINTENANCE BATTERY No Caps Non removable sealed Top Polaris Sticker L Side View ELECTRICAL CONVENTIONAL BATTERY Battery Activation A WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near
267. minated Inspect the grease carefully for contamination and clean the joint thoroughly if necessary Front drive axle outer boot replacement requires 30g of grease Inner boot replacement requires 20g of grease If either of the joints are cleaned double the amount of grease is required Refer to information below and illustration to the right Boot Replacement Grease Requirement Outer CV Joint Grease 30g PN 1350046 Inner Plunging Joint Grease 20g PN 1350059 Before installing the new boot remove all grease from the boot area and shaft NOTE It is very important to use the correct type and quantity of grease by using the grease contained in the boot kit DO NOT use a substitute grease and DO NOT overfill or underfill the CV joint 9 10 11 7 10 Slide the new clamp and boot small end first over the splined shaft then slide tap the CV joint into the splines of the axle Install small boot clamp Add grease through large end of boot Position large end of boot on CV joint purge excess air by partially compressing axle into CV bell lift one edge of boot to let out excess air Secure the CV boot with clamp FRONT DRIVE SHAFT Joint Capacity 30 Grams Joint Capacity 20 Grams Boot Capacity 20 Grams CV joint capacity 30g if boot is replaced only Another 30g 60g total if joint is cleaned Plunging joint capacity 20g if boot is replaced only Another 20g 40g total if joint is cleaned
268. module NOTE See Page 4 21 for a complete list of Diagnostic Blink Codes 1 Engage the parking brake 2 Stop the engine 3 Tum the key switch to the ON position 4 Turn the key switch off and on three times in less than five seconds then leave the switch on The word Wait will appear on the screen along with a flashing Check Engine light ELECTRICAL 5 Any blink code numbers stored in the EFI module will display one at a time on the screen Example below shows a Blink Code of 42 6 The number 61 and or the word End displays after all codes have been transmitted Instrument Cluster Removal NOTE Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens 1 Lift the hood and disconnect the wire connectors from the back side of the instrument cluster 2 Push the instrument cluster out from the back side of the dash panel while securely holding the panel and rubber mount Dash Panel Push Instrument Cluster Outward Rubber Mount Instrument Cluster Bezel NOTE Do 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 Sprayasoap 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
269. ms and longer cranking times Injector problems due to dirt or clogging are unlikely due to the design of the injectors the high fuel pressure the use of filters and the detergent additives in the gasoline Symptoms that could be caused by dirty clogged injectors include rough idle hesitation stumble during acceleration or triggering of fault codes related 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 contributing factors to injector clogging include dirty air filters higher than normal operating temperatures short operating intervals and dirty incorrect or poor quality fuel Cleaning of clogged injectors is not recommended they should be replaced Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem Fuel Injector Replacement 1 Engine must be cool Depressurize fuel system through test valve in fuel rail Remove the front fender assembly and fuel tank 3 Thoroughly clean the area around and including the throttle body manifold and the injectors 4 Disconnect the fuel injector harness s at the ECU 5 Remove the fuel rail mounting screw and carefully loosen pull the rail away from the injectors Reverse the procedures to install the new injector s and reassemble Use new O rings any time an injector is removed new replacement injectors includ
270. n this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is used for when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc and the position of the decimal point For resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply ELECTRICAL SWITCHES CONTROLS Headlamp Switch 1 2 Lift the front hood The wires are located on the back side of the instrument panel Disconnect the headlamp switch harness Brown Green and Yellow by depressing the connector lock and pulling on the connector Do not pull on the wiring Test the switch connections and check for continuity at the following pins as shown in the illustration HEADLAMP SWITCH BEAM LOW BEAM WITH HARNESS CONNECTED BACK VIEW OF SWITCH INTERNAL CONNECTIONS AWD Rear Differential Switch 4x4 1 2 10 4 Lift the front hood The wires are located on the back side of the instrument panel Disconnect the switch harness Grey Orange White Brown White Green by depressing the connector lock and pulling on the connector Do not pull on the wiring 4 Test the switch connections and check for continuity at the following pins shown in the illustration AWD REAR DIFFERENTIAL SWITCH 03 GY 26 OG WH 14 06 WH 1 26 06 WH
271. n m Pull on the fuel line for removal 3 Toinstall the line verify the connector and fuel tank nipple are clean and free of debris 4 Snapthefuelline back over the nipple and slide the locking mechanism back into place Verify the connector tabs snap back into place ELECTRONIC FUEL INJECTION Principal Components The Electronic Fuel Injection EFI system is a complete engine fuel and ignition management design This system includes the following principal components Fuel Pump Fuel Rail Fuel Line s Fuel Filter s Fuel Injectors Pressure Regulator Throttle Body Intake Manifold Engine Control Unit ECU Ignition Coils Coolant Temperature Sensor Throttle Position Sensor TPS Crankshaft Position Sensor CPS Intake Air Temperature and Barometric Air Pressure Sensor T BAP Wire Harness Assembly Check Engine Light 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 Engine Control Unit ECU which manages system operation determining the best combination of fuel mixture and ignition timing for the current operating conditions An in tank electric fuel pump is used to move fuel from the tank through the fuel line and
272. nd then the negative black cable Coat terminals and bolt threads with Nyogel Grease PN 2871329 4 Install clear battery vent tube from vehicle to battery vent WARNING Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion The vent tube should be routed away from frame and body to prevent contact with electrolyte Avoid skin contact with electrolyte as severe burns could result If electrolyte contacts the vehicle frame corrosion will occur 5 Reinstall the holder strap Conventional Battery Testing Whenever a service complaint is related to either the starting or charging systems the battery should be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Load Test 10 28 OCV Open Circuit Voltage Test Battery voltage should be checked with a digital multitester Readings of 12 6 volts or less require further battery testing and charging See charts and Load Test on below NOTE Lead acid batteries should be kept at or near a full charge as possible Electrolyte level should be kept between the low and full marks If the battery is stored or used in a partially charged condition or with low electrolyte levels hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery OPEN CIRCUIT VOLTAGE
273. nd the other to ground The resistance should be 2 8 3 6 ohms Refer to Electric Starter System Testing in this section to further test the solenoid 10 36 Starter Drive Pinion Gear Anti kick Out Shoe Garter Spring Replacement If the garter spring is damaged the overrun clutch may fail to return properly Use either of the following methods to remove and install a new garter spring A Con Thrust Washer C Busing D Retaining Ring E Thrust Washer F Stopper G Cover H Spring 1 Screw the overrun clutch out to the engaged position on the pinion shaft assembly Use a small piece of wire with the end bent in a hook and pick the old spring out of its channel Slide it off the end of the shaft Slide the new spring over the overrun clutch and into the spring groove Make sure that the spring is positioned between the shoe alignment pins and the back flange of the anti kick out shoes 2 Remove the retaining ring thrust washer spring retainers and clutch return spring Screw the overrun clutch off the end of the pinion shaft Remove the old spring and install anew 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 ELECTRICAL Starter Exploded View Indicates Do not reuse Replace with new parts
274. ned into the container remove the two caliper mounting bolts and remove caliper CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 4 Clean disc caliper body and pistons with brake cleaner or alcohol 5 Caliper Removal 6x6 Caliper Disassembly 1 Safely support the rear of the machine 1 Remove brake pad adjuster screw A 2 Pushupper pad retainer pin inward and slip brake pads past A CAUTION edge if pads are still installed Use care when supporting vehicle so that it does 3 Remove mounting bracket B and dust boot C not tip or fall Severe injury may occur if machine tips or falls 2 Use a wrench to remove the brake line Place a container to catch brake fluid draining from brake lines Remove Banjo Bolt 4 Remove piston D and square O rings E from the caliper body F 3 After the fluid has drained into the container remove the two caliper mounting bolts and remove caliper 5 Clean the caliper body piston and retaining bracket with brake cleaner or alcohol NOTE Be sure to clean seal grooves in caliper body 4 Clean disc caliper body and pistons with brake cleaner or alcohol 9 23 5 Caliper Inspection 1 2 3 9 24 Inspect caliper body for nicks scratches or wear Measure bore size and compare to sp
275. nesses Remove 2 screws holding hinge pins Tap out hinge pins Lift the box off the frame with assistance FUEL TANK EE E ve e a Raise the cargo box Disconnect the vent and fuel lines note locations Disconnect electrical connection Remove the RH rear fender and fuel cap Remove the 2 inner bolts and 2 outer bolts that hold the tank to the frame Carefully lift the tank out through the side LH STORAGE BOX Raise the cargo box Remove the 2 bottom T27 Torx screws Remove the 2 top T27 Torx screws Remove the 3 T27 Torx screws on the front edge Lift the storage box outward from frame 5 3 BODY STEERING SUSPENSION Lower Body Components Main Floor Foam Foll 4 5 ft lbs Drive Shaft Floor Cover Engine Access Cover 4 5 ft lbs 5 6 Nm 1 27 Front Fender Wheel Well Panels x 3 xix c 1 A 2226 A 6 8 ftlbs f 8 10 Nm Skid Plate Storage Box 4x4 BODY STEERING SUSPENSION Hood Dash Components Glove Box Assembly 8 10 Ibs T 30 0 9 1 0 Nm 4 5 ft Ibs 5 6 Nm 1 27 Torx Grille Hood Latch Strap Hood Liner BODY STEERING SUSPENSION Dash Instruments and Controls A Speedometer B Headlight Switch C 2WD AWD Switch D 12 Volt Accessory Receptacle E Speedometer Mode Button F Key Switch G Speedometer Mount Plate
276. new machines is normal as the system is purging itself of trapped air Observe coolant levels often during the break in period Overheating of engine could occur if air is not fully purged from system Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water Coolant Level Inspection The recovery bottle located on the left side of the machine must be maintained between the minimum and maximum levels indicated on the recovery bottle Surge Tank Cap 59 With the engine at operating temperature the coolant level should be between the upper and lower marks on the coolant reservoir If not 1 Removereservoir cap Inner splash cap vent hole must be clear and open 2 Fill reservoir to upper mark with Polaris Premium 60 40 Anti Freeze Coolant or 50 50 or 60 40 mixture of antifreeze and distilled water as required for freeze protection in your area 3 Reinstall cap 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 2 25 GENERAL INFORMATION Radiator Coolant Level Inspection NOTE This procedure is only required if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry or if overheating is evident the level in the radiator should be inspected and coolant added if necessary Radiator Cap A WARNING
277. ng Can engine be rotated easily Starter Motor Turns Over Slowly Battery discharged low specific gravity Excessive circuit resistance poor connections see Voltage Drop Test Engine problem seized or binding Can engine be rotated easily Faulty or worn brushes in starter motor Starter Motor Turns Engine Does Not Rotate Faulty starter drive Faulty starter drive gears or starter motor gear Faulty flywheel gear or loose flywheel Voltage Drop Test The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 1 VDC per connection or component To perform the test place the meter on DC volts and place the meter leads across the connection to be tested Refer to the voltage drop tests on the starter system in this chapter Voltage should not exceed 1 DC volts per connection Starter Motor Removal Disassembly NOTE Use electrical contact cleaner 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 mar
278. ning index tab Install O ring two small phenolic spacers large phenolic washer flat washer lock washer and terminal nut While holding brush springs away from brushes push brushes back and hold in place Slide armature into field magnet housing Release brushes 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 Roller Bearing Be sure wire insulation is in place around positive brush wire and pushed completely into slot on phenolic plate 10 35 ELECTRICAL 7 Using Dielectric Grease PN 2871329 lubricate brush end bushing and install shims 8 Align brush plate and install cover and screws 9 Lightly grease pinion shaft and install pinion spring stopper and snap ring 10 Completely assembly starter motor ud torque set bolts to 35 52 in Ibs 3 9 5 9 Nm 11 Install the starter onto the engine case Hand tighten each of the starter bolts Torque the bottom bolt first to 9 ft Ibs 12 Nm Then torque the top bolt to the same specification NOTE It is important to tighten the bottom starter bolt first circle as the bottom hole acts as a pilot hole to properly align the starter drive bendix with the flywheel This helps to prevent binding and starter damage Starter Solenoid Bench Test To measure the resistance of the pull in coil connect one meter lead to the solenoid lead wire a
