2010 Ranger 800 XP HD 6X6 Service Manual

GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL: 2010 RANGER XP 800 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
DETAILED: 2010 RANGER XP 800 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL: 2010 RANGER HD 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
DETAILED: 2010 RANGER HD 800. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
GENERAL: 2010 RANGER CREW 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DETAILED: 2010 RANGER CREW 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
GENERAL: 2010 RANGER 6X6 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DETAILED: 2010 RANGER 6X6 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
1.1
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 10 TH 76 AG
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Model Year Emissions &
Designation Model Option
Basic Chassis
Designation Engine Designation
Engine Designation Number

EH076OLE030 / EH076OLE032 / EH076OLE033 ....................... Twin Cylinder, Liquid Cooled, 4-Cycle OHV, Electric Start
VIN Identification
World
Mfg. ID Vehicle Description Vehicle Identifier
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A T H 7 6 A * 0 P 0 0 0 0 0 0
}
Engine Model
Body Style Year Individual Serial No.
Emissions
Plant No. * This could be either
Powertrain a number or a letter
Check Digit
Vehicle and Engine Serial Number Locations

Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the vehicle identification number (VIN) and
the engine model number and serial number.
The VIN can be found stamped on the lower frame rail on the front LH side of the vehicle (see Figure 1-1).
The engine model and serial number can be found on a decal applied to the side of the engine cylinder head (see Figure 1-2).
Figure 1-1 Figure 1-2
VIN Engine Serial Number
1.2
GENERAL INFORMATION
VEHICLE INFORMATION
1
Publication Numbers
Model Model No. Owners Manual PN Parts Manual PN
2010 RANGER XP 800 R10TH76AG, AH, AL, AR, AW, AY 9922522 9922523
2010 RANGER XP 800 EPS R10TY76AZ 9922522 9922523
2010 RANGER HD 800 R10TY76AN 9922522 9922523
2010 RANGER CREW 800 R10WH76AG, AH, AR, AV 9922522 9922540
2010 RANGER 6x6 800 R10HR76AG, AR 9922522 9922527
NOTE: When ordering service parts be sure to use the correct parts manual.
NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from

www.purepolaris.com.
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
20 4010278
P/N 5533534
21 4010278
22 4010321
23 4010321
Key Series 27 4010321
Number 28 4010321
31 4110141
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, SPX Corporation, by phone at 1-800-328-6657 or on-line at
http://polaris.spx.com/.
1.3
GENERAL INFORMATION
GENERAL SPECIFICATIONS
MODEL: 2010 RANGER XP 800 / EPS
MODEL NUMBER: R10TH76AG, AH, AL, AR, AW, AY
MODEL NUMBER: R10TY76AZ (EPS MODEL)
ENGINE MODEL: EH076OLE
Category Dimension / Capacity
Length 114 in. / 289.6 cm
Width (cargo box) 60 in. / 152.4 cm
Width (tires) 58 in. / 147.3 cm
Height 76 in. / 193 cm
Wheel Base 76 in. / 193 cm
Ground Clearance 12 in. / 30.5 cm
Turning Radius 158 in. / 401.3 cm
Dry Weight 1237 lbs. / 561 kg
Gross Vehicle Weight 2887 lbs. / 1310 kg
Cargo Box Capacity 1000 lbs. / 454 kg
Cargo Box Dimensions L-36 x W-50 x H-11 in.
(inside dimensions) (91.4 x 127 x 27.9 cm)
1500 lbs. / 681 kg
(Includes weight of
Vehicle Payload
operator, passenger,
cargo and accessories.
Hitch Towing Capacity 2000 lbs. / 907 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
1.4
GENERAL INFORMATION
MODEL: 2010 RANGER XP 800 / EPS Drivetrain
MODEL NUMBER: R10TH76AG, AH, AL, AR, AW, AY Transmission Type Polaris Automatic PVT 1
MODEL NUMBER: R10TY76AZ (EPS MODEL) Shift Type In Line Shift - H / L / N / R
ENGINE MODEL: EH076OLE Transmission Gear Ratio:
Engine High Front: 3.60:1 / Rear: 11.18:1
Low Front: 7.70:1 / Rear: 23.91:1
High Output Domestic Twin Cyl, Reverse Front: 7.00:1 / Rear: 21.74:1
Platform
Liquid Cooled, 4-Stroke
Front Gearcase Lubricant Demand Drive Plus
Engine Model Number EH076OLE030 Requirements 9 oz. (265 ml)
Engine Displacement 760 cc Transmission Lubricant Full Synthetic AGL
Number of Cylinders 2 Requirements 33.8 oz. (1000 ml)
Bore & Stroke (mm) 80 x 76.5 mm Drive Belt 3211133
Compression Ratio 9.78:1 Clutch Center Distance 10.05 (255 mm)
Compression Pressure 165-185 psi Steering / Suspension
Engine Idle Speed 1200 100 RPM Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Lubrication Pressurized Wet Sump Front Suspension Dual A-arm
Oil Requirements PS-4 PLUS Front Travel 9.6 in. (24.4 cm)
Oil Capacity 2 qts. (1.9 L) Rear Suspension Independent (IRS)
Coolant Capacity 3.25 qts. (3.1 L) Rear Travel 9 in. (22.9 cm)
Overheat Warning Instrument Cluster Indicator Shock Preload Adjustment Cam Adjustment
Exhaust System 2 to 1 Canister Style Wheels / Brakes
Fuel System 12 x 6 / Steel
Front Wheel Size / Type
12 x 6 / Cast Aluminum
Fuel System Type Bosch EFI
12 x 8 / Steel
Fuel Delivery Electronic Fuel Pump (in tank) Rear Wheel Size / Type
Fuel Pressure 39 psi
Front Tire Titan / AT489 / 25 x 10 R12
Fuel Capacity 9 gal. (34 L) Make / Model / Size Carlisle / PXT / 26 x 9 R12
Fuel Requirement 87 Octane (minimum) Rear Tire Titan / AT489 / 25 x 11 R12
Electrical Make / Model / Size Carlisle / PXT / 26 x 11 R12
Alternator Max Output 500 Watts @ 3000 RPM Tire Air Pressure 8-12 psi (69 kPa)
Main Headlights 50 Watt / Halogen x 2 Brake System 4 Wheel Hydraulic Disc
Tail Lights 0.3 Watts / L.E.D. x 2 Brake Fluid DOT 4
Brake Lights 3.1 Watts / L.E.D. x 2 Parking Brake Hand Actuated (in dash)
Starting System Electric Start CLUTCH CHART

Ignition System Bosch EFI (ECU Controlled)
Ignition Timing 0 BTDC @ 1200 RPM Shift Drive Driven
Altitude
Weight Spring Spring
Spark plug / Gap RC7YC3 / .035 in. (0.9 mm)
0-1500 23-62 Black Blk / Almd
Yuasa YB30L-B /
Battery / Model / Amp Hr Meters (0-5000) (5632337) (7043594) (7043167)
30 Amp Hr. / 12 Volt
(Feet) 1500-3700 23-58 Black Blk / Almd
Instrumentation Multifunction Speedometer
(5000 - 12000) (5632218) (7043594) (7043167)
DC Outlets (2) - Standard
Relays Fan / EFI / Brake Light / Rear Diff
Circuit Breaker Fan Motor: 15 Amp
Steering: 30 Amp (EPS Model)
Main Chassis: 20 Amp
Accessory: 15 Amp
Fuses EFI: 15 Amp
ECM: 15 amp
Lights: 15 Amp
120 Resistor (EPS Model)
1.5
GENERAL INFORMATION
MODEL: 2010 RANGER HD 800
MODEL NUMBER: R10TY76AN
Length 114 in. / 289.6 cm
Turning Radius 166 in. / 422 cm
1500 lbs. / 681 kg
(Includes weight of
Vehicle Payload
1.6
GENERAL INFORMATION
MODEL: 2010 RANGER HD 800 Drivetrain
MODEL NUMBER: R10TY76AN Transmission Type Polaris Automatic PVT 1

ENGINE MODEL: EH076OLE Shift Type In Line Shift - H / L / N / R
Engine Transmission Gear Ratio:

High Front: 3.60:1 / Rear: 11.18:1
Domestic Twin Cylinder, Low Front: 7.70:1 / Rear: 23.91:1
Platform
Liquid Cooled, 4-Stroke Reverse Front: 7.00:1 / Rear: 21.74:1
Engine Model Number EH076OLE032 Front Gearcase Lubricant Demand Drive Plus
Engine Displacement 760 cc Requirements 9 oz. (265 ml)
Number of Cylinders 2 Transmission Lubricant Full Synthetic AGL
Bore & Stroke (mm) 80 x 76.5 mm Requirements 33.8 oz. (1000 ml)
Compression Ratio 9.78:1 Drive Belt 3211133
Compression Pressure 165-185 psi Clutch Center Distance 10.05 (255 mm)
Engine Idle Speed 1200 100 RPM Steering / Suspension
Lubrication Pressurized Wet Sump Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Oil Requirements PS-4 PLUS Front Suspension Dual A-arm
Oil Capacity 2 qts. (1.9 L) Front Travel 9.6 in. (24.4 cm)
Coolant Capacity 3.25 qts. (3.08 L) Rear Suspension Self Leveling (IRS)
Overheat Warning Instrument Cluster Indicator Rear Travel 7.5 in. (19.1 cm)
Exhaust System 2 to 1 Canister Style Shock Preload Adjustment Cam Adjustment (front only)
Fuel System Wheels / Brakes
Fuel System Type Bosch EFI Front Wheel Size / Type 12 x 6 / Cast Aluminum
Fuel Delivery Electronic Fuel Pump (in tank) Rear Wheel Size / Type 12 x 8 / Cast Aluminum
Fuel Pressure 39 psi Front Tire

Carlisle / PXT / 26 x 9 R12
Make / Model / Size
Fuel Capacity 9 gal. (34 L)
Rear Tire
Fuel Requirement 87 Octane (minimum) Carlisle / PXT / 26 x 11 R12
Make / Model / Size
Electrical Tire Air Pressure 8-12 psi (69 kPa)
Alternator Max Output 500 Watts @ 3000 RPM Brake System Type 4 Wheel Hydraulic Disc
Main Headlights 50 Watt / Halogen x 2 Brake Fluid DOT 4
Tail Lights 0.3 Watts / L.E.D. x 2 Parking Brake Hand Actuated (in dash)
Brake Lights 3.1 Watts / L.E.D. x 2
CLUTCH CHART
Starting System Electric Start
Ignition System Bosch EFI (ECU Controlled) Shift Drive Driven
Altitude
Ignition Timing 0 BTDC @ 1200 RPM Weight Spring Spring
Champion RC7YC3 / 0-1500 23-62 Black Blk / Almd
Spark plug / Gap
.035 in. (0.9 mm) Meters (0-5000) (5632337) (7043594) (7043167)
Yuasa YB30L-B / (Feet) 1500-3700 23-58 Black Blk / Almd
Battery / Model / Amp Hr
30 Amp Hr. / 12 Volt (5000 - 12000) (5632218) (7043594) (7043167)
Steering: 30 Amp
Accessory: 15 Amp
Fuses EFI: 15 Amp
ECM: 15 amp
Lights: 15 Amp
120 Resistor (CAN Bus)
1.7
GENERAL INFORMATION
MODEL: 2010 RANGER CREW 800
MODEL NUMBER: R10WH76AG, AH, AR, AV
Length 145 in. / 386 cm
Ground Clearance 11.5 in. / 29 cm
1750 lbs. / 794 kg
(Includes weight of
Vehicle Payload
1.8
GENERAL INFORMATION
MODEL: 2010 RANGER CREW 800 Drivetrain
MODEL NUMBER: R10WH76AG, AH, AR, AV Transmission Type Polaris Automatic PVT 1
Engine Transmission Gear Ratio:

High Front: 4.63:1 / Rear: 14.37:1
Domestic Twin Cylinder, Low Front: 7.70:1 / Rear: 23.91:1
Platform
Liquid Cooled, 4-Stroke Reverse Front: 7.00:1 / Rear: 21.74:1
Engine Model Number EH076OLE033 Front Gearcase Lubricant Demand Drive Plus
Engine Displacement 760 cc Requirements 9 oz. (265 ml)
Number of Cylinders 2 Transmission Lubricant Full Synthetic AGL
Bore & Stroke (mm) 80 x 76.5 mm Requirements 33.8 oz. (1000 ml)
Compression Ratio 9.78:1 Drive Belt 3211133
Compression Pressure 165-185 psi Clutch Center Distance 10.05 (255 mm)
Engine Idle Speed 1200 100 RPM Steering / Suspension
Lubrication Pressurized Wet Sump Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Oil Requirements PS-4 PLUS Front Suspension Dual A-arm
Oil Capacity 2 qts. (1.9 L) Front Travel 9.6 in. (24.4 cm)
Coolant Capacity 3.25 qts. (3.08 L) Rear Suspension Independent (IRS)
Overheat Warning Instrument Cluster Indicator Rear Travel 9 in. (22.9 cm)
Exhaust System 2 to 1 Canister Style Shock Preload Adjustment Cam Adjustment
Fuel System Wheels / Brakes
Fuel System Type Bosch EFI 12 x 6 / Steel

Front Wheel Size / Type
Fuel Delivery Electronic Fuel Pump (in tank)
12 x 8 / Steel
Fuel Pressure 39 psi Rear Wheel Size / Type
Fuel Capacity 9 gal. (34 L) Front Tire
Fuel Requirement 87 Octane (minimum) Make / Model / Size
Electrical Rear Tire
Make / Model / Size
Alternator Max Output 500 Watts @ 3000 RPM
Front: 12 psi (83 kPa)
Main Headlights 50 Watt / Halogen x 2 Tire Air Pressure
Rear: 16 psi (110 kPa)
Tail Lights 0.3 Watts / L.E.D. x 2
Brake System Type 4 Wheel Hydraulic Disc
Brake Lights 3.1 Watts / L.E.D. x 2
Brake Fluid DOT 4
Starting System Electric Start
Parking Brake Hand Actuated (in dash)
Ignition System Bosch EFI (ECU Controlled)
Ignition Timing 0 BTDC @ 1200 RPM CLUTCH CHART
Champion RC7YC3 /
Spark plug / Gap Shift Drive Driven
.035 in. (0.9 mm) Altitude
Weight Spring Spring
Yuasa YB30L-B /
Battery / Model / Amp Hr 0-1500 23-62 Black Blk / Almd
30 Amp Hr. / 12 Volt
Meters (0-5000) (5632337) (7043594) (7043167)
Instrumentation Multifunction Speedometer (Feet) 1500-3700 23-58 Black Blk / Almd
(2) - Front (5000 - 12000) (5632218) (7043594) (7043167)
DC Outlets
(1) - Rear
Accessory: 15 Amp
Fuses EFI: 15 Amp
ECM: 15 amp
Lights: 15 Amp
1.9
GENERAL INFORMATION
MODEL: 2010 RANGER 6X6 800
MODEL NUMBER: R10HR76AG, AR
Length 120 in. / 305 cm
Dry Weight 1551 lbs. / 703.5 kg
Storage Box Capacity 250 lbs. / 113 kg
2000 lbs. / 907 kg
(Includes weight of
Vehicle Payload
1.10
GENERAL INFORMATION
MODEL: 2010 RANGER 6X6 800 Drivetrain
MODEL NUMBER: R10HR76AG, AR Transmission Type Polaris Automatic PVT 1

Engine Transmission Gear Reduction:

High 3.85:1
Domestic Twin Cylinder, Low 8.71:1
Platform
Liquid Cooled, 4-Stroke Reverse 7.91:1
Engine Model Number EH076OLE032 Drive Ratio - Front 3.818:1
Engine Displacement 760 cc Drive Ratio - Rear 3.70:1
Number of Cylinders 2 Front Gearcase Lubricant Demand Drive Plus
Bore & Stroke (mm) 80 x 76.5 mm Requirements 9 oz. (265 ml)
Compression Ratio 9.78:1 Transmission Lubricant Full Synthetic AGL
Compression Pressure 165-185 psi Requirements 43.6 oz. (1290 ml)
Engine Idle Speed 1200 100 RPM Mid Gearcase Lubricant ATV Angle Drive Fluid
Requirements 6.75 oz. (200 ml)
Lubrication Pressurized Wet Sump
Rear Gearcase Lubricant ATV Angle Drive Fluid
Oil Requirements PS-4 PLUS Requirements 18 oz. (532 ml)
Oil Capacity 2 qts. (1.9 L) Drive Belt 3211133
Coolant Capacity 3.25 qts. (3.08 L) Clutch Center Distance 10.05 (255 mm)
Overheat Warning Instrument Cluster Indicator Steering / Suspension
Exhaust System 2 to 1 Canister Style Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Fuel System Front Suspension Dual A-arm
Fuel System Type Bosch EFI Front Travel 9.6 in. (24.4 cm)
Fuel Delivery Electronic Fuel Pump (in tank) Mid Suspension Independent (IRS)
Fuel Pressure 39 psi Mid Travel 9 in. (22.9 cm)
Fuel Capacity 9 gal. (34 L) Rear Suspension Independent (IRS)
Fuel Requirement 87 Octane (minimum) Rear Travel 9 in. (22.9 cm)
Electrical Shock Preload Adjustment Cam Adjustment
Alternator Max Output 500 Watts @ 3000 RPM Wheels / Brakes
Main Headlights 50 Watt / Halogen x 2 Front Wheel Size / Type 12 x 6 / Steel
Tail Lights 0.3 Watts / L.E.D. x 2 Rear Wheel Size / Type 12 x 8 / Steel
Brake Lights 3.1 Watts / L.E.D. x 2 Front Tire
Titan / AT489 / 25 x 10 R12
Starting System Electric Start Make / Model / Size
Ignition System Bosch EFI (ECU Controlled) Rear Tire
Titan / AT489 / 25 x 11 R12
Make / Model / Size
Ignition Timing 0 BTDC @ 1200 RPM
Tire Air Pressure 8-12 psi (69 kPa)
Champion RC7YC3 /
Spark plug / Gap Brake System Type 4 Wheel Hydraulic Disc
.035 in. (0.9 mm)
Yuasa YB30L-B / Brake Fluid DOT 4
Battery / Model / Amp Hr
30 Amp Hr. / 12 Volt Parking Brake Hand Actuated (in dash)
CLUTCH CHART
Relays Fan / EFI / Brake Light / Rear Diff Shift Drive Driven
Altitude
Circuit Breaker Fan Motor: 15 Amp Weight Spring Spring
Main Chassis: 20 Amp 0-1500 23-62 Black Blk / Almd
Accessory: 15 Amp Meters (0-5000) (5632337) (7043594) (7043167)
Fuses EFI: 15 Amp (Feet) 1500-3700 23-58 Black Blk / Almd
ECM: 15 amp (5000 - 12000) (5632218) (7043594) (7043167)
Lights: 15 Amp
1.11
GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS

Conversion Table
C to F: 9/5(C + 32) = F F to C: 5/9(F - 32) = C
1.12
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
1
engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.
1.13
GENERAL INFORMATION
SAE Tap / Drill Sizes Decimal Equivalents
Metric Tap / Drill Sizes
1.14
GENERAL INFORMATION
Glossary of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
1
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 instrument 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. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in: Pounds per 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 a 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.
Ohm: The unit of electrical resistance opposing current flow.
oz.: 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)
qt.: 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.
1.15
GENERAL INFORMATION
NOTES
1.16
MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
BREAK-IN PERIOD / MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
50 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2
100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
SERVICE PRODUCTS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
FLUID MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE ADJUSTMENT (XP / HD / CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE ADJUSTMENT (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
FUEL LINES / FUEL FILTER / VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE / PVT AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
AIR INTAKE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
TRANSMISSION LUBRICATION (XP / HD / CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
TRANSMISSION LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
MID GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
REAR GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
RADIATOR INSPECTION / CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
WHEEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2.1
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
BATTERY FLUID LEVEL (CONVENTIONAL BATTERY) . . . . . . . . . . . . . . . . . . . . . . . 2.29
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BATTERY STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
SPRING PRE-LOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
SHOCK POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
PARKING BRAKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
PARKING BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
2.2
MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
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 parts, use
genuine Pure Polaris parts available from your Polaris dealer. 2
NOTE: Service and adjustments are critical. If youre 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.
Break-In Period
The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. Careful treatment
of a new engine and drive components will result in more efficient performance and longer life for these components.
Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.
Pull only light loads.
Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
Change both the engine oil and filter after 25 hours or one month.
See Owners Manual for additional break-in information.
Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:
= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
= SEVERE USE ITEM: See information provided above.
E = Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING
Improperly performing the procedures marked could result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
2.3
MAINTENANCE
Pre-Ride - 25 Hour Maintenance Interval
Maintenance Interval
(whichever comes first)
Item Remarks
Miles
Hours Calendar
(KM)
Steering - Pre-Ride -
Front Suspension - Pre-Ride -
Rear Suspension - Pre-Ride -
Tires - Pre-Ride -
Brake Fluid Level - Pre-Ride -
Make adjustments as needed.
Brake Pedal Travel - Pre-Ride - See Pre-Ride Checklist on Page 2.10.
Brake Systems - Pre-Ride -
Wheels / Fasteners - Pre-Ride -
Frame Fasteners - Pre-Ride -
Engine Oil Level - Pre-Ride -
E
Air Filter / Pre-Filter - Daily - Inspect;clean often
E
Air Box Sediment Tube - Daily - Drain deposits when visible
E
Check level daily, change coolant every 2
Coolant Level - Daily -
years
Check operation; apply dielectric grease if
Head Lamp / Tail Lamp - Daily -
replacing
Air Filter, - Weekly - Inspect; replace as needed
E Main Element
Brake Pad Wear / Inspect 10 H Monthly 100 (160) Inspect periodically
Parking Brake Pads
Battery 20 H Monthly 200 (320) Check terminals; clean; test
Parking Brake Cable 25 H - - Inspect; adjust tension after first 25 hours
Adjustment
Front Gearcase Lubricant 25 H Monthly 250 (400) Inspect level; change yearly
Mid Gearcase Lubricant 25 H Monthly 250 (400) Inspect level; change yearly
(6x6)
Rear Gearcase Lubricant
(6x6) 25 H Monthly 250 (400) Inspect level; change yearly
Transmission Lubricant 25 H Monthly 250 (400) Inspect level; change yearly

Engine Breather 25 H Monthly 250 (400) Inspect; replace if necessary
E Filter (if equipped)
Engine Oil Change 25 H 1M -
Perform a break-in oil change after the first
E (Break-In Period) 25 hours or one month of operation
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
2.4
MAINTENANCE
50 - 100 Hour Maintenance Interval
Item Remarks
Miles
Hours Calendar
(KM)
General Lubrication 50 H 3M 500 (800)

Lubricate all grease fittings, pivots, cables, 2
etc.
Shift Linkage 50 H 6M 500 (800) Inspect, lubricate, adjust
Steering 50 H 6M 500 (800) Lubricate (if applicable)
Front Suspension 50 H 6M 500 (800) Lubricate (if applicable)
Mid Suspension
(6x6) 50 H 6M 500 (800) Lubricate (if applicable)
Rear Suspension 50 H 6M 500 (800) Lubricate (if applicable)

Throttle Cable / Throttle Inspect; adjust; lubricate; replace if
50 H 6M 500 (800)
E Pedal necessary
Throttle Body Air Intake
E 50 H 6M 500 (800) Inspect ducts for proper sealing/air leaks
Ducts / Flange
Drive Belt 50 H 6M 500 (800) Inspect; adjust; replace as needed
Inspect coolant strength seasonally;
Cooling System 50 H 6M 500 (800)
pressure test system yearly
Parking Brake Cable 100 H 6M 1000 (1600) Inspect; adjust tension as needed
Adjustment
Engine Oil Change 100 H 6M 1000 (1600)
Perform a break-in oil change after the first
E 25 hours or one month of operation
Oil Filter Change 100 H 6M 1000 (1600) Replace with oil change
E
2.5
MAINTENANCE
100 - 300 Hour Maintenance Interval
Item Remarks
Miles
Hours Calendar
(Km)
Check for leaks at tank cap, fuel lines, fuel

Fuel System 100 H 12 M 1000 (1600) pump, and fuel rail.
E
Replace lines every two years.
Radiator 100 H 12 M 1000 (1600) Inspect; clean external surfaces
Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks
Engine Mounts 100 H 12 M 1000 (1600) Inspect
Exhaust Silencer / Pipe 100 H 12 M 1000 (1600) Inspect

Spark Plug 100 H 12 M 1000 (1600) Inspect; replace as needed
E
Inspect for wear, routing, security; apply
Wiring 100 H 12 M 1000 (1600) dielectric grease to connectors subjected
to water, mud, etc.
Clutches (Drive and Driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed
Brake Fluid 200 H 24 M 2000 (3200) Change every two years (DOT 4)
Spark Arrestor 300 H 36 M 3000 (4800) Clean out
Inspect periodically; adjust when parts are
Toe Adjustment -
replaced
Headlight Aim - Adjust as needed
Grease Lubrication Points

There is a grease fitting on the front propshaft yoke. Apply a maximum of 3 pumps of grease.
Item Recommended Lube Method Frequency

Grease before long periods
Grease fittings of storage, and after pressure
Front Propshaft Yoke Polaris Premium U-Joint Grease
(3 pumps maximum) washing or submerging the
vehicle.
2.6
MAINTENANCE
SERVICE PRODUCTS AND LUBRICANTS
Polaris Lubricants, Maintenance and Service NOTE: Each item can be purchased separately at
Products your local Polaris dealer.
Part No. Description Part No. Description
Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc. 2

2870791 Fogging Oil (12 oz. Aerosol) Loctite Threadlock 242
2871950
(6 ml.) (12 count)
PS-4 PLUS Performance Synthetic
2876244 Premium Carbon Clean
4-Cycle Engine Oil (Quart) 2871326
(12 oz.) (12 count)
PS-4 PLUS Performance Synthetic
2876245 2870652 Fuel Stabilizer (16 oz.) (12 count)
4-Cycle Engine Oil (Gallon)
Gearcase / Transmission Lubricants 2872189 DOT 4 Brake Fluid (12 count)
Demand Drive Plus 2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)

2877922
(Quart)
NOTE: The number count indicated by each part
Demand Drive Plus number in the table above indicates the number of
2877923
(2.5 Gallon) units that are shipped with each order.
Premium AGL Synthetic Gearcase Lube
2873602
(Quart) (12 count)
Premium AGL Synthetic Gearcase Lube
2873603
(Gallon) (4 count)
ATV Angle Drive Fluid
2876160
(Quart) (12 count)
ATV Angle Drive Fluid
2872276
(2.5 Gallon) (2 Count)
2870465 Oil Pump for 1 Gallon Jug
Grease / Specialized Lubricants
Premium All Season Grease
2871322
(3 oz. cartridge) (24 Count)
Premium All Season Grease
2871423
(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)
2.7
MAINTENANCE
FLUID MAINTENANCE REFERENCES
Component Quick Reference
III. # Item Lube Rec. Method Frequency*

Change after 1st month or first
25 hours of operation, 100 hours
Polaris PS-4 PLUS
Engine Oil Add oil to proper level on thereafter; Change more often
1 Performance Synthetic
dipstick (25 hours) in severe duty
4-Cycle Engine Oil
conditions or short trip cold
weather operation
Maintain coolant level in Check level daily, change
2 Engine Coolant Polaris 60/40 Coolant
coolant reservoir bottle. coolant every 2 years
Maintain fluid level between Check level during pre-ride
3 Brake Fluid Polaris DOT 4 Brake Fluid MAX and MIN lines on the inspection; change fluid every
master cylinder reservoir two years
* More often under severe use, such as operated in water or under severe loads.
2.8
MAINTENANCE
Component Quick Reference, Continued.....
III. # Item Lube Rec. Method Frequency*

Add lubricant until it is visible Check level every 25 hours;
4 Front Gearcase Polaris Demand Drive Plus
at the fill hole threads change fluid yearly
5 Mid Gearcase
Polaris ATV Angle Drive
Fluid (ADF)
Add lubricant until it is visible
at the fill hole threads
Check level every 25 hours;
change fluid yearly
2
Polaris ATV Angle Drive Add lubricant until it is visible Check level every 25 hours;
6 Rear Gearcase
Fluid (ADF) at the fill hole threads change fluid yearly
Polaris Full Synthetic Add lubricant until it is visible Check level every 25 hours;
7 Transmission
Gearcase Lubricant (AGL) at the fill hole threads change lubricant yearly
* More often under severe use, such as operated in water or under severe loads.
2.9
MAINTENANCE
GENERAL VEHICLE INSPECTION Shift Cable Adjustment (XP / HD / CREW)

AND MAINTENANCE NOTE: The shift cable should be adjusted at the rear
adjustment point located near the transmission. If
Pre-Ride / Daily Inspection adjustment is needed beyond that, remove the dash
panel to access the shift cable adjustment point
Perform the following pre-ride inspection daily, and when located underneath the shift lever.
servicing the vehicle at each scheduled maintenance.
1. Place gear selector in neutral. Make sure the transmission
Tires - check condition and pressures bell crank is engaged in the neutral position detents.
Fuel tank - fill tank to proper level
All brakes - check operation, fluid level and adjustment

(includes parking brake) Adjustment
Point
Throttle - check for free operation and closing
Headlight/Taillight/Brakelight - check operation of all

indicator lights, instrument cluster and switches
Ignition 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
Neutral Position
pins
Air cleaner element - check for dirt; clean or replace

2. Locate the shift cable adjustment point at the engine-to-
Steering - check for free operation noting any unusual transmission mount bracket.
looseness in any area
3. With two open-end wrenches, loosen the outside jam nut
Loose parts - visually inspect vehicle for any damaged counterclockwise. Turn the outside jam nut 1 1/2 turns.
or loose nuts, bolts or fasteners
Engine coolant - check for proper level at the recovery Inside Jam Nut
bottle
Check all 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. Refer to specific fastener torques listed in each chapter.
Outside Jam Nut
Shift Cable Inspection
Shift cable adjustment is necessary when symptoms include: 4. After turning the outside jam nut 1 1/2 turns. Hold the
outside jam nut with a wrench and tighten the inside jam
Noise on deceleration
nut clockwise, until it is tight against the bracket.
Inability to engage a gear
5. Repeat Step 3 and Step 4 until the proper adjustment is
Excessive gear clash (noise) made to the shift cable.
Gear selector is moving out of desired range
6. Use this procedure to loosen or tighten the shift linkage
Inspect shift cable, clevis pins, and pivot bushings and replace cable as needed.
if worn or damaged.
2.10
MAINTENANCE
Shift Cable Adjustment (6x6)
NOTE: The shift cable should be adjusted at the rear
adjustment is needed beyond that, remove the dash
located underneath the shift lever.
2
bell crank is engaged in the neutral position detents.
Adjustment
Point
Neutral Position
2. Locate the shift cable adjustment point attached to the

frame in front of the transmission.
3. With two open-end wrenches loosen the outside jam nut

counterclockwise. Turn the outside jam nut 1 1/2 turns.
Outside Jam Nut
Inside Jam Nut
4. 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.

made for the transmission cable.

cable as needed.
2.11
MAINTENANCE
FUEL SYSTEM AND AIR INTAKE Throttle Pedal Inspection

If the throttle pedal has excessive play due to cable stretch or
Fuel System
cable misadjustment, it will cause a delay in throttle speed and
the throttle may not open fully. If the throttle pedal has no play,
WARNING it may be hard to control, and the idle speed may be erratic.
Check the throttle pedal play periodically in accordance with the

Gasoline is extremely flammable and explosive Periodic Maintenance Chart and adjust the play if necessary.
under certain conditions.
Always stop the engine and refuel outdoors or in
Throttle Freeplay Adjustment
a well ventilated area.
Do not smoke or allow open flames or sparks in Inspection
or near the area where refueling is performed or
where gasoline is stored. 1. Apply the parking brake.
Do not overfill the tank. Do not fill the tank neck. 2. Put the gear shift lever in the N (Neutral) position.
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately. 3. Start the engine, and warm it up thoroughly.
If you spill gasoline on your skin or clothing, 4. Measure the distance the throttle pedal moves before the
immediately wash it off with soap and water engine begins to pick up speed. Free play should be 1/16
and change clothing. - 1/8 (1.5 - 3 mm).
Never start the engine or let it run in an enclosed
area. Engine exhaust fumes are poisonous and Adjustment
can result in loss of consciousness or
death in a short time. 1. Remove the seat.
Never drain the fuel when the engine is hot. 2. Locate the throttle cable adjuster.
Severe burns may result.
3. Squeeze the end of the rubber boot and slide it far enough
to expose the end of the inline cable adjuster.
Fuel Lines
1. Check fuel lines for signs of wear, deterioration, damage
or leakage. 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. Boot
Fuel Filter
The fuel pump on the RANGER 800 EFI is non-serviceable. If
the internal fuel pump filters require service, the fuel tank and Lock Nut
fuel pump must be replaced as an assembly. Adjuster
4. Loosen the adjuster lock nut.
NOTE: See the Electronic Parts Catalog for more
information. 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.
NOTE: For all other information related to the EFI
NOTE: While adjusting, lightly flip the throttle pedal
System refer to Chapter 4.
in and out.
Vent Lines 6. Tighten the lock nut.
1. Check fuel tank vent lines for signs of wear, deterioration, 7. Squeeze the end of the rubber boot and slide it over the
damage or leakage. Replace every two years. cable adjuster to its original position.
2. Be sure vent line is routed properly and secured with cable 8. Start the engine.
ties. CAUTION: Make sure line is not kinked or pinched. 9. Disengage the parking brake and field test unit to ensure
proper throttle operation.
2.12
MAINTENANCE
Air Filter Service Installation
It is recommended the air filter be replaced annually. When riding 5. Clean airbox of any oil or water deposits and apply a small
in extremely dusty or wet conditions, or at wide open throttle for amount of grease to the sealing surfaces of the filter.
extended periods, replacement is required more often. 6. Reinstall the air filter into the airbox container. Be sure the
filter fits tightly in the air box and engage the (2) clips.
The filter should be inspected periodically before each ride, using
the following procedure.
Engine Air Intake Inspection 2
Removal 1. Open the hood to access the engine intake air baffle box.
1. Lift the rear cargo box to access the airbox cover. 2. Remove the filter element from the baffle box.
Filter Element
Airbox Cover
3. If the filter element is dirty, clean it with a high flash point