279. njury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Battery Charging Reference Table SE Voltage Action Charge Time None check 100 2 813V 0886 at MOS None Required after manufacture date 75 100 12 512 May need slight 36 hours charge 50 75 12 0 12 5 Needs Charge 5 11 hours At least 13 25 50 11 5 12 0 V Needs Charge hours verify state of charge 0 25 11 5 V or less Needs Charge At least 20 hours A WARNING To avoid the possibility of sparks and explosion connect positive red cable first and negative black cable last ELECTRICAL STARTER SYSTEM Troubleshooting Starter Motor Does Not Run Battery discharged Low specific gravity Loose or faulty battery cables or corroded connections see Voltage Drop Tests Related wiring loose disconnected or corroded Poor ground connections at battery cable starter motor or starter solenoid see Voltage Drop Tests Faulty key switch Faulty kill switch Faulty Start Diode Use a digital multi meter to test diode operation Unplug the diode from the harness and measure between the Orange and Orange Green diode connections Continuity should flow one direction only 06 START B ILS Faulty starter solenoid or starter motor START Engine problem seized or bindi
280. nstrument which uses a dial indicator Good for showing taper and out of round in the cylinder bore Electrical Open Open circuit An electrical circuit which isn t complete Electrical Short Short circuit An electrical circuit which is completed before the current reaches the intended load i e a bare wire touching the chassis End Seals Rubber seals at each end of the crankshaft Engagement RPM Engine RPM at which the drive clutch engages to make contact with the drive belt ft Foot feet Foot Pound Ft Ib A force of one pound at the end of a lever one foot in length applied in a rotational direction 6 Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In Ib 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 lor Itr Liter Ibs in Pounds per square inch Left or Right Side Always referred to based on normal operating position of the driver m Meter meters Mag Magneto Magnetic Induction As conductor coil is moved through a magnetic field a voltage will be generated in the windings Mechanical energy is converted to electrical energy in the stator mi Mile miles mm Millimeter Unit of length in the metric system 1 mm approximately 040 Nm Newton meters OD Outside diameter
281. ntains 14 rollers and roller cam The difference in rpm by input shaft and front axles the forces the rollers up the external cam The rollers engage themselves to the output hubs that link both front axles resulting in True All Wheel Drive 7 14 AA CAUTION If the rear wheels are spinning release the throttle before turning the AWD switch on If AWD is engaged while the wheels are spinning severe drive shaft and clutch damage could result Roller Cage and Roller s Rotate Inward and Grip the Output hub for AWD Engagement Rollers Output Hub Roller Cage amp Bearings Disengagement As the front and rear wheels gain traction rotating very close to the same speed the front wheels overdrive the output hubs and the rollers are forced outward disengaging the AWD The vehicle is now back to rear wheel drive until the next loss of traction FINAL DRIVE Centralized Hilliard Exploded View 17 ft Ibs 23 Nm 15 17 ft Ibs 23 Nm 22 T 10 ft Ibs 9 14 14 Nm 21 8 30 ft Ibs 11 41 Nm DESCRIPTION REF DESCRIPTION QTY 1 Set Screw 1 14 Kit Includes O Rings and Seals 1 2 Cover Plate Asm 1 15 Screw 11 3 Thrust Button 1 16 Input Cover 1 4 Thrust Plate 1 17 Roller Ball Bearing 1 5 Armature Plate Shim 1 18 Pinion Shaft 11T 1 6 Roller Ball Bearing 2 19 B
282. o Top Ring Limit gt 15 Leakdown Groove Clearance Second Ring Standard 0 0028 0 0008 0 070 0 020 mm Second Ring Limit 1596 Leakdown Connecting Rod Connecting Rod Small End 0 789 0 78841 20 030 20 015 mm Connecting Rod Small End Radial Clearance 0 0098 0 00039 0 025 0 010mm Connecting Rod Big End Side Clearance 0 01181 0 00591 0 030 0 015mm Connecting Rod Big End Radial Clearance 0 0015 0 00006 0 0038 0 0015mm Crankshaft Crankshaft Runout Limit 0 00236 0 060mm 3 12 Special Tools Part Number Tool Description PV 43527 OIL FILTER WRENCH 2200634 VALVE SEAT RECONDITIONING KIT PU 45257 VALVE SPRING COMPRESSOR PU 45652 VALVE PRESSURE HOSE 2871043 FLYWHEEL PULLER 2870390 PISTON SUPPORT 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 GENERAL ENGINE SERVICE Piston Identification Four stroke engine rings have a rectangular profile See PISTON RING INSTALLED for ring installation Use
283. ock Preload Adjustment Cam Adjustment Electrical Alternator Max Output 500 watts 3000 RPM Lights Main Headlights 2 Dual Beam 35 watts quartz Tail 5 watts x 2 Brake 5 watts x 2 Indicator Panel Lights watt ea Starting System Electric Start Ignition System Bosch EFI ECU Controlled Ignition Timing 7 BTDC 1200 RPM Front Rear 2 2 Twin Tubes Turning Radius 180 in 457 cm Toe Out 1 8 1 4 in 3 6 35 mm Wheels Brakes Front Wheel Size 12x 6 10 gauge Middle Rear Wheel Size 12x 8 10 gauge Front Tire Make Model Size Titan AT489 25 x 10 R12 Middle Rear Tire Make Model Size Titan AT489 25 x 11 R12 F M R Tire Air Pressure 8 12 psi Front 8 12 psi Rear Spark plug Gap Champion RC7YC3 035 in 0 9 mm Brake Front Rear Foot Actuated 4 Wheel Hydraulic Disc Battery Model Amp Hr Yuasa YB30L B 30 Amp Hr 12 Volt Parking Brake Foot Actuated Mechanical Brake Fluid DOT 3 or DOT 4 Instrument Panel Type Multifunction Speedometer DC Outlet Standard Circuit Breakers Fan 20 Amp Dash Harness 20 Amp Accessory Terminal 20 Amp Power Relay 15 Amp ECU Battery Supply 6 Amp 1 8 CLUTCH CHART 2 n A Altitude Shift Weight Drive Spring Spring 0 1500 20 60 Blu Gray Blk Almd Meters 0 5000
284. of the case to aid in removal Remove the shift gears from the case NOTE Depending on what gear the transmission is in upon disassembly the stamped timing marks may not be lined up To avoid confusion mark the two gears as described in Step 8 12 Remove the upper gear cluster and shift forks You may need to move the assembly back and forth to aid in removal 9 Remove the bolts on the LH transmission case cover Tap the cover off with a soft face hammer if necessary 13 Set the upper gear cluster on a flat surface and inspect the components 10 Lift shift rail 0 5 1 12 70 25 40 mm Then rotate the shift rail forks and shift drum so the forks pins disengage from the drum 11 Remove the shift drum 8 6 TRANSMISSION 14 Remove the shift forks from the assembly Note the correct 17 Remove the bearing from the input shaft with a puller position of each fork Y NOTE The picture above depicts a transmission with a park dog on the end of the shaft instead of a regular shift dog The transmission will have a regular shift dog in the location indicated by the arrow in the photo 15 Remove the bearing from the reverse shaft with a puller _ 16 Remove the park lock engagement dog Remove the wave spring and reverse engagement dog Engagement 20 Remove the reverse gear shaft 8 7 TRANSMISSION 2 Remove the rest of the bearings from the shafts 24
285. of the piston To Remove A Remove the top rail first followed by the bottom rail B Remove the expander Compression Cylinder Inspection 1 2 Remove all gasket material from the cylinder sealing surfaces Inspect the top of the cylinder B for warp using a straight edge and feeler gauge C Refer to 1 and Il 2 Measure at different points on surface l y t In mm Cylinder Warp 004 0 1 mm Max 3 ar scratches or damage e DEE Xx Y 8 gt Inspect cylinder for we Inspect cylinder for taper and of round with a telescoping gauge or a 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 1 2 Down From Top of Cylinder 1 2 Up From Bottom H lt X Cylinder Taper Limit 002 9 05mm Cylinder Out of Round Limit 002 0 mm 700 Standard Bore Size Both Cylinders 3 1496 80 mm 3 33 Piston to Cylinder Clearance Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin Subtract this measurement from the maximum cylinder meas
286. olaris Premium 4 Synthetic Oil PN2871281 1 Remove the clean out plugs located on the bottom of the 2 muffler as shown below Crankcase Drain Plug Torque 192 24 in lbs 21 7 2 7 Nm Oil Filter Torque Turn by hand until filter gasket contacts sealing surface then turn an additional 1 2 turn Clean Out Plug 2 Place the transmission in Park and start the engine Purge Oil Filter Wrench accumulated carbon from the system by momentarily PV 43527 revving the engine several times 3 If some carbon is expelled cover the exhaust outlet and 14 Place gear selector in neutral and set parking brake lightly tap on the pipe around the clean out plugs with a 15 Start the engine and let it idle for one to two minutes rubber mallet while revving the engine several more times Stop the engine and inspect for leaks 16 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 17 Dispose of used oil and oil filter properly 2 19 GENERAL INFORMATION 4 If particles are still suspected to be in the muffler back the machine onto an incline so the rear of the machine is one foot higher than the front Set the hand brake and block the wheels Make sure the machine is in Park and repeat Steps 2 and 3 SEE WARNING 5 Ifparticles are still suspected to be in the muffler drive the machine onto the incline so the front of the machine is one foot highe
287. ompound to the face of the valve NOTE Lapping is not required with an interference angle valve job 10 Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem 11 Rotate the valve rapidly back and forth until the cut sounds smooth Lift the valve slightly off of the seat rotate 1 4 turn and repeat the lapping process Do this four to five times until the valve is fully seated and repeat process for the other valve s 12 Thoroughly clean cylinder head and valves 3 30 Cylinder Head Reassembly NOTE Assemble the valves one at a time to maintain proper order 1 Apply engine oil to valve guides and seats 2 Coat valve stem with molybdenum disulfide grease or OW 40 Synthetic oil 3 Install valve carefully with a rotating motion to avoid damaging valve seal 4 Valve seals should be installed after the valves in the head to avoid valve seal damage Install new valve seals on valve guides 5 Dip valve spring and retainer in clean engine oil and install 6 Place retainer on spring and install Valve Spring Compressor PU 45257 Install split keepers with the gap even on both sides NOTE A small magnet can be used to aid in the installation of the keepers 7 Repeat procedure for remaining valves When all valves are installed tap lightly with soft faced hammer on the end of the valves to seat the split keepers NOTE To p
288. on may be adjusted to provide a stiffer suspension if necessary 1 Remove the top shock mounting bolts from the inside mounting holes Reposition the shocks to the outside mounting holes 3 Reinstall the shock mounting bolts Torque to 30 ft Ibs 40 Nm Outside Mounting Holes Inside Mounting Holes Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjustment cam either clockwise or counterclockwise to increase or decrease spring tension To adjust the suspension use the adjustment cam located near the bottom of the rear shock This will allow you to increase or decrease the amount of spring preload Rear Spring Adjustment Cam Shock Spanner Wrench PN 2870872 2 34 BRAKE SYSTEM Brake System Inspection The following checks are recommended to keep the brake system in good operating condition Service life of brake system components depends on operating conditions Inspect brakes in accordance with the maintenance schedule and before each ride Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir Use Polaris DOT 3 or DOT 4 Brake Fluid Check brake system for fluid leaks Check brake for excessive travel or spongy feel Check friction pads for wear damage or looseness Check surface condition of the disc Brake Pad Inspection Pads should be changed when the friction material is worn to 180 4 6 mm When the
289. on the existing bolts were destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation New Bolt Apply Loctite 242 Vehicle Frame 30 ft Ibs 41 Nm Q Joint New Bolt Stud 30 ft Ibs 41 Nm A Arm Bushing A Arm Shaft a e 3 Ka 4 K ft Ibs 5 8 ft Ibs 20 CV Joint Shield 20 30 in Ibs New Cotter Pin 99 Nm 11 Nm 2 3 5 Nm 5 13 BODY STEERING SUSPENSION FRONT STRUT Exploded View Top Pivot Ball Spring Retainer Bottom Pivot Ball Spacer Rubber Front Strut 4 18 ft Ibs Strut Bumper 24 Nm Bearing Retaining Ring 5 14 Clamp 18 ft Ibs 24 Nm Wheel Speed Sensor Hall Effect Sensor BODY STEERING SUSPENSION Front Strut Cartridge Replacement 4 Remove cotter pin A from ball joint castlenut Refer to Illustration on Page 5 14 1 2 E es 10 Ball Joint Replacement 1 5 Remove castle nut and separate A arm from ball joint stud Hold strut rod and remove top nut 6 Remove screws D and ball joint retaining plate E Compress spring using strut spring compressor tools 7 Usingball joint removal installation tool kit PN 2870871 remove ball joint F from strut housing Strut Spring Compressor Tools nstall puller guide G with extension cap H PN 2871573 and PN 2871574 Apply grease to e