2. Unhook the (2) clips from airbox cover and remove cover.
solvent, followed by hot soapy water. Rinse and dry the
Inspect the cover seal. It should adhere tightly to the cover.
filter element thoroughly. Inspect element for tears or
3. Remove the air filter assembly. Inspect the air filter and damage. Replace if necessary.
replace if necessary. 4. Reinstall the filter element into the air baffle box.
4. Remove debris from filter using low pressure, compressed
air. Blow out air filter (lightly) from the inside, out. PVT Air Intake Inspection
IMPORTANT: If the filter has been soaked with fuel or 1. Lift the cargo box to access the PVT air intake baffle box.
oil it must be replaced. Do not attempt to wash the air 2. Remove the cover and filter element from the baffle box.
filter. If cleaning is required, replace the filter.
Filter Element
3. If the filter element is dirty, clean it with a high flash point

solvent, followed by hot soapy water. Rinse and dry the
filter element thoroughly. Inspect element for tears or
damage. Replace if necessary.
4. Reinstall the filter element into the air baffle box.
2.13
MAINTENANCE
Air Intake Exploded View
2.14
MAINTENANCE
ENGINE Engine Oil Level
The twin cylinder domestic engine is a wet-sump engine,
Compression and Leakdown Test
meaning the oil is contained in the bottom of the crankcase. To
NOTE: This engine does NOT have decompression check the oil level, follow the procedure listed below.
components. Compression readings will vary in
proportion to cranking speed during the test.
Average compression (measured) is about 165-185 2
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: 165-185 PSI
Cylinder Leakdown 1. Set machine on a level surface and set the parking brake.
Service Limit 15%
2. Be sure the machine has sat for awhile before removing the
dipstick.
(Inspect for cause if test exceeds 15%)
IMPORTANT: Do not run the machine and then check
the dipstick.
Breather Hose Inspection
3. Stop engine, remove the seat base and unlock the dipstick
The engine is equipped with a breather hose (A). Inspect the lever. Remove dipstick and wipe dry with a clean cloth.
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.
4. Reinstall dipstick and push it into place. Do not lock the

dipstick.
NOTE: Make certain the dipstick is inserted all the

NOTE: Make sure lines are not kinked or pinched. 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.
2.15
MAINTENANCE
5. Remove dipstick and check to see that the oil level is in the Engine Oil and Filter Change
SAFE range. Add oil as indicated by the level on the
dipstick. Do not overfill (see NOTE below!).
=
Recommended Engine Oil:
Maintain Oil Level In SAFE Range PS-4 PLUS Synthetic 4-Cycle Engine Oil
(PN 2876244) (Quart)
DO NOT Overfill the Engine
1. Place vehicle on a level surface and allow the engine to run
for two to three minutes until warm. Stop engine.
NOTE: Due to the dipstick entry angle into the 2. Clean the area around the drain plug at the bottom of the
crankcase, the oil level will read higher on the crankcase. Drain plug is accessible through the skid plate.
bottom side of the dipstick. Proper level indication is
determined on the upper surface of the dipstick as it Drain Plug
is being removed, regardless of the level marks
being on top or on bottom (see the next illustration).
Dipstick
Always read top side of dipstick to

properly check oil level in crankcase
WARNING
Personal injury can occur when handling used

NOTE: A rising oil level between checks in cool oil. Hot oil can cause burns or skin damage.
weather driving can indicate contaminants such as
gas or moisture collecting in the crankcase. If the oil 3. Place a drain pan beneath the crankcase and remove drain
level is over the full mark, change the oil plug. CAUTION: Oil may be hot. Do not allow hot oil to
immediately. come into contact with skin as serious burns may result.
4. Allow oil to drain completely.
5. Replace the sealing washer on the drain plug.
NOTE: The sealing surface on the drain plug should

be clean and free of burrs, nicks or scratches.
6. Reinstall drain plug and torque to specification.
=T
Engine Crankcase Drain Plug:
16 2 ft. lbs. (21.7 2.7 Nm)
2.16
MAINTENANCE
7. Remove the lower seat base. Exhaust Pipe
8. Remove the storage container located under the drivers
side of the seat. WARNING
9. Place shop towels beneath oil filter. Using Oil Filter
Do not perform clean out immediately after the engine
Wrench (PU-50105), turn the filter counter-clockwise to
remove it.
has been run, as the exhaust system becomes very hot.
Serious burns could result from contact
2
with exhaust components.
Oil Filter 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
hand brake and block the wheels to prevent roll back.
Failure to heed these warnings could result in
serious personal injury or death.
The exhaust pipe must be periodically purged of accumulated

Oil Filter Wrench:
carbon as follows:
PU-50105: 2.5 (64 mm)
1. Remove the clean out plugs located on the bottom of the
muffler as shown below.
10. Using a clean, dry cloth, clean filter sealing surface on
crankcase.
11. Lubricate O-ring on new oil filter with a film of fresh engine
oil. Check to make sure the O-ring is in good condition.
12. Install new filter and turn by hand until filter gasket contacts
the sealing surface, then turn an additional 1/2 turn.
Clean Out Plug
=T 2. Set the parking brake and start the engine. Purge

accumulated carbon from the system by momentarily
Oil Filter Torque: revving the engine several times.
Turn by hand until filter gasket contacts sealing
surface, then turn an additional 1/2 turn. 3. If some carbon is expelled, cover the exhaust outlet and
lightly tap on the pipe around the clean out plugs with a
13. Remove the dipstick and fill the sump with 2 quarts (1.9 l) rubber mallet while revving the engine several more times.
of Polaris PS-4 PLUS Synthetic Engine Oil (PN 2876244).
14. Place gear selector in neutral and set parking brake.
15. Start the engine and let it idle for one to two minutes.
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.
2.17
MAINTENANCE
4. If particles are still suspected to be in the muffler, back the TRANSMISSION AND GEARCASES
machine onto an incline so the rear of the machine is one
foot higher than the front. Set the parking brake, block the Transmission Lubrication (XP / HD / CREW)
wheels and repeat Steps 2 and 3.
NOTE: It is important to follow the transmission
maintenance intervals described in the Periodic
Maintenance Chart. Regular fluid level inspections
should be performed as well.
The transmission lubricant level should be checked and changed

in accordance with the maintenance schedule.
Be sure vehicle is positioned on a level surface when
checking or changing the lubricant.
Check vent hose to be sure it is routed properly and
unobstructed.
Transmission Lubricant Level Check

The fill plug is located on the right side of the transmission.
5. If particles are still suspected to be in the muffler, drive the Access the fill plug from the rear right-hand side of the vehicle.
machine onto the incline so the front of the machine is one Maintain the fluid level even with the bottom threads of the fill
foot higher than the rear. Set the parking brake, block the plug hole.
wheels and repeat Steps 2 and 3.
1. Position vehicle on a level surface.
6. Repeat steps 2 through 5 until no more particles are
expelled when the engine is revved. 2. Remove the fill plug and check the lubricant level.
7. Stop the engine and allow the arrestor to cool.
8. Reinstall the clean out plugs.
3. If lubricant level is not even with the bottom threads, add

the recommended lubricant as needed. Do not overfill.
4. Reinstall the fill plug and torque to specification.
=T
Drain / Fill Plug Torque:
10-14 ft. lbs. (14-19 Nm)
2.18
MAINTENANCE
Transmission Lubricant Change Transmission Lubrication (6x6)
The drain plug is located on the right side of the transmission. NOTE: It is important to follow the transmission
Access the drain plug from the rear right-hand side of the maintenance intervals described in the Periodic
vehicle. Maintenance Chart. Regular fluid level inspections
1. Remove the fill plug (refer to Transmission Lubricant
Level Check). The transmission lubricant level should be checked and changed 2
in accordance with the maintenance schedule.
2. Place a drain pan under the transmission drain plug.
3. Remove the drain plug and allow lubricant to drain checking or changing the lubricant.
completely. Check vent hose to be sure it is routed properly and
unobstructed.
Transmission Lubricant Level Check

The fill plug is located on the right side of the transmission.
Access the fill plug from the rear right-hand side of the vehicle.
Maintain the fluid level even with the bottom threads of the fill
plug hole.
2. Remove the fill plug and check the lubricant level.
4. Clean the drain plug magnetic surface. Reinstall drain plug

with a new O-ring and torque to specification.
5. Add the recommended amount of lubricant through the fill

plug hole. Maintain the lubricant level at the bottom of the
fill plug hole when filling the transmission. Do not overfill.
Recommended Transmission Lubricant:

Full Synthetic AGL (PN 2873602) (Quart)
Capacity: 33.8 oz. (1000 ml)

6. Reinstall fill plug with a new O-ring and torque to the recommended lubricant as needed. Do not overfill.
specification.
=T
=T
10-14 ft. lbs. (14-19 Nm) Drain / Fill Plug Torque:
10-14 ft. lbs. (14-19 Nm)
7. Check for leaks. Dispose of used lubricant properly.
2.19
MAINTENANCE
Transmission Lubricant Change Front Gearcase Lubrication
Access the drain plug on the right-hand side of the vehicle NOTE: It is important to follow the front gearcase
through the skid plate. maintenance intervals described in the Periodic
1. Remove the fill plug (refer to Transmission Lubricant should be performed as well.
Level Check).
The front gearcase fluid level should be checked and changed in
2. Place a drain pan under the transmission drain plug.
accordance with the maintenance schedule.
3. Remove the drain plug and allow lubricant to drain Be sure vehicle is positioned on a level surface when
completely. checking or changing the fluid.
unobstructed.
Front Gearcase Fluid Level Check

The fill plug is located on the front left side of the front gearcase.
Access the fill plug from the front of the vehicle. Maintain the
fluid level even with the bottom threads of the fill plug hole.
2. Begin by removing the front bumper to gain access to the

gearcase fill plug.
3. Remove the (2) T27 Torx-head screws retaining the fascia

screen and remove the screen.
4. Clean the drain plug magnetic surface. Reinstall drain plug

with a new O-ring and torque to specification.

plug hole. Maintain the lubricant level at the bottom of the
fill plug hole when filling the transmission. Do not overfill.

Full Synthetic AGL (PN 2873602) (Quart)
Capacity: 43.6 oz. (1290 ml) 4. Remove the (3) bolts from the lower portion of the bumper.
6. Reinstall fill plug with a new O-ring and torque to 5. Remove the fasteners from each side of the upper portion
specification. of the bumper.
6. Carefully remove the bumper from the vehicle.

=T
10-14 ft. lbs. (14-19 Nm)
2.20
MAINTENANCE
7. Remove the fill plug and check the fluid level. 4. Clean the drain plug magnetic surface.
5. Reinstall drain plug with a new O-ring and torque to

specification.
6. Add the recommended amount of fluid through the fill hole.

Maintain the fluid level even with the bottom threads of the
fill plug hole. 2
=
Recommended Front Gearcase Fluid:

Polaris Demand Drive Plus
(PN 2877922) (Quart)
Capacity: 9 oz. (265 ml)

8. If fluid level is not even with the bottom threads, add the
7. Reinstall fill plug with a new O-ring and torque to
recommended fluid as needed. Do not overfill.
specification.
=T
=T
Drain / Fill Plug Torque: 8-10 ft. lbs. (11-14 Nm)
8-10 ft. lbs. (11-14 Nm)
8. Check for leaks. Dispose of used fluid properly.
Front Gearcase Fluid Change: 9. Reinstall the front bumper.

The drain plug is located on the bottom side of the front
gearcase. Access the drain plug through the skid plate.
1. Remove the fill plug (refer to Front Gearcase Fluid Level

Check).
2. Place a drain pan under the front gearcase drain plug.
3. Remove the drain plug and allow fluid to drain completely.
10. Install the fasteners on each side of the upper portion of the
bumper. Torque fasteners to 30 ft. lbs. (41 Nm).
11. Install the (3) bolts in the lower portion of the bumper.
Torque bolts to 14 ft. lbs. (19 Nm).
12. Install the (2) T27 Torx-head screws retaining the fascia
screen. Torque screws to 4-6 ft. lbs. (6-8 Nm).
2.21
MAINTENANCE
Mid Gearcase Lubrication (6x6) 5. Add the recommended amount of lubricant through the fill
hole. Maintain the lubricant level even with the bottom
NOTE: It is important to follow the mid gearcase threads of the fill plug hole.
maintenance intervals described in the Periodic
=
The gearcase lubricant level should be checked and changed in
accordance with the maintenance schedule. Recommended Mid Gearcase Lubricant:
Be sure vehicle is level with parking brake on before ATV Angle Drive Fluid (PN 2876160)
proceeding.
unobstructed.
6. Reinstall fill plug and torque to specification.
Mid Gearcase Lubricant Level Check: 7. Check for leaks. Dispose of used lubricant properly.
The fill plug is located on the left side of the mid gearcase.
Maintain the lubricant level even with the bottom threads of the Make sure vent is unobstructed
fill plug hole. Side View
1. Position the vehicle on a level surface.
2. Remove the fill plug and check the lubricant level (see
Side View).

=T
Fill Plug Torque:
14 ft. lbs. (19 Nm) Fill to bottom of Fill Plug
fill plug hole 14 ft. lbs. (19 Nm)
threads: 6.75 oz.
Mid Gearcase Lubricant Change:
The drain plug is located on the bottom right side of the mid Bottom View
gearcase. Access the drain plug through the skid plate.
1. Remove the fill plug (refer to Mid Gearcase Lubricant

Level Check).
2. Place a drain pan under the mid gearcase drain plug.
3. Remove the drain plug and allow the lubricant to drain

completely (see Bottom View).
4. Clean and reinstall drain plug. Torque to specification.
=T
Drain Plug
Drain Plug Torque: 14 ft. lbs. (19 Nm)
14 ft. lbs. (19 Nm)
2.22
MAINTENANCE
Rear Gearcase Lubrication (6x6) Rear Gearcase Lubricant Change:
NOTE: It is important to follow the rear gearcase The drain plug is located on the bottom right side of the rear
maintenance intervals described in the Periodic gearcase. Access the drain plug from the rear of the vehicle
Maintenance Chart. Regular fluid level inspections through the skid plate.
The rear gearcase lubricant level should be checked and

1. Remove the fill plug (refer to Rear Gearcase Lubricant
Level Check). 2
changed in accordance with the maintenance schedule.
2. Place a drain pan under the rear gearcase drain plug.
checking or changing the lubricant. 3. Remove the drain plug and allow the lubricant to drain
Check vent hose to be sure it is routed properly and completely.
unobstructed.
Rear Gearcase Lubricant Level Check:
The fill plug is located on the right side of the rear gearcase.
Maintain the lubricant level even with the bottom threads of the
fill plug hole.
2. Remove the fill plug and check the lubricant level.
4. Clean the drain plug magnetic surface.
5. Reinstall drain plug with a new O-ring and torque to

specification.
=T
Drain Plug Torque:
30-45 in. lbs. (3-5 Nm)

hole. Maintain the lubricant level even with the bottom
threads of the fill plug hole.
=
=T
Recommended Rear Gearcase Lubricant:
Fill Plug Torque: ATV Angle Drive Fluid (PN 2876160)
40-50 ft. lbs. (54-68 Nm)
Capacity: 18 oz. (532 ml)
7. Reinstall fill plug with a new O-ring and torque to

specification.
2.23
MAINTENANCE
COOLING SYSTEM 2. Check the coolant level in the recovery bottle, located on
the ride side of the machine. The coolant level must be
Liquid Cooling System Overview maintained between the MAX and MIN levels
indicated on the recovery bottle
The engine coolant level is controlled or maintained by the
recovery system. The recovery system components are the Recovery
recovery bottle, radiator filler neck, radiator pressure cap and Bottle
connecting hose.
MAX
As coolant operating temperature increases, the expanding MIN
(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 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 3. If the coolant level is below the MIN mark, open the hood
system. to access the radiator pressure cap and recovery bottle cap.
Polaris Premium 60/40 is already premixed and ready to use. Do NOTE: If overheating is evident, allow system to
not dilute with water. cool completely and check coolant level in the
radiator and inspect for signs of trapped air in
Coolant Level Inspection system.
The recovery bottle and radiator pressure cap are located under
the hood. WARNING
Never remove the pressure cap when the

engine is warm or hot. Escaping steam can
cause severe burns. The engine must be cool
Recovery Bottle before removing the pressure cap.
Radiator Cap 4. Remove the pressure cap. Using a funnel, add coolant to the
top of the radiator filler neck.
5. Reinstall the pressure cap.
NOTE: Use of a non-standard pressure cap will not

allow the recovery system to function properly.
6. Remove the recovery bottle cap.

With the engine at operating temperature, the coolant level 7. Fill the recovery bottle to the MAX mark with Polaris
should be between the MAX and MIN marks on the Premium 60/40 Anti-Freeze/Coolant or a 50/50 mixture of
recovery bottle. If not, perform the following: antifreeze/coolant and distilled water as required for freeze
protection in your area.
1. Position the vehicle on a level surface
8. Reinstall the recovery bottle cap.
9. If coolant was required, start engine and check for leaks.

Make sure radiator fins are clean to prevent overheating.
2.24
MAINTENANCE
Coolant Strength / Type Radiator Inspection / Cleaning
Test the strength of the coolant using an antifreeze hydrometer. 1. Check radiator air passages for restrictions or damage.
Antifreeze Hydrometer
2
A 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. Straight water
or antifreeze may cause the system to freeze, corrode,
or overheat.
= 2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with compressed air or low

Recommended Anti-Freeze/Coolant:
pressure water.
Polaris 60/40 Anti-Freeze/Coolant
(PN 2871534) (Quart)
CAUTION
Cooling System Hoses
Washing the vehicle with a high-pressure
1. Inspect all hoses for cracks, deterioration, abrasion or washer could damage the radiator fins and
leaks. Replace if necessary. impair the radiators effectiveness. Use of a high-
pressure washer is not recommended.
Coolant Drain / Radiator Removal

1. Remove the push rivets and front RH wheel well panel to
access the radiator drain valve.
2. Place a suitable drain pan underneath the radiator.
3. Allow the vehicle to cool down if recently operated.
WARNING
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.
2. Check tightness of all hose clamps.
4. Open the hood and slowly open the radiator pressure cap
to relieve system pressure.
CAUTION
Do not over-tighten hose clamps at radiator, or

radiator fitting may distort. Radiator hose clamp
torque is 36 in. lbs. (4 Nm).
2.25
MAINTENANCE
5. Open the drain valve on the front side of the radiator and 9. Remove the (4) bolts that retain the fan motor and shroud
allow the coolant to completely drain. Properly dispose of to the radiator.
the used coolant.
10. Remove the (2) mounting screws that secure the upper
6. Remove the (2) T25 screws that retain the recovery bottle portion of the radiator to the frame (see Figure 2-26).
to the frame bracket. Set the recovery bottle out of the way.
Figure 2-26
Spring
Support
Radiator
11. Remove the (2) lower hood latch screws and remove the
lower hood latch spring support (see Figure 2-26).
7. Remove the push rivets and front LH wheel well panel.
12. Remove the recovery bottle return line (see Figure 2-26).
8. Remove the upper and lower coolant lines from the 13. Carefully lift the radiator straight up and out of the vehicle.
radiator. Take care not to damage the cooling fins.
2.26
MAINTENANCE
Installation FINAL DRIVE / WHEEL AND TIRE
14. Reverse this procedure for installation.
Wheel and Hub Torque Table
15. Upon installation, be sure the lower radiator mounts are
placed properly in the frame support. Item Nut Type Specification
Aluminum Wheels
(Cast)
Lug Nut (1) 90 ft. lbs. (122 Nm) 2
Steel Wheels
Flange Nut (2) 35 ft. lbs. (47 Nm)
(Black / Camo)
Front Hub Nut - 80 ft. lbs. (108 Nm)
Mid / Rear
- 110 ft. lbs. (150 Nm)
Hub Retaining Nut
#1 #2
16. After the radiator is installed, be sure the mounts have

remained in place.
Aluminum Wheel Steel Wheel
(LE Models) (Standard Models)
17. After installation and reassembly, remove the pressure cap 90 ft. lbs. (122 Nm) 35 ft. lbs. (47 Nm)
and fill the radiator and recovery bottle with coolant.
18. Refer to the Cooling System Bleeding Procedure in CV Shaft Boot Inspection
Chapter 3. 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.
Inspect Boots
Inspect Boots
2.27
MAINTENANCE
Wheel Removal Tire Inspection
Improper tire inflation may affect vehicle
maneuverability.
Wheel Nuts (4)
When replacing a tire always use original equipment
size and type.
The use of non-standard size or type tires may affect

Front Hub Nut
vehicle handling.
80 ft. lbs. (108 Nm)
Tire Tread Depth
Always replace tires when tread depth is worn to 1/8" (3 mm) or
less.
Mid/Rear Hub Nut
110 ft. lbs. (150 Nm) Tread
Depth 1/8" (3 mm)
1. Stop the engine, place the transmission in gear and lock the
parking brake.
2. 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 WARNING
hub. Be sure the valve stem is toward the outside and
rotation arrows on the tire point toward forward rotation. Operating a RANGER with worn tires will
increase the possibility of the vehicle skidding
2. Install the washers (if applicable) and wheel nuts and finger easily with possible loss of control.
tighten them.
Worn tires can cause an accident.
3. Lower the vehicle to the ground.
Always replace tires when the tread depth
4. Securely tighten the wheel nuts to the proper torque listed
measures 1/8", (.3 cm) or less.
in the torque table at the beginning of this section.
Tire Pressure
CAUTION
If wheels are improperly installed it could affect

CAUTION
vehicle handling and tire wear. On vehicles with
tapered rear wheel nuts, make sure tapered end Maintain proper tire pressure.
of nut goes into taper on wheel. Refer to the warning tire pressure decal
applied to the vehicle.
Tire Pressure Inspection (PSI - Cold)

Model Front / Rear
XP / HD / 6x6 8-12 psi / 8-12 psi
CREW 12 psi / 16 psi
2.28
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM Battery Fluid Level (Conventional Battery)
A poorly maintained battery will deteriorate rapidly. Check the
Battery Maintenance
battery fluid level often. Maintain the fluid level between the
Keep battery terminals and connections free of corrosion. If upper and lower level marks.
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
Upper Level
2
shop towels. Coat the terminals with dielectric grease or
petroleum jelly.
Be careful not to allow cleaning solution or tap water into the

battery.
WARNING
CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related Lower Level
accessories contain lead and lead compounds,
and other chemicals known to the State of Add only distilled water. Tap water contains minerals that are
California to cause cancer and birth defects harmful to a battery.
or other reproductive harm.
WASH HANDS AFTER HANDLING. Battery Removal
1. Open the hood to access the battery.
WARNING
Battery
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. 2. Remove the hold-down strap and vent tube from the
Keep sparks, flame, cigarettes, etc. away. battery.
Ventilate when charging or using in an enclosed 3. Disconnect the black (-) (negative) battery cable.
space. Always shield eyes when
working near batteries. 4. Disconnect the red (+) (positive) battery cable.
KEEP OUT OF REACH OF CHILDREN. 5. Lift the battery out of the vehicle, being careful not to tip
it sideways and spill any electrolyte.
NOTE: Batteries must be fully charged before use or
battery life will be reduced by 10-30% of full
CAUTION
potential. Charge battery for 3-5 hours at a current
equivalent of 1/10 of the batterys rated amp/hour
capacity. Do not use the alternator to charge a new To reduce the chance of sparks: Whenever
battery. removing the battery, disconnect the negative
(black) cable first. When reinstalling the battery,
install the negative cable last.
2.29
MAINTENANCE
Battery Installation Battery Storage
Using a new battery that has not been fully charged can damage Whenever the vehicle is not used for a period of three months or
the battery and result in a shorter life. It can also hinder vehicle more, remove the battery from the vehicle, ensure that it's fully
performance. Follow the battery charging procedure before charged, and store it out of the sun in a cool, dry place. Check
installing the battery. battery voltage each month during storage and recharge as
needed to maintain a full charge.
1. Ensure that the battery is fully charged.
NOTE: Battery charge can be maintained by using a
2. Place the battery in the battery holder. Polaris battery tender charger or by charging about
once a month to make up for normal self-discharge.
3. Install the battery vent tube and route it down in front of the Battery tenders can be left connected during the
shift cable, into the front left wheel well. storage period, and will automatically charge the
battery if the voltage drops below a pre-determined
point.
Vent Tube
Battery Charging
1. Remove the battery from the vehicle to prevent damage
Shift Cable from leaking or spilled electrolyte during charging.
2. Charge the battery with a charging output no larger than

1/10 of the batterys amp/hr rating. Charge as needed to
raise the specific gravity to 1.270 or greater.
3. Reinstall the battery.
4. Route the vent tube through the triangular hole in the frame
support from the back side and place it behind the panel.
Route through
hole in frame
Route behind
the panel
IMPORTANT: Route vent tube as shown to prevent

electrolyte from damaging critical components (i.e.
wire harness, brake lines, throttle cable).
5. Coat the terminals with dielectric grease or petroleum jelly.
6. Connect and tighten the red (+) (positive) cable first.
7. Connect and tighten the black (-) (negative) cable last.
8. Verify that cables are properly routed and install the hold-
down strap.
2.30
MAINTENANCE
Spark Plug Service 8. Install spark plug and torque to specification.
1. Remove both spark plug high tension leads (A). Clean plug
area so no dirt and debris can fall into engine when plug is Recommended Spark Plug:
removed. Champion RC7YC3
A Spark Plug Torque:

18 Ft. Lbs. (24 Nm)
2
Engine To Frame Ground

Inspect engine ground cable connection. Be sure it is clean and
B tight. The ground cable runs from the engine to the terminal
block located under the front hood next to the battery.
Black Ground
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
Terminal Block
electrodes.
(under hood)
Inspect electrode for
wear and buildup
4. Clean with electrical contact cleaner or a glass bead spark

plug cleaner only. CAUTION: A 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
Gap - .035" (0.90 mm)
6. If necessary, replace spark plug 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.
2.31
MAINTENANCE
STEERING If abnormal movement is detected, inspect the hub and

wheel assembly to determine the cause (loose wheel
Steering Inspection nuts or loose front hub nut).
Refer to the Body/Steering or Final Drive chapter for
The steering components should be checked periodically for
more information.
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. Wheel Toe Alignment Inspection
Replace any worn or damaged steering components. Steering 1. Place machine on a smooth level surface and set steering
should move freely through entire range of travel without wheel in a straight ahead position. Secure the steering
binding. Check routing of all cables, hoses, and wiring to be sure wheel in this position.
the steering mechanism is not restricted or limited. 2. Place a chalk mark on the center line of the front tires
approximately 10 (25.4 cm) from the floor or as close to
NOTE: Whenever steering components are the hub/axle center line as possible.
replaced, check front end alignment. Use only
genuine Polaris parts.
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 parts.
Tie Rod End / Steering Inspection

To check for play in the tie rod end, grasp the steering
tie rod, pull in all directions feeling for movement.
Replace any worn steering components. Steering should
move freely through entire range of travel without NOTE: It is important the height of both marks be
binding. equally positioned to get an accurate measurement.
3. Measure the distance between the marks and record the
measurement. Call this measurement A.
4. Rotate the tires 180 by moving the vehicle forward.
Position chalk marks facing rearward, even with the hub/
axle center line.
5. Again measure the distance between the marks and record.
Call this measurement B. Subtract measurement B
from measurement A. The 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).
Elevate front end of machine so front wheels are off the

ground. Check for any looseness in front hub/wheel = In. / mm.
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. Wheel Toe-Out: (A) - (B) = 1/8 - 1/4" (.3 to .6 cm)
2.32
MAINTENANCE
Toe Adjustment IMPORTANT: When tightening the tie rod end jam
nuts, the rod ends must be held parallel to prevent rod
If toe alignment is incorrect, measure the distance between end damage and premature wear. Damage may not be
vehicle center and each wheel. This will tell you which tie rod immediately apparent if done incorrectly.
needs adjusting.
After alignment is complete, torque jam nuts to 12-14
ft. lbs. (16-19 Nm).
2
=T
Tie Rod Jam Nut Torque:
12-14 ft. lbs. (16-19 Nm)
SUSPENSION
Suspension Inspection
Compress and release the suspension. Damping should be
smooth throughout the range of travel.
Check all suspension components and mounting

fasteners for wear or damage.
Inspect each shock body for leakage.
Spring Pre-Load Adjustment

The front and rear shock absorber springs are adjustable (front
only on HD models). Rotate the adjuster cam either direction to
increase or decrease spring tension. Always adjust both left and
NOTE: Be sure steering wheel is straight ahead
right sides equally.
before determining which tie rod needs adjustment.
CAUTION
During tie rod adjustment, it is 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 tie 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 Vehicle loads effect suspension spring pre-load requirements.
required to achieve the proper toe setting as specified in Use Spanner Wrench (PN 2871095) to adjust pre-load as
Wheel Toe Alignment. necessary to avoid bottoming of the shocks.
Shock Spanner Wrench

(PN 2871095)
2.33
MAINTENANCE
Shock Position Adjustment BRAKE SYSTEM
The front and rear shock position may be adjusted to provide a
Brake Fluid Inspection
stiffer suspension if necessary.
Always check the brake pedal travel and inspect the brake fluid
1. Elevate the vehicle and safely support the main frame. reservoir level before each operation. If the fluid level is low,
add DOT 4 brake fluid only.
CAUTION Brake fluid should be changed every two years. The fluid should
also be changed anytime the fluid becomes contaminated, the
Serious injury may result if machine tips or falls. fluid level is below the minimum level, or if the type and brand
Be sure machine is secure before adjusting. of the fluid in the reservoir is unknown.
2. Remove the top shock mounting bolts on each side. The brake master cylinder reservoir can be accessed through the
front left wheel well.
3. Reposition the shocks to the outside mounting holes.
2. Place the transmission in Neutral (N) and set the parking

brake.
3. View the brake fluid level in the reservoir. The level should
be between the MAX and MIN level lines.
4. If the fluid level is lower than the MIN level line, add brake
fluid until it reaches the MAX level line.
5. Install the reservoir cap and apply the brake pedal

forcefully for a few seconds and check for fluid leakage
around the master cylinder fittings and the brake caliper
fittings.
Rear Shock
Position Adjustment
Outside
(Stiff)
Master Cylinder
Brake Hose and Fitting Inspection

Check brake system hoses and fittings for cracks, deterioration,
abrasion, and leaks. Tighten any loose fittings and replace any
Inside worn or damaged parts.
(soft)
4. Reinstall the shock mounting bolts and torque to 30 ft. lbs.

(41 Nm).
2.34
MAINTENANCE
Brake Pad / Disc Inspection Loss of tension in the parking brake cable will cause
illumination of the parking brake light and activation of the
1. Check the brake pads for wear, damage, or looseness. limiting feature. If this occurs, inspect and adjust parking brake
cable tension. If performing this service is difficult due to
2. Inspect the brake pad wear surface for excessive wear. conditions or location, open the hood and temporarily
disconnect the parking brake connector. Reconnect the
3. Pads should be changed when the friction material is worn
to .040 (1 mm).
connector as soon as practicable and adjust the parking brake
cable to proper tension.
2
1. Pull back on the parking brake lever (located in the dash).
2. After 3 to 4 clicks the P light should illuminate on the

instrument cluster and the wheels of the vehicle should not
rotate when turning by hand. After 8 full clicks of lever
travel, the vehicle should not roll while parked.
Measure Pad Material 3. If the vehicle moves, adjustment is necessary.

Thickness Service Limit:
4. Adjust the parking brake cable where the cable attaches to
.040" (1 mm)
the caliper mount bracket. The mount bracket is located on
the left-hand side of the transmission behind the outer PVT
cover (4x4) or on the rear gearcase (6x6).
4. Check surface condition of the brake discs.
Adjustment Procedure: Refer to Chapter 9 Brakes
5. Measure the thickness of the front and rear brake discs. for complete adjustment procedure.
6. The disc(s) should be replaced if thickness is less than the

specified service limit (see Chapter 9 for specifications). Parking Brake Pad Inspection
Measure Brake Disc Thickness Measure the thickness of the rear caliper parking brake pads.
Replace assembly as needed. See illustration below for proper
readings.
6x6 Shown Inboard Pad Thickness
New .304 (7.72 mm)
Limit: 0.24 (6.1 mm)
Front Rear
Disc Disc Outboard
Inboard Pad
Pad
Outboard Pad Thickness

New 0.360 (9.14 mm)
Parking Brake Cable Adjustment Limit: 0.31 (7.87 mm)
When the parking brake is fully engaged and the parking brake
indicator is illuminated, engine speed is limited to 1300 RPM in Installed Disc to Park Brake
0.375 (0.953 cm)
all gears, including neutral. If throttle is applied, this limiting
feature prevents operation, which protects the parking brake
pads from excessive wear. New Rotor Disc Thickness
0.150 - 0.164
NOTE: Inspect the parking brake cable tension after (3.81 - 4.16 mm)
the first 25 hours of operation and every 100 hours
of operation afterwards to ensure proper cable
tension.
2.35
MAINTENANCE
MAINTENANCE LOG
Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician
2.36
ENGINE
CHAPTER 3
ENGINE
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
CRANKCASE EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
800 EFI ENGINE SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
COOLING SYSTEM SPECIFICATIONS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 3.11
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3
ENGINE INTAKE RESTRICTOR PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
ENGINE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
CYLINDER HEAD ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
PUSH RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
CYLINDER HEAD INSPECTION / WARP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
VALVE SEAL / SPRING SERVICE (ON ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
VALVE LIFTER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
CYLINDER HONE SELECTION AND HONING PROCEDURE . . . . . . . . . . . . . . . . . . . 3.29
HONING TO DEGLAZE / CLEANING THE CYLINDER AFTER HONING. . . . . . . . . . . 3.29
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
STARTER DRIVE BENDIX REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
FLYWHEEL / STATOR REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
ENGINE CRANKCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
FLYWHEEL / STATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
OIL PUMP PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
ENGINE BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
3.1
ENGINE
ENGINE SPECIFICATIONS
Crankcase Exploded View
3.2
ENGINE
Oil Pump / Water Pump / Engine Cover Exploded View
3.3
ENGINE
Stator Cover / Starter / Water Pump Oil Filter / Pressure Relief / Exploded View
3.4
ENGINE
Cylinder / Cylinder Head / Piston Exploded View
3.5
ENGINE
Engine EFI Sensors / Valve Cover / General Component Exploded View
NOTE: See Chapter 4 for more information on the EFI System
3.6
ENGINE
Engine Torque Specifications
Component Torque Specifications

Fastener Size in. lbs. (Nm) ft. lbs. (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 2.7)
Counterbalance Gear 8 mm 22 2 (30 3)
Crankcase Bolts 8 mm * 22 2 (30 3)
3
Crankcase Breather 5 mm 20 5 (2.5 0.55) -
Cylinder Head Bolts 11 mm * 35 4 (47.5 5.5)
Exhaust Manifold 8 mm 216 24 (24.5 2.70) 18 2 (24.5 2.7)
Flywheel 14 mm 65 7 (88 9.50)
Injector Rail 8 mm 216 24 (24.5 2.70) 18 2 (24.5 2.7)
Magneto Cover 6 mm * 96 3 (10.85 0.35) -
Oil Baffle Weldment 5 mm 60 6 (6.8 0.68) -
Oil Drain Bolt (Crankcase) 12 mm 192 24 (21.7 2.7) 16 (21.7)
Oil Fill Tube Bolt 5 mm 50 5 (5.64 0.56) -
Oil Filter Pipe Fitting 20 mm 35 4 (47.5 5.4)
Oil Pick Up 5 mm 60 6 (6.8 0.68) -
Oil Pressure Relief Plug 10 mm 22 2 (30 3) -
Oil Pump Housing Screw 6 mm * 84 8 (9.50 0.90) -
Rocker Arm 8 mm * 22 2 (30 3)
Rocker Cover 6 mm * 84 8 (9.5 0.9) -
Spark Plug 14 mm 216 24 (24.5 2.7) 18 2 (24.5 2.7)
Starter Motor 6 mm * 84 8 (9.5 0.9) -
Stator Assembly 6 mm 96 3 (10.85 0.35) -
Stator Housing 6 mm * 96 3 (10.85 0.35) -
Temperature Switch 3/8 NPT 17 2 (23 3)
Thermostat Housing 6 mm 84 8 (9.5 0.9) -
Timing Plug 3/4-16 7 - 9 (10 - 12)
Trigger Coil/Stator Wire Holddown 5 mm * 96 3 (10.85 0.35) -
Water Pump Housing Cover 6 mm * 96 3 (10.85 0.35) -
Water Pump Impeller Nut 8 mm 108 3 (12 0.35) -
NOTE: * See exploded views for notes or torque sequences.
3.7
ENGINE
800 EFI Engine Service Specifications
Cylinder Head - Engine Specifications
Main Component: Cylinder Head EH076OLE030 / EH076OLE032 / EH076OLE033
Cam Lobe Height - Intake 1.319 (33.512 mm)
Cam Lobe Height - Exhaust 1.319 (33.512 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
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 mm)
Counter Balance Counter Balance End Play 0.005" (0.127 mm)
Cylinder Head - Surface warp limit 0.00394" (0.1 mm)

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 - 0.10 mm)
Valve Seat Valve Seat - Contacting Width - Exhaust 0.0591" 0.00787" - 0.0039"
(1.50 0.20 - 0.10 mm)
Valve Seat Angle 45.5 0.255
Valve Guide Inner diameter 0.2367" 0.00029" (6.012 0.007 mm)

Valve Guide
Valve Guide Protrusion Above Head 0.807" 0.0039" (20.50 0.01 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
Valve Stem Oil Clearance - Exhaust 0.00275" 0.00098" (0.0870 0.025 mm)
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 Overall Length - Free Length 1.735" (46.069 mm)

Valve Spring
Valve Spring Overall Length - Installed Height Intake - 1.4638" (37.18 mm)
Exhaust - 1.4736" (37.43 mm)
3.8
ENGINE
Cylinder / Piston - Engine Specifications
Main Components: Cylinder / Piston / Connecting Rod EH076OLE030 / EH076OLE032 / EH076OLE033
Cylinder - Surface warp limit

0.004" (0.10 mm)
(mating with cylinder head)
Cylinder Bore - Standard 3.1495" (80 mm)
Cylinder
Cylinder Taper Limit 0.00031" (0.008 mm)
Cylinder Out of Round Limit 0.00030" (0.0075 mm)
Cylinder to Piston Clearance
Lifter Outer Diameter Standard
.0015" .00059" (.040 .015 mm)
0.84245" 0.00025" (21.39 8 0.00635 mm)
3
Lifter
Lifter Block Bore 0.8438" 0.00062" (21.4322 0.0157 mm)
Piston - Standard 3.14803" .00028" (79.960 .007 mm)
Piston Piston Standard Inner Diameter of
0.70902" .00012" (18.009 0.003 mm)
Piston Pin Bore
Piston Pin Outer Diameter 0.70866" - 0.70846" (18 - 17.995 mm)
Piston Pin - Standard Clearance - Piston Pin to
Piston Pin 0.00047" 0.00024" (0.012 0.006 mm)
Pin Bore
Piston Pin - Degree of Fit Piston pin must be push fit (by hand) at 68 F (20 C)
Piston / Connecting Rod / Crankshaft - Engine Specifications

Main Components: Piston / Connecting Rod EH076OLE030 / EH076OLE032 / EH076OLE033
Top Ring - Standard 0.0059 - 0.0138" (0.15 - 0.35 mm)

Top Ring - Limit > 15% Leakdown
Installed Second Ring - Standard 0.0098 - 0.0197" (0.25 - 0.50 mm)

Gap Second Ring - Limit > 15% Leakdown
Oil Ring - Standard 0.0197 0.0098" (0.50 0.25 mm)
Piston Ring
Oil Ring - Limit > 15% Leakdown
Top Ring - Standard 0.0024" 0.0008" (0.060 0.020 mm)
Ring to Top Ring - Limit > 15% Leakdown
Groove
Clearance Second Ring - Standard 0.0028" 0.0008" (0.070 0.020 mm)
Second Ring - Limit > 15% Leakdown
Connecting Rod Small End I.D. 0.7096" 0.70846" (18 17.995 mm)
Connecting Rod Small End
0.00098" 0.00039" (0.025 0.010 mm)
Radial Clearance
Connecting Rod Connecting Rod Big End
0.01181" 0.00591" (0.30 0.15 mm)
Side Clearance
Connecting Rod Big End
0.0015" 0.0006" (0.038 0.015 mm)
Radial Clearance
Crankshaft Crankshaft Runout Limit 0.00236" (0.060 mm)
3.9
ENGINE
Special Tools
Part Number Tool Description

PU-50105 OIL FILTER WRENCH
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
3.10
ENGINE
ENGINE COOLING SYSTEM Cooling System Pressure Test
Cooling System Specifications and Testing 1. Open the front hood.
Condition Specification WARNING

Thermostat Open 180 F (82 C)
Never remove radiator cap when engine is
Thermostat Full Open Lift 6 mm at 203 F (95 C) warm or hot. The cooling system is under
pressure and serious burns may result.
Thermostat Closed 171 F (77 C)
Allow the engine and cooling system to
System Capacity 3.25 Quarts (2.13 L) cool before servicing. 3
Radiator Cap Pressure 13 PSI
2. Remove the pressure cap from the radiator and pressure test
the cooling system using a commercially available tester.
Polaris Premium Antifreeze 3. The system must retain 10 psi for five minutes or longer. If
2871534 - Quart pressure loss is evident within five minutes, check radiator,
2871323 - Gallon all cooling system hoses and clamps and water pump seal
for leakage.
Recommended Coolant Radiator Cap Pressure Test
Use only high quality antifreeze/coolant mixed with distilled 1. Open the front hood (see Warning under Cooling System
water in a 50/50 or 60/40 ratio, depending on freeze protection Pressure Test).
required in your area.
2. Remove radiator pressure cap and test using a cap tester
IMPORTANT: Using tap water in the cooling system (commercially available).
will lead to a buildup of deposits which may restrict
coolant flow and reduce heat dissipation, resulting in 3. The radiator cap relief pressure is 13 lbs. Replace cap if it
possible engine damage. Polaris Premium 60/40 does not meet this specification.
Antifreeze/Coolant is recommended for use.
COOLANT FLOW
3.11
ENGINE
Cooling System Bleeding Procedure
CAUTION
WARNING
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning
Always wear safety glasses and proper shop
this service procedure.
clothing when performing the procedures in this
manual. Failing to do so may lead to possible
injury or death. 5. Start the engine and allow it to idle for 5-10 minutes or until
the thermostat opens and allows coolant to flow through the
system.
CAUTION
6. Squeeze coolant hoses by hand to help purge system of air.
Use caution when performing these procedures. 7. Slightly loosen the bleed screw (C) on the thermostat
Coolant may be hot and may cause housing to allow the trapped air to escape. If no air is
severe injury or burns. present, a steady stream of coolant will stream out. If air is
present, the screw will bubble and sputter as the air escapes.
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 recovery bottle.
NOTE: Use this procedure when overheating occurs C

and no apparent leaks in the cooling system are
found.
1. Place the vehicle in Neutral and set the parking brake.
CAUTION
Top LH Side
Be sure the engine has cooled and there is no of Engine
pressure built up in the cooling system before
removing the radiator cap. The coolant may be
hot and could cause severe injury or burns. 8. Add Polaris Premium Antifreeze to the radiator if the level
goes down.
2. Remove radiator cap and top off coolant.
9. Tighten the bleed screw to 70 in. lbs. (8 Nm) on the
3. Remove recovery bottle cap and fill to the MAX line. thermostat housing and properly install the radiator cap.
WARNING
Be sure to install the radiator cap before

Recovery Bottle
shutting off the engine.
Coolant may spit out of the radiator.
Radiator Cap
10. Stop the engine and allow it to cool. Top off the radiator
with coolant. If you hear or see a glug at the filler neck
or the coolant level drops indicating that coolant has been
pulled into the system, fill the radiator first before filling the
recovery bottle.
11. Any air remaining in the system should continue to bleed
out through the recovery bottle
4. Elevate the drivers side of the vehicle 20 (50.8 cm) off
the ground so the thermostat housing is at the highest point 12. Repeat this procedure if you are still having difficulty
on the cylinder head. This will allow any trapped air to bleeding the system.
accumulate near the thermostat housing bleed screw.
3.12
ENGINE
GENERAL ENGINE SERVICE Engine Lubrication Specifications
Engine Intake Restrictor Plate

Some RANGER 800 models are equipped with an intake =
restrictor plate in order to meet vehicle class regulations. This
plate MUST NOT be removed for any reason. Capacity: Approximately 2 U.S. Quarts (1.9 l)
Oil Type: Polaris PS-4 PLUS Synthetic
Filter Wrench: PU-50105 - 2.5 (64 mm)
- Oil Pressure Specification -

3
27-35 PSI @ 6000 RPM, PS-4 PLUS 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.
IMPORTANT: Removal of the intake restrictor plate 3. Start engine and allow it to reach operating temperature,
will void the warranty of any RANGER HD, CREW or while monitoring the gauge.
6x6 model.
NOTE: Use only Polaris PS-4 PLUS Synthetic 4-
Cycle Engine Oil.
Accessible Components
The following components can be serviced or removed with the Oil Pressure at 6000 RPM (Engine Hot):
engine installed: Minimum: 27 PSI
Standard: 31 PSI
Flywheel
Maximum: 35 PSI
Alternator (Stator)
Starter Motor/Drive
Cylinder Head
Cylinder
Piston / Rings
Camshaft
Rocker Arms
Oil pump / Water Pump / Oil Pump Drive Gear
Gear Train Components
The following components require engine removal for service:
Counterbalance Shaft or Bearings
Connecting Rod
Crankshaft
Crankshaft Main Bearings
Crankcase
3.13
ENGINE
Oil Flow Chart
This chart describes the flow of oil through the 800 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.
3.14
ENGINE
Engine Removal 9. Remove the (4) exhaust pipe bolts and remove the pipe.
IMPORTANT: Some engine repair procedures can be

performed without removing the engine. Refer to
Accessible Components for further information.
NOTE: Upon engine removal, use a mechanical lift

or have an assistant help remove the engine from
the vehicle to prevent personal injury or damage to
vehicle components.
WARNING 3
Always wear safety glasses and proper shop
clothing when performing the procedures in this
10. Place a small catch-container under the fuel rail and
manual. Failing to do so may lead to
carefully disconnect the fuel line from the rail.
possible injury or death.
1. Clean your work area.

2. Thoroughly clean the engine and chassis.
3. Open the hood and disconnect battery (-) negative cable.
4. Drain the engine oil and engine coolant (see Chapter 2).
NOTE: Drain and dispose of the fluids properly.
5. Remove the lower seat base and storage container.

6. Remove the rear floor to better access the engine. The floor
can be removed by removing (3) fender screws (3) rear
floor screws as shown below.
11. Remove the breather line (A), and disconnect the Throttle
Position Sensor (TPS) at the electrical connector (B).
Loosen the clamps that secure the throttle body (C) to the
air intake track. Remove the throttle body (C) and support
it out of the way. Do not allow the throttle body to hang
from the throttle cable.
C A
B
7. Disconnect the ECU harness to allow the floor to be
removed from the vehicle.
8. Remove the springs from exhaust pipe.
12. Insert a shop towel into the engine intake to prevent dirt
from entering the intake port.
3.15
ENGINE
13. Disconnect the fuel injectors at the harness connectors as 18. Disconnect the engine coolant temperature (ECT) sensor
shown below. from the left side of the cylinder head.
ECT
14. Remove the spark plug high tension leads. 19. Remove the coolant hoses from the engine. Properly
dispose of any coolant drained from the engine or hoses.
20. Remove the battery cables from the starter motor. When
removing starter cables, note and mark ground cable and
positive (+) cable mounting angle and locations.
21. Remove engine mount fasteners as shown below.
15. Disconnect the stator harness and crankshaft position

sensor (CPS) harness or remove the (CPS) from the
magneto cover.
CPS
Stator
Harness 22. Carefully remove the engine through the top of the seat base
frame. Lift the engine forward to free it from the rear mount
and then lift the engine out from the vehicle.
16. Remove the outer clutch cover with PVT outlet duct, drive
belt, drive clutch, driven clutch and inner clutch cover (see NOTE: Rotating the engine to the left 90 degrees
Chapter 6 Clutching). (valve cover facing left) may ease engine removal.
17. Remove the rear PVT inlet hose from the engine crankcase. NOTE: Use caution when lifting the engine out of
frame. Use an engine lift or other means, if the
engine appears too heavy to be lifted manually.
3.16
ENGINE
Engine Installation Notes 1. Fill fuel tank with unleaded or leaded fuel which has a
minimum pump octane number of 87= (R+ M)/2.
After the engine is installed in the frame, review this checklist
and perform all steps that apply: 2. Check oil level indicated on dipstick. Add oil if necessary
(Refer to Chapter 2, Engine Oil Level ).
General Items 3. Drive slowly at first to gradually bring engine up to
1. Install previously removed components using new gaskets, operating temperature.
seals, and fasteners where applicable. 4. Vary throttle positions. Do not operate at sustained idle or
NOTE: Properly route all electrical harnesses and sustained high speed.
re-attach any fasteners or protective tubing. Check 5. Perform regular checks on fluid levels, controls and all
for any possible rubbing points of electrical wires.
2. Perform regular checks on fluid levels, controls, and all 6.
important bolt torques.
Pull only light loads during initial break-in.
3
other areas of the vehicle as outlined in the daily pre-ride
inspection checklist (refer to Chapter 2 Maintenance). 7. Change oil and oil filter after break-in period at 25 hours.
PVT System
1. Adjust clutch center distance, clutch offset, clutch
alignment, and belt deflection (see Chapter 6 Clutching).
2. Clean clutch sheaves thoroughly and inspect inlet and
outlet ducts for proper routing and sealing (see Chapter 6).
Transmission
1. Inspect transmission operation and adjust the shift cable if
necessary. Refer to Chapter 2 and Chapter 8.
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 25 hours of operation, or the time it takes to use 2 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 result in more efficient performance and longer life for the
engine. Perform the following procedures carefully:
CAUTION
Use only Polaris PS-4 PLUS Synthetic 4-Cycle

engine oil or an 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.
3.17
ENGINE
ENGINE DISASSEMBLY AND INSPECTION
Cylinder Head Assembly Exploded View
Rocker Arms
Retainer Locks (keepers)

Push Rods
Spring Retainers
Springs
Valve Seals
Valve Spring Seats
Cylinder Head
Hydraulic Lifters
Valves
3.18
ENGINE
Rocker Arms 5. If the push rod (A) is visibly bent, it should be replaced.
1. Remove the valve cover.

A
2. Mark or tag rocker arms in order of disassembly to keep
them in order for reassembly.
Cylinder Head Removal

1. Loosen the six cylinder head bolts evenly 1/8 turn each in
a criss-cross pattern until loose.
3. Inspect the wear pad at the valve end of the rocker arm for
indications of scuffing or abnormal wear. If the pad is 2. Remove bolts (A) and tap cylinder head (B) lightly with a
grooved, replace the rocker arm. soft face hammer until loose. CAUTION: Tap only in
reinforced areas or on thick parts of cylinder head casting
NOTE: Do not attempt to true this surface by to avoid damaging the head or cylinder.
grinding.
3. Remove cylinder head (B) and head gasket (C) from the
4. Check the rocker arm pad and fulcrum seat for excessive cylinder (D).
wear, cracks, nicks or burrs.
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
B
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, C
roughness or excessive wear.
4. The push rods (A) can be visually checked for straightness

D
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.
3.19
ENGINE
Cylinder Head Inspection Valve Seal / Spring Service (On Engine)
Thoroughly clean cylinder head surface to remove all traces of NOTE: The following procedure is only for servicing
gasket material and carbon. the top end of the valve train when replacing valve
springs or replacing valve seals.
CAUTION 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
Use care not to damage sealing surface. to their location in the cylinder head.
Cylinder Head Warp WARNING

1. Lay a straight edge (A) across the surface of the cylinder
head (B) at several different points and measure warp by Wear eye protection or a face shield during
inserting a feeler gauge between the straight edge and the cylinder head disassembly and reassembly.
cylinder head surface. If warp exceeds the service limit,
replace the cylinder head. 1. Having already removed the valve cover, rocker arms and
pushrods, align the cylinder to be worked on at top dead
center (TDC). Install the Valve Pressure Hose (PU-45652)
A 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.
B
NOTE: A small parts magnet (A) can aid in the
Measure at different removal of the retainers (B).
points on the surface.
= In. / mm.
Cylinder Head Warp Limit: A

.004" (.1016 mm) max
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. The valve seals are now serviceable.
3.20
ENGINE
Cylinder Head Disassembly 4. Remove valve guide seals.
1. Carefully remove the cylinder components. IMPORTANT: It is recommended to replace seals

whenever the cylinder head is disassembled.
Hardened, cracked or worn valve seals will cause
excessive oil consumption and carbon buildup.
5. Mark the valves with a white pen. Remove the valves from
the cylinder head. This will ensure that the valves are
properly placed during engine reassembly.
Mark the Valves 3
2. Place the hydraulic lifters (C), pushrods (D), and rocker

arms (E) in a safe, clean area.
C D
3. Measure free length of spring with a Vernier caliper.

Compare to specifications. Replace spring if measurement
is out of specification.
Valve Spring
Free Length
= In. / mm.
Valve Spring Free Length:

Std: 1.735" (44.069 mm)
3.21
ENGINE
Valve Inspection
1. Remove all carbon from valves with a soft wire wheel or = In. / mm.
brush.
2. Check valve face for runout, pitting, and burnt spots. To Valve Stem Diameter:
check for bent valve stems, mount valve in a drill or use V Intake: 0.2356" 0.00039"
blocks and a dial indicator. (5.985 0.01 mm)
Exhaust: 0.2351" 0.00039"
(5.972 0.01 mm)
5. Measure valve guide (C) inside diameter at the top middle

and end of the guide using a small hole gauge and a
micrometer. Measure in two directions.
3. Check end of valve stem for flaring, pitting, wear or damage

(A). Inspect split keeper groove for wear or flaring of the
keeper seat area (B).
= In. / mm.
B
Valve Guide I.D.:
0.23672" 0.000295"
(6.0617 0.0075 mm)
NOTE: The valves can be re-faced or end ground, if
necessary. They must be replaced if extensively
6. Subtract valve stem measurement from the valve guide
worn, burnt, bent, or damaged.
measurement to obtain stem to guide clearance.
4. Measure diameter of valve stem with a micrometer in three
NOTE: The valve guides cannot be replaced. Be
places, then rotate 90 degrees and measure again (six
sure to measure each guide and valve combination
measurements total). Compare to specifications.
individually.
Measure valve stem in several places.
Rotate the valve 90 degrees and measure
for wear.
3.22
ENGINE
Combustion Chamber NOTE: Valve seat width and point of contact on the
valve face is very important for proper sealing. The
1. Clean all accumulated carbon deposits from combustion valve must contact the valve seat over the entire
chamber and valve seat area with carbon cleaner and a soft circumference of the seat, and the seat must be the
plastic scraper. proper width all the way around. If the seat is
uneven, compression leakage will result. If the seat
IMPORTANT: Do not use a wire brush, metal scraper, is too wide, seat pressure is reduced, causing
or abrasive cleaners to clean the bottom of the carbon accumulation and possible compression
cylinder head. Extensive damage to the cylinder head loss. If the seat is too narrow, heat transfer from
may result. Wear safety glasses during cleaning. valve to seat is reduced. The valve may overheat and
warp, resulting in burnt valves.
Combustion Area 3
1. Install pilot into valve guide.

Valve Seat Reconditioning
2. Apply cutting oil to valve seat and cutter.
NOTE: Polaris recommends that the work be done
by a local machine shop that specializes in this area. 3. Place 46 cutter on the pilot and make a light cut.
NOTE: The cylinder head valve guides cannot be

replaced.
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. If the valve seat is
cracked the cylinder head must be replaced.
Follow the manufacturers instructions provided with the valve

seat cutters in the commercially available cylinder head
reconditioning kit. Abrasive stone seat reconditioning
equipment can also be used. Keep all valves in order with their
respective seat.
3.23
ENGINE
4. Inspect the cut area of the seat: NOTE: When using an interference angle, the seat
contact point on the valve will be very narrow, and is
* If the contact area is less than 75% of the circumference of the a normal condition. Look for an even and continuous
seat, rotate the pilot 180 and make another light cut. contact point all the way around the valve face (A).
* If the cutter now contacts the uncut portion of the seat, check B
the pilot. Look for burrs, nicks, or runout. If the pilot is bent it
must be replaced.
* If the contact area of the cutter is in the same place, the valve
guide is distorted from improper installation A
* If 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 Proper Seat Contact
necessary to repair the seat surface. on Valve Face
5. To check the contact area of the seat on the valve face, apply
a thin coating of Prussian Blue paste to the valve seat. If Bottom 60 Seat 45
using an interference angle (46) apply black permanent Top 30
marker to the entire valve face (A).
6. Insert valve into guide and tap valve lightly into place a few
times.
7. Remove valve and check where the Prussian Blue Seat
indicates seat contact on the valve face. The valve seat Width
should contact the middle of the valve face or slightly
above, and must be the proper width.
* If the indicated seat contact is at the top edge of the valve face
and contacts the margin area (B) it is too high on the valve face.
Use the 30 cutter to lower the valve seat.
* If too low, use the 60 cutter to raise the seat. When contact
area is centered on the valve face, measure seat width.
= In. / mm.
* If the seat is too wide or uneven, use both top and bottom
cutters to narrow the seat.
Valve Seat Width:
Intake Std: .028" (.7 mm)
* If the seat is too narrow, widen using the 45 cutter and re-
Limit: .055" (1.4 mm)
check contact point on the valve face and seat width after each
Exhaust Std: .039 (1.0 mm)
cut.
Limit: .071" (1.8 mm)
3.24
ENGINE
8. Clean all filings from the area with hot soapy water. Rinse Cylinder Head Reassembly
and dry with compressed air.
NOTE: Assemble the valves one at a time to
9. Lubricate the valve guides with clean engine oil, and apply maintain proper order.
oil or water based lapping compound to the face of the
valve. 1. Apply engine oil to valve guides and seats.
NOTE: Lapping is not required with an interference 2. Coat valve stem with molybdenum disulfide grease or
angle valve job. PS-4 PLUS Synthetic 4-Cycle engine oil.
10. Insert the valve into its respective guide and lap using a 3. Install valve carefully with a rotating motion to avoid
damaging valve seal.
lapping tool or a section of fuel line connected to the valve
stem.
4. Valve seals should be installed after the valves are in the
3
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.
PU-45257
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.
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 prevent damage to the valve seals, do not

compress the valve spring more than necessary to
install the keepers.
3.25
ENGINE
Valve Sealing Test Valve Lifter Removal / Inspection
1. Clean and dry the combustion chamber area (A). 1. Remove the valve lifters by reaching into the crankcase
and pushing the lifter up through the lifter bore by hand.
A
2. Thoroughly clean the lifters in cleaning solvent and wipe
them with a clean, lint-free cloth.
3. Mark the lifters with a white pen if using the lifters for
reassembly. This will ensure that the lifters are properly
placed during engine reassembly.
Mark Hydraulic Lifter
2. Pour a 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 4. Check the lifters for wear or scores.
1. Follow engine disassembly procedures to remove rocker 5. Check the bottom end of lifter to make sure that it has a
cover and cylinder head. slight convex.
2. Tap cylinder (A) lightly with a rubber mallet in the 6. If the bottom surface has worn flat, it may be used with the
reinforced areas only until loose. original camshaft only.
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).
Inspect Hydraulic 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.
3.26
ENGINE
Piston Removal The oil control ring is a three piece design consisting of a top and
bottom steel rail and a center expander section. The top rail has
1. Remove the circlip. Mark the piston with a white pen to a locating tab on the end which fits into a notch (B) in the upper
ensure proper orientation (if reused) during assembly. oil ring land of the piston.
To Remove:
A) Remove the top rail first followed by the bottom rail.
B) Remove the expander.
Compression B
Rings 3
Oil Ring
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.
4. Repeat procedure for second ring.
5. Remove the oil control ring.
3.27
ENGINE
Cylinder Inspection 4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in two
1. Remove gasket material from cylinder sealing surfaces. different directions, front to back and side to side, on three
different levels (1/2, down from top, in the middle, and 1/
2. Inspect the top of the cylinder (B) for warp using a straight
2, up from bottom). Record measurements. If cylinder is
edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2.
tapered or out of round beyond .002", the cylinder must be
replaced.
A
1/2 Down From Top of Cylinder
Measure at different
points on surface.
1/2 Up From Bottom
C = In. / mm.
Cylinder Taper Limit:

.002" (.050 mm) Max.
= In. / mm. Cylinder Out of Round:

Limit: .002" (.050 mm) Max.
Cylinder Warp: .004" (0.1 mm) Max.

Standard Bore Size
3. Inspect cylinder for wear, scratches, or damage.
(Each Cylinder): 3.1496" (80 mm)
3.28
ENGINE
Cylinder Hone Selection and Honing If cylinder wear or damage is excessive, it will be necessary to
Procedure replace the cylinder. The cylinders are lined with a nicasil
coating and are not repairable. Hone only enough to de-glaze the
Cylinders may be wet or dry honed depending upon the hone outer layer of the cylinder bore.
manufacturers 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 a common spring loaded glaze breaker
3
for honing is not advised for nicasil cylinders.
Polaris recommends using a rigid hone or arbor
honing machine. Cylinders may be wet or dry Example of Cross Hatch Pattern
honed depending upon the hone manufacturer's
recommendations.
Wet honing removes more material faster and IMPORTANT: Clean the cylinder after honing
leaves a more distinct pattern in the bore.
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
Honing To Deglaze
outer layer of the cylinder bore.
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 Cleaning the Cylinder After Honing
manufacturer's instructions, or these guidelines:
It is very important that the cylinder be thoroughly cleaned after
Honing should be done with a diamond hone. Cylinder honing to remove all grit material. Wash the cylinder in a
could be damaged if the hone is not hard enough to solvent, then in hot, soapy water. Pay close attention to areas
scratch the nicasil lining. where the cylinder sleeve meets the aluminum casting (transfer
port area). Use electrical contact cleaner if necessary to clean
Use a motor speed of approximately 300-500 RPM, run these areas. Rinse thoroughly, dry with compressed air, and oil
the hone in and out of the cylinder rapidly until cutting the bore immediately with Polaris Lubricant.
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.
3.29
ENGINE
Piston-to-Cylinder Clearance 2. Measure piston pin O.D. Replace piston and/or piston pin
if out of specification.
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 bore

measurement obtained during the Cylinder Inspection
procedure.
5 mm
Piston Pin Measurement Locations
Piston
Piston Pin
Piston Pin O.D.:
See 800 EFI Engine Service
Specifications on page 3.8
Piston to Cylinder Clearance:
Specifications on page 3.8 3. Measure connecting rod small end ID.
Piston O.D.:
Piston / Rod Inspection

1. Measure piston pin bore.
Connecting Rod Small End I.D.:

Piston Pin Bore:

3.30
ENGINE
4. Measure piston ring to groove clearance by placing the ring 3. If the bottom installed gap measurement exceeds the
in the ring land and measuring with a thickness gauge. service limit, replace the rings. If ring gap is smaller than
Replace piston and rings if ring-to-groove clearance the specified limit, file ring ends until gap is within
exceeds service limits. specified range.
NOTE: Always check piston ring installed gap after
Piston
re-boring a cylinder or when installing new rings. A
re-bored cylinder should always be scrubbed
Ring 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 3

Feeler Gauge 1. Remove stator housing bolts and remove housing.
2. Remove the flywheel nut and washer. Install Flywheel
Puller (PN 2871043) and remove flywheel.
See 800 EFI Engine Service NOTE: Do not thread the puller bolts into the
Specifications on page 3.8 flywheel more than 1/4, or stator coils may be
damaged.
3. Remove starter bendix assembly (A). Note the thrust
Piston Ring Installed Gap washers located on both sides of the bendix.
1. Place each piston ring (A) inside cylinder (B) using a
piston to push ring squarely into place as shown.
A
B 25-50 mm
4. Inspect the thrust washer for wear or damage and replace

if necessary.
Piston Ring Installed Gap: 5. After the bendix is removed, remove the two bolts retaining
See 800 EFI Engine Service the starter. Tap on the starter assembly (B) with a soft faced
Specifications on page 3.8 mallet to loosen the starter from the crankcase.
B
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 indicates
cylinder taper. The cylinder should be measured for
excessive taper and out of round.
3.31
ENGINE
6. Inspect gear teeth 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.
C
2871043 A
4. Use caution when removing the wire holddown (B) and the
stator assembly (D). Do not tap or bump the gear /stator
housing cover or the stator. This could cause the seal
around the gear/stator housing cover and the crankcase to
break, causing a leak.
Flywheel / Stator Removal / Inspection
1. Remove stator housing bolts and remove housing.
E D
Remove Stator B
Cover
5. Remove the bendix (E) if necessary.
Engine Crankcase Disassembly / Inspection

1. Remove the stator cover (A) and water pump cover (B).
2. Remove flywheel nut and washer.
3. Install Flywheel Puller (PN 2871043) and remove flywheel
(A).
CAUTION B
Do not thread the puller bolts into the flywheel

more than 1/4, or stator coils may be damaged.
3.32
ENGINE
2. Remove the nut (C), washer (D) and water pump impeller 5. Remove the starter bendix (G), wire holddown plate (H),
(E). Remove part of the water pump seal behind the and the woodruff key (I) from the crankshaft. The stator
impeller. does not have to be removed at this point.
I
E
3
G
D H
C
6. Remove the gear/stator housing bolts and remove the gear/
3. Remove flywheel nut and washer. stator housing cover (J) and gasket from the crankcase. Be
sure to catch the excess oil from the crankcase.
4. Install Flywheel Puller (PN 2871043) and remove flywheel
(F).
CAUTION
Do not thread the puller bolts into the flywheel

more than 1/4, or stator coils may be damaged.
7. Note the position of the gears in the photo.
Camshaft Gear
2871043 F
Crank Gear
Counterbalance Gear
3.33
ENGINE
8. Use a white 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 CAUTION
alignment and timing during reassembly of the gears.
Wear safety glasses at all times. Use caution
K Water Pump Gear when working with the top gear.
The springs could cause injury or become lost
Timing Marks should they pop out.
12. Remove all three springs using one of the tapered pins from
the Tapered Pins (PU-45497-1).
N
M
NOTE: If replacing one of the gears, it is

recommended that all of the gears be replaced. A
gear kit is available.
9. Use the Cam Gear Tooth Alignment Tool (PU-45497-2) to
align and hold the cam split gear assembly. With the split
gear aligned, remove the bolt and cam gear assembly. PU-45497-1
NOTE: Install the Cam Gear Tooth Alignment Tool
(PU-45497-2) into the assembly hole counter
clockwise from the timing mark (see page 3.36). 13. With a white marking pen, accent the timing mark on the
10. Inspect the cam gear teeth and check to make sure there is gear that contains the springs.
spring tension offsetting the teeth between the two gears.
If there is no tension, check the springs inside of the cam
gear assembly.
3 Loaded Springs
Accent Timing Marks
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.
3.34
ENGINE
14. Inspect the gear teeth and the three tabs on the gears for To Assemble:
wear. Hold the spring with one finger.
Start the pointed end of the tapered pin into the cam
Inspect Teeth & Tabs gear hole. Slowly push the dowel through the hole until
the end of the dowel is almost flush with the spring.
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 photograph that the Tapered Pins (PU-45497-1) are
3
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:
(PU-45497-1)
16. Insert the pointed dowels from the Tapered Pins (PU- Cam Gear Tooth Align Tool:
45497-1) into the cam gear. (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
together, using both hands and hold securely.
Align Timing Marks
PU-45497-1
3.35
ENGINE
19. Once the gears are pressed together, firmly hold the gears 21. To remove the balance shaft gear, the flat side of the
together with one hand. Carefully remove the Tapered Pins camshaft (P) must face the balance shaft gear. To rotate the
(PU-45497-1) by pulling them out one at a time with the camshaft, use the Cam Spanner Wrench (PU-45498) to
other hand. rotate the camshaft so the flat side of the camshaft faces the
balance shaft gear.
PU-45498
20. After the tapered pins are removed, be sure the cam gear NOTE: This Cam Spanner Wrench (PU-45498) is
assembly is held together tightly. Place the cam gear only needed to rotate the camshaft when the entire
assembly on a flat surface. Use the Cam Gear Tooth valve train is assembled. If the rocker arms are
Alignment Tool (PU-45497-2) to align the teeth of the cam removed, the cam-shaft can be turned by hand.
gears, as shown in the picture. 22. Remove the bolt and nut from the balance shaft gear. Try
NOTE: Install the Cam Gear Alignment Tool (PU- to remove the balance shaft gear. If the gear does not come
45497-2) into one assembly hole counter clockwise off manually, use the Flywheel Puller (PN 2871043) to
from the timing mark. remove the balance shaft gear.
2871043
PU-45497-2
NOTE: For ease of installing the Cam Gear

Alignment Tool (PU-45497-2), use a twisting motion
when pushing down on the tool.
3.36
ENGINE
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).
S
Q
3
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
24. Install the two puller bolts (R). Tighten the puller bolts up
previously installed.
so that the bolts are at equal length.
Mark Rotors
R
NOTE: If replacing the old rotors, new replacement

25. Install the Flywheel Puller (PN 2871043) and remove the rotors will fit into the original oil/water pump
crankshaft gear, if needed. housing.
28. Use a feeler gauge to measure the clearance between the
2871043 two rotors. Measure the gap between the two rotor tips as
shown below. The clearance should not exceed 0.006"
(0.15 mm).
Max Tip Clearance

0.006 (0.15 mm)
3.37
ENGINE
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 possible obstructions.
Use compressed air to blow out any debris.
Press Off Gear
CAUTION
30. Reinstall the valve (dowel chamfered end first). Install the Wear appropriate safety gear during this
spring, washer, and bolt. Torque to specification . procedure. Protective gloves, clothing and eye
wear are required.
22 2 ft. lbs.
(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
Chamfer assembly.
End First
Bearing
=T
22 2 ft. lbs. (30 3 Nm)
NOTE: Be sure to place the tapered end of the valve Retaining Ring
(dowel) in first. If the valve is installed incorrectly, oil
pressure and oil priming problems will occur.
33. Place the shaft in a press to remove the bearing.
Press Off Bearing
3.38
ENGINE
34. Press shaft into the new bearing.. 37. Remove thrust plate (U).
Press On Bearing
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 Tap 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
36. Press gear onto shaft while supporting the housing. NOTE: Only remove the oil baffle if the baffle is
damaged. When removing the oil baffle bolts, use a
heat gun to heat the bolts and loosen the Loctite.
This will prevent any possible damage to the bolts or
to the crankcase casting.
3.39
ENGINE
39. Remove and clean oil pick up (V) and oil baffle weldment Camshaft Inspection
(W).
1. Thoroughly clean the camshaft.
2. Visually inspect each cam lobe for wear, chafing or

damage.
W 3. Measure height of each cam lobe using a micrometer.