290. onnector to the control unit or any individual components with the ignition on This can send a damaging voltage spike through the ECU Do not allow the battery cables to touch opposing terminals When connecting battery cables attach the positive cable to positive battery terminal first followed by negative cable to negative battery terminal Never start the engine when the cables are loose or poorly connected to the battery terminals Never disconnect battery while engine is running Never use a battery boost pack to start the engine Do not charge battery with key switch on Always disconnect negative battery cable lead before charging battery Always unplug ECU from the wire harness before performing any welding on the unit 4 4 FUEL INJECTION EFI System Exploded View Electronic Control Unit ECU Intake Air Temperature Barometric Air Pressure Sensor T BAP Crankshaft Position Sensor CPS Fuel Injectors Fuel Filter Fuel Pump Regulator Gauge Sender Asm Located in tank as an assembly Fuel Rail Engine Coolant Sensor ECT Throttle Position Sensor TPS 10 Throttle Body 11 Wire Harness Part of main harness 5 4 5 FUEL INJECTION EFI System Component Locations 4 Fuel Injectors Fuel Rail Attached to the fuel rail located in the intake track of the 1 Electronic Control Unit ECU cylinder head Located under
291. oot Replacement 7 9 Front Driveshaft Installation 7 11 Front Driveshaft Removal 7 8 Front Gearcase Lubrication 2 21 Front Gearcase Assembly 7 20 Front Gearcase Backlash Pad Adjustment 7 22 Front Gearcase Centralized Hilliard 7 14 Front Gearcase Disassembly Inspection 7 18 Front Gearcase Installation 7 23 Front Gearcase Removal 7 17 Front Hub iet 7 3 Front Propshaft Removal 7 11 Front Propshaft U Joint Service 7 12 Front Strut Cartridge Replacement 5 15 Front Strut Exploded View 5 14 Front Suspension 2 33 Fuel Filter SM bene s 2 14 Fuel Injection Component Locations 4 6 Fuel Injection Exploded View 4 5 Fuel Injection Service Notes 4 4 Fuel Injection Special Tools 4 2 Fuel Inject e oe UR ROC STR GR 4 14 Fuel Lines 2i ileeinteIeBRhreBResSebMe5v M 2 14 Fuel Pressure Regulator 4 14 Fuel Pump Tank Assembly 4 11 Fuel Sender Testi ces Rez 10 20 Fuel System 2 dE 2 14 Fuel Tank Location 4 8 Buses ues S
292. or to ensure the solenoid has power to be activated Check the operator s switch wires for loose connections Remove solenoid from carrier and ensure the solenoid plunger is actuating AA CAUTION Do not power the solenoid with 12 Volts for more than 1 second or damage may occur to the solenoid Brake Light Switch 1 Thebrake light switch is located near the steering gearbox along the frame The brake pressure switch is installed into this block f Brake Switc 2 Disconnect wire harness from switch z T 2 3 Connect an ohmmeter across switch contacts Reading should be infinite 4 Apply foot brake and check for continuity between switch contacts If there is no continuity or greater than 5 ohms resistance when the brake is applied with slight pressure first clean the switch contacts and re test Replace switch if necessary 10 5 ELECTRICAL Parking Brake Switch TESTING PARK BRAKE SWITCH The parking brake switch is located under the dash or under the 1 Disconnect the Orange Red wire and Red White wire from hood Follow the parking brake lever under the dash to locate the the switch switch 2 Placethe ohmmeter leads onto terminal leads A and C The reading should be infinite Parking Brake Switch RD WH M B OG RD Test for resistance between terminals A and C Terminal B is not used in this application The switch re
293. orque bolts as shown Locate grease fitting in center of A arm tube and pump A arm full of grease Upon A arm installation completion test vehicle A WARNING at low speeds before putting into regular service RANGER 6X6 Mid Drive A arm Attaching Bolt torque 30 ft Ibs 41 Nm Upper Bearing Carrier Bolt Torque 30 ft Ibs 41 Nm Lower Bearing Carrier Bolt Torque 50 ft Ibs 68 Nm New Bolt A 30 ft Ibs 41 Nm Shaft s 30 ft Ibs F 41 Nm Upper Mid Wheel Bearing Carrier Lower Mid A Arm BODY STEERING SUSPENSION REAR A ARM 4X4 Replacement NOTE Use the exploded view on the next page as reference during the procedure 1 Elevate and safely support vehicle with weight removed from the rear wheel s 2 Remove the wheel nuts washers and wheel NOTE To ease the removal of the spindle bolt remove the hub cap and loosen the spindle bolts before removing the wheel 3 Remove the hub cap cotter pin spindle bolt and washer 4 Remove the brake caliper Suspend the brake caliper from the frame with a wire NOTE Do not let the brake caliper hang from the brake line or damage may occur 10 Remove the hub and brake disc assembly by sliding it off of the axle Remove the bolt that secures the shock and coil to the upper A arm Remove the bolt that secures the wheel carrier to the upper A arm Shock Bolt ki Wheel
294. output of 25 liters per hour at 39 psi and has a non serviceable internal 60 micron filter Fuel pump is not replaceable picture is for reference only Regulator Fuel Pump Internal 60 Micron Strainer Bottom When the key switch is turned to ON the ECU activates the fuel pump which pressurizes the system for start up The ECU switches off the pump preventing the continued delivery of fuel in these instances e If the key switch is not promptly turned to the start position e f the engine fails to start or f 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 4 11 FUEL INJECTION Fuel Pump Test NOTE FUEL GAUGE SENDER TEST To test fuel gauge sender function refer to Chapter 10 The fuel pump tank assembly is non serviceable and must be replaced if determined to be faulty If a fuel delivery problem is suspected make certain the filters are not plugged that the pump is being activated through the ECU all electrical connections are properly secured the fuses are good and a minimum of 7 0 volts is being supplied If during starting the battery voltage drops below 7 0 volts the ECU will fail to operate the system A WARNING Check the fuel test valve fo
295. pect E Spark Plug 100 H 12M Inspect replace as needed Inspect for wear routing security apply gt Wiring 100 H 12M dielectric grease to connectors subjected to water mud etc Clutches Drive and Driven 100 12M Inspect clean replace worn parts m Front Wheel Bearings 100 H 12M Inspect replace as needed m Adjustment 100 H Inspect periodically adjust when parts are replaced m Brake Fluid 200 H 24M Change every two years DOT 3 or DOT 4 Spark Arrestor 300 H 36M Clean out Inspect daily adjust as needed Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 2 6 GENERAL INFORMATION GENERAL COMPONENT LOCATIONS RH Side 4X4 and Dash View cs SZ E CC Be 7 Z CY 25 5 Rear Gearcase Front Gearcase Behind Radiator Engine under seat Dash Components AWD Differential S witch Instrument en Cluster Light if equipped Holder Switch Cup Holder Ignition Storage Switch prn Storage Box Compartment Storage with lid Tray Mode Button GENERAL INFORMATION LH Side and Rear View 4X4 Battery er Te 7e Li renne EA VAI SAX 8 J 1 15 3 Storage Ms Rear Prop Shaft f Compartment 5 7
296. pinion shaft into the differential housing FINAL DRIVE 3 Replace the pinion shaft cover O ring and install the cover NOTE The O ring is a smaller diameter than the Install the four pinion shaft cover bolts and torque the bolts gearcase Use two hands to work the O ring onto the to 26 ft Ibs 35 Nm gearcase lip a Pinion Gear Cover New O Ring New O Ring Install the output cover onto the differential assembly Pinion Shaft Cover Bolt Torque 8 The output cover must be properly aligned and installed 26 ft Ibs 35 Nm straight with the differential when installed This will ensure that the O ring is not damaged during output cover installation This also helps to prevent any gearcase leaks after assembly 4 Install the wave spring into the differential assembly Be sure to properly seat the wave spring into the differential 9 Torque the output cover bolts to 30 ft Ibs 41 Nm 5 Reinstall the output shaft and ring gear Output Cover Bolt Torque 30 ft Ibs 41 Nm Gearcase Axle Installation 1 Lube the splines of the rear gearcase with anti seize Reinstall the axle spacer seals Reinstall the axle onto the rear gearcase both sides Reinstall the axle tube over the axle and attach it to the gearcase 3 Install and tighten the four bolts onto the right side of the gearcase Install and tighten the two bottom bolts to the left 6 Install a new O ring onto the lip of the gearca
297. queal caused by vibration If cleaning does not reduce the occurrence of brake noise Permatex Disc Brake Quiet PN 2872113 can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust Brake Noise Troubleshooting Possible Cause Remedy Dirt dust or imbedded material on pads or disc Spray disc and pads with Brakeleen or an equivalent non flammable aerosol brake cleaner Remove pads and or disc hub to clean imbedded material from disc or pads Pad s dragging on disc noise or premature pad wear Improper adjustment Insufficient lever or pedal clearance Master cylinder reservoir overfilled Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston s not returning Operator error riding the brake park brake applied Adjust pad stop front calipers Check position of controls amp switches Set to proper level Clean compensating port Inspect Repair as necessary Clean piston s seal Educate operator Loose wheel hub or bearings Check wheel and hub for abnormal movement Brake disc warped or excessively worn Replace disc Brake disc misaligned or loose Inspect and repair as necessary Noise is from other source axle hub disc or wheel If noise does not change when brake is applied check other
298. r details on backlash setting 7 19 FINAL DRIVE 16 Remove the other output hub K from the main gearcase 19 Install new seals into the gearcase housing and use new O Inspect the inner bearing L for wear If there is excessive rings for the gearcase input and output covers wear replace bearing as needed 17 Remove the input cover M bearing N and the pinion gear O Inspect the pinion gear O for chipped broken Gearcase Reassem bly Inspection or missing teeth Replace the input cover O ring 1 As mentioned in the disassembly section replace all O rings seals and worn components 2 Press the pinion shaft seal into the pinion cover until the seal is flush with the sealing surface 3 Inspect bearings on output and pinion shafts To replace press new bearing on to shaft NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement side to side 4 Install pinion shaft bearing and input cover with new o ring and torque bolts to 17 ft Ibs 23 Nm Input Cover Bolts Torque 17 ft Ibs 23 Nm 7 20 FINAL DRIVE 5 Install the output hub A into the gearcase housing The output hub should spin freely
299. r using both hands and hold securely PU 45497 1 3 39 19 Once the gears are pressed together firmly hold the gears together with one hand Carefully remove the Tapered Pins PU 45497 1 by pulling them out one at a time with the other hand 20 After the tapered pins are removed be sure the cam gear assembly is held together tightly Place the cam gear assembly on a flat surface Use the Cam Gear Tooth Alignment Tool PU 45497 2 to align the teeth of the cam gears as shown in the picture 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 only needed to rotate the camshaft when the entire valve train is assembled If the rocker arms removed the cam shaft can be turned by hand 22 Remove the bolt and nut from the balance shaft gear Try NOTE Install the Cam Gear Alignment Tool PU 45497 2 into one assembly hole counter clockwise from the timing mark PU 45497 2 to remove the balance shaft gear If the gear does not come off manually use the Flywheel Puller PN 2871043 to remove the balance shaft gear NOTE For ease of installing the Cam Gear Alignment Tool PU 45497 2 R use a twisting motion when pushing down on
300. r any possible fuel seepage after performing any tests or procedures Fuel is extremely flammable and may cause severe burns injury or death Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors 1 Remove the cap from the fuel test valve 2 Connect the pressure hose of the Polaris pressure tester PN PU 43506 to the test valve on the fuel rail Route the clear hose into a portable gasoline container or the equipment fuel tank 4 12 3 Turn on the key switch to activate the pump and check the system pressure on the gauge If system pressure of 39 psi 3 is observed the ignition switch ECU fuel pump and pressure regulator are working properly Turn the key switch off and depress the valve button on the tester to relieve the system pressure Normal Fuel Pressure 39 psi 3 NOTE If the pressure is too high or too low replace the fuel tank assembly 4 If the pump did not activate Step 2 disconnect the plug from the fuel pump Connect a DC voltmeter across terminals and in the plug turn on the key switch and observe if a minimum of 7 volts is present If voltage is between 7 and 14 turn key switch off and connect an ohmmeter between the terminals A and on the pump to check for continuity NOTE If there was no continuity between the pump terminals replace the fuel tank assembly NOTE If the voltage was below 7V
301. r intake hose Disconnect the Throttle Position Sensor at the electrical connector E Remove the clamps that secure the throttle body F to the air intake boot and engine intake boot Remove the throttle body F Insert a shop towel into the engine intake to prevent dirt from entering the intake port Relieve the fuel pressure in the fuel rail refer to Chapter 4 FUEL INJECTION for proper procedure Carefully remove the fuel rail G and injectors plug high tension leads H 16 Remove the crank position sensor I located on the mag cover 17 Disconnect the coolant temperature sensor J from the left side of the cylinder 18 Disconnect the coolant hoses Properly dispose of any antifreeze from the engine or hoses 19 When removing starter cables note and mark ground cable and positive cable mounting angle and locations Remove the cables 20 Remove all engine mount nuts and or engine mount plates 21 With all hoses and wires disconnected the engine be pulled straight out of the chassis NOTE Rotating the engine to the left 90 degrees valve cover facing left may ease engine removal NOTE Use caution when lifting the engine out of frame Use an engine lift or other means if the engine is too heavy to be lifted manually 22 For engine installation reverse procedures Engine Installation Notes After the engine is installed in the frame review