Compare to specification.
40. Remove balance shaft and crankshaft.
Cam Lobe Height
= In. / mm.
Cam Lobe Height
Intake / Exhaust (Std):
1.319 (33.512 mm)

41. Remove and inspect crankshaft main journal bearings for
abnormal wear. It is recommended to replace the
bearings anytime the engine is disassembled.
3.40
ENGINE
4. Measure camshaft journal outside diameters (O.D.). ENGINE REASSEMBLY
Crankcase Reassembly
CAUTION
After any reassembly or rebuild, the engine

must be primed using the Oil Priming Adapter
C (PU-45778) and a 3/4-full oil filter before initial
start-up (see Oil Pump Priming).
B NOTE: Before assembly, clean bolts and bolt holes
3
with Primer N (PN 2874275) to remove any debris.
A
This will ensure proper sealing when installing bolts.
1. Install oil pick up (A), if removed. Torque to specification.
= In. / mm.
Camshaft Journal O.D. : B

A. (Mag): 1.654" .00039" (42 .010 mm)
B. (Ctr.): 1.634" .00039" (41.50 .010 mm)
C. (PTO): 1.614" .00039" (41 .010 mm) A
5. Measure ID of camshaft journal bores.
= In. / mm.
2. Install oil baffle weldment (B). Torque to specification.
Camshaft Journal Bore I.D.:
(Mag): 1.656" 0.00039" (42.07 0.010 mm)
(Ctr.): 1.637" 0.00039" (41.58 0.010 mm) =T
(PTO): 1.617" 0.00039" (41.07 0.010 mm)
Oil Baffle Weldment &
6. Calculate oil clearance by subtracting journal O.D.s from Oil Pick Up Bolt Torque:
journal bore I.D.s. Compare to specification. 60 6 in. lbs. (6.8 0.68 Nm)
= In. / mm.
Calculated Camshaft Oil Clearance:

Std: .0027" (.070 mm)
Limit: .0039" (.10 mm)
NOTE: Replace camshaft if damaged or if any part is

worn past the service limit.
NOTE: Replace the engine crankcase assembly if

camshaft journal bores are damaged or worn
excessively.
3.41
ENGINE
3. Install the balance shaft. Inspect balance shaft clearance (C) 6. Apply Crankcase Sealant (PN 2871557) to the top gearcase
in both gearcase halves. Rotate balance shaft to ensure there halve.
is clearance between it and the oil baffle weldment.
NOTE: Do not apply sealant to cam relief hole (E).
7. Assemble the crankcase halves. Apply LocTite 242 (PN

NOTE: Always install new balance shaft bearings.
2871949) to the threads and pipe sealant to the bolt flanges.
4. Apply assembly lube to cam journals and balance shaft Torque bolts to specification following torque pattern at
bearing surfaces of the MAG case halve. Install camshaft beginning of this chapter.
and balance shaft.
=T
Crankcase Bolt Torque:
22 2 ft. lbs. (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.
Lifters
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.
3.42
ENGINE
NOTE: Always replace the camshaft and lifters as a 12. Orientate the piston rings on the piston before installation
set. into the cylinders. Set the gaps of the rings every 120 (See
Illustration Below).
1
Piston Ring
Orientation 2
3
1. Top Ring 2. Second Ring

3
3. Oil Ring
10. Lubricate connecting rods with PS-4 PLUS Synthetic
4-Cycle engine oil. 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.
11. Install new cylinder gasket on crankcase. Align gasket on

the dowel pins for proper gasket alignment.
NOTE: To help align the pistons, slide a rod that is

close to the same diameter as the wrist pin holes to
properly align them in the cylinder.
3.43
ENGINE
14. Position cylinder and piston assemblies onto the connecting NOTE: New bolts have patch lock on the threads
rods and push the piston pins through the piston and and do not require Loctite.
connecting rods.
Push in Piston Pins
15. Install the piston pin circlips. The circlip ends should be =T
installed at the 12 O'clock position.
Thrust Plate Screw Torque:
115 12 in. lbs. (13 1.35 Nm)
17. Assemble rotors as marked when disassembled. Use a

cleaner to remove the marks previously made on the rotors.
Line Up Marks
Piston Pin Cirlcip in

12 Oclock position
NOTE: While installing in piston circlips, cover all

engine passages. The clip could fall into the engine
during installation.
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.
Lubricate Rotors
16. Install camshaft thrust plate (G) with new bolts. Torque
bolts to specification.
3.44
ENGINE
19. Align the bolt holes and install oil pump assembly into 21. Apply Loctite 242 (PN 2871949) to the crankshaft.
crankcase. Rotate the rotors in the housing during
installation, as this checks for binding if new rotors are
used.
NOTE: For assembly of the gears, the cam gear and
the crankshaft gear are stamped with This Side
Out." This indicates the side of the gear that faces
outward or away from the case.
22. Before installing the crankshaft gear (I), heat the crankshaft
gear to 250 F (121C) on a hot plate (J).
NOTE: Before assembly, clean the bolts and bolt

holes with Primer N (PN 2874275) to remove any I J
debris. This will ensure proper sealing when
installing bolts and new Loctite.
20. Install oil pump housing bolts (H). The new bolts contain
patch lock, so Loctite is not needed on the new bolts.
Torque bolts to specification and follow the torque
sequence at beginning of the chapter.
CAUTION
The crankshaft gear is extremely hot! Severe

burns or injury can occur if the gear is not
handled with extreme care and caution. Follow
the procedure below to help ensure safety.
23. Use extreme caution when removing the crankshaft gear

NOTE: Occasionally spin the oil pump when from the hot plate. Use a pair of pliers and leather gloves
installing bolts to check for binding of the rotors. when handling the crankshaft gear.
=T
Oil Pump Bolt Torque:
84 8 in. lbs. (9.50 0.90 Nm)
* Torque in Sequence
3.45
ENGINE
24. Install the crankshaft gear (I) onto the crankshaft. 26. Use the Cam Gear Alignment Tool (PU-45497-2) to align
the teeth of the cam gear (M). Install the cam gear (M) (with
NOTE: For assembly of the gears, the cam gear and the Cam Gear Alignment Tool still in place) onto the
the crankshaft gear are stamped with This Side Out." camshaft. The timing marks on the camshaft gear should
This indicates the side of the gear that faces outward align with the keyway on the balance shaft gear.
or away from the case.
PU-45497-2
I
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.
25. Install counter balance shaft gear (J) with new key, aligning
NOTE: Cam Spanner Wrench (PU-45498) is only
timing marks with crankshaft gear (I). Install washer and
needed to rotate the camshaft when the entire valve
bolt. Use the Gear Holder (PU-45838). Torque to
train is assembled.
specification.
J
I PU-45498
PU-45838
27. Reinstall the camshaft gear; so the timing marks are

=T properly aligned. Install the washer and bolt. Torque to
specification.
Balance Shaft Gear Bolt Torque:
22 2 ft. lbs. (30 3 Nm)
3.46
ENGINE
NOTE: Be sure all of the timing marks are properly IMPORTANT: Due to seal design and construction,
aligned. 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
Timing Marks 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
3
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.
Timing Marks
29. Install a new crankshaft seal (P) into the gear/stator housing
cover. Use the Universal Driver Handle (PU-45543) and
the Main Seal Installer (PA-45483) to seat the crankshaft
seal into place.
PU-45543
=T
Counterbalance Gear and Camshaft
Gear Bolt Torque: PA-45483
22 2 ft. lbs. (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 NOTE: Install the crankshaft seal (P) with the seal lip
/ stator housing. Use the Water Pump Mechanical Seal facing out (towards the crankcase).
Installer (PA-44995) to properly install the seal to the
correct depth in the cover.
P
PA-44995
O
PA
-4 4
99
N
5
Seal lip goes towards the crankcase.
3.47
ENGINE
30. Once the crankshaft seal is installed into the gear / stator 32. Before installing the gear/stator housing cover, install the
housing cover, set the direction of the paper lip by sliding Water Pump Seal Saver (PA-45401) onto the water pump
the Main Crankshaft Seal Saver (PA-45658) into the shaft.
crankshaft seal from the rubber lipped side to the paper lip
side (back to front). Remove the tool.
Important: Set the direction PA-45401

of the paper lip seal
PU-45658
33. Install a NEW gasket to the gear/stator housing cover and

crankcase. With the tools installed, carefully place the gear/
31. Carefully install the tapered end of the Crankshaft Seal stator housing cover over the protection tools.
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.
PU-45658
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.
3.48
ENGINE
NOTE: Before assembly, clean the bolts and bolt
holes with Primer N (PN 2874275) to remove any
installing bolts.
37. Install shaft seal with ceramic surface facing inward.
3
35. Install the gear/stator housing gasket onto the crankcase.
Gear / Stator
Housing Gasket
38. Install water pump impeller (P). Secure the impeller with
the washer and a new nut (Q). Torque the nut to
specification.
36. Secure the gear / stator housing cover to the crankcase with
the cover bolts. Torque bolts in proper sequence to
specification. Remove seal protectors from the shaft ends
once the cover is secure.
=T
PA-45401
Water Pump Impeller Nut Torque:
108 6 in. lbs. (6.8 0.68 Nm)
PA-45658
=T
Gear/Stator Housing Bolt Torque:
96 3 in. lbs. (10.85 0.35 Nm)
*Torque in proper sequence
3.49
ENGINE
39. Install water pump cover (R) with new O-ring seal. Torque Flywheel / Stator Installation
bolts to specification in proper sequence (see front of this
chapter). NOTE: Before assembly, clean the bolts and bolt
Install the O-ring dry, no lubricants
installing bolts.
1. Install stator assembly (S) and bolts. Torque bolts to
specification.
R 2. Install the wire hold down bracket (T). Install two new wire
hold down bolts. New bolts contain patch-lock. Torque
bolts to specification, following the proper bolt torque
sequence. Coat the stator wire grommet (U) with Nyogel
Grease (PN 2871329).
NOTE: Verify stator wires are routed properly under
the wire hold down bracket.
96 3 in. lbs.
(10.85 1.35 Nm)
Replace 2 bolts with new bolts
=T
Water Pump Housing Bolt Torque:
96 3 in. lbs. (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. T S
NOTE: There are thrust washers on both sides of U
starter drive.
=T
Stator Assembly Bolt Torque:
96 3 in. lbs. (10.85 0.35 Nm)
3. Install the flywheel, washer, nut, and key. Torque flywheel

nut to specification.
65 7 ft. lbs.
(88 9.50 Nm)
3.50
ENGINE
3. Lubricate threads and top of washers underside of bolt head
with engine oil. Install head bolts (C) and torque to
=T
specification.
Flywheel Nut Torque
65 7 ft. lbs. (88 9.50 Nm) C
4. Install stator housing with new O-ring. Torque the bolts to
specification and follow proper bolt torque sequence at the
beginning of this chapter.
96 3 in. lbs.
(10.85 0.35 Nm) 3
=T
Cylinder Head Bolt Torque:
1) Torque to 15 2 ft. lbs. (20.5 2.5 Nm)
2) Back off head bolts 5 turns (in sequence)
=T 3) Torque to 35 4 ft. lbs. (47.5 5.4 Nm)
4) Tighten in sequence another 90 (1/4 turn)
Stator Housing Bolt Torque: Torque Bolts In Sequence
96 3 in. lbs. (10.85 0.35 Nm)
4. Lubricate push rods (D) and install into lifters.
Cylinder Head Reassembly

D
NOTE: Before reassembly, clean the bolts and bolt
installing bolts.
1. Install the head gasket (A) on the cylinder (B).
2. Install cylinder head on cylinder.

3.51
ENGINE
5. Lubricate rockers (E) with engine oil.
=T
E
Breather Bolt Toque:
20 5 in. lbs. (2.5 0.55 Nm)
NOTE: When applying RTV, do not get any RTV

inside the reed assembly.
9. Place a new seal (I) 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 2874275) to remove any
debris. This will ensure proper sealing when installing
6. Verify pushrods are engaged in lifters. bolts.
7. Install rockers. Be sure that tab of fulcrum (F) is seated in
head stand-off. Torque bolts to specification. 10. Install rocker cover. Torque bolts to specification.
=T =T
Rocker Arm Bolt Torque Rocker Cover Bolt Torque:

22 2 ft. lbs. (30 3 Nm) 84 8 in. lbs. (9.5 0.9 Nm)
Torque in Sequence
8. Install breather reed (G) into rocker cover (H). Lightly
apply black RTV sealant to the outer edges of the breather 11. Install thermostat (J), new O-ring, and thermostat housing.
reed. The reed has a tab and will assemble one-way only. Torque to specification.
Torque the breather bolts to specification.
17 2 ft. lbs.
20 5 in. lbs. K
(23 3 Nm)
(2.5 .55 Nm)
J
G I
84 8 in. lbs.
(9.5 0.9 Nm)
3.52
ENGINE
2. Remove primer plug from the engine. Install Oil System
Priming Adapter (PU-45778) into the oil plug hole. Push
=T
3-5 oz. (approx.) of Polaris PS-4 PLUS Synthetic 4-Cycle
engine oil into the adapter or until resistance is felt. Remove
Thermostat Housing Bolt Torque:
the adapter. Apply sealant to the plug threads. Install the
84 8 in. lbs. (9.5 0.9 Nm)
plug and torque to specification.
12. Install temperature sender (K) and torque to specification.
PU-45778
K
3
=T
Temperature Sender Torque:
17 2 ft. lbs. (23 3 Nm)
Oil Pump Priming =T

1. After the engine is completely assembled and ready for Primer Plug Torque
installation, the engine must be properly primed. Fill the 18 2 ft. lbs. (24.4 2.71 Nm)
oil filter three-quarters full with Polaris PS-4 PLUS
Synthetic 4-Cycle Engine Oil (PN 2876244). Let the oil
soak into the filter for 8-10 minutes. Install the filter onto CAUTION
the engine.
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 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.
Engine Break-In
Fill 3/4 full
with PS-4 PLUS Refer to Engine Break-In Period under Engine Installation
Notes listed earlier in this chapter.
3.53
ENGINE
TROUBLESHOOTING Engine Idles But Will Not Accelerate
Spark plug fouled/weak spark
Engine
Broken throttle cable
Spark Plug Fouling
Obstruction in air intake
Spark plug cap loose or faulty
Air box removed (reinstall all intake components)
Incorrect spark plug heat range or gap
Incorrect ignition timing
PVT system calibrated incorrectly/ components worn or
mis-adjusted Restricted exhaust system
Cam worn excessively
Fuel quality poor (old) or octane too high
Low compression Engine Has Low Power
Restricted exhaust Spark plug fouled
Weak ignition (loose coil ground, faulty coil, or stator) Cylinder, piston, ring, or valve wear or damage (check
compression)
Restricted air filter (main or pre-cleaner) or breather
system PVT not operating properly
Restricted exhaust muffler
Improperly assembled air intake system
Cam worn excessively
Restricted engine breather system
Oil contaminated with fuel Piston Failure - Scoring
Engine Turns Over But Fails To Start Lack of lubrication

Dirt entering engine through cracks in air filter or ducts
No fuel
Engine oil dirty or contaminated
Dirt in fuel line or filter
Fuel will not pass through fuel valve Excessive Smoke and Carbon Buildup
Fuel pump inoperative/restricted Excessive piston-to-cylinder clearance
Tank vent plugged or pinched Wet sumping
Engine flooded Worn rings, piston, or cylinder
Low compression (high cylinder leakage) Worn valve guides or seals
No spark (Spark plug fouled) ignition component Restricted breather

failure Air filter dirty or contaminated
Engine Does Not Turn Over Piston Failure - Scoring
Dead battery Lack of lubrication
Starter motor does not turn Dirt entering engine through cracks in air filter or ducts
Engine seized, rusted, or mechanical failure Engine oil dirty or contaminated
Engine Runs But Will Not Idle
Low compression
Crankcase breather restricted
3.54
ENGINE
Excessive Smoke and Carbon Buildup Cooling System
Excessive piston-to-cylinder clearance Overheating
Wet sumping due to over-full crankcase Low coolant level
Worn rings, piston, or cylinder Air in cooling system
Worn valve guides or seals Wrong type/mix of coolant
Restricted breather Faulty pressure cap or system leaks
Air filter dirty or contaminated Restricted system (mud or debris in radiator fins
Low Compression causing restriction to air flow, passages blocked in
radiator, lines, pump, or water jacket, accident damage) 3
Cylinder head gasket leak
Lean mixture (restricted jets, vents, fuel pump or fuel
No valve clearance ( cam wear ) valve)
Cylinder or piston worn
Fuel pump output weak
Piston rings worn, leaking, broken, or sticking
Electrical malfunction
Bent valve or stuck valve
Water pump failure/ Loose impeller
Valve spring broken or weak
Thermistor failure
Valve not seating properly (bent or carbon accumulated
Cooling fan inoperative or turning too slowly (perform
on sealing surface)
current draw test)
Rocker arm sticking
Low oil level
Backfiring Spark plug incorrect heat range
Speed limiter system malfunction Faulty hot light circuit
Fouled spark plug or incorrect plug or plug gap Thermostat stuck closed or not opening completely
Exhaust system air leaks Radiator is missing its internal diverter plate not
Exhaust system air leaks allowing coolant to flow through entire radiator
Valve sticking Temperature Too Low

Ignition system faulty: Thermostat stuck open
Spark plug cap cracked / broken
Leak at Water Pump Weep Hole
Ignition coil faulty
Faulty water pump mechanical seal (coolant leak)
Ignition switch circuit faulty
Faulty pump shaft oil seal (oil leak)
Poor connections in ignition system
Ignition timing incorrect
Sheared flywheel key
3.55
ENGINE
NOTES
3.56
ELECTRONIC FUEL INJECTION
CHAPTER 4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
EFI SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
FUEL TANK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
EFI SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
EFI SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
FUEL LINES - QUICK CONNECT REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . 4.8
ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
COMPONENTS / EFI OPERATION / INITIAL PRIMING PROCEDURE . . . . . . . . . . . . . 4.9
ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
ECU SERVICE / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FUEL SENDER TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
4
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
FUEL PRESSURE REGULATOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 4.13
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL INJECTOR SERVICE / TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
CPS TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP). . . . . . . . . . . . . 4.17
T-BAP TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
TPS LEARN FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
TPS TESTER / REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
CHECKING TPS READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
TPS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
TPS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
ECT SENSOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
IGNITION COIL / HT LEAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
GENERAL TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
DIAGNOSTIC BLINK CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
EFI TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
DIGITAL WRENCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
DIAGNOSTIC SOFTWARE VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
GUIDED DIAGNOSTIC AVAILABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
DIGITAL WRENCH COMMUNICATION ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
DIGITAL WRENCH - DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
DIGITAL WRENCH SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
DIGITAL WRENCH VERSION AND UPDATE ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
DIGITAL WRENCH UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26
DIGITAL WRENCH FEATURE MAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27
ENGINE CONTROLLER REPROGRAMMING (REFLASH). . . . . . . . . . . . . . . . . . . . . . 4.28
EFI SYSTEM BREAKOUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
4.1
GENERAL INFORMATION Fuel Pressure Gauge Kit - PU-43506-A
IMPORTANT: The EFI fuel system remains under high

WARNING pressure, even when the engine is not running. Before
attempting to service any part of the fuel system,
pressure must be relieved (if applicable). The Fuel
* Gasoline is extremely flammable and explosive
Pressure Gauge Kit has an integrated pressure relief
under certain conditions.
valve that can be used to bleed off pressure once you
* EFI components are under high pressure. Verify
have completed the fuel pressure test.
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 Relief Valve
when the fuel reaches the bottom of the filler neck.
Leave room for expansion of fuel.
* Never start the engine or let it run in an enclosed
area. Gasoline powered engine exhaust fumes are
poisonous and can cause loss of consciousness and
death in a short time.
* Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or where Adaptor shown is
gasoline is stored. included with kit.
* If you get gasoline in your eyes or if you should
swallow gasoline, seek medical attention immediately.
* If you spill gasoline on your skin or clothing,
immediately wash with soap and water and change Fuel Pressure Gauge Adaptor - PV-48656
clothing.
* Always stop the engine and refuel outdoors or in a Adaptor works with
PU-43506-A
well ventilated area.
Special Tools
PART Disconnect here and connect

TOOL DESCRIPTION in-line w/fuel pump outlet
NUMBER
PU-43506-A Fuel Pressure Gauge Kit
PV-48656 Fuel Pressure Gauge Adaptor
Digital Wrench Diagnostic Software
PU-47063-A (Includes most recent version of software
w/serial number, standard interface cable
and SmartLink Module Kit)
Digital Wrench SmartLink Module Kit Digital Wrench Diagnostic Software - PU-47063-A
PU-47471
(PU-47470, PU-47469, PU-47468)
This dealer-only software installs on laptop computers equipped
Digital Wrench with a CD drive and serial port connection, and is designed to
PU-47470
PC Interface Cable replace multiple shop tools often used to test EFI components.
Digital Wrench It also includes step-by-step diagnostic procedures to aid
PU-47469 technician repair and troubleshooting.
Vehicle Interface Cable
Digital Wrench
PU-47468
SmartLink Module Digital Wrench SmartLink Module Kit - PU-47471
2201519-A Throttle Position Sensor (TPS) Tester This module kit contains the necessary cables and hardware to
PU-47466 TPS Tester Wire Harness communicate between the vehicle ECU and the Digital
547927 TPS Tester Regulator Wrench diagnostic software.
4.2
Polaris dealers can also order the following separately: Throttle Position Sensor (TPS) Tester - 2201519-A
SmartLink Module PU-47468, Vehicle Interface Cable PU-
This tester allows the use of a digital multi-meter to test TPS
47469 and PC Interface Cable PU-47470. This kit is available
function as well as perform the TPS adjustment procedure.
to Polaris dealers through SPX by calling 1-800-328-6657 or by
visiting their website: http://polaris.spx.com. NOTE: This TPS Tester replaces the existing tester
(PU-47082), which included the 4010264 regulator. If
your dealership has PU-47082 and 4010264 you DO
NOT need to order 2201519-A as a replacement
PU-47469
PU-47468
PU-47470 4
Digital Wrench - Diagnostic Connector

Located under the hood as shown below.
TPS Tester Wire Harness - PU-47466

This TPS wire harness is part of 2201519-A and incorporates
two TPS connectors to allow for multi-use applications.
NOTE: Voltage Regulator (547927) is required if

using TPS Tester Wire Harness (PU-47466).
TPS Tester Regulator - 547927

This tester regulator regulates the 9 volt battery voltage to a 5
volt reference input, required when using the TPS Tester Wire
Harness (PU-47466).
Digital Wrench - Download Website
NOTE: You may already have this regulator (marked
Located at: www.polaris.diagsys.com
4010264) as part of another TPS Tester Kit. If you do
not have this regulator, you must order one from
SPX at 1-800-328-6657.
4.3
EFI 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 800 EFI of
the same model may be used without damaging system or engine components.
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 connector 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 Tank Exploded View
PFA Nut
Fuel Sender
Float Arm
Fuel Pump / Regulator

4
PFA Gasket
Preliminary Filter
Fuel Tank Assembly
Fuel Flow
Fuel Rail Fuel Injectors
Fuel Tank
Pressure Regulator
Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line
4.5
EFI System Exploded View
1. Electronic Control Unit (ECU)
2. Intake Air Temperature / Barometric Air Pressure Sensor (T-BAP)
3. Crankshaft Position Sensor (CPS)
4. Fuel Injectors
5. Fuel Filter (non-serviceable)
6. Fuel Pump / Regulator / Fuel Level Sender Asm. (located in fuel tank)
7. Fuel Rail
8. Engine Coolant Sensor (ECT)
9. Throttle Position Sensor (TPS)
10. Throttle Body
11. Wire Harness (part of main harness)
4.6
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 the seat on the drivers side.
4
2. Intake Air Temperature and Barometric Air Pressure 5. Fuel Pump / Regulator / Fuel Gauge Sender Assembly
Sensor (T-BAP) Located in fuel tank as an assembly.
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.
Throttle
Body
4.7
7. Throttle Position Sensor (TPS) Fuel Lines - Quick Connect
Located on the right-hand side of the throttle body. Removal / Installation
TPS
CAUTION
Verify fuel system has been depressurized

before performing this procedure.
RANGER 800 EFI models use quick connect fuel lines. Refer to
the steps for fuel line removal / installation:
1. Thoroughly clean the connector and place a shop towel

around the fuel line to catch any dripping fuel.
8. Engine Coolant Temperature Sensor (ECT) 2. Squeeze the connector tabs together and slide the green
Located in the cylinder head. retainer forward.
Squeeze Connector Tabs
3. Lift up on the fuel line to remove from the fuel pump outlet.
4. To install the line, verify the connector and fuel pump outlet
are clean and free of debris.
5. Place the connector end over the fuel pump outlet and push
the green retainer and tabs back into place.
6. Repeat this process to remove the fuel line from the fuel rail.
4.8
ELECTRONIC FUEL INJECTION The ECU controls the amount of fuel being injected and the
ignition timing by monitoring the primary sensor signals for air
Principal Components temperature, barometric air pressure, engine temperature, speed
(RPM), and throttle position (load). These primary signals are
The Electronic Fuel Injection (EFI) system is a complete engine compared to the programming in the ECU computer chip, and
fuel and ignition management design. This system includes the the ECU adjusts the fuel delivery and ignition timing to match
following principal components: the values.
Fuel Pump
During operation, the ECU has the ability to re-adjust
Fuel Rail
temporarily; providing compensation for changes in overall
Fuel Line(s) engine condition and operating environment, so it will be able
Fuel Filter(s) to maintain the ideal air/fuel ratio.
Fuel Injectors
During certain operating periods such as cold starts, warm up,
Pressure Regulator acceleration, etc., a richer air / fuel ratio is automatically
Throttle Body / lntake Manifold calculated by the ECU.
Engine Control Unit (ECU) 4
Ignition Coils
Initial Priming / Starting Procedure
Coolant Temperature Sensor
Throttle Position Sensor (TPS) NOTE: The injection system must be purged of all
air prior to the initial start up, and / or any time the
Crankshaft Position Sensor (CPS)
system has been disassembled.
Intake Air Temperature and Barometric Air
Pressure Sensor (T-BAP) If the EFI system is completely empty of fuel or has been
Wire Harness Assembly disassembled and repaired:
Check Engine Light
1. Cycle the key switch from OFF to ON 6 times, waiting
for approximately 3 seconds at each ON cycle to allow
the fuel pump to cycle and shut down.
EFI Operation Overview 2. Once step 1 is completed, turn the key switch to START
The EFI system is designed to provide peak engine performance until the engine starts or 5 seconds has passed.
with optimum fuel efficiency and lowest possible emissions. 3. If the engine failed to start, repeat step 1 for 2 more cycles
The ignition and injection functions are electronically and attempt to start the engine.
controlled, monitored and continually corrected during
operation to maintain peak performance. If the engine fails to start, a problem may still exist, and should
be diagnosed.
The central component of the system is the Bosch Engine
Control Unit (ECU) which manages system operation, NOTE: Accurate testing of EFI components is
determining the best combination of fuel mixture and ignition recommended utilizing the Digital Wrench
timing for the current operating conditions. Diagnostic Software (dealer only).
An in-tank electric fuel pump is used to move fuel from the tank
through the fuel line and 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.
4.9
ELECTRONIC CONTROL UNIT (ECU) ECU Service
Never attempt to disassemble the ECU. It is sealed to prevent
Operation Overview
damage to internal components. Warranty is void if the case is
The ECU is the brain or central processing computer of the opened or tampered with in any way.
entire EFI fuel/ignition management system. During operation,
sensors continuously gather data which is relayed through the All operating and control functions within the ECU are pre-set.
wiring harness to input circuits within the ECU. Signals to the No internal servicing or readjustment may be performed. If a
ECU include: ignition (on/off), crankshaft position and speed problem is encountered, and you determine the ECU to be
(RPM), throttle position, engine coolant temperature, air faulty, contact the Polaris Service Department for specific
temperature, intake manifold air pressure and battery voltage. handling instructions. Do not replace the ECU without factory
The ECU compares the input signals to the programmed maps authorization.
in its memory and determines the appropriate fuel and spark
The relationship between the ECU and the throttle position
requirements for the immediate operating conditions. The ECU
sensor (TPS) is very critical to proper system operation. If the
then sends output signals to set the injector duration and ignition
TPS is faulty, or the mounting position of the TPS to the throttle
timing.
body is altered, the TPS must be adjusted.
For the purpose of troubleshooting, a known-good ECU from

another Polaris RANGER 800 EFI of the same model may be
used without system or engine component damage.
ECU Replacement
1. Remove the (2) retaining screws holding the ECU.
2. With the ignition turned off, disconnect the wire harness

from the ECU.
ECU
3. To install, reverse the procedures and tighten screws to
specification.
During operation, the ECU continually performs a diagnostic
check of itself, each of the sensors, and system performance. If =T
a fault is detected, the ECU turns on the Check Engine light
in the speedometer and stores the fault code in its fault memory. ECU Retaining Screws
Depending on the significance or severity of the fault, normal 10 in. lbs. (1.1 Nm)
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 Wrench. 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 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.
Engine RPM Limit:
6350 RPM
4.10
FUEL PUMP Fuel Sender Test
If the fuel gauge reading on the instrument cluster is not
Operation Overview
working, or if the display reading differs in large comparison to
NOTE: All EFI units utilize quick connect lines. the fuel in the tank, perform a resistance test on the fuel sender.
An electric fuel pump assembly is used to transfer fuel to the EFI Disconnect the fuel pump / sending unit connection and measure
system from inside the fuel tank. This assembly includes the fuel the resistance between the Purple and Brown wires (see chapter
pump, regulator and fuel gauge sender. The pump is rated for a 10 for further details). If out of specification, replace the fuel
minimum output of 25 liters per hour at 39 psi and has a non- pump assembly.
serviceable internal 60-micron filter.
Fuel Sender Resistance Specifications:
Fuel Pump Full: 90
Empty: 5
Regulator 4
Fuel Gauge Fuel Pump Test
Sender Float
NOTE: If a fuel delivery problem is suspected, make
certain the fuel pump is being activated by 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.
Internal 60 Micron WARNING

Strainer (Bottom)
Fuel is extremely flammable and may cause
severe burns, injury, or death.
Do not use any device that produces a flame or
When the key switch is turned to "ON", the ECU activates the
electrical devices that may spark around
fuel pump, which pressurizes the system for start-up.
fuel or fuel vapors.
The ECU switches off the pump preventing the continued
delivery of fuel in these instances: 1. Cover the fuel line connection with a shop towel and
disconnect the fuel line from the fuel pump.
If the key switch is not promptly turned to the "start"
position. 2. Install the Fuel Pressure Gauge Adaptor (PV-48656) in-line
between the fuel pump outlet and fuel line.
If the engine fails to start.
If the engine is stopped with the key switch "ON" (as in

the case of an accident).
In these situations, the check engine light will go on, but will
turn off after 4 cranking revolutions if system function is OK.
Once the engine is running, the fuel pump remains on.
4.11
3. Connect the hose from the Fuel Pressure Gauge Kit (PU- Fuel Tank Removal
43506-A) to the test valve on the Fuel Pressure Gauge
Adaptor. Route the clear hose into a portable gasoline
container or the vehicles fuel tank. WARNING
PV-48656 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 can be replaced as an

individual part. Instructions for replacing the fuel
pump assembly are included in the fuel pump
service kit. Refer to the "Electronic Parts Catalog".
1. Open hood and disconnect the negative (-) battery cable.
2. Remove the lower seat base.
PU-43506-A 3. Disconnect the fuel line and electrical harness from the fuel
pump.
4. Turn on the key switch to activate the pump and check the Harness
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.
Fuel Line
Fuel Pump Pressure: 39 psi. 3
NOTE: If the pressure is too high or too low, replace

the fuel pump assembly.
5. If the pump did not activate (Step 4), disconnect the plug Vent Hose
from the fuel pump. Connect a DC voltmeter across
terminals A and C in the plug on the vehicle harness NOTE: A small amount of fuel may come out of the
side. Turn on the key switch and observe voltage to ensure fuel line or tank. Plug the fuel line and tank inlet or
a minimum of 7 volts is present. use a shop towel during removal.
NOTE: If the voltage was below 7 VDC, test battery, 4. Remove the fuel tank vent hose.
ignition switch, relay(s), wiring harness and ECU.
5. Remove the right rear fender/rocker panel assembly and the
6. If the reading is between 7 and 14 volts, turn key switch off fuel cap. Reinstall the fuel cap after the fender/rocker panel
and connect an ohmmeter between the terminals A and has been removed.
C' in the plug on the pump harness to check for continuity
within the fuel pump.
NOTE: If there was no continuity between the pump
terminals, replace the fuel pump assembly.
7. If voltage at the plug was within the specified range, and
there was continuity across the pump terminals, reconnect
the plug to the pump, making sure you have clean
connections. Turn on the key switch and listen for the pump
to activate.
NOTE: If the pump starts, verify you have the
correct amount of fuel pressure.
NOTE: If the pump still does not operate, replace the
fuel pump assembly.
4.12
6. Remove the (4) bolts retaining the fuel tank to the frame Fuel Tank Installation
support.
1. Reinstall the fuel tank assembly.
2. Reinstall the (4) fuel tank mounting bolts.
3. Reinstall the baffle box and the (2) retaining screws.
4. Reconnect the fuel pump electrical harness.
5. Install the fuel line and vent line, and verify they are secure.
6. Reinstall the right rear fender/rocker panel assembly.
7. Reconnect the negative battery cable. Test the fuel pump

by turning on the key and listening for the pump to activate.
4
FUEL PRESSURE REGULATOR
Operation Overview
The fuel pressure regulator maintains the required operating
7. Remove the (2) screws retaining the rear engine air intake system pressure of 39 psi 3 psi. A rubber-fiber diaphragm
baffle box and allow the box to hang down out of the way. 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 the tank.
Fuel Pressure Regulator Test

Refer to the Fuel Pump Test procedure.
See Fuel Pump Test on page 4.11.
8. Carefully remove the fuel tank out the RH side of the frame. Fuel Pressure Regulator Replacement
The regulator is a sealed, non-serviceable assembly. If it is
faulty, the fuel pump assembly must be replaced.
NOTE: Properly drain fuel into a suitable container.

4.13
FUEL INJECTORS NOTE: Do not apply voltage directly to the fuel
injector(s). Excessive voltage will burn them out. Do
Operation Overview not ground the injector(s) with the ignition on.
lnjector(s) will open/turn on if relay is energized.
The fuel injectors mount into the intake manifold, and the fuel
rail attaches to them at the top end. O-rings on both ends of the If an injector is not operating, it can indicate either a bad injector,
injector prevent external fuel leaks and also insulate it from heat or a wiring/electrical connection problem. Check as follows:
and vibration.
Injector leakage is very unlikely, but in rare instances it can be
internal (past the valve needle), or external (weeping around the
injector body). The loss of system pressure from leakage can
cause hot restart problems and longer cranking times.
Injector problems due to dirt or clogging are unlikely due to the

design of the injectors, the high fuel pressure, the use of filters
and the detergent additives in the gasoline. Symptoms that could
be caused by dirty/clogged injectors include rough idle,
hesitation/stumble during acceleration, or triggering of fault
codes related 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
When the key switch is on, the fuel rail is pressurized, and injectors is not recommended; they should be replaced.
voltage is present at the injector. At the proper instant, the ECU Additives and higher grades of fuel can be used as a preventative
completes the ground circuit, energizing the injector. The valve measure if clogging has been a problem.
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
Fuel Injector Test
series of calibrated openings which directs the fuel into the NOTE: The Bosch harness connector and locking
intake port in a cone-shaped spray pattern. spring is bonded to the fuel injectors with an epoxy.
The injector is opened and closed once for each crankshaft DO NOT attempt to disconnect the Bosch connector
revolution, however only one-half the total amount of fuel from the fuel injectors. Damage will occur to the
needed for one firing is injected during each opening. The injector and/or harness if attempting to separate at
amount of fuel injected is controlled by the ECU and determined that location. Separate the fuel injector from the
by the length of time the valve needle is held open, also referred vehicle harness as shown in the illustration.
to as the injection duration or pulse width. It may vary in Fuel Disconnect Here
length from 1.5-8 milliseconds depending on the speed and load Injector
requirements of the engine.
Harness
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. DO NOT
Disconnect Here
With the engine running at idle, feel for operational
vibration, indicating that they are opening and closing. The fuel injectors are non-serviceable. If diagnosis indicates a
When temperatures prohibit touching, listen for a problem with either injector, test the resistance of the fuel
buzzing or clicking sound with a screwdriver or injector(s) by measuring between the two harness pin terminals:
mechanic's stethoscope.
Disconnect the electrical connector from an injector and Fuel Injector Resistance Specification:
listen for a change in idle performance (only running on 13.8 - 15.2
one cylinder) or a change in injector noise or vibration.
4.14
Fuel Injector Replacement 6. Loosen the fuel rail mounting screw from the cylinder head.
Carefully pull the rail away from the injectors and remove
1. Be sure the engine has cooled enough to work on. the injector(s) from the cylinder head along with the
harness.
2. Thoroughly clean the area around the throttle body, intake
boot and fuel injectors.
3. Place a suitable container below the quick connect plug at Fuel Rail
the end of the fuel rail. Hold a shop rag over the plug and Mounting
remove it to depressurize the fuel system. Screw
Fuel Injectors
Fuel Rail
Quick Connect
Plug
7. Reverse this procedure to install the new injector(s) and

4. Remove the seat base and storage container to access the reassemble the fuel system.
fuel injector harnesses.
IMPORTANT: The PTO fuel injector harness wires are
5. Disconnect the fuel injector harness(s) as shown below. Red/Black and White. The MAG fuel injector harness
wires are Red/Black and White/Black.
Disconnect
Here 8. Lubricate O-rings lightly with oil to aid installation. Torque
the fuel rail mounting screw to specification.
=T
Fuel Rail Mounting Screw
16-20 ft. lbs. (22.6-27 Nm)
NOTE: The Bosch harness connector and locking

spring is bonded to the fuel injectors with an epoxy.
DO NOT attempt to disconnect the Bosch connector
from the fuel injectors. Damage will occur to the
injector and/or harness if attempting to separate at
that location. Separate the fuel injector from the
vehicle harness as shown above.
4.15
CRANKSHAFT POSITION SENSOR CPS Test
(CPS) The crankshaft position sensor is a sealed, non-serviceable
assembly. If fault code diagnosis indicates a problem within this
Operation Overview area, test and correct as follows:
The crankshaft position sensor is essential to engine operation, 1. Disconnect main harness connector from ECU.
constantly monitoring the rotational speed (RPM) and position
of the crankshaft. 2. Connect an ohmmeter between the pin terminals. A
resistance value of 560 10% at room temperature (20
C, 68 F) should be obtained. If resistance is correct, check
CPS the mounting, air gap, toothed ring gear (damage, runout,
etc.), and flywheel key.
Crankshaft Position Sensor:

560 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 560 10% should
again be obtained.
A ferromagnetic 60-tooth ring gear with two consecutive teeth NOTE: If the resistance is incorrect, remove the
missing is mounted on the flywheel. The inductive speed sensor screw securing the sensor to the mounting bracket
is mounted 1.0 0.26 mm (0.059 0.010 in.) away from the ring and replace the sensor. If the resistance in step 2
gear. During rotation, an AC pulse is created within the sensor was incorrect, but the resistance of the sensor alone
for each passing tooth. The ECU calculates engine speed from was correct, test the main harness circuit between
the time interval between the consecutive pulses. The two-tooth the sensor connector terminals and the
gap creates an interrupt input signal, corresponding to specific corresponding pin terminals in the main connector.
crankshaft position for PTO cylinder. This signal serves as a Correct any observed problem, reconnect the
reference for the control of ignition timing by the ECU. sensor, and perform step 2 again.
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 CPS Replacement
fails or becomes disconnected for any reason, the engine will
quit running. 1. Disconnect the sensor from the vehicle harness at the
connector.
2. Using a 6 mm hex wrench, remove the retaining bolt and

replace the sensor.
3. Use a light coating of oil on the O-ring to aid installation.
4. Torque the retaining bolt to specification.
=T
CPS Retaining Bolt Torque:
25 in. lbs. (2.8 Nm)
4.16
TEMPERATURE / BAROMETRIC AIR THROTTLE POSITION SENSOR (TPS)
PRESSURE SENSOR (T-BAP) Operation Overview
Operation Overview The throttle position sensor (TPS) is used to indicate throttle
plate angle to the ECU. Mounted on the throttle body and
Mounted on the throttle body intake, the temperature and operated directly off the end of the throttle shaft, the TPS works
barometric air pressure sensor (T-BAP) performs two functions like a rheostat, varying the voltage signal to the ECU in direct
in one unit. correlation to the angle of the throttle plate. This signal is
processed by the ECU and compared to the internal pre-
T-BAP programmed maps to determine the required fuel and ignition
settings for the amount of engine load.
Stop Screw
(Factory Set)
DO NOT ADJUST
4
Throttle Body
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
TPS
by the ECU and compared to its programming for determining
the fuel and ignition requirements during operation. Yellow
(Output)
TPS Connector
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 Blue Black
sensor should only be tested using the Digital Wrench (Input) (Ground)
Diagnostic Software (dealer only).
The correct position of the throttle body stop screw
T-BAP Replacement is established and set at the factory.
DO NOT loosen the throttle body stop screw or alter
1. Disconnect sensor from engine harness.
its position in any manner. The stop screw controls
2. Using a 10mm wrench, remove the retaining bolt and the air flow calibration of the throttle body. If the
replace the sensor. stop screw is repositioned or adjusted, the throttle
body assembly must be replaced.
3. Use a light coating of oil on the O-ring to aid installation.
4. Torque the retaining bolt to specification. TPS Learn Function

The TPS automatically learns the idle setting at every key-on
=T occurrence. This function provides more consistent calibration
by compensating for TPS drift. However, if the TPS reading gets
T-BAP Retaining Bolt Torque: below .690 Vdc or above .730 Vdc, the learn function is set to
29 in. lbs. (3.3 Nm) default to the last successfully learned point and the Check
Engine or MIL indicator will illuminate. Performing the
TPS Adjustment procedure will remedy this problem.
4.17
TPS Tester / Regulator Verify TPS Tester Reference Voltage
The TPS reading can be checked by using the Throttle Position A 5 volt reference voltage from the TPS Tester harness is
Sensor (TPS) Tester (2201519-A). required for the TPS test to be accurate. Refer to the instructions
provided with the TPS Tester (2201519-A) or follow the bullet
IMPORTANT: TPS Tester 2201519-A replaces the point steps below to check reference voltage.
existing TPS tester (PU-47082), which included the
4010264 regulator. If your dealership has PU-47082 Reference Voltage Test:
and 4010264 you DO NOT need to order 2201519-A as Insert black voltmeter probe into the test port as shown.
a replacement.
Insert red voltmeter probe into the test port as shown
Set-up the TPS Tester Wire Harness (PU-47466) and TPS Tester and verify the voltage reads 4.99-5.01 Vdc. If the
Regulator (547927) according to the instructions that reading is low, replace the 9 volt battery.
accompanied the tester. Make sure the 9 Volt battery is new.
TPS Reference Voltage

5 Vdc Input
IMPORTANT: Always use a fresh 9 Volt battery.
4.18
Checking TPS Reading 8. Allow the throttle foot pedal to rest in the idle position. The
voltmeter should read within the specification.
1. Remove the lower seat base to access the sensor connector.
2. Assemble the TPS Tester according to the instructions.
Refer to TPS Tester / Regulator for proper set-up and
testing. Verify the 9 volt tester battery is new.
3. Disconnect the vehicle chassis harness from the TPS.
Throttle
Body
4
TPS
TPS
Connector
4. Plug the TPS Tester harness into the TPS harness.

Figure 4-28
5. Set your voltmeter to read DC Volts. Insert the red and
black voltmeter probes into the test ports as shown.
6. Move the throttle open and closed slowly while reading the TPS Output Reading
display. The voltage should increase and decrease .690 - .730 Vdc
smoothly without any jumps when the throttle is applied.
9. If the voltage does not read within the specification,
proceed to the TPS Adjustment procedure. If the voltage
reading is within specification, no adjustment is required.
TPS Adjustment
NOTE: This procedure should be performed after
you have checked the TPS reading. Refer to
Checking TPS Reading procedure before making
any adjustments.
1. Make sure the TPS Tester harness is still connected to the

TPS harness.
2. Loosen the mounting screw (B) holding the TPS to the
throttle body (see Figure 4-29).
3. Rotate the TPS until your voltmeter reads within
specification (see Figure 4-28).
TPS Output Reading

.690 - .730 Vdc
4. Retighten the mounting screw, and verify the voltage did

not change. If the voltage changed, repeat steps 2 - 4.
7. If voltage varies with throttle movement, continue on to
Step 8. If the sensor did not function correctly, replace it. 5. Reconnect the TPS harness to the vehicle chassis harness.
4.19
TPS Replacement Coolant passes through the cylinder and by the sensor probe,
varying a resistance reading which is relayed to the ECU. This
NOTE: The correct position of the TPS angle on the signal is processed by the ECU and compared to its
throttle body is established and set at the factory. If programming for determining the fuel and ignition
the TPS is replaced, repositioned or loosened it requirements during operation. The ECU also uses this signal to
must be recalibrated. Refer to the TPS Adjustment determine when to activate the fan during operation. If for any
procedure. reason the engine temperature sensor circuit is interrupted, the
fan will default to ON.
1. Remove the lower seat base to access the TPS.
2. Disconnect the TPS harness connection (A). ECT Sensor Test
To quickly rule out other components and wiring related to the
A TPS ECT, disconnect the harness from the ECT. The fan should turn
on. This indicates all other components are working properly.
ECT Sensor
B
Figure 4-29 Refer to Chapter 10 for ECT testing. Polaris dealers can also test
3. Remove the mounting screw (B) and replace the sensor. the sensor by using the Digital Wrench Diagnostic Software
(dealer only).
NOTE: If replacing the TPS or throttle body, you
must perform the TPS Adjustment procedure. ECT Sensor Resistance Readings
4. Refer to TPS Adjustment for setting the TPS voltage. Temperature F (C) Resistance
68F (20C) 2.5 k 6%

ENGINE COOLANT TEMPERATURE 212F (100C) 186 2%
SENSOR (ECT)
Operation Overview ECT Sensor Replacement
Mounted on the cylinder head, the engine coolant temperature 1. Drain coolant so the level is below the sensor.
sensor measures the coolant temperature. The sensor is a
Negative Temperature Coefficient (NTC) type sensor, as the 2. Disconnect sensor from engine harness.
temperature increases the resistance decreases. 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. lbs. (23 Nm).
=T
ECT Retaining Bolt Torque:
17 ft. lbs. (23 Nm)
5. Add the required amount of coolant and properly bleed the

cooling system (see Chapter 3).
ECT Sensor
4.20
IGNITION COIL Primary Test
Operation Overview
The ignition coil is used to provide high voltage to fire the spark
plugs. When the ignition key is on, DC voltage is present in
primary side of the ignition coil windings. During engine
rotation, an AC pulse is created within the crankshaft position
sensor for each passing tooth on the flywheel. 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. The ECU then
calculates the time interval between the consecutive pulses, and
determines when to trigger the voltage spike that induces the
voltage from the primary to the secondary coil windings to fire
the spark plugs.
4
Measure Between
Connector Pins
0.4
Secondary Test
Ignition Coil
Ignition Coil Tests

The ignition coil can be tested by using an ohm meter. Use the Measure Between
following illustrations and specification table to test the ignition End Caps
coil resistance. 5k
NOTE: The under-seat storage container must be
removed to properly access the ignition coil harness
Ignition Coil / HT Lead Replacement
for testing purposes.
1. Remove the lower seat base and lift out the under-seat
Ignition Coil Resistance Readings storage container to access the ignition coil.
Test Pin Connection Resistance 2. Disconnect the ignition coil harness and remove the high
tension leads from the coil.
Between 1 & 2
Primary 0.4 3. Remove the fastener retaining the coil and remove the coil
Between 3 & 2
from the vehicle. If replacing the high tension lead(s),
Between High remove the other end of the lead(s) from the spark plug.
Secondary 5k
Tension Lead Ends
4. Install the new ignition coil and/or high tension lead(s).
=T
Ignition Coil Retaining Bolt Torque:
75 in. lbs. (8.5 Nm)
4.21
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 on the instrument cluster display.
4. The word End will display after all of the codes have been
NOTE: The EFI diagnostic mode is intended to
displayed or if no codes are present.
quickly view 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 3 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
blink codes. NOTE: To clear codes manually, disconnect the
positive battery lead for 20 seconds.
DIAGNOSTIC BLINK CODES CHART

P-Code Blink Code Name Check Engine
P0335 21 Loss of Synchronization Yes
P0122 TPS: Open or Short Circuit to Ground Yes
P0123 22 TPS: Short Circuit to Battery or Ground Circuit is Open Yes
P1120 TPS: Voltage is Below Minimum specification Yes
P0601 RAM Error: Defective ECU Yes
23
P1601 RAM Error: Defective ECU Yes
P0914 25 Gear Switch Signal Voltage: Outside Acceptable Range Yes
P0500 26 Vehicle Speed Sensor: Implausible Yes
P1121 27 TPS: Set Error Yes
P0112 Intake Air Temp Sensor: Short Circuit to Ground Yes
41
P0113 Intake Air Temp Sensor: Open or Short Circuit to Battery Voltage Yes
P0117 Engine Temperature Sensor Circuit: Short To Ground Yes
42
P0118 Engine Temperature Sensor Circuit: Open or Short to Battery Voltage Yes
P0107 45 Barometric Pressure Sensor: Circuit Low Input Yes
P0108 46 Barometric Pressure Sensor: Circuit High Input Yes
P1260 Injector 1 (PTO): Driver Circuit is Open Yes
P0261 51 Injector 1 (PTO): Short Circuit to Ground Yes
P0262 Injector 1 (PTO): Short Circuit to Battery Voltage Yes
P1263 Injector 2 (MAG): Driver Circuit is Open Yes
P0264 52 Injector 2 (MAG): Short Circuit to Ground Yes
P0265 Injector 2 (MAG): Short Circuit to Battery Voltage Yes
P1691 Rear Differential Lock Control Circuit: Open Yes
P1692 53 Rear Differential Lock Control Circuit: Shorted to Voltage Yes
P1693 Rear Differential Lock Control Circuit: Shorted to Ground Yes
P0655 Engine Temperature Lamp: Open Load Yes
P1657 54 Engine Temperature Lamp: Short Circuit to Ground Yes
P1658 Engine Temperature Lamp: Short Circuit to Battery Voltage Yes
P1652 Check Engine Lamp: Short Circuit to Ground Yes
55
P1653 Check Engine Lamp: Short Circuit To Battery Voltage Yes
P1231 Fuel Pump Driver Circuit: Open Yes
P1232 56 Fuel Pump Driver Circuit: Short Circuit to Ground Yes
P1233 Fuel Pump Driver Circuit: Short Circuit to Battery Voltage Yes
- 61 End of Blink Code Sequence -
4.22
EFI Troubleshooting Poor Idle
Symptom: Idle Too High (If greater than 1300 RPM when
Fuel Starvation / Lean Mixture engine is warm)
Symptoms: Hard start or no start, bog, backfire, popping
Throttle stop screw set incorrect
through intake / exhaust, hesitation, detonation, low power,
spark plug erosion, engine runs hot, surging, high idle, idle Throttle cable sticking, improperly adjusted, routed
speed erratic. incorrectly
No fuel in tank Symptom: Idle Too Low (if less than 900 RPM when engine is
warm)
Restricted tank vent, or routed improperly
Plugged air filter
Fuel lines or fuel injectors restricted
Leaking injector (rich condition)
Fuel filter plugged
Fuel pump inoperative

Belt dragging
4
Throttle stop screw tampering
Air leak in system
Symptom: Erratic Idle
Intake air leak (throttle shaft, intake ducts, airbox or air
cleaner cover) Throttle cable incorrectly adjusted
Incorrect throttle stop screw adjustment Air Leaks, dirty injector
Rich Mixture TPS damaged or adjusted

Symptoms: Fouls spark plugs, black, sooty exhaust smoke, Tight valves
rough idle, poor fuel economy, engine runs rough/ misses, poor
performance, bog, engine loads up, backfire. Ignition timing incorrect
Air intake restricted (inspect intake duct) Belt dragging
Air filter dirty/plugged Dirty air cleaner
Poor fuel quality (old fuel) Engine worn
Fouled spark plug Spark Plug fouled
TPS setting incorrect Throttle stop screw set incorrectly (out of sync with
ECU)
Injector failure
4.23
DIGITAL WRENCH OPERATION
Digital Wrench Diagnostic Software Overview
IMPORTANT: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench Diagnostic
Kit to install the Polaris Digital Wrench diagnostic software on your computer.
The Digital Wrench diagnostic software allows the technician to perform the following tests and observations:
View or clear trouble codes Perform guided diagnostic procedures
Analyze real-time engine data Create customer service account records
Reflash ECU calibration files Perform output state control tests (on some models)
Special Tools (also refer to page 4.2)
DIGITAL WRENCH DIAGNOSTIC SOFTWARE PART NUMBER

Digital Wrench Diagnostic Kit PU-47063-A
Digital Wrench Software: PU-48731
PU-47063-A (listed above) INCLUDES: Standard Interface Cable: PU-47151
SmartLink Module Kit: PU-47471
Fuel Pressure Gauge Kit PU-43506-A
Fuel Pressure Gauge Adapter PV-48656
Fluke 73 Digital Multi-Meter or Fluke 77 DMM PV-43546 (Fluke 77: PV-43568)
Laptop or Desktop Computer Commercially Available (refer to diagnostic software user
USB/Serial Adaptor: Saelig RS-232 manual or HELP section for minimum requirements)
Diagnostic Software Version Diagnostic procedures are added to subsequent versions of

Digital Wrench as they become available. Check your release
Always use the most current version of the Digital Wrench version often and upgrade when available to be sure you are
software to ensure you have the latest updates or enhancements. using the most current software available.
New reprogramming files and guided diagnostic procedures are
added to these updates as they become available. For Digital Wrench Communication Errors
information on how to determine if you have the latest update
available, refer to Digital Wrench Version and Update ID. If you experience problems connecting to a vehicle or any
Digital Wrench related problem, visit the Digital Wrench
ECU Replacement Knowledge Base for the most current troubleshooting
information, FAQs, downloads and software updates at:
Although the need for ECU replacement is unlikely, a specific http://polaris.diagsys.com/.
replacement procedure is required to ensure that all essential
data contained within the original ECU is transferred to the
replacement ECU.
Refer to procedure and carefully follow all instructions provided

in Digital Wrench.
Guided Diagnostic Available

Guided diagnostics are available within Digital Wrench for
all supported Trouble Codes (that is, any fault that will turn on
the Check Engine indicator).
In addition, guided diagnostics are also available for many other

electrical sub systems.
4.24
Digital Wrench - Diagnostic Connector Digital Wrench Version and Update ID
The diagnostic connector is located under the hood as shown Knowing what Digital Wrench version and update is installed
below. will help determine which updates are required.
NOTE: Versions and updates are subject to change.
1. Open the Digital Wrench software. Locate the version

ID shown on the lower right side of the Digital Wrench
start-up screen.
Version: 3.1 03/13/09

4
Follow these steps to connect the diagnostic interface cable to
the vehicle to allow Digital Wrench use:
1. Assemble the SmartLink Module and attach the PC

Interface Cable to your laptop (see page 4.3).
2. In this case, the version number is 3.1 with a 03/13/09
2. Remove the protective cap from the Digital Wrench update. Proceed to http://polaris.diagsys.com to see if a
connector. newer update is available.
3. Connect the Vehicle Interface Cable to the Digital

Wrench diagnostic connector.
4. Turn the ignition key to the ON position, select the

appropriate vehicle and wait for the status to display
Connected in the lower left corner of the screen.
Digital Wrench Update 04-27-09
5. Once connected, proceed with using Digital Wrench.
Digital Wrench Serial Number Location

Open the configuration screen by clicking on the wrench icon.
The serial number is located on the right side of the screen. 3. In this case, a newer update (04-27-09) is available and
should be downloaded before using Digital Wrench (see
Digital Wrench Updates).
IMPORTANT: Always operate with the latest update.
4.25
Digital Wrench Updates 6. If the update file date listed is newer than your current
version and update (see Digital Wrench Version and
Updates are released for Digital Wrench via the Internet at: Update ID), download the file.
http://polaris.diagsys.com. The Digital Wrench website can
also be accessed through the dealer website at:
www.polarisdealers.com.
NOTE: Only authorized Polaris dealers and

distributors can access the dealer website.
1. Log on to www.polarisdealers.com.
2. Locate the Service and Warranty drop-down menu.
3. Click on Digital Wrench Updates.
7. Click on the link shown above, save the file to your hard
disk and then double-click the icon to start the update
process.
NOTE: Do not "run" or "open" the file from where

they are. Select "save" and download them to your
PC before running the install.
8. When the update is complete, the version shown on the

right side of the Digital Wrench start-up screen should
match the update you just downloaded.
4. The Digital Wrench portal website should appear in a
new web browser.
5. Click on Digital Wrench Version 3.1 Updates.
Digital Wrench Update 04-27-09
IMPORTANT: You must already have version 3.1

installed before adding these updates. They will not
install if you have version 3.0 or older on your PC. Version: 3.1 04/27/09
NOTE: Versions and updates are subject to change.
4.26
Digital Wrench Feature Map
4.27
Engine Controller Reprogramming (Reflash) KNOW THE PROCESS: If you are not familiar with
the entire reprogramming process, review the HELP
Process Overview section of the diagnostic software before you attempt
reprogramming. Click on the ? on the tool bar or press
The reprogramming feature is in the Special Tests menu on the F11. The information in the on-line help is the most
Digital Wrench screen. Start Digital Wrench and click on current and complete information available. This
the Special Tests menu icon (red tool box). A technician should should be your first step until you are familiar with the
be familiar with the process and with computer operation in process.
general before attempting to reprogram an ECU.
COMMUNICATION PROBLEMS: If you have had
The Digital Wrench Engine Controller Reprogramming (or problems communicating with a vehicle while
Reflash) feature allows reprogramming of the ECU fuel and performing diagnostic functions, do not attempt
ignition map. To successfully reprogram the ECU, an reprogramming until the cause has been identified and
Authorization Key must be obtained by entering a Request Code fixed. Check all connections, and be sure battery
in the box provided on the Reflash Authorization site. The voltage is as specified.
Request Code is automatically generated by Digital Wrench
during the reprogramming process. The Reflash Authorization Proceed to http://polaris.diagsys.com for specific
site is located under the Service and Warranty drop down information and FAQs on how to troubleshoot
menu on the dealer website at: www.polarisdealers.com. communication problems.
IMPORTANT: Failure to follow the reprogramming

instructions completely and correctly can result in an
engine that does not run! Replacement ECUs are
programmed as no-start and require a reflash for
them to work.
Reprogramming (Reflash) Tips:
BATTERY VOLTAGE: The majority of problems with

reprogramming can be attributed to a low battery. Be
sure the battery voltage (no load) is at least 13 volts and
at least 12.5 volts with the key ON. Connect a battery
charger if necessary to bring voltage level above
minimum. Fully charge the battery before you attempt
to reprogram.
DEDICATED LAPTOP: Best results are obtained using

a laptop computer that is dedicated to Digital
Wrench. A laptop that is used by a variety of people
and in several applications around the dealership is
more likely to cause a reprogramming problem than one DONT DISTURB THE PC: While reprogramming is
dedicated to Digital Wrench diagnostics only. in progress, dont move the mouse and dont touch the
keyboard. The process only takes a few minutes, and is
OBTAINING THE LATEST UPDATE: best left alone until complete.
Reprogramming updates are provided periodically and
contain the most recent calibrations (see Digital Reprogramming (Reflash) Procedure:
Wrench Updates).
If you are not familiar with the reprogramming process, review
CLOSE NON-ESSENTIAL PROGRAMS: Polaris the Reprogramming (Reflash) Tips before you begin. Follow
recommends that you DO NOT install non-essential the on-screen instructions as you progress through the steps. If
programs on a Service Department laptop. Camera you encounter a problem, always check the On-Line help for
detection software, Virus Scanners, Tool Bars, etc. may current tips and information.
clog up memory if running in the background and make
it harder for the diagnostic software to operate. 1. Verify the most current update has been downloaded and
loaded into Digital Wrench. See Digital Wrench
Version and Update ID on page 4.25.
4.28
2. Connect the SmartLink Module cables to the PC and 6. Select Engine Controller Reprogramming.
vehicle. See Digital Wrench - Diagnostic Connector
on page 4.25.
7. Select the file you want to load into the ECU then click the
Continue icon to proceed to the Integrity Check.
4
3. Open the Digital Wrench program.
4. Select the model year, product line and vehicle description

by selecting the Change Vehicle Type icon.
8. Follow the on screen instructions and connect a 9V battery

to the reflash battery connector located off the main
diagnostic connector. Click the Continue icon to obtain
a Request Code.
5. Select the Special Tests icon.
4.29
9. Copy (CTRL+C) the Request Code that will be required on 12. Select the same file type from the list that you selected
the dealer website in the next step. DO NOT CLOSE previously while in Digital Wrench. Enter the VIN along
Digital Wrench or the Request Code will be invalid. with the customers name and address. When completed,
NOTE: All characters are letters; there are no numbers click the Authorize button once to proceed.
in a request code.
Authorization Key goes here after

obtained from the dealer website
Copy Request Code to

obtain Authorization Key
Enter ALL the information and
click on the Authorize button
13. An Authorization Key will appear in the upper left corner

of the screen. Copy (CTRL+C) this key exactly as it
NOTE: Request Codes and Authorization Keys must
appears.
be entered EXACTLY as they appear on the screen.
10. Go to www.polarisdealers.com and click on ReFlash

Authorization from the Service and Warranty drop-
down menu.
Authorization Key
14. Enter or paste (CTRL+V) the Authorization Key in the box

Service and Warranty Reflash Authorization located on the Digital Wrench screen. Click the
Continue button and follow instructions provided on the
screen to complete the reprogramming procedure.
11. Enter or paste (CTRL+V) the Request Code into the box.
Enter the
Request Code
Enter the
Authorization Key
4.30
15. At this point the reflash process will begin. Do not touch 16. Once the ECU reprogramming procedure is complete, click
the vehicle or PC during the process. the Finish button on the screen. Verify the reflash was a
success by starting the vehicle.
4
EFI SYSTEM BREAKOUT DIAGRAM
4.31
NOTES
4.32
BODY / STEERING / SUSPENSION
CHAPTER 5
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
CHASSIS / MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
EXPLODED VIEW (XP / HD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
EXPLODED VIEW (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
EXPLODED VIEW (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
CAB FRAME / SEAT BACK / HEADREST / PVT AIR INTAKE BAFFLE BOX . . . . . . . . . 5.6
EXPLODED VIEW / ASSEMBLY (XP / HD / 6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
EXPLODED VIEW / ASSEMBLY (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
BODY EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
DASH INSTRUMENTS / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
HOOD / DASH / FRONT FENDERS / FRONT FASCIA . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
FLOOR / REAR FENDERS (XP / HD / 6X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
FLOOR / REAR FENDERS (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
SEAT MOUNTING / SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
REAR CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
CARGO BOX - PANELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
CARGO BOX - TAILGATE / BOX SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
5
BOX REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
REAR STORAGE BOX (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
LOWER SEAT BASE / WHEEL WELL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
FRONT BUMPER / FRONT FASCIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
FRONT FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
HOOD / DASH / GLOVE BOX / STORAGE PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
REAR FENDERS AND FLOOR (XP / HD / 6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
MID / REAR FENDERS AND FLOOR (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
POWER STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
POWER STEERING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
POWER STEERING UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
FRONT A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
BALL JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
MID / REAR A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
REAR STABILIZER BAR / LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32
DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
SHOCKS / SPRINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
SHOCK REMOVAL / INSTALLATION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 5.33
SELF-LEVELING SUSPENSION (HD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34
NIVOMAT SHOCK OPERATION / DISPOSAL / REPLACEMENT . . . . . . . . . . . . . . . 5.34
5.1
TORQUE SPECIFICATIONS SPECIAL TOOLS
ITEM TORQUE VALUE TOOL DESCRIPTION PART NUMBER
ft. lbs. (Nm)
Shock Spanner Wrench 2871095
Front Frame to Rear Frame
38-40 ft. lbs. (52-54 Nm) Shock Spring Compressor Tool 2870623
Support Fasteners (CREW)
Multi-Function Pliers 2876389
Main Frame to Rear Frame
34-36 ft. lbs. (46-49 Nm)
Fasteners (6x6)
Multi-Function Pliers
Front Upper / Lower
30 ft. lbs. (41 Nm)
A-Arm Bolts Included in the tool kit, the multi-function pliers is designed to
remove the plastic push rivets used to fasten body components.
Mid Upper / Lower
30 ft. lbs. (41 Nm)
A-Arm Bolts
Rear Upper / Lower
30 ft. lbs. (41 Nm)
A-Arm Bolts
Front Ball Joint Pinch Bolts 17 ft. lbs. (23 Nm)
Mid / Rear Lower
30 ft. lbs. (41 Nm)
Bearing Carrier
Mid / Rear Upper
30 ft. lbs. (41 Nm)
Bearing Carrier
Upper / Lower
30 ft. lbs. (41 Nm)
Shock Bolts
Stabilizer Bar to Frame 17 ft. lbs. (23 Nm)
Stabilizer Bar
17 ft. lbs. (23 Nm)
Linkage Bushings
Front Wheel Hub
80 ft. lbs. (108 Nm)
Castle Nut
Mid / Rear Wheel Hub
110 ft. lbs. (150 Nm)
Castle Nut
Wheel Nuts (Cast Rims) 90 ft. lbs. (122 Nm)
Wheel Nuts (Steel Rims) 35 ft. lbs. (47 Nm)
Outer Tie Rod to
40 ft. lbs. (54 Nm)
Bearing Carrier
Tie Rod End Jam Nut 12-14 ft. lbs. (17-19 Nm
Seat Belt to Cab Frame 35-40 ft. lbs. (47-54 Nm)
Seat Belt to Seat Base 36-44 ft. lbs. (49-60 Nm)
Steering Wheel to Shaft 25-31 ft. lbs. (34-42 Nm)
Upper Steering Shaft to
15-19 ft. lbs. (20-26 Nm)
U-Joint Shaft
Lower Steering Shaft to
30 ft. lbs. (41 Nm)
Steering Box Pliers
Steering Box 17 ft. lbs. (23 Nm)
NOTE: Refer to exploded views throughout this

chapter for more torque specifications, component Push Rivet
identification, and location of components.
5.2
CHASSIS / MAIN FRAME
Exploded View (XP / HD)
Seat Base
Dash Support
RH Floor Support
Main Frame
5
Cap
28-32 ft. lbs.
Fascia (38-43 Nm)
Screen
28-32 ft. lbs.
(38-43 Nm)
T27
Screws
Cap
4-6 ft. lbs.
(6-8 Nm) 13-15 ft. lbs.
Bumper (17-20 Nm)
Screen
Bumper Guard
Bracket
Bumper LH Floor Support
5.3
Exploded View (CREW)
Rear Seat Base
Front Seat Base
Rear Frame
Dash Support
38-40 ft. lbs.

(52-54 Nm)
28-32 ft. lbs.

(38-43 Nm) Frame 38-40 ft. lbs.
(52-54 Nm)
Supports
RH Floor Support
Cap 38-40 ft. lbs.

(52-54 Nm)
Fascia
Screen
28-32 ft. lbs.
(38-43 Nm)
38-40 ft. lbs.

(52-54 Nm)
T27 Front Frame

Screws 13-15 ft. lbs.
Cap
4-6 ft. lbs. (17-20 Nm)
(6-8 Nm)
LH Floor Support
Bumper
Screen
Bumper Guard
Bracket
Bumper
5.4
Exploded View (6x6)
Seat Base
Dash Support
ROPS
Rear
Bracket
Frame
34-36 ft. lbs.
(46-49 Nm)
RH Floor Support 28-32 ft. lbs.