302. r than the rear Set the hand brake and block the wheels Make sure the machine is in Park and repeat Steps 2 3 SEE WARNING 6 Repeat steps 2 through 5 until no more particles are expelled when the engine is revved 7 Stop the engine and allow the arrestor to cool 8 Reinstall the clean out plugs TRANSMISSION AND GEARCASES Transmission Lubrication NOTE It is very important to follow a regular transmission fluid check change schedule The service manual of the RANGER recommends the level be checked every twenty five 25 hours of operation and changed once 1 a year TRANSMISSION SPECIFICATIONS Specified Lubricant AGL Synthetic Gearcase Lubricant PN 2873602 32 oz Approximate Capacity at Change 15 2 oz 450 ml Drain Plug Fill Plug Torque 14 ft Ibs 19 Nm 2 20 The transmission lubricant level should be checked and changed in accordance with the maintenance schedule Be sure vehicle is level with the parking brake on before proceeding Check vent hose to be sure it is routed properly and unobstructed To check the level 1 Remove the fill plug on the backside of the transmission The fluid should be at the bottom of the threads fill plug hole Figure 7 26 GENERAL INFORMATION To change lubricant The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid 1 Remove skid plate if necessary 2 Place a drain pan beneath the
303. r when piston is pushed back into caliper Remove excess fluid from reservoir as required 6 Remove the brake pads 5 Pad Inspection Pad Installation 1 Clean the caliper with brake cleaner or alcohol 1 Install new pads in caliper body 2 Measure the thickness of the pad material Replace pads if worn beyond the service limit a D Ota Thickness 2 Rear Brake Pad Thickness New 298 007 7 56 178 mm Service Limit 180 4 6 mm Rear Brake Caliper Mounting Bolt Torque 18 ft Ibs 24 Nm 3 Turnadjuster screw back in fingertight using a hex wrench 4 Slowly pump the brake pedal until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the master cylinder Pump the Brake Pedal 9 21 5 REAR CALIPER Rear Caliper Exploded View Bleeder Screw 30 60 IN LBS Caliper Body 4 6 5 NM Adjuster Screw Finger Tight Caliper Removal 4x4 1 2 Use a wrench to remove the brake line Place a container to catch brake fluid draining from brake lines Safely support the rear of the machine DURING ASSEMBLY 4 APPLY POLARIS DOT 4 BRAKE FLUID TO COMPONENT mg APPLY POLARIS ALL PURPOSE GREASE Square i O rings Pads X a Caliper Mount Dust Boots NOTE IF PADS ARE DIRTY GREASY OILY OR FLUID SOAKED REPLACE WITH NEW PADS 3 After the fluid has drai
304. radiator if the level goes down 8 Tighten the bleed screw to 70 10 in Ibs 8 1 13 Nm on the thermostat housing and properly install the radiator cap A WARNING Be sure to install the radiator cap before shutting off the engine Coolant may spit out of the radiator 9 Stop the engine and let cool top off the radiator filler neck with coolant If you hear or see a glug at the filler neck or there is a dropping of the coolant level indicating that coolant has been pulled into the system Fill the surge tank only after you have completely filled the cooling system at the radiator filler neck 10 Repeat this procedure if overheating still occurs If overheating occurs after repeating this procedure proceed to Procedure 2 3 16 PROCEDURE 2 1 Drive the machine onto a slight incline or use properly weight rated ramps Place the machine in Neutral and set the parking brake Block the rear wheels The radiator neck should be above the level of the top of the engine AA CAUTION Be sure the engine has cooled and there is no pressure built up in the cooling system before removing the radiator cap The coolant maybe hot and could cause severe injury or burns 2 Removeradiator cap and top off coolant Fillthe surge tank to the full line 3 Leave the cap off of the radiator to allow any possible air to escape Start the engine and let it idle for 5 10 minutes or until the the
305. rankcase casting drawing air into the system through an intake duct The opening for this intake duct is located at a high point on the vehicle location varies by model Theintake duct draws fresh air through a vented cover All connecting air ducts as well as the inner and outer covers must be properly sealed to ensure clean air is being used for cooling the PVT system and also to prevent water and other contaminants from entering the PVT area This is especially critical on units subjected to frequent water forging 6 3 CLUTCHING Overheating Diagnosis During routine maintenance or whenever PVT system overheating is evident it s important to check the inlet and outlet ducting for obstructions Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures The vehicle should be operated in Low when pulling or plowing heavy loads or if extended low speed operation is anticipated CLUTCH DRIVE BELT amp COVER RELATED ISSUES DIAGNOSIS Possible Causes Solutions What to do Loading the vehicle into a truck or tall trailer when in high range Starting out going up a steep incline from When starting out on an incline use Low or dismount the vehicle after first Shifttransmission to Low during loading of the vehicle to prevent belt burning a stopped position applying the park brake and perform the K turn Driving at low RPM or low ground speed
306. rcase lubricant 1 With the RANGER on a level surface remove the fill plug and check the lubricant level Lubricant should be kept at the specified level according to the proper gearcase specifications listed 2 Support the vehicle securely with a jack stand and remove the front tire on the driver s side 3 Remove gearcase drain plug located on the bottom of the gearcase and drain oil The drain plug is accessible through the skid plate Catch and discard used oil properly Clean and reinstall drain plug using a new sealing washer 5 Remove fill plug 6 Fill with the recommended fluid amount or fill to the bottom of the threads of the fill plug hole 7 Install fill plug Check for leaks MIDDLE GEARCASE 6X6 Make sure vent is unobstructed Side View Fill to bottom of fill plug hole Fill Plu 5 9 threads 6 75 oz 14 ft Ibs 19 Nm Bottom View Drain Plug 14 ft Ibs 19 Nm Rear Gearcase Lubrication 4x4 REAR GEARCASE SPECIFICATIONS Specified Lubricant ATV Angle Drive Fluid PN 2871653 Capacity 18 oz 532 ml Fill Plug Torque 40 ft Ibs 54 Nm Drain Plug Torque 30 45 in Ibs 3 5 Nm To check the level 1 2 4 With machine on level ground and with the parking brake on remove fill plug from rear gearcase The fluid level should be 0 75 in 1 9 cm from the bottom of the fill plug hole threads Use a light colored and non absorbent measuring instrument w
307. rectly adjusted stationary pad Worn or damaged master cylinder or components Damaged break pad noise insulator Pedal Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port plugged Pad clearance set incorrectly Parking brake lever incorrectly adjusted Brake pedal binding or unable to return fully Parking brake left on Residue build up under caliper seals Operator riding brakes Brakes Lock Alignment of caliper to disc Caliper pistons sticking Improper assembly of brake system components 9 26 ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION 5 ks hn Rc CR C RC UR s 10 3 SPECIAL TOOLS eser EY ei gU oe Rr kae d pais 10 3 ELECTRICAL SERVICE 5 10 3 UNDER HOOD COMPONENTS 10 3 SWITCHES 1 CONTROLS x5 tir ee CORRER Ga ARE UE Y Roxas 10 4 HEADLAMP SWITCH er rk Rr RR D dde 10 4 AWD REAR DIFFERENTIAL SWITCH 4 4 10 4 DIFFERENTIAL SOLENOID 4 4 1 10 4 BRAKE LIGHT 2 1 10 5 PARKING BRAKE 1 10 6 INSTRUMENT CLUSTER 5 ied rk exem kc ex NEE e Y CR
308. reload in the spring the outer sheave moves inward and contacts the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive belt rotates low in the drive clutch sheaves As engine RPM increases centrifugal force causes the drive belt to be forced upward on drive clutch sheaves CLUTCHING Driven Clutch Operation Driven clutches primarily sense torque opening and closing according to the forces applied to it from the drive belt and the transmission input shaft If the torque resistance at the trans mission input shaft is greater than the load from the drive belt the drive belt is kept at the outer diameter of the driven clutch sheaves As engine RPM and horsepower increase the load from the drive belt increases resulting in the belt rotating up toward the outer diameter of the drive clutch sheaves and downward into the sheaves of the driven clutch This action which increases the driven clutch speed is called upshifting Should the throttle setting remain the same and the vehicle is subjected to a heavier load the drive belt rotates back up toward the outer diameter of the driven clutch and downward into the sheaves of the drive clutch This action which decreases the driven clutch speed is called backshifting In situations where loads vary such as uphill and downhill and throttle settings are constant the
309. revent damage to the valve seals do not compress the valve spring more than necessary to install the keepers Valve Sealing Test 1 Clean Gs the combustion chamber area Pour small amount of clean solvent onto the intake port and check for leakage around each intake valve The valve seats should hold fluid with no seepage 3 Repeat for exhaust valves by pouring fluid into exhaust port Cylinder Removal 1 Follow engine disassembly procedures to remove rocker cover and cylinder head 2 Tap cylinder A lightly with a rubber mallet in the reinforced areas only until loose 3 Rock cylinder forward and backward while lifting it from the crankcase supporting pistons and connecting rods Support pistons with Piston Support Block PN 2870390 Valve Lifter Removal Inspection 1 Remove the valve lifter s 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 pss during engine E ear Hydraulic Lifter er 4 Check the lifters for wear or scores 5 Check the bottom end of lifter to make sure that it has a slight convex 6 Ifthe bottom surface has worn flat it may be used with the original camshaft only Inspect Hydraul
310. rfaces B Inspect the ring gear C for consistent wear patterns The surfaces should be free of nicks and scratches Ku 9 Inspect roll cage B sliding surface This surface must be clean and free of nicks burrs or scratches Remove and inspect the H springs FINAL DRIVE 10 Use a flat head screwdriver to remove the retaining ring from the output cover Retaining Ring E E 24 11 Remove the spacer washer D armature plate E and rubber O ring from the output cover 12 Inspect the armature plate E for a consistent wear pattern Uneven wear of the armature plate E indicates a warped plate which may cause intermittent operation NOTE See FRONT GEARCASE DIAGNOSIS earlier in this chapter for more details 13 Remove the output hub G from the cover remove the thrust bearing F from the output hub G Inspect the thrust bearing F and the dowel H 14 Inspect the magnetic coil J in the output housing NOTE See FRONT GEARCASE DIAGNOSIS earlier in this chapter for more details on the coil 15 Inspect the back lash pad J for excessive wear NOTE The backlash for the centralized hilliard is set at the factory No adjustment is required unless the front cover needs to be replaced or the back lash pad screw is removed See the Backlash Pad Adjustment procedure later in this chapter fo
311. rmostat opens and allows coolant to flow through the system NOTE If there is air in the system you will see air bubbles forming through the radiator fill neck 4 Add coolant as needed If no bubbles are seen at the filler neck the system should be purged of air 5 Install the radiator cap and turn off the machine A WARNING Be sure to install the radiator cap before shutting off the engine Coolant may spit out of the radiator Valve Cover Removal 6x6 Models Engine Installed The RANGER 6x6 models have a different engine mounting system that makes it more difficult to access and remove the engine valve cover Use the procedure provided in this section of the chapter to remove the valve cover and allow for engine top end component service 1 Remove the seat base 2 Remove the clamp from the valve cover breather hose and remove the hose and valve cover vent Valve Cover Screws 7 Breather Hose Remove the 7 screws that retain the valve cover Remove the front dog house cover located in the floor panel of the RANGER The valve cover will have to be removed through the dog house Dog House Cover Floor Panel Remove the heat shield shown below and loosen the exhaust mounts Loosen Remove the upper engine mount Loosen the lower engine mount bolts but DO NOT completely remove them Remove the front engine mount bolts from the engine case NO
312. rom the caliper body F See Figure 9 15 5 Clean the caliper body piston and retaining bracket with brake cleaner or alcohol NOTE Be sure to clean seal grooves in caliper body Caliper Inspection 1 Inspect caliper body for nicks scratches or wear Measure bore size and compare to specifications Replace if damage is evident or if worn beyond service limit Front Caliper Piston Bore I D Std 1 5050 1 5040 32 27 30 202 mm Service Limit 1 5060 38 252 mm 9 16 2 Inspect piston for nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit Front Caliper Piston O D Std 1 4985 1 5000 38 062 38 10 mm Service Limit 1 4980 38 049 mm 3 Inspect the brake disc and pads as outlined for brake pad replacement in this chapter Caliper Assembly 1 Install new square O rings A in the caliper body Be sure that the grooves are clean and free of residue or brakes may drag 2 Coat the piston with clean Polaris DOT 4 Brake Fluid P N 2872189 Install piston B with a twisting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 5 3 Lubricate the mounting bracket pins with Polaris Premium 3 Install the adjuster screw and turn until stationary pad Season Grease PN 2871423 and install the rubber contacts disc then back off 1 2 turn dust seal boots AA CAUTION