(38-43 Nm)
34-36 ft. lbs.
Main Frame (46-49 Nm)
Cap
Fascia
Screen
28-32 ft. lbs.
(38-43 Nm)
Mount
Brackets
34-36 ft. lbs.
(46-49 Nm)
T27
Screws
Cap 13-15 ft. lbs.
4-6 ft. lbs. (17-20 Nm)
(6-8 Nm)
Bumper
Screen LH Floor Support
Bumper Guard
Bracket
Bumper
5.5
CAB FRAME / SEAT BACK / HEADREST / PVT AIR INTAKE BAFFLE BOX
Exploded View / Assembly (XP / HD / 6x6)
1. Assemble the RH and LH cab frame side hoops by sliding the tube over the rear coupler. Secure using (2) 5/16 bolts and nuts. Line up
the front side hoop couplers with the front frame couplers and secure using (4) 3/8 screws and nuts. Leave all fasteners finger tight.
2. Attach the front cab frame cross tube to the side hoops using (4) M10 bolts. Attach the rear cab frame cross tube to the side hoops using
(4) M10 bolts. Leave all fasteners finger tight.
3. Loosely install the rear cab frame X brace to the side hoops using (8) M8 bolts and nuts. Leave all fasteners finger tight.
4. Tighten the (8) front and rear cab frame cross tube fasteners installed during Step 2 to 25-28 ft. lbs. (34-38 Nm).
5. Tighten the (2) 5/16 fasteners installed during Step 1 to 16-18 ft. lbs. (20-24 Nm) and the (4) 3/8 fasteners to 25-28 ft. lbs. (34-38 Nm).
6. Tighten the (8) M8 X brace fasteners installed during Step 3 to 16-18 ft. lbs. (20-24 Nm).
7. Fasten the seat back to the X brace using (8) #14 self-tapping screws. Tighten fasteners to 18-20 in. lbs. (2-2.25 Nm).
8. Place the 2.5 hose clamp over the clutch air inlet hose and slide the clutch intake box assembly into the hose. Tighten the hose clamp to
18 in. lbs. (2 Nm).
9. Attach the clutch air intake box to the seat back using (4) #14 self-tapping screws. Tighten fasteners to 18-20 in. lbs. (2-2.25 Nm).
10. Attach each headrest to the rear cab frame using four 1/4 self-tapping fasteners. Place washers between the fastener head and headrest
as shown below. Torque fasteners to 10 in. lbs. (1 Nm).
5.6
Exploded View / Assembly (CREW)
1. Assemble the RH and LH front cab frame side hoops by sliding the tube over the rear coupler. Secure using (2) 5/16 bolts and nuts. Line
up the front side hoop couplers with the front frame couplers and secure using (4) 3/8 screws and nuts. Leave all fasteners finger tight.
2. Attach the front cab frame cross tube to the side hoops using (4) M10 screws. Install the rear cab frame cross tube to the side hoops using
(4) M10 screws. Leave all fasteners finger tight.
3. Loosely install the rear cab frame K brace to the side hoops using (8) M8 screws and nuts. Leave all fasteners finger tight.
4. Tighten the (8) front and rear cab frame cross tube fasteners installed during Step 2 to 25-28 ft. lbs. (34-38 Nm).
5. Tighten the (2) 5/16 fasteners installed during Step 1 to 16-18 ft. lbs. (20-24 Nm) and the (4) 3/8 fasteners 25-28 ft. lbs. (34-38 Nm).
6. Tighten the (8) M8 K brace fasteners installed during Step 3 to 16-18 ft. lbs. (20-24 Nm).
7. Assemble the RH and LH rear cab frame side hoops by sliding the tube over the rear coupler. Secure using (2) 5/16 bolts and nuts. Line
up the front upper rear hoop couplers with the rear cab frame cross tube holes and secure using (2) M10 screws and nuts. Leave all fasteners
finger tight.
8. Install the rear cab frame cross tube to the rear side hoops using (4) M10 screws. Leave all fasteners finger tight.
9. Loosely install the rear cab frame X brace to the rear side hoops using (8) M8 screws and nuts. Leave all fasteners finger tight.
10. Tighten the (2) 5/16 fasteners installed during Step 7 to 16-18 ft. lbs. (20-24 Nm) and the (4) M10 fasteners to 25-28 ft. lbs. (34-38 Nm).
11. Tighten the (4) rear cab frame cross tube fasteners installed during Step 8 to 25-28 ft. lbs. (34-38 Nm).
12. Tighten the (8) M8 X brace fasteners installed during Step 9 to 16-18 ft. lbs. (20-24 Nm).
13. Fasten the seat back to the rear cab frame X brace using (8) #14 self-tapping screws. Tighten fasteners to 18-20 in. lbs. (2-2.25 Nm). Repeat
this step to attach the front seat back to the mid cab frame K brace.
14. Place the 2.5 hose clamp over the clutch air inlet hose and slide the clutch intake box assembly into the hose. Tighten the hose clamp to
18 in. lbs. (2 Nm).
5
15. Attach the clutch air intake box to the seat back using (4) #14 self-tapping screws. Tighten fasteners to 18-20 in. lbs. (2-2.25 Nm).
16. Attach the headrest to the rear cab frame using (4) 1/4 self-tapping fasteners. Place washers between the fastener head and headrest as
shown below. Torque fasteners to 10 in. lbs.
5.7
BODY EXPLODED VIEWS
Dash Instruments / Controls
A. Instrument Cluster (Speedo)
B. Speedometer Mode Button
C. Headlight Switch
D. 2WD/AWD Switch
E. 12 Volt Accessory Receptacle (2)
F. Rubber Mount
G. Key Switch
H. Grommet
I. Push Rivet
J. Dash Plug
K. Dash Panel
K A
J
D
C
I
H
B
E
5.8
Hood / Dash / Front Fenders / Front Fascia
T27
Screws
4-6 ft. lbs.
T30
(6-8 Nm)
Screws
Hood
Front
RH Fender
Dash
T20
Screws
Push
Rivets Hinge
T27
Screws
4-6 ft. lbs.
(6-8 Nm)
Cup Holder
T27
Screw 5
4-6 ft. lbs.
(6-8 Nm)
Front
Fascia T27
Screws
4-6 ft. lbs.
Front
(6-8 Nm) T27 LH Fender
Screws
U-Type
T27 Speed Nut
Screws
Push
Rivets
T27 U-Type Hood

Screws Speed Nut Liner
4-6 ft. lbs.
(6-8 Nm) T27
Screws
Fascia
Screen
5.9
Floor / Rear Fenders (XP / HD / 6x6)
Rear RH Fender T27 INSTALLING NEW FOAM: Make

Rocker Panel Screws sure surface is clean and has
4-6 ft. lbs. been flame treated. Be sure to
(6-8 Nm) compress foam > 50%, and
T27 make sure you dont trap any air.
Screws
U-Type
4-6 ft. lbs.
Speed Nut Foam
(6-8 Nm)
Storage
Container
Push
Rivets
Rear
Floor
Floor
Cover
U-Type
Speed Nut
T27
Screws
4-6 ft. lbs.
(6-8 Nm)
T27
Screws
Main
Push
Floor Rivets
T27
Screws
4-6 ft. lbs.
Push (6-8 Nm)
Rivets
Wheel Well Rear LH Fender

Panels Rocker Panel
Push
Rivets
Skid Plate
Screws
6-8 ft. lbs.
(8-10 Nm)
5.10
Floor / Rear Fenders (CREW)
Plugs Storage
Underseat Container
Storage box Rear Foam
Floor
Plug
T27
Screws
4-6 ft. lbs. U-Type
Floor (6-8 Nm) Speed Nut
Cover
Rear
Floor
Main
Floor
Mid
Floor Rear Lower
Floor
RH Fenders U-Type 5
Rocker Panels Speed Nut INSTALLING NEW FOAM: Make
sure surface is clean and has
been flame treated. Be sure to
compress foam > 50%, and
U-Type make sure you dont trap any air.
T27 Speed Nut
Screws Grommet
4-6 ft. lbs.
(6-8 Nm) T27
Screws
Push
Rivets
U-Type
Speed Nut
Push
Rivets
Push
Rivets T27 Rear LH Fender
Screws Rocker Panel
4-6 ft. lbs.
(6-8 Nm)
T27
Wheel Well Screws Front LH Fender
Panels Push Rocker Panel
Rivets
Skid Plates
Screws
6-8 ft. lbs.
(8-10 Nm)
5.11
Seat Mounting / Seat Belts
Bolt
RH 3-Point 35-40 ft. lbs.
Seat Belt (47-54 Nm)
Bolt
35-40 ft. lbs.
Seat Back (47-54 Nm)
T30 Screws
18-20 in. lbs.
(2-2.5 Nm)
LH 3-Point
Seat Belt
Foil
RH 3-Point Seat Base

Seat Belt Lab Belt
Bolt Bolt
36-44 ft. lbs. 36-44 ft. lbs.
(49-60 Nm) (49-60 Nm)
Grommet
Bolt
36-44 ft. lbs.
(49-60 Nm)
LH 3-Point
Seat Belt
Seat Base
Frame
Grommet Bolt
36-44 ft. lbs.
(49-60 Nm)
5.12
REAR CARGO BOX
Cargo Box - Panels
RH Box Panel T20

Screw T27 Latch
Taillight Screw
T30 Tailgate Support
Screws
T30
Screw
Latch
5
Bumpers
Taillight
T20
T20 Bumpers Screw
Seal Foam Screws
T30
Screws
Front
Box Panel Cargo Box
T20
Screws
T20 Seal Foam
Screw
RH Box Panel
5.13
Cargo Box - Tailgate / Box Support
Outer Panel Tailgate Cap

Tailgate
Bracket
Tailgate Latch
Cable
Rod
T30
Screws
T20
Screws
Rod
Tailgate
Inner Cable
Panel T27
Screws
4-6 ft. lbs.
(6-8 Nm)
T27
Screw
Tailgate Tube
T30
Screws
Box Support
Box Latch Heat

Shield
Hinge Pin
Bumper
Bushings
Springs
Shock Pins Screw

Clip
Shock
Clip
5.14
Box Removal
1. Lift the cargo box into the dump position. Slide Hinge Pin Out
2. Disconnect the rear wire harness attached to the tail lights.
3. Remove the upper clip and pin attaching the shock to the
cargo box.
Shock Pin
6. With both hinge pins removed, remove the box from the
frame. Two people may be needed to remove the box from
the frame.
CAUTION 5
Use caution when removing the box. It is
CAUTION recommended to have two people carefully
remove the box from the frame.
Safely support the box during the remainder of

the removal process. The box is not as stable Box Installation
with the shock removed. 1. If the shock was replaced, install the lower portion of the
shock to the frame and secure it with the pin and clip.
4. Remove the screw (A) that secures the hinge pin to the
frame on both sides.
A
Lower
Shock Pin
2. Place the cargo box onto the frame. Align the hinges of the
box with the bracket on the frame.
5. Remove the hinge pin from both sides.
3. Install the box hinges on both sides.
CAUTION 4. Secure the box hinges with the hinge screws on both sides.
Safely support the box during the remainder of 5. With the hinges installed, attach the shock to the cargo box
the removal process. The box is not as stable by inserting the pin and clip.
with the hinge pins removed.
6. Lower the box and secure the latch.
5.15
REAR STORAGE BOX (6X6)
Exploded View
Rivets RH Lid
Latch
LH Lid
Seal
Hex
Screws
Latch T25
Screws Rivets
Plug Latch
Rivets
Tabs
Hex Seal
Screws
Plug
Latch
Storage Box
Base
Rivets
Mount Brackets
5.16
BODY COMPONENT REMOVAL Front Bumper
Lower Seat Base
1. Lift up on the front of the seat base to disengage the seat
from the rubber grommets.
2. Remove the (3) bolts from the lower portion of the bumper. 5
2. Pull the seat base forward to disengage the rear tabs and 3. Remove the fasteners from each side of the upper portion
remove the seat base from the vehicle. of the bumper.
4. Carefully remove the bumper from the vehicle.

Wheel Well Panels
1. Using the multi-function pliers, remove the (6) push rivets Front Fascia
from the LH panel and the (5) push rivets from the RH
panel.
2. Pull both panels out from the wheel wells.

2. Remove the remaining T27 Torx-head screws retaining the
front fascia.
3. Turn the headlight bulbs counter-clockwise 90 and

remove the bulbs from the head lamps.
4. Carefully remove the fascia from the vehicle.
5.17
Front Fenders 5. Open the glove box and remove the (4) T20 Torx-head
screws from the dash.
1. Remove the lower T27 Torx-head screws retaining the
front fascia (see Front Fascia).
6. Remove the (5) T25 Torx-head screws retaining the rear

portion of the dash.
2. Remove the (4) push rivets retaining the front fender and
remove the fender from the vehicle. 7. Remove the (8) fasteners from each side of the dash where
it attaches to the front and rear fenders.
3. Repeat this procedure to remove the other front fender.
8. Remove the rubber boots from around the parking brake
Hood / Dash and shift lever.
9. Remove the (2) push rivets from the dash panel (see Dash
1. Remove the front fascia (see Front Fascia removal).
Instruments/Controls). Unhook all electrical components
2. Unlatch the hood and remove the (2) T27 Torx-head screws to allow the panel to be completely removed.
to remove the hood assembly.
10. Carefully remove the dash assembly from the vehicle.
Glove Box / Storage Panel

1. Remove the hood / dash (see Hood / Dash).
3. Remove the front portion of the cab frame on each side to

allow dash removal (see Cab Frame - Exploded View).
4. Remove the (2) T25 Torx-head screws retaining the front 2. Remove the (7) T27 Torx-head screws retaining the glove
of the dash to the hood liner. box storage panel.
3. Disconnect 12V power outlets and remove the assembly.
5.18
Rear Fenders (XP / HD / 6x6) NOTE: If removing the RH side, remove the fuel cap
as well. Reinstall fuel cap after fender removal.
1. Remove the (11) T27 Torx-head screws and (3) push rivets
retaining the rear fender. 2. Repeat this procedure to remove the other rear fender.
Floor (XP / HD / 6x6) 3. Loosen the glove box/storage panel fasteners to access the
screws retaining the upper portion of the main floor (see
1. Remove the (7) T27 Torx-head screws retaining the rear Glove Box / Storage Panel).
floor. Disconnect ECU harness and remove the rear floor.
4. Remove the (14) T27 Torx-head screws retaining the main
2. Remove the (8) T27 Torx-head screws retaining the floor floor. Remove the (4) nuts retaining the brake/throttle pedal
cover and remove the floor cover from the vehicle. mount and remove the main floor from the vehicle.
INSTALLING NEW FOAM: Make

make sure you dont trap any air.
5.19
Mid / Rear Fenders (CREW) NOTE: If removing the rear RH side, remove the fuel
cap as well. Reinstall fuel cap after fender removal.
1. Remove the (19) T27 Torx-head screws and (6) push rivets
2. Repeat this procedure to remove the other fenders.
retaining the fenders.
Floor (CREW) 3. Loosen the glove box/storage panel fasteners to access the
screws retaining the upper portion of the main floor (see
1. Remove the (7) T27 Torx-head screws retaining either rear Glove Box / Storage Panel).
floor. Disconnect ECU harness if removing the passenger 4. Remove the (14) T27 Torx-head screws retaining the main
rear floor. floor and remove the (4) nuts retaining the brake/throttle
2. Remove the (8) T27 Torx-head screws retaining the floor pedal mount and remove the main floor from the vehicle.
cover and remove the floor cover from the vehicle. 5. See the illustration below if further disassembly is required.
INSTALLING NEW FOAM: Make

make sure you dont trap any air.
5.20
STEERING ASSEMBLY
Exploded View
Cap
Steering Wheel
25-31 ft. lbs. 15-19 ft. lbs.
(34-42 Nm) (20-26 Nm)
Wave Washers
Upper Lower
Steering Shaft Steering Shaft
23 ft. lbs.
(31 Nm)
Bushing
5
Pivot Tube
40 ft. lbs.
Bushing (54 Nm)
12 ft. lbs. Bushing Bushing

(16 Nm)
30 ft. lbs.
(41 Nm)
12 ft. lbs.
(16 Nm)
23 ft. lbs. Bushing LH Boot
(31 Nm) 12-14 ft. lbs.
(16-19 Nm)
Gear Box
Asm.
Oil Locking
Shock Asm.
RH Boot
40 ft. lbs.
(54 Nm)
Boot
17 ft. lbs.
17 ft. lbs. (23 Nm)
(23 Nm)
12-14 ft. lbs.
(16-19 Nm)
Nut Tie Rod
Cotter Pin
Rod End
5.21
POWER STEERING ASSEMBLY
Exploded View
Upper
PS Shaft
15-19 ft. lbs.

(20-26 Nm)
Power Steering
Unit
Mounting
Bracket
15-19 ft. lbs.

(20-26 Nm)
20-24 ft. lbs.

(27-33 Nm)
Lower
PS Shaft
30 ft. lbs.
(41 Nm)
Nut
5.22
Power Steering Unit Removal 5. Disconnect the (2) electrical harnesses and remove the
pinch bolt retaining the upper power steering shaft to the
1. Remove the cup holders from the upper dash panel. power steering unit.
Remove
Remove
2. Remove the fasteners retaining the lower dash panel and 6. Remove the upper fastener retaining the steering tilt shock
glove box. to the pivot tube and swing the shock down out of the way.
5
3. Carefully remove the lower dash panel assembly from the 7. Lift the steering wheel up and remove the pinch bolt
vehicle. Disconnect the 12V outlets upon removal. retaining the upper power steering shaft to the steering
wheel shaft.
4. Locate the power steering unit under the steering column.
Remove
PS Unit
5.23
8. Lift up on the steering wheel and remove the steering wheel 10. Remove the pinch bolt retaining the lower power steering
shaft from the pivot tube. shaft to the power steering unit.
CAUTION Remove
Striking the steering wheel or steering shaft

can permanently damage the EPS unit
and cause a Power Steering Fault.
11. Remove the (3) bolts retaining the power steering unit to
the mounting bracket and remove the power steering unit
from the vehicle.
NOTE: Remove the flat washer and both wave

washers along with the steering wheel shaft.
9. Remove the upper power steering shaft from the power

steering unit.
WARNING
Electronic Power Steering (EPS) units are not

interchangeable between ATV and RANGER
product lines.
5.24
Power Steering Unit Installation 4. Install the upper power steering shaft and align the skip-
tooth spline on the power steering stub shaft with the
Refer to the Power Steering Unit Removal procedure for opening in the upper power steering shaft.
detailed photos and illustrations during installation.
1. Install the power steering unit onto the mounting bracket Shaft
and align the skip-tooth spline on the power steering stub Opening
shaft with the opening in the lower power steering shaft.
Skip-Tooth
Skip-Tooth
Shaft CAUTION
Opening
Striking the steering wheel or steering shaft 5
can permanently damage the EPS unit
2. Torque the mounting bolts to specification. and cause a Power Steering Fault.
5. Install the pinch bolt and torque to specification.
=T
Upper Power Steering Shaft Pinch Bolt:
15-19 ft. lbs. (20-26 Nm)
6. Install the steering wheel shaft assembly into the pivot tube.
Be sure the front wheels are pointing straight ahead and that
the steering wheel is straight when installing the steering
wheel shaft into the upper power steering shaft.
7. Install the pinch bolt and torque to specification.
=T
Steering Wheel Shaft Pinch Bolt:
15-19 ft. lbs. (20-26 Nm)
=T 8. Install the tilt shock and torque fastener to specification.
Power Steering Unit Mounting Bolts:
20-24 ft. lbs. (27-33 Nm) =T
3. Install the pinch bolt retaining the lower power steering Tilt Shock Fastener: 12 ft. lbs. (16 Nm)
shaft to the power steering unit and torque to specification.
9. Reconnect both electrical harnesses onto the power steering
unit. Be sure the connectors snap into place.
=T
10. Reinstall the lower dash panel and glove box. Be sure to
Lower Power Steering Shaft Pinch Bolt: reconnect the 12V outlets upon assembly.
15-19 ft. lbs. (20-26 Nm) 11. Turn the key switch on and test EPS operation.
5.25
FRONT A-ARMS 15. Using a soft face hammer, tap on bearing carrier to loosen
the lower A-arm ball joint end while pushing downward on
Removal / Replacement the lower A-arm. Completely remove the ball joint end
from the bearing carrier.
The following procedure details upper and lower A-arm
removal and replacement on one side of the vehicle. 16. Loosen and remove the lower A-arm through-bolt fasteners
(E) and remove the lower A-arm from the vehicle.
1. Elevate and safely support the front of the vehicle and
remove the front wheel. 17. Examine A-arm bushings and pivot tubes (see Exploded
View). Replace if worn. Discard hardware.
2. Remove the lower shock fastener (A) from the upper A-
arm. 18. If not replacing the A-arm, thoroughly clean the A-arm and
pivot tubes.
3. Remove the brake line clamp from the A-arm.
19. Install new ball joint into A-arm. Refer to Ball Joint
4. Remove the upper ball joint pinch bolt (B) from the front Replacement section.
bearing carrier.
20. Insert new A-arm bushings and pivot tubes into new A-arm.
5. Using a soft face hammer, tap on bearing carrier to loosen
the upper A-arm ball joint end while lifting upward on the 21. Install new lower A-arm assembly onto vehicle frame.
upper A-arm. Completely remove the ball joint end from Torque new bolts to 30 ft. lbs. (41 Nm).
the bearing carrier.
22. Insert lower A-arm ball joint end into the bearing carrier.
6. Loosen and remove the upper A-arm through-bolt fasteners Install the lower ball joint pinch bolt (D) into the bearing
(C) and remove the upper A-arm from the vehicle. carrier and torque bolt to 17 ft. lbs. (23 Nm).
7. Examine A-arm bushings and pivot tubes (see Exploded

View). Replace if worn. Discard hardware. WARNING
Upon A-arm installation completion, test vehicle
WARNING at low speeds before putting into service.
The locking agent on the existing bolts was

destroyed during removal. DO NOT reuse old Upper / Lower A-arm Bolt Torque:
hardware. Serious injury or death could result if 30 ft. lbs. (41 Nm)
fasteners come loose during operation.
Ball Joint Pinch Bolt Torque:
17 ft. lbs. (23 Nm)
8. If not replacing the A-arm, thoroughly clean the A-arm and
pivot tubes.
9. Install new ball joint into A-arm. Refer to Ball Joint C Remove
Replacement section. C Clamp
10. Insert new A-arm bushings and pivot tubes into new A-arm.
11. Install new upper A-arm assembly onto vehicle frame.

Torque new bolts to 30 ft. lbs. (41 Nm).
12. Insert upper A-arm ball joint end into the bearing carrier. B A
Install the upper ball joint pinch bolt (B) into the bearing
carrier and torque bolt to 17 ft. lbs. (23 Nm). D
E
13. Attach shock to A-arm with fastener (A). Torque lower
shock bolt to 30 ft. lbs. (41 Nm). E
14. Remove the lower ball joint pinch bolt (D) from the front
bearing carrier.
5.26
Exploded View BALL JOINT SERVICE
30 ft. lbs.
Removal
(41 Nm)
IMPORTANT: Do not reuse a ball joint if it has been
Pivot removed for any reason. If removed, it must be
Nuts Tube replaced. Use this removal procedure only when
Upper replacing the ball joint.
Bushings
A-arm
1. The A-arm must be removed to perform this procedure
(see FRONT A-ARMS - Removal / Replacement).
30 ft. lbs.
(41 Nm)
Ball
Joint Ball Joint
Pivot
Tube
Bearing
Pinch Carrier
Bolts
17 ft. lbs.
Nuts
Pivot
Tube
(23 Nm) Upper A-arm
5
Bushings Retaining Ring
30 ft. lbs. 2. Remove the retaining ring from the ball joint.
30 ft. lbs. (41 Nm)
(41 Nm) Ball
Joint 3. A driver must be used for the removal of the ball joint. Use
the dimensions below to fabricate or locate the correct size
driver to use in the following process.
Driver Dimensions
1.375 in.
(3.49 cm)
Screws Lower 3 in.

A-arm (7.62 cm)
CV Shield
1.75 in.
(4.45 cm)
- Outside diameter of driver cannot be any

larger than 1.75 in. (4.45 cm).
- Inside diameter cannot be any smaller than
1.375 in. (3.49 cm).
- Driver must be at least 3 in. (7.62 cm) tall.
5.27
4. Use a press and correct size driver to remove the ball joint Installation
from the A-arm.
1. Place the A-arm in the correct position for ball joint
Correct installation. Face the A-arm end flat on top of the driver.
Driver Placement Carefully drive the ball joint into place until the ball joint
is properly seated.
Press into the A-arm

in this direction
The driver must fit the

inside diameter of the
A-arm end. Place driver HERE
to support A-arm
Upper A-arm Shown

Upper A-arm Shown
NOTE: The driver must fit the ball joint housing in 2. After the new ball joint is installed into the A-arm, install
the A-arm. This will allow the ball joint to be properly a NEW retaining ring.
pressed out of the A-arm without damaging the A-
arm.
Ball Joint
Press out of the A-arm
in this direction
Upper A-arm Shown

Upper A-arm
Place driver HERE Retaining Ring

to support A-arm
3. Reinstall the A-arm (see FRONT A-ARMS - Removal /
Replacement).
4. Repeat the ball joint service procedure for any additional

A-arm ball joint replacements.
5.28
MID / REAR A-ARMS 3. Remove the fastener attaching the upper A-arm to the
bearing carrier.
Removal / Replacement
The following procedure details upper and lower A-arm
removal and replacement on one side of the vehicle. Repeat the
following steps to remove the A-arm(s) from the opposite side.
NOTE: Use the exploded view in this section as a

reference during the procedure.
1. Elevate and safely support the rear of vehicle off the

ground and remove the mid or rear wheel.
4. Remove the fasteners attaching the upper A-arm to the

frame and remove the upper A-arm from the vehicle.
Upper A-arm Removal

2. Remove the fastener retaining the lower portion of the
shock and stabilizer linkage to the upper A-arm.
5. Examine A-arm and bearing carrier bushings and pivot

tubes (see Exploded View). Replace if worn. Discard
hardware.
WARNING
destroyed during removal. DO NOT reuse old
hardware. Serious injury or death could result if
6. If not replacing the A-arm, thoroughly clean the a-arm and

pivot tubes.
7. Insert new A-arm bushings and pivot tubes into the new
A-arm.
5.29
Lower A-arm Removal Installation
8. Remove the fastener attaching the lower A-arm to the 1. Install lower A-arm assembly onto vehicle frame. Torque
bearing carrier. new fasteners to 30 ft. lbs. (41 Nm).
2. Attach lower A-arm to bearing carrier. Torque new fastener

to 30 ft. lbs. (41 Nm).
3. Route the brake line over the top of the lower A-arm and
secure it in the retainer.
Retainer
9. Remove the fasteners attaching the lower A-arm to the

frame and remove the lower A-arm from the vehicle.
4. Install upper A-arm assembly onto vehicle frame. Torque

new fasteners to 30 ft. lbs. (41 Nm).
5. Attach upper A-arm to bearing carrier. Torque new fastener

to 30 ft. lbs. (41 Nm).
6. Reinstall the lower portion of the shock and stabilizer

linkage to the upper A-arm. Torque shock / linkage fastener
to 30 ft. lbs. (41 Nm).
7. Install wheel and torque wheel nuts to specification (see

Chapter 2).
10. Examine A-arm and bearing carrier bushings and pivot
tubes (see Exploded View). Replace if worn. Discard
hardware. WARNING
Upon A-arm installation completion, test vehicle

WARNING at low speeds before putting into service.
destroyed during removal. DO NOT reuse old
hardware. Serious injury or death could result if
11. If not replacing the A-arm, thoroughly clean the a-arm and
pivot tubes.
12. Insert new A-arm bushings and pivot tubes into the new
A-arm.
5.30
Exploded View
30 ft. lbs.
(41 Nm) Spring
30 ft. lbs.
(41 Nm)
Shaft
Nuts
Bushings
Shock
Bushings Upper A-arm
Shaft
Bushings
5
30 ft. lbs.
30 ft. lbs. (41 Nm)
(41 Nm) Shaft
Shaft Bearing
CV Carrier
Shield
30 ft. lbs.
(41 Nm)
30 ft. lbs.
Bushings (41 Nm)
Screws
Bushings
Bearing
Snap Ring
Shaft 30 ft. lbs.
(41 Nm) Bushings
Lower A-arm Shaft
5.31
REAR STABILIZER BAR / LINKAGE 9. If the stabilizer linkage was removed, torque the lower
shock retaining bolt to 30 ft. lbs. (41 Nm).
Removal / Installation
Exploded View
1. Elevate and safely support vehicle with weight removed
from the rear wheel(s).
17 ft. lbs.
2. Remove the retaining nut from the upper portion of the Carriage Bolts (23 Nm)
stabilizer bar linkage bushing on each side of the vehicle.
Stabilizer Bar
Remove Nut Bushing

Bracket
Bushings
Rubber
Bushings
Linkage
17 ft. lbs.
(23 Nm)
3. Remove the two fasteners that secure the stabilizer bar to

the main frame on each side.
Upper
A-arm
Stabilizer Spacer
Bar
30 ft. lbs.
(41 Nm)
Nut
4. Remove the stabilizer bar from the frame and inspect the
stabilizer bar for straightness.
5. Inspect the stabilizer bar bushings and replace if needed.
6. Inspect the rubber bushings on the stabilizer linkage rod

and replace if needed. If replacing the stabilizer linkage,
remove the lower shock bolt from the upper A-arm.
7. Reverse this procedure for installation.
8. Torque the stabilizer retaining bolts and upper rubber

bushing nuts to 17 ft. lbs. (23 Nm).
5.32
DECAL REPLACEMENT SHOCKS / SPRINGS
Exploded View
WARNING
Spring 30 ft. lbs.
(41 Nm)
The following procedure involves the use of an
open flame. Perform this procedure in a well
ventilated area, away from gasoline or other Spring
flammable materials. Be sure the area to be Retainer
flame treated is clean and free of gasoline
or flammable residue.
Shock
WARNING
Do not flame treat components that are installed Adjusting Cam

on the vehicle. Remove the component from the
vehicle before flame treating.
30 ft. lbs.
The side panels, front and rear fender cabs are plastic
polyethylene material. Therefore, they must be flame treated
(41 Nm)
5
prior to installing a decal to ensure good adhesion. A bonus of Shock Removal / Installation
the flame treating procedure is it can be used to reduce or
eliminate the whitish stress marks that are sometimes left after 1. Elevate the vehicle off the ground to relieve the suspension
a fender or cab is bent, flexed, or damaged. load.
2. Remove the upper and lower fasteners retaining the shock

CAUTION and remove the shock from the vehicle.
3. Reverse the procedure to reinstall the shock. Torque new

Do not flame treat painted plastic components. fasteners to 30 ft. lbs. (41 Nm).
Painted plastic surfaces should only be wiped
clean prior to decal adhesion. Shock Replacement
To flame treat the decal area: 1. Using a spring compressor, compress the shock spring far
enough to remove the spring retainer.
1. Pass the flame of a propane torch back and forth quickly
over the area where the decal is to be applied until the Shock Spring
surface appears slightly glossy. This should occur after just Compressor Tool
a few seconds of flame treating. Do not hold the torch too 2870623
close to the surface (2-3 inches from the flame tip is
recommended). Keep the torch moving to prevent damage.
2. Apply the decal on one edge first. Slowly lay down

remainder of the decal while rubbing lightly over the decal
surface to eliminate any air bubbles during the application.
2. Remove the spring and adjusting cam from the existing

shock and install components onto the new shock.
3. Compress the shock spring and install the spring retainer.
4. Reinstall the shock onto the vehicle and torque new

fasteners to 30 ft. lbs. (41 Nm).
5.33
SELF-LEVELING SUSPENSION (HD) 3. Drill a hole in the shock absorber at the center punch using
a 3/16 (5 mm) drill bit. Gas or a gas/oil mixture will
Nivomat Shock Operation exhaust when the drill bit penetrates the shock absorber.
Use an oil pan and shop towels in order to contain the
The self-leveling Nivomat shocks eliminate rear-end squat escaping oil.
when carrying heavy loads.
When the RANGER HD starts moving, the Nivomat shocks

start working, automatically adjusting the box to near its
unloaded height.
Automatically
adjusts height.
No adjustments
are necessary.
Nivomat Shock Disposal / Replacement
CAUTION
Gas charged shock absorbers contain high

pressure gas. Do not attempt to cut the shock
open before all gas pressure is released.
CAUTION 4. Make another indentation 1 in. (25 mm) from the bottom
of the tube with a center punch.
To prevent personal injury, wear safety glasses
when center punching the shock absorber. 5. Drill a second hole in the shock absorber at the indentation
Use care not to puncture the shock absorber using a 3/16 (5 mm) drill bit. Oil will exhaust when the
tube with the center punch. drill bit penetrates the shock absorber. Use an oil pan and
shop towels in order to contain the escaping oil.
1. Make an indentation 2 in. (50 mm) from the top of the tube
using a center punch. 6. Remove the shock absorber from the vise. Hold the shock
absorber horizontally with the holes down to drain the oil
2. Clamp the shock absorber in a vise horizontally with the from the tube. Move the shock rod in and out of the tube to
shock absorber completely extended. completely drain the oil from the shock.
7. Properly dispose the oil and discard the shock.
5.34
CLUTCHING
CHAPTER 6
CLUTCHING
SPECIAL TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
MAINTENANCE / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
OVERHEATING / DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
PVT SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT SEALING, GUARD, AND DUCTING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 6.5
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BELT INSPECTION / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
CLUTCH ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
CLUTCH CENTER DISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
SPRING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
SHIFT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
6
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
ROLLER, PIN, AND THRUST WASHER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6.14
BUTTON TO TOWER CLEARANCE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
MOVEABLE SHEAVE BUSHING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BUSHING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
CLUTCH DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
6.1
CLUTCHING
SPECIAL TOOLS AND SUPPLIES PVT SYSTEM OVERVIEW
TOOL DESCRIPTION PART NUMBER General Operation
Drive Clutch Puller 2870506
Clutch Holding Wrench 9314177 WARNING
Clutch Holding Fixture 2871358 All PVT maintenance or repairs should be performed by
Drive Clutch Spider Removal and a certified Polaris Master Service Dealer (MSD)
2870341 technician who has received the proper training and
Install Tool
understands the procedures outlined in this manual.
Roller Pin Tool 2870910 Because of the critical nature and precision balance
Clutch Bushing Replacement Tool Kit 2871226 incorporated into the PVT components, it is
absolutely essential that no disassembly or repair
Piston Pin Puller 2870386 be made without factory authorized special tools
Clutch Compression Tool 8700220 and service procedures.
Clutch Bushing Replacement Tool Kit 2871025 The Polaris Variable Transmission (PVT) consists of three
Clutch Alignment Tool PA-49011 major assemblies:
1) The Drive Clutch

SPECIAL SUPPLIES PART NUMBER
2) The Driven Clutch
Loctite 609 N/A
3) The Drive Belt
RTV Silicone Sealer 8560054
The internal components of the drive clutch and driven clutch
control engagement (initial vehicle movement), clutch upshift
and backshift. During vehicle development, the PVT system is
TORQUE SPECIFICATIONS matched first to the engine power curve; then to average riding
conditions and the vehicles intended usage. Therefore,
PVT System Fastener Torques modifications or variations of components at random are never
recommended. Proper clutch setup and careful inspection of
ITEM TORQUE VALUE existing components must be the primary objective when
troubleshooting and tuning.
Drive Clutch Retaining Bolt 47 ft. lbs. (64 Nm)
Driven Clutch Retaining Bolt 17 ft. lbs. (23 Nm)
PVT Inner Cover
Drive Clutch Operation
50 in. lbs. (5.6 Nm)
Phillips-Head Screws Drive clutches primarily sense engine RPM. The two major
PVT Inner Cover components which control its shifting function are the shift
12 ft. lbs. (16 Nm)
Hex-Head Screws weights and the coil spring. Whenever engine RPM is
PVT Outer Cover Bolts 45-50 in. lbs (5-5.6 Nm) increased, centrifugal force is created, causing the shift
weights to push against rollers on the moveable sheave, which
Drive Clutch Spider 200 ft. lbs. (271 Nm) is held open by coil spring preload. When this force becomes
Drive Clutch Cover Plate 90 in. lbs. (10 Nm) higher than the preload 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.
6.2
CLUTCHING
Driven Clutch Operation Maintenance / Inspection
Driven clutches primarily sense torque, opening and closing Under normal use the PVT system will provide years of trouble
according to the forces applied to it from the drive belt and the free operation. Periodic inspection and maintenance is required
transmission input shaft. If the torque resistance at the trans- to keep the system operating at peak performance. The
following list of items should be inspected and maintained to
mission input shaft is greater than the load from the drive belt,
ensure maximum performance and service life of PVT
the drive belt is kept at the outer diameter of the driven clutch
components. Refer to the troubleshooting checklist at the end of
sheaves. this chapter for more information.
As engine RPM and horsepower increase, the load from the
drive belt increases, resulting in the belt rotating up toward the 1. Belt Inspection, Drive to Driven Clutch Alignment, and
outer diameter of the drive clutch sheaves and downward into Clutch Center Distance.
the sheaves of the driven clutch. This action, which increases the
driven clutch speed, is called upshifting. 2. Drive and Driven Clutch Buttons and Bushings, Drive
Clutch Shift Weights and Pins, Drive Clutch Spider
Should the throttle setting remain the same, and the vehicle is Rollers and Roller Pins, Drive and Driven Clutch
subjected to a heavier load, the drive belt rotates back up toward Springs.
the outer diameter of the driven clutch and downward into the
sheaves of the drive clutch. This action, which decreases the 3. Sheave Faces. Clean and inspect for wear.
driven clutch speed, is called backshifting.
4. PVT System Sealing. Refer to appropriate illustrations on
In situations where loads vary (such as uphill and downhill), and the following pages. The PVT system is air cooled by fins
throttle settings are constant, the drive and driven clutches are on the drive clutch stationary sheave. The fins create a low
continually shifting to maintain optimum engine RPM. At full pressure area in the crankcase casting, drawing air into the
throttle a perfectly matched PVT system should hold engine system through an intake duct. The opening for this intake
RPM at the peak of the power curve. This RPM should be duct is located at a high point on the vehicle (location varies
maintained during clutch upshift and backshift. In this respect,
the PVT system is similar to a power governor. Rather than vary
by model). The intake duct draws fresh air through a vented
cover. All connecting air ducts (as well as the inner and
6
throttle position, as a conventional governor does, the PVT outer covers) must be properly sealed to ensure clean air is
system changes engine load requirements by either upshifting or being used for cooling the PVT system and also to prevent
backshifting. water and other contaminants from entering the PVT area.
This is especially critical on units subjected to frequent
water forging.
PVT Break-In (Drive Belt / Clutches)
A proper break-in of the clutches and drive belt will ensure a
longer life and better performance. Break in the clutches and
drive belt by operating at slower speeds during the 10 hour
break-in period as recommended (see Chapter 3 Engine
Break-In Period for break-in example). Pull only light loads.
Avoid aggressive acceleration and high speed operation during
the break-in period.
6.3
CLUTCHING
Overheating / Diagnosis
During routine maintenance, or whenever PVT system overheating is evident, its 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 plowing or pulling heavy loads, or if extended low speed operation is anticipated.
CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS

Possible Causes Solutions / What to do
Loading the vehicle into a truck or tall Shift transmission to Low during loading of the vehicle to prevent belt
trailer when in high range. burning.
Starting out going up a steep incline from
When starting out on an incline, shift the transmission to Low.
a stopped position.
Driving at low RPM or low ground speed 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.
Warm engine at least 5 min., then with transmission in neutral, advance
Insufficient engine warm-up when
throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
exposed to low ambient 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
Climbing over large objects from a
application to engage clutch. WARNING: Excessive throttle may cause loss
stopped position.
of control and vehicle overturn.
Shift the 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.
For inspection of clutch components, please contact your Polaris dealer.
Clutch malfunction. 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
Poor engine performance.
you dealer for further service information.
Low: Heavy pulling, basic operational speeds less than 7 MPH, riding
GENERAL RANGE OPERATION through rough terrain (swamps, mountains, ect.), low ground speeds.
GUIDELINES:
High: High ground speeds, speeds above 7 MPH.
Operating in Low Gear

Low gear is the primary driving gear range for RANGERs. Low should be used in ALL driving applications except for driving on
hard packed level surfaces with light loads. In this circumstance, High range may be used.
IMPORTANT: Using High range for heavy loads, hilly terrain, or in wet, muddy conditions will increase the
chance of drive belt burning.
6.4
CLUTCHING
PVT SYSTEM SERVICE
PVT Sealing, Guard, and Ducting Components
Disassembly
Some fasteners and procedures will vary. Refer to the 5. Install the Drive Clutch Holder (PN 9314177) (A).
appropriate parts manual for proper fasteners and fastener
placement. 6. Remove drive clutch retaining bolt and remove drive clutch
using the Drive Clutch Puller (PN 2870506) (B).
1. Remove seat and storage container to gain access to the
PVT outer cover.
Drive Clutch Puller (PN 2870506)
2. Remove PVT air outlet duct hose.
Drive Clutch Holder (PN 9314177)
3. Remove outer PVT cover screws.
4. Mark the drive belt direction of rotation and remove drive 7. Remove the driven clutch retaining bolt and driven clutch.
belt. See Drive Belt Removal.
Retaining Bolt
A
6.5
CLUTCHING
8. Remove the driven clutch alignment washer(s) from the 3. Apply RTV silicone sealant to outside edge of inner cover-
transmission input shaft. to-engine seal, to ensure a water tight fit between the seal
and the cover. Surfaces must be clean to ensure adhesion.
Note Number of Washers
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.
B
C
9. Remove screws and retainer plate. A
Seal outer edge to cover

with RTV silicone sealant
6. Torque rear inner cover bolts (B) to specification.
7. Install clutch alignment washer(s) on transmission input

shaft.
Alignment Washer(s)
10. Remove inner cover retaining bolts at rear of cover.
11. Remove cover along with foam seal on back of cover or

shaft.
Assembly
1. Inspect PVT inner cover-to engine seal. Replace if cracked
or damaged.
Apply RTV Silicone Here
8. Clean splines inside driven clutch and on the transmission
input shaft.
9. Apply a light film of grease to the splines on the shaft.
10. Install the driven clutch, washer, lock washer, and retaining
bolt. Torque to specification.
11. Clean end of taper on crankshaft and the taper bore inside
drive clutch.
12. Install drive clutch and torque retaining bolt to

specification.
2. Place a new foam seal on transmission input shaft.
6.6
CLUTCHING
13. Reinstall drive belt noting direction of rotation. If a new belt DRIVE BELT
is installed, install so numbers can be easily read.
Belt Removal
14. Replace PVT outer clutch cover rubber gasket.
1. Remove outer PVT cover as described in PVT SYSTEM
15. Reinstall PVT outer clutch cover and secure with screws. SERVICE - Disassembly.
Torque screws to specification.
2. Mark the drive belt direction of rotation so that it can be
16. Install the PVT cover outlet duct and tighten the clamps. installed in the same direction.
NOTE: Belt is normally positioned so that part

numbers are easily read.
3. To remove drive belt, put transmission in gear, apply brake,

pull upward and rearward on belt to open driven clutch
sheaves.
Inner Cover Screw Torque:

Front Screws: 50 in. lbs. (5.6 Nm)
Rear Screws: 12 ft. lbs. (16 Nm)
6
Outer Cover Screw Torque:
45-50 in. lbs. (5-5.6 Nm) 4. Pull out and down on the drive belt to slip over the driven
clutch outer sheave.
Driven Clutch Retaining Bolt Torque:
17 ft. lbs. (23.5 Nm)
Drive Clutch Retaining Bolt Torque:

47 ft. lbs. (64 Nm)
5. Slip belt over the drive clutch outer sheave and remove the
belt from the vehicle.
6.7
CLUTCHING
Belt Inspection PVT Break-In (Drive Belt / Clutches)
1. Inspect belt for hour glassing (extreme circular wear in at A proper break-in of the clutches and drive belt will ensure a
least one spot and on both sides of the belt). Hour glassing longer life and better performance. Break in the clutches and
occurs when the drive train does not move and the drive drive belt by operating at slower speeds during the 10 hour
clutch engages the belt. break-in period as recommended (see Chapter 3 Engine
Break-In Period for break-in example). Pull only light loads.
2. Inspect belt for loose cords, missing cogs, cracks, Avoid aggressive acceleration and high speed operation during
abrasions, thin spots, or excessive wear. Compare belt the break-in period.
measurements with a new drive belt. Replace if necessary.
3. Belts with thin spots, burn marks, etc., should be replaced

to eliminate noise, vibration, or erratic PVT operation. See CLUTCH ALIGNMENT
the troubleshooting chart at the end of this chapter for
possible causes. Clutch Alignment Tool Use
Clutch alignment is controlled by the number of washers that are
Belt Installation
placed behind the driven clutch on the transmission input shaft.
1. Loop belt over the drive clutch and over top of the driven Adding washers behind the driven clutch will move the drive
sheave. belt toward the moveable sheave of the drive clutch. Removing
washers from behind the driven clutch will move the drive belt
toward the stationary sheave of the drive clutch.
1. Remove the lower seat base.
2. Remove the LH storage container to gain access to the outer

PVT cover.
3. Loosen the hose clamp and remove the PVT air outlet duct
hose from the outer PVT cover.
4. Remove all outer PVT cover screws and remove the cover.
5. Mark the drive belt direction of rotation and remove drive

belt (see Drive Belt Removal).
2. While pushing down on top of belt, turn the back or 6. Install the Clutch Alignment Tool.
moveable driven sheave clockwise.
CLUTCH ALIGNMENT TOOL
PA-49011
3. The belt then should be able to be pushed down into and

between the sheaves.
NOTE: Be sure to position the drive belt so part

number is easily read.
6.8
CLUTCHING
7. Place the alignment tool in the sheaves of the driven clutch 10. If the alignment tool touches the shaft bearing but has an
and hold firmly as you rotate it down between the sheaves excessive amount of clearance between the tool and
of the drive clutch. stationary sheave, the driven clutch will need to be moved
in to correct the alignment.
PA-49011
Remove the driven clutch. Remove the required amount
of washers to obtain roughly .020 clearance between
the tool and stationary sheave.
NOTE: The number of washers behind the driven

clutch will vary between vehicles.
IMPORTANT: It may not be possible to achieve

perfect alignment with the tool as previously
described, because of the thickness of the alignment
washers. It is better to have clearance between the
tool and stationary sheave of the drive clutch than to
have the tool touch the stationary sheave before it
touches the shaft bearing.
Clutch Alignment Tool
11. After completing the clutch alignment procedure, the belt
PA-49011 should ride in the drive clutch with an approximate .020
gap between the belt and stationary sheave and a larger gap
8. As you rotate the tool down between the drive clutch of approximately .130 between the belt and moveable
sheaves, the tool should touch the clutch shaft bearing while sheave. There should always be clearance on both sides of
the drive belt.
maintaining a clearance of roughly .020 between the tool
and stationary sheave of the drive clutch. 6
.020 Gap
Stationary
Sheave
Shaft Bearing
CLUTCH CENTER DISTANCE

9. If the alignment tool hits the stationary sheave before it
reaches the shaft bearing, the driven clutch will need to be
spaced out to correct the alignment.
Remove the driven clutch. Add the required amount of

alignment washers to obtain the correct measurement
with the alignment tool. You may need to add more
than one alignment washer.
Alignment Washers:
Center
Distance
(.060) PN: 7556120 10.05 in. / 255 mm
6.9
CLUTCHING
DRIVE CLUTCH SERVICE
Spring Specifications
The drive clutch spring has two primary functions:
1. To control clutch engagement RPM. The springs,
which have a higher rate when the clutch is in
neutral, will increase clutch engagement RPM.
2. To control the rate at which the drive belt moves Red/White

7043349
upward in the drive clutch sheaves. This is referred Red/Blue

7043372
to as drive clutch upshift.
There are other components which control upshift, but the

spring is one of the primary components in insuring Red/Green
7043382
optimum performance. It is very important that the spring
is of the correct design and is in good condition.
CAUTION
Never shim a drive clutch spring to increase its

compression rate. This may result in complete Blue/Red
7043199
stacking of the coils and subsequent Black
7043594
clutch cover failure.
The drive clutch spring is one of the most critical components of the PVT
system. It is 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. Refer to the spring specification chart for specific free
length measurements and tolerances. Also check to see that spring coils are
parallel to one another. Distortion of the spring indicates stress fatigue,
requiring replacement.
Primary Clutch Springs

PART NUMBER COLOR CODE WIRE DIAMETER FREE LENGTH .125
7041021 Plain .157" 4.38"
7041022 Black .140" 4.25"
7041063 Purple .168" 4.37"
7041132 White .177" 2.92"
7041157 Blue / Green .177" 2.53"
7041168 Green .177" 3.05"
7043199 Blue / Red .177" 2.53"
7043349 Red / White .200" 2.58"
7043372 Red / Blue .187" 2.56"
7043382 Red / Green .177" 2.63"
7043594 Black .177" 2.80"
6.10
CLUTCHING
Shift Weights
Shown below are the shift weights which have been designed for this 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.
6.11
CLUTCHING
Exploded View
Limiter Spacer Bushing Lock

XP / HD Washer
Models Only
Spring Cover
Bearing Bolt
Spider
Bearing
Flat
Non-Braking
Cover Washer
Bearing Spacer Button Screws
Roller
Pin
Washers
Nut
Button
Bolt Shift
Weight
Washers
Clutch Disassembly
1. Using a permanent marker, mark the cover, spider, and 4. Inspect cover bushing (A). The outer cover bushing is
moveable and stationary sheaves for reference, as the cast manufactured with a Teflon coating. Wear is determined
in X's may not have been in alignment before disassembly. by the amount of Teflon remaining on the bushing.
2. Mark the stationary sheave and clutch shaft to verify the

Cover Bushing Inspection:
shaft has not turned in the sheave after tightening the spider
during clutch assembly. Replace the cover bushing if more
brass than Teflon is visible on
3. Remove cover bolts evenly in a cross pattern and remove the bushing. Refer to bushing
cover plate. replacement in this chapter.
6.12
CLUTCHING
5. Inspect area on shaft where bushing rides for wear, galling, NOTE: It is important that the same number and
nicks, or scratches. Replace clutch assembly if worn or thickness of washers are reinstalled beneath the
damaged. spider during assembly. Be sure to note the number
and thickness of these washers.
Inspect Shaft
To maintain proper clutch balance and
belt-to-sheave clearance, be sure to
reinstall original quantity and thickness
washers
6. Remove and inspect the clutch spring. See Drive Clutch

Spring Specifications for spring inspection. Moveable Sheave Bushing Inspection
3. Inspect the Teflon coating on the moveable sheave
Spider Removal bushing.
1. Remove the limiter spacer from the shaft (XP / HD models

only).
2. Install clutch in holding fixture (PN 2871358) and loosen 6

the spider (counterclockwise) using Clutch Spider
Removal Tool (PN 2870341).
TeflonTM
Moveable Sheave Bushing Inspection:
Replace the cover bushing if more brass

than Teflon is visible on the bushing.
Refer to Bushing Service
in this chapter.
Clutch Holding Fixture:

(PN 2871358)
Spider Removal Tool:

(PN 2870341)
6.13
CLUTCHING
Roller, Pin, and Thrust Washer Inspection Button To Tower Clearance Inspection
1. Inspect all rollers, bushings and roller pins by pulling a flat 1. Inspect for any clearance between spider button to tower.
metal rod across the roller. Turn roller with your finger. If If clearance exists, replace all buttons and inspect surface
you notice resistance, galling, or flat spots, replace rollers, of towers. See Spider Removal procedure.
pins and thrust washers in sets of three. Also inspect to see
if roller and bushing are separating. Bushing must fit
tightly in roller. Use the Roller Pin Tool (PN 2870910) to
replace rollers and pins. Take care not to damage roller
bushing or bearing surface of the new pin during
installation.
Button to Tower Clearance:

000-.001
2. Inspect sheave surfaces. Replace the entire clutch if worn,

damaged or cracked.
2. Rubber backed buttons can be used in all RANGER clutches
if the hollow roller pin is changed to the solid roller pin.
Shift Weight Inspection
NOTE: The rubber side of the button is positioned
toward the solid roller pin.
WARNING
The clutch assembly is a precisely balanced

unit. Never replace parts with used parts from
another clutch assembly!
1. If clutch is not disassembled, inspect as shown, using a

clutch holding tool to compress the moveable sheave. The
contact surface of the weight should be smooth and free of
dents or gall marks.
6.14
CLUTCHING
2. Remove shift weight bolts and weights. Inspect as shown. Clutch Inspection
The contact surface of the weight should be smooth and free
of dents or gall marks. Inspect the weight pivot bore and NOTE: Remove cover, spring, and spider following
pivot bolts for wear or galling. If weights or bolts are worn instructions for drive clutch removal, then proceed
or broken, replace in sets of three with new bolts. as follows:
NOTE: A damaged shift weight is usually caused by 1. Remove the moveable sheave spacer (1) and the thrust
a damaged or stuck roller in the spider assembly. washer (2). Visually inspect the washer for damage.
See Roller, Pin and Thrust Washer Inspection.
2. Measure the thickness and compare to specification.
Replace if worn or damaged.
Bearing Inspection 1
1. Rotate non-braking clutch bearing in both clockwise and
counter-clockwise directions. The non-braking bearing
should rotate both directions on the shaft with only a slight
amount of drag.
2. Verify there is no binding or rough spots. If problems are

noted in either direction, continue with disassembly.
2
= In. / mm.
6
Thrust Washer Thickness
Standard: .030 (.76 mm)
Service Limit: .025 (.64 mm)
3. Remove the moveable clutch sheave.
4. Lift bearing (3) and thrust washer (4) off shaft. Replace as
an assembly if worn, damaged, or if problems were noted.
6.15
CLUTCHING
5. Inspect surface of shaft for pitting, grooves, or damage. Moveable Sheave Bushing Inspection
Measure the outside diameter and compare to
specifications. Replace the drive clutch assembly if shaft is Inspect the Teflon coating (arrow) on the moveable sheave
worn or damaged. bushing. Inspect both sheaves for signs of wear, grooving or
cracking. De-glaze sheave surfaces with a 3M Scotch-Brite
Pad if needed.
= In. / mm.
Moveable Sheave Bushing Inspection:
Shaft Diameter: Replace the cover bushing if more brass
Standard: 1.3745 - 1.375 (34.91 - 34.93 mm) than Teflon is visible on the bushing.
Service Limit: 1.3730 (34.87 mm) Refer to Bushing Service
in this chapter.
6. Visually inspect PTFE thrust washer for damage. Measure
the thickness and compare to specification. Replace if worn
or damaged.
= In. / mm.
PTFE Washer Thickness

Standard: .030 (.76 mm)
6.16
CLUTCHING
Bushing Service
IMPORTANT: Special Tools Required CAUTION
EBS Clutch Bushing Tool Kit - 2201379 Clutch components will be hot! In order to avoid
serious burns, wear insulated gloves
Item Qty. Part Description Part # during the removal process.
A, B 1 EBS Puller Tool 5132027
C 1 EBS Puller Nut 5132501 Moveable Sheave - Bushing Removal
D 1 EBS Main Adapter 5132029 1. Remove clutch as outlined previously in this chapter.
E 1 EBS Bushing Removal Tool 5132028
2. Install handle end of the Piston Pin Puller (PN 2870386)
-- 1 Instructions 9915111
securely into bench vise and lightly grease puller threads.
Additional Special Tools
Qty. Part Description Part #
Piston Pin Puller (PN 2870386)
1 Clutch Bushing Replacement Tool Kit 2871226
1 Piston Pin Puller 2870386 3. Remove nut from puller rod and set aside.
*Clutch Bushing Replacement Tool Kit (PN 2871226)

Piston Pin Puller
#2 (PN 2870386)
#3
#5
6
Main Puller Adaptor (#8)
(PN 5020632)
#9
#10 4. Install puller adapter (Item 10 from kit PN 2871226).
#8
5. Install main adapter (Item D) onto puller.
Item Qty. Part Description Part # Puller Tool (A,B) Nut (C)
P-90 Drive/Driven Clutch Side A toward
#2 1 5020628
Bushing Install Tool sheave
Drive Clutch Cover
Bushing Removal/
#3 1 5020629
Installation Tool (all
clutches)
P-90 Driven Clutch Cover
#5 1 5020631
Bushing Removal Tool
#8 1 Main Puller Adapter 5020632
Puller
#9 1 Adapter Reducer 5010279 Adapter (10)
Number Two Puller
#10 1 5020633 Main Piston Pin
Adapter Adapter (D) Puller
NOTE: Bushings are installed at the factory using
Loctite. In order to remove bushings it will be 6. With towers pointing toward the vise, slide sheave onto
puller rod.
necessary to apply heat evenly to the area around
each bushing. Clean all residual Loctite from 7. Install removal tool (Item A, B) into center of sheave with
bushing bore prior to installing new bushing. A side" toward sheave.
6.17
CLUTCHING
NOTE: Use Bushing Tool PA-47336. Cover Bushing Removal
8. Install nut (C) onto end of puller rod and hand tighten. Turn 1. Install main adapter (Item 8) on puller.
puller barrel to increase tension on sheave if needed. Using Removal Tool Nut (C)
a hand held propane torch, apply heat around outside of (3)
bushing until tiny smoke tailings appear.
9. Turn sheave counterclockwise on puller rod until it comes

free. Lift sheave off puller.
10. Remove nut from puller rod and set aside.
11. Pull bushing removal tool and adapter from puller rod.
Remove bushing from tool and discard.
Adapter Reducer
Drive Clutch Bushing Installation (9)
Main Piston Pin
1. Place main adapter (Item 8) on puller. Adapter (8) Puller
Puller Tool (A,B) Nut (C)
Side A toward 2. Install adapter reducer (Item 9).
sheave
3. From outside of clutch cover, insert removal tool (Item 3)
into cover bushing.
4. With inside of cover toward vise, slide cover onto puller.
5. Install nut onto puller rod and hand tighten. Turn puller
barrel to increase tension as needed.
Bushing
Piston Pin 6. Turn clutch cover counterclockwise on puller rod until
Puller bushing is removed and cover comes free.
Main Adapter
(8) 7. Remove nut from puller rod and set aside.
2. Apply Loctite 609 evenly to bushing bore inside 8. Remove bushing and bushing removal tool from puller.
moveable sheave. Discard bushing.
3. Set bushing in place on sheave. Cover Bushing Installation

1. Apply Loctite 609 evenly to bushing bore in cover.
4. Insert installation puller tool (Item A/B) with A side
down, into center of bushing. 2. Working from inside of cover, insert new bushing and
NOTE: 800 EFI Clutch - Use Bushing Tool PA-47336. bushing installation tool into center of clutch cover.
5. With towers pointing upward, slide sheave, bushing and
3. With main adapter on puller, insert cover onto puller rod,
tool onto puller rod.
placing outside of cover toward vise.
6. Install nut on puller rod and hand tighten. Turn barrel to 4. Install nut on rod and hand tighten. Turn puller barrel to
apply additional tension if needed. apply more tension if needed.
7. Turn sheave counterclockwise, making sure bushing is 5. Turn clutch cover counterclockwise on puller rod until
drawn straight into bore. Continue until bushing is seated. bushing is seated.
8. Remove nut from puller rod and set aside.
6. Remove nut from puller rod. Take installation tool and
clutch cover off rod.
9. Remove sheave from puller.
10. Remove installation tool.
6.18
CLUTCHING
Clutch Assembly 4. Torque spider to specification using the holding fixture and
spider tool. Torque with smooth motion to avoid damage
NOTE: It is important that the same number and to the stationary sheave.
thickness of washers are reinstalled beneath the
spider during assembly. The Teflon bushings are
self-lubricating. =T
Spider Torque:
CAUTION 200 ft. lbs. (271 Nm)
Do not apply oil or grease to the bushings.

CAUTION
Reassemble the drive clutch in the following sequence. Be sure
the X, or the marks that were made earlier are aligned during Be sure the spider spacer washers are fully
each phase of assembly. 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.
5. Install the limiter spacer over the shaft and on top of spider
(XP / HD models only).
6. Install shift weights using new lock nuts on the bolts.
6
1. Install moveable sheave onto fixed sheave.
2. Install spider spacers. Use same quantity and thickness as

were removed.
Nut on trailing side Rotation
7. Reinstall clutch spring.
8. Reinstall cover, aligning X mark with other marks.
9. Torque cover bolts evenly to specification.

Spacer washers
=T
3. Compress spider buttons for each tower and install spider,
making sure that X, or the marks that were made earlier,
Cover Screw Torque:
on spider aligns with X, or the marks that were made
90 in. lbs. (10.4 Nm)
earlier, in moveable sheave.
6.19
CLUTCHING
DRIVEN CLUTCH SERVICE
Exploded View
DRIVEN CLUTCH
Compression Spring
Outer Spring Retainer

Secondary Stationary Sheave
Inner Spring Retainer Retaining Ring
Moveable Inner Sheave
Clutch Disassembly / Inspection 3. Place the clutch into the Clutch Compression Tool PN
8700220. Using Compression Extensions PN PS-45909,
apply and hold downward pressure on the outer spring
CAUTION retainer. Carefully remove the snap ring. Remember the
outer spring retainer contains strong spring pressure.
Wear eye protection when removing snap ring to
prevent serious personal injury.
Remove Snap Ring
Use caution when removing, the snap ring
pressure is loaded by the compression spring.
1. Remove driven clutch from the transmission input shaft.

2. Mark the position of the clutch sheaves before disassembly
or use the Xs on the sheaves for reference. This aids in
reassembly and maintains clutch balance after reassembly.
Outer Spring Retainer
NOTE: Spring is compression only and has no

torsional wind.
6.20
CLUTCHING
4. With the snap ring (A) removed and spring pressure 7. Remove the inner spring retainer from the inner sheave.
relieved, remove the outer spring retainer (B), compression Inspect for wear and replace as needed.
spring (C), and inner spring retainer (D).
A C
Inspect for Abnormal Wear
8. Check the rollers in the stationary sheave for wear. If rollers

are worn, a new driven clutch assembly may be needed.
B
A
D
C
5. Separate the two clutch sheaves.

6
Check Rollers for Wear
9. Inspect the bearings inside the moveable sheave.
Inspect Bearings for Wear
6. Inspect the helix on the moveable sheave.
Inspect for Abnormal Wear
Moveable Sheave Bearing Inspection:

Replace the bearing if more brass than
Teflon is visible on the bearing.
6.21
CLUTCHING
10. Inspect the Teflon coating on the moveable sheave
bearings.
11. Inspect driven clutch sheave faces for wear or damage.
12. Clean and inspect splines on helix and transmission input

shaft.
13. Lube splines with a light film of grease. Do not lubricate

the bearings!
Clutch Assembly
1. Install the inner spring retainer if removed. Do not apply Assemble Sheaves
oil or grease to the bearings.
3. Install spring into inner retainer.
4. Install outer retainer on top of spring.
2. Align the X marks on each of the sheaves during

reassembly.
5. Place the clutch into Clutch Compression Tool PN
8700220. Using Compression Extensions PN PS-45909,
apply and hold downward pressure on the outer spring
retainer. Carefully install the snap ring.
6. Compress the outer retainer and install the snap ring.
Snap Ring
6.22
CLUTCHING
TROUBLESHOOTING
Situation Probable Cause Remedy
-Wrong or broken drive clutch spring. -Replace with recommended spring.
Engine RPM below
specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine
range, although application.
engine is properly
tuned. -Driven clutch spring broken or installed in wrong -Replace spring; refer to proper installation location.
helix location.
-Drive clutch binding. A. 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.
Erratic engine
operating RPM -Belt worn unevenly - thin / burnt spots. Replace belt.
during acceleration or
load variations. -Driven clutch malfunction. A. Replace ramp buttons.
B. Inspect movable sheave for excessive bushing
clearance.
-Sheave face grooved. -Replace the clutch.

-Incorrect drive clutch spring (too high spring rate). -Install correct recommended spring.
-Drive clutch shift weights incorrect for application -Install correct recommended shift weights.
(too light). 6
-Drive clutch binding. -Disassemble and clean clutch, inspecting shift weights
and rollers. Reassemble without the spring and move
Engine RPM above
sheaves through entire range to further determine
specified operating
probable cause.
range.
-Driven clutch binding. -Disassemble, clean, and inspect driven clutch, noting
worn sheave bushing and ramp buttons and helix spring
location.
-Converter sheaves greasy; belt slipage. -Clean sheaves with denatured alcohol or brake cleaner,
install new belt.
-Drive belt worn too narrow. -Replace belt.
Harsh drive clutch
engagement. -Excessive belt / sheave clearance with new belt. -Perform belt / sheave clearance adjustment with shim
washers beneath spider.
-Wrong belt for application. -Replace with correct belt.
Drive belt turns over -Clutch alignment out of spec. -Adjust clutch alignment.
-Engine mount broken or loose. -Inspect / adjust or replace.

-Abuse (continued throttle application when -Caution operator to operate machine within guidelines.
vehicle is stationary, excess load)
Belt burnt, thin spots -Dragging brake -Vehicle operated with park brake on. Inspect brake
system.
-Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement.
6.23
CLUTCHING
Troubleshooting, Continued.....
Situation Probable Cause Remedy
-Plugged air intake or outlet. -Clear obstruction
-Belt slippage due to water, oil, grease, etc., rubbing -Inspect system. Clean , repair or replace as necessary.
on cover. Seal PVT system ducts.
PVT cover
-Clutches or weight being applied to cover while in -Remove weight. Inform operator.
overheating (melting)
operation.
-High vs. low range. -Instruct operator on guidelines for operation in proper
driving range for different terrain as outlined in Owners
Safety and Maintenance Manual.
-Cover seals or ducts leaking -Find leak and repair as necessary.
Water ingestion -Operator error -Instruct operator on guidelines for operation in wet
terrain as outlined in Owners 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.
PVT noise
-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.
6.24
FINAL DRIVE
CHAPTER 7
FINAL DRIVE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
FRONT BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING CARRIER INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
FRONT PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
REMOVAL / INSTALLATION (XP / HD / 6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
REMOVAL / INSTALLATION (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
SUPPORT BEARING REPLACEMENT (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
FRONT GEARCASE - CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
EXPLODED VIEW (VEHICLES BUILT BEFORE 3/05/2010) . . . . . . . . . . . . . . . . . . . . . 7.11
EXPLODED VIEW (VEHICLES BUILT AFTER 3/05/2010) . . . . . . . . . . . . . . . . . . . . . . 7.12
ALL WHEEL DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
GEARCASE REMOVAL / DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . 7.15
ASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
SETTING RING GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
MID / REAR BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
DISASSEMBLY / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
MID / REAR DRIVE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
7
MID PROPSHAFT (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
MID GEARCASE (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
MID GEARCASE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
DRIVE SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40
DRIVE SHAFT EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.42
REAR PROPSHAFT (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.43
REAR GEARCASE (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44
GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.46
REAR GEARCASE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.48
REAR GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51
REAR GEARCASE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.52
7.1
FINAL DRIVE
SPECIAL TOOLS 2. Check bearings for side play by grasping the top and bottom
of the tire firmly and checking for movement. The tire
should rotate smoothly without binding or rough spots.
PART NUMBER TOOL DESCRIPTION
2872608 Roll Pin Removal Tool
PU-48951 Axle Boot Clamp Tool
TORQUE SPECIFICATIONS
Wheel and Hub Torque Table
ITEM NUT TYPE SPECIFICATION
Aluminum Wheels
Lug Nut (1) 90 ft. lbs. (122 Nm)
(Cast)
Steel Wheels 3. Remove the (4) wheel nuts and remove the front wheel.
Flange Nut (2) 35 ft. lbs. (47 Nm)
(Black / Camo)
4. Remove the cotter pin and loosen the front wheel hub castle
Front Hub
- 80 ft. lbs. (108 Nm) nut. Remove the nut, and (2) cone washers from the front
Castle Nut
wheel hub assembly.
Mid / Rear Hub
- 110 ft. lbs. (150 Nm)
Castle Nut Castle Nut
Cone
Washers
#1 #2
Aluminum Wheel Steel Wheel

(LE Models) (Standard Models)
35 ft. lbs. (47 Nm)
Cotter Pin
90 ft. lbs. (122 Nm)
5. Remove the two brake caliper mounting bolts.

FRONT BEARING CARRIER CAUTION: Do not hang the caliper by the brake line. Use
wire to hang caliper to prevent damage to the brake line.
Bearing Carrier Inspection / Removal
1. Elevate front of vehicle and safely support machine under
the frame area.
CAUTION

Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
7.2
FINAL DRIVE
6. Remove the front wheel hub assembly. 12. Rotate bearing by hand and check for smooth rotation.
Visually inspect bearings for moisture, dirt, or corrosion.
7. Remove the steering tie rod end fastener from the front
bearing carrier. NOTE: Due to extremely close tolerances and
minimal wear, the bearing 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.
13. Replace bearing if moisture or corrosion is evident.

Steering
Tie Rod End Bearing Replacement
Bearing Removal
1. Remove outer snap ring.
8. Remove the lower shock mounting fastener attached to the

upper A-arm and remove the shock from the A-arm.
Snap
Ring
7
2. From the back side of the bearing carrier, tap on the outer
bearing race with a drift punch in the reliefs as shown.
9. Remove the upper and lower ball joint pinch bolts.
Pinch
Bolts
3. Drive bearing out evenly by tapping on outer race only.

Once bearing is at bottom of casting, support casting on
10. Using a soft faced hammer, lightly tap on the bearing carrier outer edges so bearing can be removed.
while removing the upper and lower ball joint ends.
4. Inspect the bearing carrier housing for scratches, wear or
11. Remove the bearing carrier from the front drive shaft. damage. Replace front bearing carrier if damaged.
7.3
FINAL DRIVE
Bearing Installation Bearing Carrier Installation
5. Thoroughly clean the front bearing carrier housing and the 1. Install the end of the drive shaft through the backside of the
outer race on the new bearing. Be sure that all oil residue bearing carrier.
has been removed from each surface.
2. Install the upper and lower ball joint ends into the front
6. Support the bottom of the bearing carrier housing. bearing carrier.
3. Install pinch bolts and torque to specification

CAUTION
Use an arbor and press only on the outer race,
otherwise bearing damage may occur.
7. Apply Loctite 603 retaining compound to the outer

circumference of the new bearing race and carefully press
the new bearing into the bearing carrier housing. 17 ft. lbs.
(23 Nm)
Apply
Loctite 603
Snap Ring
=T
Pinch Bolts:
Bearing 17 ft. lbs. (23 Nm)
4. Install shock to A-arm and torque fastener to specification.

NOTE: Use care to not allow any of the Loctite
compound to get in the bearing.
8. Wipe the housing clean of any excess compound and install 30 ft. lbs.
the snap ring. (41 Nm)
=T
Shock Mounting Bolts:
30 ft. lbs. (41 Nm)
5. Apply grease to the drive shaft splines.
7.4
FINAL DRIVE
6. Install front wheel hub assembly, cone washers, and hand
tighten the castle nut. Install washers with domed side out. =T
Cone Washers Front Caliper Mounting Bolts:
30 ft. lbs. (41 Nm)
Wheel
Hub CAUTION
New bolts have a pre-applied locking agent

Out which is destroyed upon removal. Always use
new brake caliper mounting bolts
7. Install the steering tie rod end onto the front bearing carrier upon assembly.
and torque fastener to 40 ft. lbs. (54 Nm).
9. Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a
NEW cotter pin. Tighten nut slightly if necessary to align
cotter pin holes.
80 ft. lbs.
(108 Nm)
40 ft. lbs.
54 (Nm)
=T
NEW Cotter Pin
7
Tie Rod End Fastener:
40 ft. lbs. (54 Nm) =T
Front Hub Castle Nut:
8. Install the front brake caliper. Install the mounting bolts and
80 ft. lbs. (108 Nm)
torque to 30 ft. lbs. (41 Nm).
10. Install wheel and (4) wheel nuts. Torque wheel nuts to
specification.
=T
30 ft. lbs. Wheel Nuts:
(41 Nm) Steel Wheels: 35 ft. lbs. (47 Nm)
Aluminum Wheels: 90 ft. lbs. (122 Nm)
11. Rotate wheel and check for smooth operation. Bend both
ends of cotter pin around the end of the shaft.
7.5
FINAL DRIVE
FRONT DRIVE SHAFT Installation
Removal 1. Install new spring ring on the end of the drive shaft. Apply
an anti-seize compound to splines.
1. Perform the Bearing Carrier Inspection / Removal
procedure listed under the FRONT BEARING
CARRIER section within this chapter.
NOTE: Perform all removal steps with the exception

of removing the steering tie rod end. It will not be
necessary to remove the tie rod end from the front
bearing carrier when removing the front drive shaft.
CAUTION

2. Remove the drive shaft from the front bearing carrier.
3. With a short, sharp jerk, remove drive shaft from the front
gearcase.
2. Align splines of drive shaft with front gearcase and reinstall
the drive shaft. Use a rubber mallet to tap on the outboard
end of the drive shaft if necessary.
4. Refer to the DRIVE SHAFT SERVICE procedure if

repairing the drive shaft.
3. Install drive shaft into the front bearing carrier.
4. Perform the Bearing Carrier Installation procedure listed

under the FRONT BEARING CARRIER section within
this chapter.
7.6
FINAL DRIVE
FRONT PROPSHAFT Removal / Installation (6x6)
1. Elevate and safely support vehicle under the frame. The
Removal / Installation (XP / HD)
use of a vehicle hoist is recommended for this procedure.
CAUTION
CAUTION Serious injury may result if machine tips or falls.