313. rt the shaft into the carrier cover Place 9 Install the carrier cover bolts Tighten and torque the bolts the shift yoke assembly into the carrier cover and secure in a criss cross pattern to 25 35 ft lbs 34 48 Nm with the shift yoke pivot shaft H Install Shift Yoke Assembly 10 Install the rear differential mount brackets from the rear Install the differential lock solenoid into the carrier cover differential onto the rear differential Torque the bracket to differential bolts to 26 33 ft lbs 35 45 Nm 30 40 ft Ibs 41 54 Nm 26 33 ft Ibs 35 45 Nm Bracket to Differential FINAL DRIVE Differential Installation 1 Place the differential assembly into the frame Torque the bracket to frame bolts to 38 42 ft Ibs 35 45 Nm 2 Slide the rear propshaft onto the rear differential input shaft 3 Reverse the removal procedure for the rest of the installation 4 Add Polaris ATV Angle Drive Fluid PN 2871653 to rear carrier Refer to maintenance information in Chapter 2 for more details Torque drain plug to 30 45 in Ibs 3 5 Nm Torque fill plug to 40 ft Ibs 54 Nm Drain Plug 30 45 Ibs 3 5 Nm Rear Gearcase capacity 18 fl oz 532 ml 0 75 1 9 cm below bottom of fill plug hole threads See Chapter 2 7 51 FINAL DRIVE Differential Exploded View 30 45 in Ibs 3 5 Nm 4 40ft Ibs 7 54 Se 25 35 ft 1 5 bes 34 4
314. s 34 42 Nm Upper Steering Shaft to U Joint Shaft 15 19 ft Ibs 20 26 Nm Lower Steering Shaft to Box 30 ft Ibs 41 Nm Steering Box 14 18 ft Ibs 19 24 Nm NOTE Refer to exploded views throughout this chapter for more torque specifications component identification and location of components 5 2 BODY STEERING SUSPENSION BODY COMPONENT REMOVAL Removal Procedures TO REMOVE PERFORM THESE STEPS SEAT P ull up on front of seat and then pull forward DASH 1 Remove the gear selector handle Then remove the 4 screws that attach the hood to the dash Remove the remaining dash screws that attach the RANGER emblem Disconnect the dash component wires Remove the steering wheel 1 nut HOOD Disconnect headlights Remove the 4 hinge screws CAB N Remove seat back and seat base Remove the bolts for the front mounts Remove the bolts for the rear mounts HOOD LINER N Remove liner darts and screws Disconnect the wiring harnesses Remove the air baffling boxes FRONT BUMPER Lu N Lift the hood Remove the 3 front Torx screws from LH and RH wheel well panels Remove the 2 top bumper mounting bolts Remove the 3 lower bumper mounting bolts CARGO BOX WwW N Place box in the dump position Remove the pin and clip from the shock at the cargo box Disconnect light har
315. s shown 16 Install the shock and tighten shock bolt to 30 ft Ibs 41 Nm 17 Re install wheel and caliper Refer to Chapter 2 for wheel toque specifications A WARNING Upon A arm installation completion test vehicle at low speeds before putting into regular service 30 ft Ibs 41 Nm C e T a we N 30 ft lbs 41 Nm IS _ li Oo Shaft Caliper Wheel Bearing Carrier Pr Me e Bushings A R 4 e SET Lower A arm Shaft A a 68 Nm 5 18 SN Carrier Bolt 30 ft Ibs 50 ft be Bearing F G i on Shaft Snap Ring e Bushings e 41 Nm S BODY STEERING SUSPENSION REAR STABILIZER BAR 4X4 Removal Installation 1 Elevate and safely support vehicle with weight removed from the rear wheel s 2 Remove the rear wheel to gain access to the stabilizer bar each side gt r La b EMRL Bar 3 Removethe stabilizer bar nut from the lower A arm on each side Remove the two bolts that secure the stabilizer bar to the main frame each side e Stabili e Remove the stabilizer from the frame Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed Inspect the rubber bushings on the linkage rod and replace if needed Reverse the procedure for installation Torque the stabilizer bolts to 16 1
316. s the injection duration or pulse width It may vary in length from 1 5 8 milliseconds depending on the speed and load requirements of the engine FUEL INJECTION Fuel Injector Service Injector problems typically fall into three general categories electrical dirty clogged or leakage An electrical problem usually causes one or both of the injectors to stop functioning Several methods may be used to check if the injectors are operating With the engine running at idle feel for operational vibration indicating that they are opening and closing When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration NOTE Do not apply voltage directly to the fuel injector s Excessive voltage will burn out the injector s Do not ground the injector s with the ignition on Injector s will open turn on if relay is energized If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows Injector leakage is very unlikely but in rare instances it can be internal past the tip of the valve needle or external weeping around the injector body The loss of system pressure from the leakage can cause hot restart proble
317. se housing side of the torque thebolts 7 57 FINAL DRIVE NOTE The two top gearcase axle tube bolts B on the left side are installed into the frame later in this assembly procedure 4 Fit the rear axle assembly up to the frame Slide the rear driveshaft yoke onto the rear gearcase input shaft e 5 Fit the rear axle assembly up to frame Attach the rear axle assembly to the shocks Leave the shock bolts finger tight until assembly is complete NOTE Use a jack or another person to assist with the rear axle assembly installation NOTE Use caution when removing the rear axle assembly Extra jacks maybe needed to raise the rear axle assembly safely 7 58 6 Install the four U bolts Align the U bolts with the white marks previously made on the axle tube for proper rear axle alignment NOTE Use a floor jack to help align the rear axle assembly for the U bolt installation WS U bolt Alignment Marks 7 Install the U bolt nuts but do not tighten the nuts 8 Install the two frame to gearcase bolts B Torque the gearcase bolts on both sides of the gearcase to 60 ft Ibs 81 Nm Axle Tube to Gear Case Bolt Torque 60 ft Ibs 81 Nm FINAL DRIVE Torque the U bolts nuts to 40 ft Ibs 54 Nm 13 Install the brake caliper Torque the bolts to 18 ft Ibs 24 8 Nm U Bolt Nut Torque 40 ft Ibs 54 Nm Brake Caliper Torque 10
318. sible causes CLUTCHING NOTE If new belt is installed check belt CLUTCH ALIGNMENT OFFSET deflection Clutch Alignment Clutch Alignment Tool Belt Installation 1 Loop belt over the drive clutch and over top of the driven S sheave ba 47346 1 8 0 1 16 3 2 mm 0 1 6 mm 2 While pushing down on top of belt turn the back or 1 Remove belt and install the Clutch Alignment Tool as moveable driven sheave clockwise shown above Clutch Alignment Tool PN PA 47346 2 With tool touching rear of driven clutch inner sheave the distance at point A should be 1 8 If the distance is greater than 1 8 or less than 1 16 clutch alignment must be adjusted as follows 3 Remove drive and driven clutch See PVT System Service Disassembly 4 Remove PVT inner cover 5 Loosen allengine mounts Move front of engine to the right or left slightly until alignment is correct 3 The belt then should be able to be pushed down into and 6 Tighten engine mounts and verify alignment is correct between the sheaves fs e Center line Be sure to position belt so part number is easily read Measure offset above and below centerline 7 Measure belt deflection and measure offset both above and below sheave centerlines Adjust if necessary 6 9 CLUTCHING NOTE On some models minor adjustments can be made by adding shims between the frame and front lower left engine
319. spected proceed with the following system check after verifying that all wires are in good condition connected and not exposed or pinched Using a multitester set on D C volts mea Remove the battery and properly ser sure the battery open circuit voltage See X Vice Reinstall the fully charged battery earlier test It should be 12 4 volts or more or a fully charged shop battery Is it Yes Meter Setting DC Volts With the transmission in Neutral start the engine and increase RPM to between 3000 and 4000 Read battery voltage with the FF Yes M multitester Readings should increase to between 13 0 and 14 6 V D C Are they Check Key off Current Draw No y Check for owner modification and Meter Setting DC Amps discuss operating habits The battery Perform system Break Even Amperage will continually discharge if operated test outlined in this chapter L3 Yes below the Break Even RPM Con tinued problems would call for battery Does charging occur as specified inspection No Ohm stator wires if bad replace stator if good E continue with alternator output test Inspect the wiring harness between Meter Setting AC Volts the panel and the stator for ng damage If no damage is found Disconnect the Yellow wires from the regulator remove the recoil and flywheel rectifier Using a multitester perform an Alterna
320. spose of the oil Remove the output cover bolts and the output cover B 3 Remove the O ring C and two shims D from the output cover NOTE The two shims are different of thickness Be sure to note the placement of the shims as they are removed from the output cover for later installation 7 29 FINAL DRIVE 4 Remove the output shaft and ring gear assembly E from 7 Remove the input cover bolts Remove the input cover the gearcase Inspect the ring gear for abnormal wear H and pinion gear assembly from the gearcase broken or chipped teeth Inspect and spin the bearings F gt the bearings should rotate smoothly 8 Remove the pinion gear assembly J from the front cover H If the pinion gear does not come loose from the front 5 Remove the wave spring G from the gearcase assembly cover use the following steps to aid in removal Hold the pinion gear assembly e Use a rubber mallet to lightly tap around the bearing cup of the front cover Tap the front cover in an X pattern follow the pattern in the photo on the right until the pinion gear assembly comes loose 7 30 FINAL DRIVE 9 Inspectthe pinion gear K and 26T output gear L for nics 12 Carefully pull the output thru shaft Q through the or uneven wear Inspect the bearing M the bearing should gearcase spin smoothly Replace the parts as needed 13 Remove the retaining ring O shim
321. ss connector from ECU Connect an ohmmeter between the pin terminals A resistance value of 560Q 10 at room temperature 20 C 68 F should be obtained If resistance is correct check the mounting air gap toothed ring gear damage runout etc and flywheel key Crankshaft Position Sensor 5600 10 20 C 68 F 3 Disconnect speed sensor connector from wiring harness the connector with one heavy black lead Viewing the connector with dual aligning rails on top test resistance between the terminals A reading of 5600 10 should again be obtained NOTE If the resistance is incorrect remove the Screw securing the sensor to the mounting bracket and replace the sensor If the resistance in step 2 was incorrect but the resistance of the sensor alone was correct test the main harness circuit between the sensor connector terminals the corresponding pin terminals in the main connector Correct any observed problem reconnect the sensor and perform step 2 again CPS Replacement 1 Disconnect sensor harness connector Using a 6 mm hex wrench remove the retaining bolt and replace the sensor using a light coating of oil on the o ring to aid installation 3 Torque the retaining bolt to specification ey T CPS Retaining Bolt Torque 25 in Ibs 2 8 Nm 4 16 TEMPERATURE BAROMETRIC AIR PRESSURE SENSOR T BAP Operation Overview Mounted on the throttle body intake the tempera
322. ss or excessive wear 4 push rods can be visually checked for straightness 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 3 24 Cylinder Head Inspection Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon CAUTION Use care not to damage sealing surface Cylinder Head Warp 1 Lay a straight edge A across the surface of the cylinder head B at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface If warp exceeds the service limit replace the cylinder head Measure at different points on the surface d re In mm Cylinder Head Warp Limit 004 1016 mm max Valve Seal Spring Service On Engine NOTE The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals In some cases the valve train can be serviced while the cylinder head is still on the engine Keep all parts in order with respect to their location in the cylinder head A WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly 1 Having already removed the valve cover rocker arms and pushrods align the cylin
323. t n 1 9 PUBLICATION 8 1 9 SCH ele 1 9 REPLACEMENT KEYS estt eret o eet toe Eege dar PEL He and 1 9 SPECIAL TOOLS o id en ber osea dot dece ota ec pn PIS Rete ene A de d 1 9 MISC SPECIFICATIONS AND 1 10 CONVERSION 1 1 10 STANDARD TORQUE SPECIFICATIONS 1 11 SAETAP7DRILL SIZES 1 12 METRIC TAP DRILL SIZES een d 1 12 DECIMAL EQUIVALENTS 1 1 12 GLOSSARY OF TERMS ae kuspi nudio dE See aa Ord Mata 1 13 GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service Machine Model Number Identification R 07 RH 68 AG kel Model 7 i y E Emissions A Model Option Designation Basic Chassis Designation ngine Designation Engine Designation Number 0680 Twin Liquid Cooled 4 Stroke Electric Start VIN Identification World de Mfg ID Vehicle Description Vehicle Identifier 12 314 5 6 789110 11 12 13 14 15 16 17 4X A R H6 BA 7 P 000000 Ge
324. t brake light does not work the lamp assembly may need to be replaced 1 From the rear of the tail light remove two screws holding lens cover in place and remove lens cover T 20 Torx 2 Remove lamp by turning the rubber base 1 4 turn and pulling the bulb out Replace it with recommended lamp Apply Dielectric Grease PN 2871329 Tail Light RD and BN Brake Light OG and RD Replacement Bulbs PN 4030040 3 Reinstall the lens cover removed in Step 1 4 Test the tail light brake light to see it is working ELECTRICAL COOLING SYSTEM Cooling System Break Out Diagram ______ 12 Volt Power 8290000000000 UU RD WH FAN MOTOR FAN 06 BK E qn 7 RD 20 CIRCUIT _BREAKER _ RD FUSE HOLDER TOP VIEW 18 14 SPLICE R DB 18 14 SPLICE D E DB 16 12 SPLICE Ec DB TERMINAL BLOCK 10 19 ELECTRICAL Fan Control Circuit Operation Testing Power is supplied to the fan via the Orange Black wire when the relay is ON The ground path for the fan motor is through the Brown harness wire Refer to RELAYS later in this chapter
325. t re use AA CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 4 Loosen the banjo bolts B for the brake lines and allow fluid to drain NOTE Make note of front and rear brake line locations to master cylinder 5 Remove the two mounting bolts C that secure the master cylinder to the frame Installation 1 Reverse Steps 1 5 for master cylinder installation Refer to the torque specifications in the illustration After installing the foot brake check pedal freeplay Pedal freeplay should not exceed 090 2 286 mm 9 6 FOOT BRAKE PEDAL Pedal Removal 1 Open the hood Locate the master cylinder 2 Remove the nut bushing tube and bolt from the brake pedal Cott Nut Bushing Ker 9 13 ft Ibs 12 18 Nm 3 Remove the clevis pin and cotter key from the master cylinder to remove the brake pedal Pedal Installation 1 Reverse Steps 1 3 for foot brake installation Torque the clevis nut to 9 13 ft Ibs 12 18 Nm After installing the foot brake check pedal freeplay Pedal freeplay should not exceed 090 2 28 mm Brake Pedal Freeplay 090 2 28 mm 5 BRAKE BLEEDING FLUID CHANGE NOTE When bleeding the brakes or replacing the fluid always start with the furthest caliper from the master cylinder Ne AA CAUTION Always wear safety glasses AA CAUTION Brake flu
326. t Yes P1260 51 Injector 1 Open Load Yes P0261 51 Injector 1 Short Circuit to Ground Yes P0262 51 Injector 1 Short Circuit to Battery Yes P1263 52 Injector 2 Open Load Yes P0264 52 Injector 2 Short Circuit to Ground Yes P0265 52 Injector 2 Short Circuit to Battery Yes P0655 54 Engine Temperature Lamp Open Load Yes P1657 54 Engine Temperature Lamp Short Circuit to Ground Yes P1658 54 Engine Temperature Lamp Short Circuit to Battery Yes P1651 55 Diagnostic Lamp Open Load Yes P1652 55 Diagnostic Lamp Short Circuit to Ground Yes P1653 55 Diagnostic Lamp Short Circuit To Battery Yes P1231 56 Pump Relay Open Load Yes P1232 56 Pump Relay Short Circuit to Ground Yes P1233 56 Pump Relay Short Circuit to Battery Yes P1480 58 Cooling Fan Open Load Yes P1481 58 Cooling Fan Short Circuit to Ground Yes P1482 58 Cooling Fan Short Circuit to Battery Yes 4 21 FUEL INJECTION EFI Troubleshooting Fuel Starvation Lean Mixture Symptoms Hard start or no start bog backfire popping through intake exhaust hesitation detonation low power spark plug erosion engine runs hot surging high idle idle speed erratic No fuel in tank Restricted tank vent or routed improperly Fuel lines or fuel injectors restricted Fuel filter plugged Fuel pump inoperative Air leak in system Intake air leak throttle shaft intake ducts airbox or air cleaner cover Incorrect throttle stop screw adjustment Rich
327. taining plate screws or install new screws with pre applied locking agent Torque screws to 8 ft 165 11 Nm Install A arm on ball joint and torque castle nut to 25 ft 165 35 Nm Reinstall cotter pin with open ends toward rear of machine MID AXLE A ARM 6X6 Replacement 1 2 5 16 Elevate and safely support the center of the vehicle with weight removed from center wheel s Remove the hub cap cotter pin spindle nut wheel nuts and wheel Refer to Chapter 7 MID DRIVE BEARING CARRIER HUB REMOVAL procedure Remove the bolts that secure the shock to the upper and lower mid A arms Loosen two bolts on A arm bushing by alternating each about 1 3 of the way until A arm can be removed Perform this procedure on the upper and lower mid A arms Examine the A arm bushing and A arm shaft Replace if worn Discard hardware Insert A arm bushings and A arm shaft into new A arm Install new lower mid A arm assembly onto vehicle frame Torque new bolts to 30 ft Ibs 41 Nm Install a new upper mid A arm assembly Torque new bolts to 30 ft Ibs 41 Nm Bushings Washer 30 ft Ibs New Bolt a 41 Nm 10 Bushing The locking features on the existing bolts were A WARNING destroyed during removal DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation Attach A arm to wheel bearing carrier Install the shock to the upper mid A arm T
328. tart up NOTE If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer 3 4 5 6 7 1 Gear Indicator This indicator displays gear shifter position High Gear L Low Gear N z Neutral Reverse Gear 2 AWD Indicator This indicator illuminates when the AWD switch is in the AWD position 3 Engine Hour Display Indicator 4 Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter Clock 7 FuelGauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immediately 8 Check Engine Warning Indicator This indicator serves two purposes The word HOT displays if the engine overheats It also appears if an EFI related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result 10 7 ELECTRICAL Standard Display Modes
329. ter than 1 10 of the battery s amp hr capacity until the electrolyte s specific gravity reaches 1 270 or greater Store the battery either in the machine with the cables disconnected or store in a cool place NOTE Recharge to full capacity every 30 to 60 days during a non use period If the battery is stored during the winter months electrolyte will freeze at higher temperatures as the battery discharges The chart below indicates freezing points by specific gravity Electrolyte Freezing Points GE Freezing Point 1 265 75 F 1 225 35 F 1 200 17 F 1 150 45 F 1 100 418 F 1 050 427 Charging Procedure 1 Remove the battery to prevent damage from leaking or spilled acid during charging 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific gravity to 1 270 or greater 3 Install battery in vehicle with positive terminal toward the front Coat threads of battery bolt with a corrosion resistant dielectric grease Dielectric Grease PN 2871329 4 Connect battery cables A WARNING To avoid the possibility of explosion connect positive cable first and negative cable last 10 29 ELECTRICAL 5 After connecting the battery cables install the cover on the battery and attach the hold down strap 6 Install clear battery vent tube from vehicle to battery vent
330. th a nicasil coating and are not repairable Hone only enough to de glaze the outer layer of the cylinder bore Example of Cross Hatch Pattern 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 are not repairable Hone only enough to de glaze the outer layer of the cylinder bore Cleaning the Cylinder After Honing Itis very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylinder in a solvent then in hot soapy water Pay close attention to areas where the cylinder sleeve meets the aluminum casting transfer port area Use electrical contact cleaner if necessary to clean these areas Rinse thoroughly dry with compressed air and oil the bore immediately with Polaris Lubricant Engine Lubrication Specifications Capacity Approximately 2 U S Quarts 1 9 I Oil Type Polaris Premium OW 40 Synthetic Filter Wrench PV 43527 or equivalent Oil Pressure Specification 35 39 PSI 5500 RPM Polaris OW 40 Synthetic Engine at operating temperature Oil Pressure Test 1 Remove blind plug sender from left side of crankcase 2 Insert a 1 8 NPT oil pressure gauge adaptor into the crankcase and attach the gauge 3 Start engine and allow it to reach operating temperature monitoring gauge indicator NOTE Use only Polaris Premi
331. the black test port and the meter to VDC Move 9V battery the throttle open and closed slowly while reading the display The voltage should increase smoothly with no jumps or decreases when the throttle is applied PU 47082 Harness No Jumps in read out 1 70 99 VERIFY TPS TESTER REFERENCE VOLTAGE Black Probe vdc Red Probe ES 5 volt reference voltage from the harness is required for the TPS test to be accurate Refer to the instructions provided with the TPS Test Adapter Harness PU 47082 or follow the bullet point steps to check reference voltage 4 17 FUEL INJECTION 3 If voltage varies with throttle movement continue on to step 3 and measure the idle air flow reading If the sensor does not function correctly replace it 4 With voltmeter still attached to the TPS Test Adapter Harness PU 47082 as shown below the voltmeter should read 710 01 volts at idle position TPS Tester Adapter Harness PU 47082 Should Read 710 V uf Black Prob ro 5 If the voltage does not read within the specification TPS Initialization will need to be performed TPS Initialization NOTE The correct position of the TPS is established and set at the factory Use this procedure only if the TPS repositioned replaced or loosened STEP 1 Establishing zero offset voltage This step is crucial as it sets the TPS position using a fixed physical stop This will insure that the corre
332. the bolt flanges Torque bolts to specification following torque pattern at beginning of this chapter e T Crankcase Bolt Torque 22 2 ft Ibs 30 3 Nm Torque in sequence 8 Lubricate cam lobes and valve lifters with Moly Lube Grease Apply Moly Lube Cam Lobes 5 Install crankshaft assembly and apply engine oil to crank pins and rods D Apply assembly lube to the main journals and bearings 9 Lubricate lifters with engine oil and install in the original order as removed in disassembly Apply Lubricant or Moly Lube to the ends of the lifters NOTE Always replace the camshaft and lifters as set 6 Apply Crankcase Sealant PN 2871557 to the top gearcase halve NOTE Do not apply sealant to cam relief hole E 3 46 10 Lubricate connecting rods with OW 40 engine oil 11 Install new cylinder gasket on crankcase Align gasket on the dowel pins for proper gasket alignment 12 Orientate the piston rings on the piston before installation into the cylinders Set the gaps of the rings every 120 See Illustration Below 2 Piston Ring Orientation 1 Ring 2 Second Ring 13 Install piston assemblies into cylinder aligning the piston pin holes to ensure proper 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
333. the cause of the Check Engine light To recall blink codes fail codes from the ECU 1 Verify the key switch is off and the transmission is in neutral with the parking brake applied 2 Turn the key switch ON and OFF times within 5 seconds and leave the key switch in the ON position on the third turn The word Wait will appear as the ECU searches for on the instrument cluster display 4 The word End will display after all ofthe codes have been displayed or if no codes are present C xz Em NOTE To clear codes manually disconnect the positive battery lead for 20 seconds DIAGNOSTIC BLINK CODES CHART SAE CODE NAME CHECK ENGINE P0335 21 Loss of Synchronization Yes P0122 22 TPS Open or Short Circuit to Ground Yes P0123 22 TPS Short Circuit to Battery Yes P0601 23 RAM Error Defective ECU Yes P0914 25 Transmission Input Invalid Gear Yes P0500 26 Vehicle Speed Sensor Implausible Yes P0113 41 Intake Air Temp Sensor Open or Short Circuit to Sensor Voltage ECU Yes P0112 41 Intake Air Temp Sensor Short Circuit to Ground Yes P0117 42 Engine Temperature Sensor Circuit Short To Ground Yes P0118 42 Engine Temperature Sensor Circuit Open or Short to Battery Yes P0107 45 Barometric Pressure Sensor Circuit Low Input Yes P0108 46 Barometric Pressure Sensor Circuit High Inpu
334. the frame The axle will slide off the mid gearcase splined output shaft Disassembly Assembly NOTE For mid drive shaft service information see REAR DRIVE SHAFT 4X4 CV Joint Boot Replacement Installation 1 Apply Anti Seize compound onto the mid gearcase output shaft splines Slide mid drive shaft A onto the mid gearcase output shaft B T ech d at D Install the outer end of the mid drive shaft into the hub carrier C Lift hub carrier into place and install bolt to upper control arm Torque bolt to 35 ft Ibs 47 Nm odi m Ew Upper Bolt Ha T M ON ss 2484 Pull drive shaft outward and install hub onto driveshaft splines Apply Anti Seize compound to the axle splines Install the flat washer A and cone washer B with domed side facing outward Refer to next photo 7 27 FINAL DRIVE 6 Install the castle nut C wheel and wheel nuts 8 Install a new cotter pin Tighten nut slightly to align holes if required 9 Install hub cap MID PROP SHAFT 6X6 Removal 1 Use the Roll Pin Removal Tool PN 2872608 to remove the roll pin from prop shaft at rear of transmission 7 Remove jackstand and torque mid hub nut to 110 ft Ibs 149 Nm and wheel nuts to 35 ft Ibs 47 Nm Mid Hub Nut Torque 110 ft Ibs 149 Nm Mid Wheel Nut Torque 35 ft Ibs 47 Nm 2 The transmission or middle dif
335. the roll pin removal tool to the roll pin for bearing cap out with a soft face hammer removal The drive shaft can be removed through egen the floor covering 3 Support U joint in vise as shown and drive inner yoke down to remove remaining bearing caps PROPSHAFT U JOINT SERVICE Disassembly 1 Remove internal or external snap ring from all bearing caps AA CAUTION Always wear eye protection NOTE If yoke or bearing is removed cross bearing must be replaced Note orientation of grease fitting and mark inner and outer yoke for correct re positioning during installation 7 12 FINAL DRIVE 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 needle bearings upon installation of cross joint Tighten vise to force bearing caps in 2 Using a suitable arbor fully seat bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled 3 Install snap ring to contain bearing cap just installed Repeat procedure for other side en 9 Install outer made before disassembly yoke aligning marks Repeat Steps 1 3 to install bearing caps on outer yoke Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown When installation is complete
336. the seat on the driver s side 5 Fuel Pump Regulator Gauge Sender Assembly 2 Intake Air Temperature and Barometric Air Pressure Located in fuel tank as an assembly Sensor T BAP Located in the rubber intake boot between the air box and throttle body 6 Throttle Body 3 Crankshaft Position Sensor CPS Located in the magneto cover on the right hand side of the engine li T ee 25 li Throttle 4 6 FUEL INJECTION 7 Throttle Position Sensor TPS Located on the right hand side of the throttle body 8 Engine Coolant Temperature Sensor ECT Located in the cylinder head 4 7 FUEL INJECTION FUEL TANK Exploded View Fuel Flow Fuel pump is included as an assembly with the fuel tank If the fuel pump is removed for any reason and needs to be reinstalled use the following procedure and seuqence Torque to 10 14 in lbs 1 13 1 58 Nm in sequence Again torque screws to 25 28 in lbs 2 82 3 16 Nm in sequence Excess Fuel gt Fuel Tank Vent Fuel Pump Pressure Regulato Unit Fuel Filter Located in Fuel Tank FUEL INJECTION Fuel Lines Quick Connect RANGER EFI models use quick connect fuel lines Refer to the steps below for fuel line removal 1 Place a shop towel around the fuel line to catch any dripping fuel Squeeze the connector tabs together and push the locking slide back A oi Squeeze Connector Tabs o H
337. the top gear The springs could cause injury or become lost should they pop out 12 Remove all three springs using one of the tapered pins from the Tapered Pins PU 45497 1 PU 45497 1 13 With white marking pen accent the timing mark on the gear that contains the springs Accent Timing Marks 14 Inspect the gear teeth and the three tabs the gears for Assemble e Hold the spring with one finger Start the pointed end of the tapered pin into the cam gear hole and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring Inspect Teeth amp Tabs Perform this procedure with all 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 the 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 Replace 3 Springs 15 Install the new springs into the grooves of the cam gear Install Springs PU 45497 1 Cam Gear Spring Installation Tool Kit PU 45497 Tapered Pins 16 Insert the pointed dowels from the Tapered Pins PU PU 45497 1 45497 1 into the cam gear Cam Gear Tooth Align Tool PU 45497 2 18 Line up the two gears using the timing marks and the three gear tabs that were referenced earlier Push the gears back togethe
338. the torch too close to the surface Keep the torch moving to prevent damage 2 Apply the decal NOTE Refer to your parts manual for decal part number Example of Decal Placement Ico mm IA b CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES 4 ee e er BEEN Rr Re OC ea 6 2 TORQUE SPECIFICATIONS tactic aed oe Sai ew GAR aoa aOR oet RR e 6 2 PVT SYSTEM FASTENER TORQUES 6 2 PVT SYSTEM OVERVIEW 255524502 crt enc dem earn ic cede coo o RW io xe 6 2 GENERAL OPERATION ze Ue qu uere d o Rte ce e 6 2 DRIVE CLUTCH 2 6 2 DRIVEN CLUTCH 6 3 MAINTENANCE 6 3 OVERHEATING DIAGNOSIS 0 0 0 2 eee 6 4 PVT SXSTENMHSERVIGE 55 eu OT bre dein ER 6 5 PVT SEALING GUARD AND DUCTING 5 6 5 DISASSEMBLY os e e tite ali ate eodd d os 6 5 ASSEMBLY ien e better iet EN 6 6 DRIVE BELT 5 282 re si SOR URS e SE ua S OCT dr a a OA 6 7 BELT DEFLECTION 12 6 7 BEETHREMOVAL S eld ec Lesen uc fr d Pete eh es 6 7 BELT INSPECTION ei etr M tatit perdet cere ten eec te e obe pae Fieri tu a 6 8 BET INSTAELEAT IO
339. this checklist and perform all steps that apply General Items 1 Install previously removed components using new gaskets seals and fasteners where applicable NOTE Properly route all electrical harnesses and re attach any fasteners or protective tubing Check for any possible rubbing points of electrical wires 2 Perform regular checks on fluid levels controls and all important areas on the vehicle as outlined in the daily pre ride inspection checklist refer to Chapter 2 or the Owner s Manual PVT System 1 Adjust center distance of drive and driven clutch Chapter 6 2 Adjust clutch offset alignment and belt deflection Chapter 6 3 Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing Chapter 6 Transmission 1 Inspect transmission operation and adjust linkage if necessary Refer to Chapter 2 and Chapter 8 3 19 Exhaust 1 Replace exhaust gaskets Seal connections with high temp silicone sealant 2 Check to be sure all springs are in good condition Bleed Cooling System NOTE Follow coolant bleeding procedure outlined earlier in this chapter Engine Break In Period The break in period for a Polaris RANGER engine is defined as the first ten hours of operation or the time it takes to use two full tanks of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will
340. tial becomes unlocked for tighter turns An electrical solenoid mounted on the rear axle housing actuates the shift yoke and slides the clutch gear to lock and unlock the rear axle housing When switch position is set to Unlock the solenoid is powered and the plunger extends to disengage the clutch gear and unlock the axle housing 7 44 When the clutch gear is unlocked the rear axle becomes differential When it s locked it becomes a solid rear axle increasing traction See images below Le 1 Clutch Gear 75 Locked Mode Gear Locked dem Unlocked Mode IRS Axle Clutch Gear Unlocked FINAL DRIVE Operation Modes Differential Locked Differential Unlocked Both rear wheels rotate at same speed Rear wheels can rotate at different speeds Allow for sharper turning AWD Mode D J J Rear Wheels rotate as same speed Front Wheels rotate as same speed when AWD activated 7 45 FINAL DRIVE Differential Removal Differential Disassembly 1 Follow Rear Drive Shaft Removal procedure to remove IMPORTANT The pinion gear assembly is NOT the drive axles from each side of the rear differential intended to be disassembled from the case as it requires special OEM tooling in order to properly 2 Disconnect the differential solenoid 2 wire harness reassemble If there is any damage to the pinion gear
341. til the pinion gear assembly comes loose Apply Polaris Crankcase Sealant PN 2871557 to the inside surface of the input cover J Install the pinion shaft assembly and input cover onto the gearcase Install the input cover bolts K Torque the bolts to 18 23 ft Ibs 24 31 Nm FINAL DRIVE Install the wave spring L into the gearcase assembly Be sure the wave spring is fully seated into the bearing cup of the gearcase L Install the output shaft and ring gear into the gearcase sure the 10 input pinion gear and the output pinion gear mesh smoothly Install the shims M into the output cover N Install the shims in the order that they were removed during the disassembly process 7 33 FINAL DRIVE 10 Install a new O ring O onto the output cover Middle Gearcase Specifications Capacity 6 75 oz 200 ml Specified Lubricant ATV Angle Drive Fluid PN 2871653 Fill Plug Torque 14 ft Ibs 19 Nm Gearcase Installation Place the middle gearcase in the frame assembly 11 Carefully install the output cover onto the gearcase l Install the output cover bolts Torque the bolts to 18 23 ft Ibs 24 31 Nm 2 Attach the mid and rear prop shafts to the mid gearcase but do not install the new roll pins yet 3 Install the four middle drive gearcase bolts Torque the Input Cover Bolt Torque bolts to 30 ft Ibs 41 Nm in a cross patt
342. to the FRONT DRIVE SHAFT REMOVAL procedure earlier in this chapter The front gearcase and drive shafts can be accessed from both sides of the vehicle and limited access from the top Remove the access panel on the side of the vehicle T 25 screws secure the panel to the frame Left Side Panel EN E Remove the roll pin from the front drive shaft Remove front drive shaft from the front gearcase splines Remove bolts securing bottom of gearcase to frame Remove vent line Remove gearcase from right side of frame 7 17 FINAL DRIVE Gearcase Disassembly Inspection 1 Drainand properly dispose of used oil Remove any metal particles from the drain plug magnet 2 Remove bolts and output shaft cover 3 Check the gearcase coil resistance The resistance value should meet the specifications listed below NOTE To test the gearcase coils resistance use the coil harness The gearcase coils should measure between 22 8 ohms and 25 2 ohms 4 Remove output shaft assembly NOTE Be careful not to misplace the thrust bearing located between the two output shafts 5 Clean all parts and inspect spacers for wear Inspect ring gear for chipped broken or missing teeth 7 18 Remove the roll cage assembly rollers and H springs 7 Thoroughly clean all parts Inspect the rollers A for nicks and scratches The rollers must slide up and down freely within the roller cage su
343. tor No gt y kie Output test See test procedure on Page 10 24 Inspect the flywheel magnets stator coils and stator wires for damage Does output meet specification Repair or replace any damaged components Yes Y Meter Setting DC Volts Reconnect the alternator wires Note Red wire must be connected to harness Battery Check stator regulator ground battery voltage must be present on red wire terminal and battery connections Also check on harness side of voltage regulator connector w No p wire connections and wire coudition Is voltage present Repair or replace faulty wiring or components Yes If all of the previous tests indicate a good condition but the charging voltage does not rise above battery voltage at the connector or wire harness replace the voltage regulator 10 25 ELECTRICAL BATTERY TERMINAL BLOCK The terminal block is located under the front hood next to the battery The terminal block provides easy access to the main battery and starting cables The terminal block also provides easy hookup for accessories TERMINAL BLOCK Orange White Black 3 Orange White Accessories Black Ground e T Terminal Block Nuts 20 25 in Ibs 2 3 2 8 Nm BATTERY SERVICE Battery Terminals Bolts Use Polaris corrosion resistant Nyogel grease PN 2871329 on battery ter
344. ts One of two methods can be used to measure toe alignment The string method and the chalk method If adjustment is required refer to following pages for procedure Tie Rod End Steering Inspection check for play in the tie rod end grasp the steering tie rod pull in all directions feeling for movement Repeat inspection for inner tie rod end on steering post 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 for any looseness in front hub wheel assembly by grasping the tire firmly at top and bottom first and then at front and rear Try to move the wheel and hub by pushing inward and pulling outward If abnormal movement is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts or loose front hub nut Refer to the Body Steering or Final Drive chapter for more information Camber and Caster The camber and caster are non adjustable 2 31 GENERAL INFORMATION Wheel Toe Alignment Inspection 1 Place machine on a smooth level surface Set steering wheel in a straight ahead position and secure the steering wheel in this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible Chalk Mark Measurement A Me
345. ture and barometric air pressure sensor T BAP performs two functions in one unit D i ee Y BD 4 H Air passing through the intake is measured by the T BAP and relayed to the ECU These signals comprised of separate air temperature and barometric air pressure readings are processed by the ECU and compared to it s programming for determining the fuel and ignition requirements during operation T BAP Test The temperature and barometric air pressure sensor T BAP is a non serviceable item If it is faulty it must be replaced This sensor requires a 5 Vdc input to operate therefore the T BAP sensor should only be tested using the Digital Wrench Diagnostic Software dealer only Refer to the EFI Diagnostic Software Manual for more information T BAP Replacement 1 Disconnect sensor from engine harness Using a 10mm wrench remove the retaining bolt and replace the sensor using a light coating of oil on the o ring to aid installation 3 Torque the retaining bolt to specification e T T BAP Retaining Bolt Torque 29 in lbs 3 3 Nm FUEL INJECTION THROTTLE POSITION SENSOR TPS Harness Test Insert black voltmeter probe into the test port Operation Overview Connect the red meter probe into the port and The throttle position sensor TPS is used to indicate throttle verify the voltage is 4 99 5 01 Vdc If this reading is plate ang
346. two caliper assembly nuts C that were previously loosened during Step 2 of Caliper Removal 9 11 5 New Brake Pad Installation NOTE Parking Brake Pads can be replaced by ordering one of the following kits PN 2203148 Brake Pad and Shim Kit PN 2203147 Brake Pad Kit There may be more parts in the service kit than your brake requires Check the parts list included with the kit for the exact quantities 1 3 9 12 Using the stationary actuator assemble the caliper components as shown below Do not install the springs or shims yet Measure the gap for the brake disc Disassemble and add shims between thrust washer and the inside brake pad as needed to close the gap to 0 203 0 193 5 156 4 902 mm For shim location see Figure 9 10 on page 10 Add shims until gap measures 0 203 0 193 5 156 4 902 mm Once you have determined the correct amount of shims to use install the assembly bolts through the sleeves Install the nuts and the correct amount of shims the inner brake pad springs and outer brake pad Torque the assembly nuts to 25 ft Ibs 34 Nm ey T Parking Brake Caliper Assembly Bolts 25 ft Ibs 34 Nm Ensure the park brake assembly functions properly by actuating the lever before reinstallation Caliper Installation 1 2 3 Install the park brake assembly into place Tighten the two mounting bolts in increments for proper
347. ug the fuel line and tank inlet or use a shop towel during removal NOTE Properly drain fuel into a suitable container 4 13 FUEL INJECTION 9 Reinstall the fuel cap and carefully pull the fuel tank out the RH side of the frame A WARNING Wear safety goggles while performing this procedure failure to do so could result in serious injuries Fuel Tank Installation 1 Reinstall the pump tank assembly 2 Reinstall the four fuel tank mounting bolts that were removed 3 Reconnect the electrical harness Install the fuel line and vent line and verify they are secure 4 Reinstall the RH rear fender 5 Reconnect the negative battery cable Test the fuel pump by turning on the key and listening for the pump to activate FUEL PRESSURE REGULATOR Operation Overview The fuel pressure regulator maintains the required operating system pressure of 39 psi 3psi A rubber fiber diaphragm divides the regulator into two separate sections the fuel chamber and the pressure regulating chamber The pressure regulating spring presses against the valve holder part of the diaphragm pressing the valve against the valve seat The combination of atmospheric pressure and regulating spring tension equals the desired operating pressure Any time the fuel pressure against the bottom of the diaphragm exceeds the desired top pressure the valve opens relieving the excess pressure returning the excess fuel back to t
348. ug with proper type CAUTION Severe engine damage may occur if the incorrect spark plug is used 7 Apply a small amount of anti seize compound to the spark plug threads GENERAL INFORMATION 8 Install spark plug and torque to specification Recommended Spark Plug Champion RC7YC3 Spark Plug Torque 18 Ft Lbs 24 Nm Engine To Frame Ground Inspect engine ground cable connection Be sure it is clean and tight The ground cable runs from the engine to the terminal Terminal Block under hood STEERING AND SUSPENSION Steering The steering components should be checked periodically for loose fasteners worn tie rod ends and damage Also check to make sure all cotter pins are in place If cotter pins are removed they must not be re used Always use new cotter pins Replace any worn or damaged steering components Steering should move freely through entire range of travel without binding Check routing of all cables hoses and wiring to be sure the steering mechanism is not restricted or limited NOTE Whenever steering components replaced check front end alignment Use only genuine Polaris parts A WARNING Due to the critical nature of the procedures outlined in this chapter Polaris recommends Steering component repair and adjustment be performed by an authorized Polaris MSD certified technician when replacing worn or damaged steering parts Use only genuine Polaris replacement par
349. um OW 40 Synthetic Engine Lubricant Oil Pressure at 5500 RPM Engine Hot Standard 39 PSI Minimum 35 PSI 3 21 Oil Flow Chart This chart describes the flow of oil through the 700 engine Beginning in the crankcase sump the oil is drawn through an oil galley to the feed side of the oil pump The oil is then pumped through the oil filter If the oil filter is obstructed a bypass valve contained in the filter allows oil to bypass the filter element 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 oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump The oil pressure switch is fed off the main oil galley Crankshaft Crankcase Main Bearing Sump on Crankshaft Bearings Main Bearing Counterbalance Counterbalance Bore Bore Bore Bore Bore MAGNETO SIDE Oil Pressure Relief Main Oil Gallery Crankcase Sump 3 22 ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Rocker Arms Retainer Locks keepers Push Rods
350. ure proper shaft function and a normal service life The complete driveshaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage to the driveshaft joints Over angling of joints beyond their capacity could result in boot or joint damage Make sure surface ground areas and splines of shaft are protected during handling to avoid damage Do not allow boots to come into contact with sharp edges or hot engine and exhaust components The driveshaft is not to be used as a lever arm to position other suspension components Never use a hammer or sharp tools to remove or to install boot clamps Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned Refer to text for grease capacity of CV joints and CV joint boots FRONT DRIVE SHAFT Removal 1 Elevate front end and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearings and seals 7 8 2 Check bearings for side play by grasping tire wheel firmly and checking for movement It should rotate smoothly without binding or rough spots Remove wheel nuts washers and wheel Remove the two brake caliper attaching bolts CAUTION
351. urement obtained in Step 5 Piston Piston Pin Piston to Cylinder Clearance See 700 EFI Engine Service Specifications on page 3 11 Piston O D See 700 EFI Engine Service Specifications on page 3 11 Piston Rod Inspection 1 Measure piston pin bore Piston Pin Bore See 700 EFI Engine Service Specifications on page 3 11 3 34 2 Measure piston pin O D Replace piston and or piston pin if out of tolerance Piston Pin Measurement Locations Piston Pin O D See 700 EFI Engine Service Specifications on page 3 11 3 Measure connecting rod small end ID 9 Connecting Rod Small End I D See 700 EFI Engine Service Specifications on page 3 11 4 Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge Replace piston and rings if ring to groove clearance exceeds service limits Piston Feeler Gauge See 700 EFI Engine Service Specifications on page 3 11 Piston Ring Installed Gap 1 Place each piston ring A inside cylinder B using piston to push ring squarely into place as shown 25 50 mm Piston Ring Installed Gap See 700 EFI Engine Service Specifications on page 3 11 NOTE Ring should be installed with the mark facing upward 2 Measure installed gap with a feeler gauge C at both the top and bottom of the cylinder IMPORTANT A difference in end gap
352. use only Polaris DOT 4 Brake Fluid P N 2872189 Polaris brake fluid is sold in 12 oz bottles WARNING Once a bottle is opened use what is necessary and discard the rest in accordance with local laws Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture This causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of serious injury 9 4 5 BRAKE SYSTEM EXPLODED VIEW Caliper Banjo Style Fittings 15 ft Ibs 20 Nm All Caliper Bleed Screws 30 60 in Ibs 3 4 6 8 Nm All Flare Style Fittings 12 15 ft Ibs 16 20 Nm LH Front Brake Line LH Rear Line MC Rear Brake Line Brake Line LH Rear Caliper Cross Fitting RH Rear Line Tm RH Front RH Front Caliper Brake Line RH Rear Caliper ES MS 1 15 ft Ibs 20 Nm Master Cylinder Side View BRAKES MASTER CYLINDER Removal 1 Open hood Locate the master cylinder 2 Remove the nut and bolt A from the brake pedal e 9 13 ft 1 5 12 18 Nm 20 22 ft Ibs O 27 30 Nm B 3 Place a container to catch brake fluid under the master cylinder brake line banjo bolts B NOTE Dispose of brake fluid properly and do no
353. ushing 1 7 Race Output Hub Asm 1 20 Gearcase LH 1 8 Dowel Pin 1 21 Oil Fill Plug 1 9 Clutch Housing Ring Gear 1 22 Drain Plug Asm Includes Plug Washer 1 10 Roll Cage Asm Includes H Springs 1 23 Roller Thrust Needle Bearing 1 11 Rollers 14 24 Clutch Asm 1 12 Bushing 1 25 Internal Retaining Ring 1 13 Fitting 1 26 Armature Plate 1 7 15 FINAL DRIVE AWD Diagnosis Symptom AWD Will Not Engage 1 7 16 Check the gearcase coil resistance test the gearcase coil resistance Test between the Grey amp Brown White wires The gearcase coils should measure between 22 8 ohms and 25 2 ohms Front Gearcase Coil Resistance 22 8 25 2 Ohms Check the minimum battery voltage at the Gray amp Brown White wires that feed the hub coil voltage There should be a minimum of 11 0 12 0 Volts present for proper operation Inspect the armature plate for a consistent wear pattern There should one or two distinct wear bands one band inside the other If only one band of wear is present or if there is wear between the two bands inspect the coil area asindicated in Step 4 A band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation See the following illustrations Armature Plate Armature plate design may differ from what is shown Check for wear bands Possible Wear Ring on Armature Plate OK
354. w Torque 115 12 in Ibs 13 1 35 Nm NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts and new Loctite 3 48 20 Install oil pump housing bolts The new bolts contain 22 Before installing the crankshaft gear heat the crankshaft patch lock so Loctite is not needed on the new bolts gear to 250 F 121 C on a hot plate 7 Torque bolts to specification and follow the torque sequence at beginning of the chapter NOTE Occasionally spin the oil pump when A CAUTION installing bolts to check for binding of the rotors The crankshaft gear is extremely hot Severe burns or injury can occur if the gear is not handled with extreme care and caution Follow Oil Pump Bolt Torque the procedure below to help ensure safety 84 8 in Ibs 9 50 0 90 Nm 23 Use extreme caution when removing the crankshaft gear Torque in Sequence 5 8 from the hot plate Use a pair of pliers and leather gloves when handling the crankshaft gear 24 Install the crankshaft gear 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 gt a 2 21 Apply Loctite 242 PN 2871949 to the crankshaft
355. wdriver PU 47315 This tool has a special D shaped end for adjusting the throttle stop screw during a TPS initialization procedure 4 3 FUEL INJECTION Service Notes For more convenient and accurate testing of EFI components it is recommended dealers utilize the Digital Wrench Diagnostic Software dealer only or testing may be done manually using the procedures provided 80 of all EFI problems are caused by wiring harness connections For the purpose of troubleshooting difficult running issues a known good ECU from another Polaris RANGER XP EFI of the same model may be used without damaging system or engine components t Never attempt to service any fuel system component while engine is running or ignition switch is on Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system Dirt even in small quantities can cause significant problems Do 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 prevent water intrusion failure avoid direct water or spray contact with system components Do not disconnect or reconnect the wiring harness c
356. weak Electrical malfunction Water pump failure Loose impeller Thermistor failure Cooling fan inoperative or turning too slowly perform current draw test Ignition timing mis adjusted Low oil level Spark plug incorrect heat range Faulty hot light circuit Thermostat stuck closed or not opening completely Temperature Too Low Thermostat stuck open Leak at Water Pump Weep Hole Faulty water pump mechanical seal coolant leak Faulty pump shaft oil seal oil leak 3 59 FUEL INJECTION CHAPTER 4 FUEL INJECTION GENERAL INFORMATION ege epe RU PE e Edd 4 2 SPECIALE TOOLS rre LEER nit T eb dust eb e 4 2 SERVIGE NOTES enel plu e Deu DIS ue sr ITE eee UE 4 4 EFI SYSTEM EXPLODED 4 5 EFI SYSTEM COMPONENT LOCATIONS 4 6 Tz BN EE 4 8 EXPLODED VIEW gt eke bn i DE Pari i P 4 8 FUEL LINES QUICK CONNECT 4 9 ELECTRONIC FUEL 4 9 PRINCIPAL COMPONENTS 4 9 EFI OPERATION 4 9 INITIAL PRIMING STARTING 4 10 ELECTRONIC CONTROL UNIT 4 1
357. with Nyogel 96 in lbs Grease PN 2871329 S 10 85 0 35 Nm NOTE Verify stator wires are routed properly under the wire hold down bracket Replace 2 bolts with new bolts Stator Housing Bolt Torque 96 3 Ibs 10 85 0 35 Nm Cylinder Head Reassembly NOTE Before reassembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts Stator Assembly Bolt Torque 96 3 in lbs 10 85 0 35 Nm 3 Install the flywheel washer nut and key Torque flywheel 1 Install the head gasket A on the cylinder nut to specification 65 7 ft Ibs 88 9 50 Nm 3 54 2 Install cylinder head on cylinder 3 Lubricate threads and top of washers underside of bolt head with engine oil Install head bolts C and torque to specification Cylinder Head Bolt Torque Initial setting 35 4 ft Ibs 47 5 5 5 Nm Allow to set for 1 minute then turn additional 90 1 4 turn Torque Bolts In Sequence 4 Lubricate push rods D and install into lifters 5 6 Verify pushrods are engaged in lifters 7 Lubricate rockers E with engine oil c T Install rockers Be sure that tab of fulcrum F is seated in head stand off Torque bolts to specification Rocker Arm Bolt Torque 22 2 ft Ibs 30 3 Nm
358. xtension cap and threads of puller bolt to ease removal Remove upper strut pivot assembly Thread bolt K with nut J onto ball joint stud as Remove coil spring and collapse strut cartridge shown Remove two pinch bolts from strut casting Remove strut cartridge Apply heat to ease removal Install cartridge until bottomed in strut casting Hold bolt K and turn nut J clockwise until ball joint Install pinch bolts with wire clamp s Torque pinch bolts is removed from strut housing to 15 ft Ibs 21 Nm Reassemble spring and top pivot assembly Be sure all parts are installed properly and seated fully Torque strut rod nut to specification Do not over torque nut Strut Rod Nut Torque 15 ft Ibs 21 Nm Loosen front wheel nuts slightly Elevate and safely support machine under footrest frame 8 To install new ball joint Serious injury may result if machine tips or falls Remove extension cap and attach puller guide using CAUTION short bolts provided in the kit nsert new ball joint L into driver M Be sure machine is secure before beginning this service procedure Remove wheel nuts and wheels Slide ball joint driver assembly into guide Apply heat to ease installation Drive new joint into strut housing until fully seated 5 15 BODY STEERING SUSPENSION 10 11 Apply LoctiteTM 242 PN 2871949 to threads of re

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