Serious injury may result if machine tips or falls. service procedure. Wear eye protection when
Be sure machine is secure before beginning this removing bearings and seals.
removing bearings and seals. 2. Access the front propshaft roll pin through the skid plate
hole.
2. Access the front propshaft roll pin through the skid plate
hole. 3. Use the Roll Pin Removal Tool (PN 2872608), to drive out
the roll pin from prop shaft.
3. Use the Roll Pin Removal Tool (PN 2872608), to drive out
the roll pin from the propshaft.
Roll Pin Removal Tool (PN 2872608)

4. Remove the (8) T27 Torx-head screws retaining the floor
cover and remove the cover from the vehicle.
4. Remove the (8) T27 Torx-head screws retaining the floor
cover and remove the cover from the vehicle. 5. Slide the propshaft back and away from front gearcase, then
pull the shaft sharply forward to remove it from the
5. Slide the propshaft back and away from front gearcase, then transmission shaft.
pull the shaft sharply forward to remove it from the
transmission shaft. 6. Using care, pull the propshaft towards the right side of the
6. Using care, pull the propshaft towards the left side of the
frame and slide it out the right rear portion of the frame.
7
frame and slide it out the left rear side of the vehicle in front See NOTE
of the PVT system.
NOTE: Avoid making contact with the shift cable

and cable mounting tab during removal to prevent
component damage.
7. Reverse this procedure to reinstall the front propshaft.
7. Reverse this procedure to install the front propshaft.
8. Use a NEW roll pin upon installation.
7.7
FINAL DRIVE
Removal / Installation (CREW) 6. Slide the rear portion of the shaft back to separate it from
the front portion.
CAUTION

2. Access the front propshaft roll pin through the skid plate
hole.
3. Use the Roll Pin Removal Tool (PN 2872608), to drive out
the roll pin from prop shaft.
7. Slide the front portion back and away from front gearcase
Roll Pin Removal Tool (PN 2872608) to remove it.
8. If removing the rear portion, remove the bearing support
4. Remove the front seat base and large storage container to (upper & lower half).
access the support bearing.
9. Using care, pull the rear portion of the propshaft towards
the left side of the frame and slide it out the left rear side
of the vehicle in front of the PVT system.
Support Bearing
5. Remove the (2) nuts and bolts retaining the bearing support.
Remove 10. Reverse this procedure to reinstall and assemble the front
propshaft.
11. Torque bearing support fasteners to specification.
=T
Bearing Support Fasteners:
30-36 ft. lbs. (41-49 Nm)
7.8
FINAL DRIVE
Support Bearing Replacement (CREW) PROPSHAFT U-JOINT SERVICE
1. Follow steps 4-6 of the Removal / Installation CREW
Disassembly
procedure.
1. Remove internal or external snap ring from all bearing
2. Remove the bearing support (upper and lower half) and the
caps.
(2) set screws retaining the bearing to the shaft.
Remove Rubber Isolator

Ring Not Shown
CAUTION
Always wear eye protection.
Remove
3. Slide the bearing off the end of the shaft.
Rubber Isolator
Ring Not Shown
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
2. Support inner yoke as shown and drive outer yoke down
(bearing cap out) with a soft face hammer.
4. Clean the surface of the shaft and install the new bearing.
5. Align the front and rear portions of the propshaft and slide
them together.
6. Install the upper and lower halves of the bearing support
along with the (2) fasteners. Finger tighten only.
7. Slide the rear portion of the propshaft forward or backward
to obtain the proper spline engagement. Torque the (2)
bearing set screws to 65-75 in. lbs. (7.3-8.4 Nm).
8. Torque the bearing support fasteners to specification.
=T
Bearing Support Fasteners:
30-36 ft. lbs. (41-49 Nm)
9. Reinstall the large storage container and front seat base.

7.9
FINAL DRIVE
3. Support U-joint in vise as shown and drive inner yoke down 3. Continually check for free movement of bearing cross as
to remove remaining bearing caps. bearing caps are assembled.
4. Install snap ring to contain bearing cap just installed.

4. Force U-joint cross to one side and lift out of inner yoke.
Repeat procedure for other side.
5. Install outer yoke, aligning marks made before
disassembly.
Assembly
6. Repeat Steps 1-4 to install bearing caps on outer yoke.
1. Install new bearing caps in yoke by hand. Carefully install
U-joint cross with grease fitting properly positioned 7. Seat all bearing caps against snap rings by supporting cross
inward toward center of shaft. Take care not to dislodge shaft and tapping on each corner as shown.
needle bearings upon installation of cross joint. Tighten
vise to force bearing caps in.
8. When installation is complete, yokes must pivot freely in

all directions without binding. If the joint is stiff or binding,
tap the yoke lightly to center the joint until it pivots freely
2. Using a suitable arbor, fully seat bearing cap in one side. in all directions.
7.10
FINAL DRIVE
FRONT GEARCASE - CENTRALIZED HILLIARD
Exploded View (Vehicles Built Before 3/05/2010)
21 20 8-10 ft. lbs.
(11-14 Nm)
28 11
9 10
15 30
6
3 8 2 23
18
17 6
32 22
16 8-10 ft. lbs. 22
15 33
15 (11-14 Nm)
14 4
29 1
13
34 19
12 24 28
27 25 26
31
7-11 ft. lbs.
1 (10-15 Nm)
7-11 ft. lbs.
7 (10-15 Nm)
7
REF# DESCRIPTION QTY REF# DESCRIPTION QTY
1 Screws, 1/4-20 8 18 Bearing 1
2 Armature Plate 1 19 Thrust Button Asm. 1
3 Bushing 1 20 Fill Plug 1
4 Output Cover 1 21 Vent Tube 1
5 Gearcase 1 22 Nylon Spacer 2
6 Output Hub 2 23 AWD Coil / Coil Pocket Insert 1
7 Plastic Clip 1 24 Thrust Plate 1
8 Roll Cage 1 25 O-Ring 1
9 Spacer, Gear 1 26 Grommet 1
10 Clutch Housing / Ring Gear 1 27 Set Screw 1
11 Bushing 1 28 Oil Seal 2
12 Input Cover 1 29 Rollers 20
13 O-Ring 1 30 H-Clip Springs 20
14 Retaining Ring 1 31 Oil Seal 1
15 Ball Bearing 3 32 Drain Plug Asm. w/Magnet 1
16 Pinion Gear 1 33 Dowel Pin 1
17 Dowel Pin 1 34 Needle Roller Bearing 1
7.11
FINAL DRIVE
Exploded View (Vehicles Built After 3/05/2010)
8-10 ft. lbs.

20 (11-14 Nm)
21
5
28
11
9 10
15 22
6 30
3 8
37
38
18 2
32
17 8-10 ft. lbs. 6 23
(11-14 Nm) 22
16 15
33
15 36
35 29
4 1
14
13
24
34 28
19 25
12 27
31 7 26
7-11 ft. lbs.
1 (10-15 Nm) 7-11 ft. lbs.
(10-15 Nm)

1 Screws, 1/4-20 8 20 Fill Plug 1
2 Armature Plate 1 21 Vent Tube 1
3 Bushing 1 22 Nylon Spacer 2
4 Output Cover 1 23 AWD Coil / Coil Pocket Insert 1
5 Gearcase 1 24 Thrust Plate 1
6 Output Hub 2 25 O-Ring 1
7 Plastic Clip 1 26 Grommet 1
8 Roll Cage 1 27 Set Screw 1
9 Spacer, Gear 1 28 Oil Seal 2
10 Clutch Housing / Ring Gear 1 29 Rollers 20
11 Bushing 1 30 H-Clip Springs 20
12 Input Cover 1 31 Oil Seal 1
13 O-Ring 1 32 Drain Plug Asm. w/Magnet 1
14 Retaining Ring 1 33 Dowel Pin 1
15 Ball Bearing 3 34 Needle Roller Bearing 1
16 Pinion Gear 1 35 Retaining Ring 1
17 Dowel Pin 1 36 Spring, Wire Form 2
18 Bearing 1 37 Torsion Spring 1
19 Thrust Button Asm. 1 38 Spring Retainer 1
7.12
FINAL DRIVE
All Wheel Drive Operation AWD Engagement: When the AWD switch is activated, the
AWD coil is powered by a 12 Vdc input which creates a
The AWD switch may be turned on or off while the vehicle is magnetic field. This magnetic field attracts an armature plate
moving, however, AWD will not enable until the engine RPM that is keyed to the roll cage. When the ring gear and roll cage
drops below 3100. Once the AWD is enabled, it remains enabled are spinning (vehicle is moving), the energized coil and
until the switch is turned off. armature plate will apply drag to the roll cage that indexes the
rollers inside the ring gear to an engagement position. While in
Engage the AWD switch before getting into conditions where the engagement position, the front drive will be in an over-
the front wheel drive may be needed. If the rear wheels are running condition (not engaged), until the rear wheels lose
spinning, release the throttle before switching to AWD. traction. Once the rear wheels begin to lose traction, the front
drive will engage by coupling the output hubs to the ring gear via
CAUTION the rollers. The front drive will remain engaged until the torque
requirement goes away (i.e. rear wheels regain traction).
Switching to AWD while the rear wheels are Ring
spinning may cause severe drive shaft and Gear
gearcase damage. Always switch to AWD while
the rear wheels have traction or are at rest.
With the AWD switch off, the vehicle drives through the rear
wheels only (2 wheel drive). When the AWD is enabled, the
front drive acts as an on-demand AWD system. This means, the
front drive will engage once the rear wheels have lost traction,
and will remain engaged until the torque requirement goes away
(i.e. rear wheels regain traction). Output Hubs
Roll Cage
Rollers & H-Springs
CAUTION
If the rear wheels are spinning, release the AWD Disengagement: Once the rear wheels regain traction,
throttle before turning the AWD switch on.
If AWD is engaged while the wheels are
the front wheels will return to the over-running condition. The
vehicle is now back to rear wheel drive until the next loss of rear 7
spinning, severe drive shaft and front wheel traction occurs.
gearcase damage could result.
Torsion Spring Operation (Vehicles Built After 3/05/2010):
The torsion spring acts as a return mechanism to help disengage
the coupling of the output hubs and ring gear by creating an
over-running condition for the rollers upon disengagement.
Centers Roll Cage and

Rollers in Ring Gear
Output
Hubs
Ring
Gear
Roll Cage Torsion

& Rollers Spring
7.13
FINAL DRIVE
AWD Diagnosis 5. Check to make sure the coil is seated in the U-shaped insert
that is pressed into the gearcase cover. The top of the coil
Symptom: AWD Will Not Engage should be seated below the U-shaped insert. The U-shaped
1. Check the gearcase coil resistance. To test the coil insert controls the pole gap. If the top of the coil is above
resistance, measure between the Grey and Brown/White the surface of the U-shaped insert it raises the armature
wires. The measurement should be within specification. 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 found, replace the cover plate assembly.
Gearcase Cover Plate Asm.
Coil
Side cutaway U-shaped insert

view of cover
Front Gearcase Coil Resistance: 6. Inspect the rollers for nicks and scratches. The rollers must
slide up, down, in and out freely within the roll cage sliding
21.6 - 26.4 Ohms surfaces and H-springs.
2. Turn the ignition switch and AWD switch on and place gear Roll Cage
Note: Rollers are non-directional
selector in High or Low gear. Check for minimum battery Assembly
voltage at the Gray and Brown/White chassis wires that
power the coil. A minimum of 11 Vdc should be present.
Rollers
3. If electrical tests are within specification, remove gearcase
(see Gearcase Removal) and inspect components.
4. Inspect the armature plate for a consistent wear pattern.

There should be two distinct wear bands (one band inside
the other). If only one band of wear is present (or if there
is wear between the two bands), inspect the coil area as
indicated in Step 5. A wear band with an interrupted wear Built Before 3/05/2010
mark may indicate a warped plate, which may cause
intermittent operation. Roll Cage Assembly
Armature Plate Rollers
Built After 3/05/2010
Check for Wear Bands 7. Inspect the roll cage assembly for cracks or excessive wear.
If damaged, replace the roll cage assembly.
7.14
FINAL DRIVE
Gearcase Removal Disassembly / Inspection
1. Stop engine, place machine in gear and set parking brake. 1. Drain and properly dispose of used lubricant. Remove any
metal particles from the drain plug magnet.
2. Elevate front of vehicle and safely support machine under
the frame area. 2. Remove the (5) screws retaining the outer cover assembly.
CAUTION

3. Remove both front drive shafts from the front gearcase

(see FRONT DRIVE SHAFT - Removal).
4. Remove the front propshaft from the front gearcase (see
FRONT PROPSHAFT - Removal).
5. Remove the LH wheel well panel and disconnect the AWD
wire harness. Cut the plastic tie strap to free the connector
end from the main harness to allow gearcase removal.
6. Remove the (4) bolts securing the bottom of the gearcase VEHICLES BUILT BEFORE 3/05/2010:
to the skid plate frame. 1. Remove the output cover assembly from the gearcase.
Thrust Bushing
7. Remove the vent line from the gearcase. NOTE: Thrust bushing located between the two
8. Remove the gearcase from the front left-hand wheel well output hubs is pressed into assembly.
area and pull it out between the upper and lower A-arms. 2. Remove the RH output hub assembly from the outer cover.
Cover Output Hub

Plate Assembly
7.15
FINAL DRIVE
3. Inspect the bearing and contact surfaces of the output hub 7. The rollers must slide up and down freely within the roller
for signs of wear or damage. Replace component if found cage surfaces.
to be worn or damaged.
8. Inspect the ring gear (C) for consistent wear patterns. The
4. Remove the armature plate, roll cage assembly and ring surfaces should be free of nicks or burrs.
gear.
9. Inspect roll cage (B) sliding surface. This surface must be
clean and free of nicks, burrs or scratches.
10. Remove and inspect the H-springs. If the spring legs appear
to be flattened or damaged, replace the roll cage and H-
springs as an assembly.
B
H-Spring
5. Remove LH output hub. Inspect the bearing and contact

surfaces of the output hub for signs of wear or damage.
Replace component if found to be worn or damaged.
IMPORTANT: Refer to the Electronic Parts Catalog

for individual part availability. Most parts are to be
replaced as an assembly or as a complete kit.
11. Proceed to Step 14 under Vehicles Built After 3/05/2010.
VEHICLES BUILT AFTER 3/05/2010:

1. Remove the output cover assembly from the gearcase.
NOTE: Thrust bushing located between the two
output hubs is pressed into assembly.
2. Remove the RH output hub assembly from the outer cover
plate assembly.
6. Thoroughly clean all parts. Inspect bearing surfaces of the
output hub. Inspect the rollers (A) for nicks, scratches and
flat spots. Inspect the roll cage (B) for damage or cracks.
Note: Rollers are non-directional
C
A
Cover Output Hub

Plate Assembly
7.16
FINAL DRIVE
3. Inspect the bearing and contact surfaces of the output hub 7. Remove LH output hub. Inspect the bearing and contact
for signs of wear or damage. Replace component if found surfaces of the output hub for signs of wear or damage.
to be worn or damaged. Replace component if found to be worn or damaged.
4. Remove and inspect the armature plate. Refer to AWD
Diagnosis for detailed inspection process.
5. Remove the torsion spring retainer and torsion spring from
the top of the ring gear.
Spring Retainer
8. Remove the roll cage assembly and rollers from the clutch
housing. Use a shop towel to cover the housing in order to
retain all the rollers.
Torsion Spring
NOTE: Rollers are spring loaded. Take care not to
allow them to fall out or lose them upon removal of
6. Remove the clutch housing / ring gear and roll cage the roll cage.
assembly from the gearcase housing.
9. Thoroughly clean all parts and inspect the rollers (A) for
Remove as nicks and scratches. The rollers must slide up and down and
an assembly in and out freely within the roll cage (B) sliding surfaces
and H-springs.
C 7
B
IMPORTANT: Refer to the Electronic Parts Catalog

for individual part availability. Most parts are to be
replaced as an assembly or as a complete kit.
10. Inspect clutch housing ring gear (C) for a consistent wear
pattern. Inspect the ring gear for chipped, broken, or
missing teeth.
7.17
FINAL DRIVE
11. Inspect the roll cage assembly (B) sliding surfaces and H- NOTE: See AWD DIAGNOSIS in this section for
springs. The sliding surfaces must be clean and free of more details.
nicks, burrs or scratches. If damaged, replace the roll cage
15. Inspect the magnetic coil (D) in the outer cover plate
assembly.
assembly. Inspect the backlash pad (E) for excessive wear.
H-Spring B
E D
12. Inspect both output hub assemblies. Inspect the bearings

NOTE: See AWD DIAGNOSIS in this section for
and replace if needed.
more details on the coil.
Bearing Thrust NOTE: The backlash for the centralized hilliard is set
Bearing 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 Setting Ring Gear
Backlash procedure later in this chapter for details
on backlash setting.
16. Remove the bolts retaining the input shaft cover and pinion
gear assembly.
Roller
Spacer Surface
13. Clean and inspect all remaining front gearcase components.

Check each for excessive wear or damage.
14. Inspect the armature plate for a consistent wear pattern.
Uneven wear of the armature plate indicates a warped plate,
which may cause intermittent operation.
7.18
FINAL DRIVE
17. Remove the snap ring retaining the input shaft assembly. Assembly / Inspection
1. Replace all O-rings, seals and worn components.
18. Remove the input shaft assembly. Inspect the pinion gear
(C) for chipped, broken, or missing teeth. Inspect the input
shaft bearing (D) for signs of wear. Replace the input shaft
cover O-ring prior to reassembly.
2. Press the pinion shaft seal into the pinion cover, until the
seal is flush with the sealing surface.
C D
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
quietly, with no detectable up and down movement 7
and minimal movement side to side.
4. Install input shaft, bearing, snap ring and input cover with
a new O-ring. Torque screws to specification.
19. Inspect the input shaft bushing.
20. Thoroughly clean the gearcase components before =T

beginning reassembly.
Input Cover Screws:
7-11 ft. lbs. (10-15 Nm)
7.19
FINAL DRIVE
5. Install the LH output hub (A) into the gearcase housing. 2. Install the ring gear and roll cage assembly into the gearcase
The output hub should spin freely. housing.
3. Install the armature plate on top of the roll cage / ring gear
A assembly. Be sure that the armature plate tabs are fully
engaged into the roll cage assembly and are resting on the
cut-out grooves of the ring gear.
6. Install the RH output hub (B) into the output cover. The
output hub should spin freely.
B
NOTE: Verify armature plate tabs are in the slots on
roll cage and are resting in the ring gear grooves.
4. Install a new O-ring onto the cover plate assembly and
install the cover plate onto the main gearcase.
New
O-Ring
VEHICLES BUILT BEFORE 3/05/2010:
1. Install the roll cage and rollers into the ring gear. Insert the
rollers as the roll cage is installed.
NOTE: Verify the square O-ring (arrow) is placed flat

on the cover surface. If the O-ring is twisted, fluid
leakage may occur.
5. Proceed to Step 8 under Vehicles Built After 3/05/2010.
NOTE: The rollers are non-directional. Grooves cut

in rollers are for manufacturing identification
purposes only.
7.20
FINAL DRIVE
VEHICLES BUILT AFTER 3/05/2010: 5. Check the action of the torsion spring to ensure proper
installation of spring and retainer.
1. Carefully install the rollers into the roll cage assembly
while installing the assembly into the clutch housing.
6. Install the armature plate on top of the roll cage / ring gear
assembly. Be sure that the armature plate tabs are fully
2. Carefully install the ring gear and roll cage assembly into
engaged into the roll cage assembly and is resting properly
the gearcase housing.
on the torsion spring retainer.
3. Install the torsion spring by wrapping each leg of the spring
7. Install a new O-ring onto the cover plate assembly and
around the dowel pin on the ring gear.
install the cover plate onto the main gearcase.
NOTE: Verify the square O-ring is placed flat on the
cover surface. If the O-ring is twisted, fluid leakage
may occur.
8. Install the output cover screws and torque to specification.
4. Align the spring retainer dowel pin with the ring gear dowel
pin and install the retainer on top of the torsion spring.
=T
Output Cover Screws
Align during
installation 7-11 ft. lbs. (10-15 Nm)
7.21
FINAL DRIVE
Setting Ring Gear Backlash 5. Set the gearcase upright. Rotate the input shaft at least 4
times. This ensures the ring gear completes one full
NOTE: Ring gear backlash is set at the factory. No rotation.
adjustment is required, unless the front cover is
replaced or the back lash pad screw is removed.
1. Lay the front gearcase on its side with the output cover
facing up.
2. The backlash screw has locking agent that holds it into

place. Use a heat gun to lightly heat up the locking agent
on the screw.
6. If a tight spot is felt during rotation, loosen the backlash

screw another 1/8 turn. Perform step 5 again. Repeat this
procedure until the pinion shaft rotates smoothly 4 times (1
revolution of ring gear).
3. Using a 3/32 hex wrench, turn the back-lash screw out 3-4
turns. Re-apply Loctite 262 onto the bottom screw
threads.
4. Turn the screw in until it is lightly seated, then turn the

screw out 1/4 turn.
7.22
FINAL DRIVE
Gearcase Installation 8. Reinstall the LH wheel well panel.
1. Install the gearcase through the front left-hand wheel well 9. Add the proper lubricant to the front gearcase. Check drain
area between the upper and lower A-arms. plug for proper torque. Refer to Chapter 2 for fluid fill and
change information.
2. Install the vent line to the gearcase and ensure its routed
properly up top under the hood.
3. Install propshaft onto the front gearcase.
4. Install new mounting bolts and torque to specification.
=T
Gearcase Mounting Bolts:
40 ft. lbs. (54 Nm)
5. Drive a new roll pin into the front propshaft (see FRONT
PROPSHAFT - Installation).
6. Install the drive shafts into the front gearcase (see FRONT
DRIVE SHAFT - Installation).
7. Connect the AWD harness and tie the harness to the main
harness using a plastic tie strap.
7.23
FINAL DRIVE
MID / REAR BEARING CARRIER 4. Remove the two brake caliper mounting bolts and remove
the caliper from the bearing carrier.
Inspection
1. Support the machine securely with rear wheels elevated.
CAUTION

2. Check the bearings for side play. Grasp the top and bottom
of the wheel or wheel hub and check for movement.
3. If movement is detected, inspect wheel hub, castle nut

torque and bearing condition. The tire should rotate CAUTION
smoothly without binding or rough spots. Correct as
necessary. Do not hang the caliper by the brake line. Use
mechanics wire to hang the caliper to prevent
possible damage to the brake line.
Removal
5. Slide the wheel hub out from the bearing carrier and drive
1. Elevate the rear end of the vehicle and safely support the shaft.
vehicle under the main frame area.
6. Remove the upper and lower A-arm fasteners from the
2. Remove wheel nuts, washers and wheel.
bearing carrier.
3. Remove the cotter pin, castle nut and washers.
Castle Nut
Washers
Cotter Pin
7. Remove the bearing carrier. Inspect the bearing again for

smoothness and side to side movement, replace as needed.
7.24
FINAL DRIVE
Disassembly Assembly
1. Remove the retaining ring from the bearing carrier. 1. Thoroughly clean the bearing carrier housing and prepare
the components for assembly.
2. From the back side, tap on the outer bearing race with a drift
punch in the reliefs as shown. 2. Support the bottom of the bearing carrier housing. Start the
bearing (A) in the bearing carrier housing (B). Use an arbor
NOTE: Drive bearing out evenly by tapping on outer press to install the bearing.
race only. Once bearing is at bottom of casting,
support casting on outer edges so bearing can be
A
removed.
7
3. Press the bearing into place until the outer bearing race
bottoms in housing.
CAUTION
3. Inspect the bearing.
Use an arbor and press only on the outer race,
NOTE: Due to extremely close tolerances and as bearing damage may occur.
minimal wear, the bearings must be inspected
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.
5. Replace the bearing carrier bushings if worn or damaged.
4. Install a new retaining ring into the bearing carrier groove.
7.25
FINAL DRIVE
Installation 8. Carefully lower the vehicle. Torque the wheel hub castle
nut to specification. Install a new cotter key.
1. Place the bearing carrier over the drive shaft.
2. Align the bottom of the bearing carrier with the lower A- =T

arm. If previously removed, install new lower A-arm
bushings. Install the lower bearing carrier fastener. Mid / Rear Hub Castle Nut:
110 ft. lbs. (150 Nm)
3. With the drive shaft placed in the bearing carrier, align the
top of the bearing carrier with the upper A-arm. If
previously removed, install new upper A-arm bushings.
Install the upper bearing carrier fastener.
NOTE: The lower shock bolt may need to be

removed to allow the upper A-arm to move freely.
4. Torque the upper and lower bearing carrier fasteners to

specification.
=T
Bearing Carrier Fasteners:
30 ft. lbs. (41 Nm)
5. Install the wheel hub assembly onto the drive shaft.
6. Install the washers (domed side out) and the wheel hub
castle nut.
7. Install the wheel, washers and wheel nuts. Torque wheel

nuts to specification.
=T
Wheel Nuts:
Steel Wheels: 35 ft. lbs. (47 Nm)
Aluminum Wheels: 90 ft. lbs. (122 Nm)
7.26
FINAL DRIVE
MID / REAR DRIVE SHAFT 5. Remove the drive shaft using short, sharp jerks to free the
circlip.
Removal
1. Perform the MID / REAR BEARING CARRIER -
Removal procedure, steps 1-5.
2. Remove the lower shock fastener to free the upper A-arm.
Remove
6. Refer to the DRIVE SHAFT SERVICE section if

repairing the drive shaft.
Installation
3. Remove the upper bearing carrier fastener and separate the 1. Install a new circlip on the end of the drive shaft or mid
bearing carrier from the upper A-arm. gearcase output shaft (6x6). Apply an anti-seize compound
to the splines.
4. Carefully slide the drive shaft out by pulling the bearing

carrier outward and tipping it down to remove the shaft.
2. Align the splines of the drive shaft with the transmission

(4x4), mid gearcase or rear gearcase (6x6) and reinstall the
drive shaft. Use a rubber mallet to tap on the outboard end
of the drive shaft if necessary.
3. Install the drive shaft into the bearing carrier.
4. Perform the MID / REAR BEARING CARRIER -
Installation procedure to properly reassemble the vehicle.
7.27
FINAL DRIVE
MID PROPSHAFT (6X6) 3. Remove the parking brake caliper assembly from the
caliper mount bracket to allow the rear propshaft to slide
Removal back on the rear gearcase input shaft during removal.
1. Drive the roll pin from the mid propshaft yoke located at
the transmission.
Roll Pin
Removal Tool
Remove
4. Slide the rear propshaft back on the rear gearcase input shaft
and remove the propshaft from the mid gearcase.
5. Loosen the (4) bolts retaining the mid gearcase to the frame.
2. Drive the roll pin from the rear propshaft yoke located at
the mid gearcase.
Roll Pin 6. Slide the mid gearcase forward. Lift up on the gearcase to
Removal Tool clear the frame and slide the gearcase towards the rear of
the vehicle to remove the mid propshaft from the
transmission.
Rear Propshaft
Mid Gearcase
7.28
FINAL DRIVE
Installation MID GEARCASE (6X6)
1. Install the mid propshaft onto the transmission output shaft
Gearcase Removal
and align the roll pin holes. Drive a NEW roll pin into the
propshaft yoke. 1. Drive the roll pin from the rear propshaft yoke located at
the mid gearcase.
2. Slide the mid gearcase forward in the frame. Install the mid
propshaft onto the mid gearcase input shaft.
3. Position the mid gearcase and install the (4) mounting bolts.
Torque the bolts to specification.
Roll Pin
Removal Tool
30-36 ft. lbs. Roll Pin Removal Tool (PN 2872608)

(41-49 Nm)
2. Remove the parking brake caliper assembly from the
=T back on the rear gearcase input shaft during removal.
Mid Gearcase - Mounting Bolts:

30-36 ft. lbs. (41-49 Nm)
4. Install the rear propshaft onto the mid gearcase and drive a
7
NEW roll pin into the propshaft yoke.
5. Install the parking brake caliper assembly. Tighten the two Remove
mounting bolts in increments and torque to specification.
18 ft. lbs.
3. Slide the rear propshaft back on the rear gearcase input shaft
(24 Nm) and remove the propshaft from the mid gearcase.
=T
Parking Brake Caliper - Mounting Bolts:
18 ft. lbs. (24 Nm)
7.29
FINAL DRIVE
4. Perform the MID / REAR DRIVE SHAFT - Removal 6. Slide the mid gearcase forward. Lift up on the gearcase to
procedure to remove the drive shafts from the mid gearcase. clear the frame and slide the gearcase rearward to remove
the mid propshaft from the mid gearcase.
Mid Propshaft
Mid Gearcase
5. Remove the (4) bolts retaining the mid gearcase to the

frame. 7. Lift the mid gearcase out of the frame.
7.30
FINAL DRIVE
Gearcase Disassembly 4. Remove the output shaft and ring gear assembly (E) from
the gearcase. Inspect the ring gear for abnormal wear,
1. Drain the oil from the mid drive gearcase. Properly dispose broken, or chipped teeth. Inspect and spin the bearings (F),
of the oil. the bearings should rotate smoothly.
2. Remove the output cover bolts (A) and the output cover (B).
E
F F
A
5. Remove the wave spring (G) from the gearcase assembly.

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
G
6. Remove the bolts from the input cover (H).
7.31
FINAL DRIVE
7. Remove the input cover bolts (I). Remove the input cover 9. Inspect the pinion gear (K) and 26T output gear (L) for nics
(H) and pinion gear assembly from the gearcase. or uneven wear. Inspect the bearing (M), the bearing should
spin smoothly. Replace the parts as needed.
K L M
I
H
10. Remove the rear output seal (N).
8. Remove the pinion gear assembly (J) from the front cover N
(H). If the pinion gear does not come loose from the front
cover, use the following steps to aid in removal:
Hold the pinion gear assembly.

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), until the pinion gear assembly comes loose.
J H
1
4 3 11. Remove the retaining ring (O) and shim (P) from the rear
output thru shaft.
O
2
7.32
FINAL DRIVE
12. Carefully pull the output thru shaft (Q) through the
gearcase.
Q
15. Replace all O-ring, seals, and worn components. Replace
13. Remove the retaining ring (O), shim (P), and input gear (R) the seals as shown in the photo.
from the output shaft (Q). Inspect the input gear for
abnormal wear, broken, or chipped teeth.
Q
7
O
14. Inspect the two flange bearings (S) inside the gearcase. Gearcase Assembly
Inspect the pinion shaft bushing (T) for wear that is inside 1. Install the shim (A) and a new retaining ring (B) onto the
the gearcase. output end of the output shaft (C). Install the output thru
shaft into the gearcase.
A&B
7.33
FINAL DRIVE
2. Install the 26T input gear (D), shim (E), and a new retaining Hold the pinion gear assembly.
ring (F) onto the output shaft. Use a rubber mallet to lightly tap on the front of the
input cover, around the bearing cup.
Tap the front cover in an X pattern (follow the pattern in
the photo), until the pinion gear assembly comes loose.
E
3
1
4 2
D
F
3. Assemble the pinion shaft assembly (if previously

disassembled). Install the 26T gear (G) and bearing (H)
onto the pinion shaft (I).
NOTE: When replacing the 26T output, be sure the

5. Apply Polaris Crankcase Sealant (PN 2871557) to the
step of the gear is facing towards the bearing (see
inside surface of the input cover (J).
below).
Pinion Shaft Assembly

J
Step Of Gear
I
G
Sealant
H
Pinion Shaft Assembly Assembled

6. Install the pinion shaft assembly and input cover onto the
gearcase. Install the input cover bolts (K). Torque the bolts
to 18 - 23 ft. lbs. (24 - 31 Nm).
4. Install the pinion shaft assembly into the input cover.

K
NOTE: Alignment of the pinion shaft bearing into the
input cover maybe be difficult. If needed, use the
following steps to aid in installation:
7.34
FINAL DRIVE
7. Install the wave spring (L) into the gearcase assembly. Be 10. Install a new O-ring (O) onto the output cover.
sure the wave spring is fully seated into the bearing cup of
the gearcase.
11. Carefully install the output cover. Install the output cover
bolts and Torque the bolts to 18 - 23 ft. lbs. (24 - 31 Nm).
8. Install the output shaft and ring gear into the gearcase. Be
sure the 10T input pinion gear and the output pinion gear
mesh smoothly.
7
Input Cover Bolt Torque:
9. Install the shims (M) into the output cover (N). Install the 18 - 23 ft. lbs. (24 - 31 Nm)
shims in the order that they were removed during the
disassembly process.
12. Remove the fill plug (P) and fill the mid gearcase with 6.75
oz. (200 ml) of Polaris ATV Angle Drive Fluid
M (PN 2876160). Torque the fill plug to 14 ft. lbs. (19 Nm).
7.35
FINAL DRIVE
4. Perform the MID / REAR DRIVE SHAFT - Installation
Mid Gearcase Specifications: procedure to reinstall the mid drive shafts.
5. Install the rear propshaft onto the mid gearcase and drive a
Capacity: 6.75 oz. (200 ml) NEW roll pin into the propshaft yoke.
6. Install the parking brake caliper assembly. Tighten the two
Specified Lubricant: ATV Angle Drive mounting bolts in increments and torque to specification.
Fluid (PN 2876160)
Fill Plug Torque: 14 ft. lbs. (19 Nm)
Gearcase Installation 18 ft. lbs.

1. Install the mid gearcase into the frame. (24 Nm)
2. Slide the mid gearcase forward and install the mid
Mid Propshaft
=T
18 ft. lbs. (24 Nm)
Mid Gearcase
3. Position the mid gearcase and install the (4) mounting bolts.
30-36 ft. lbs.

(41-49 Nm)
=T
Mid Gearcase - Mounting Bolts:
30-36 ft. lbs. (41-49 Nm)
7.36
FINAL DRIVE
Mid Gearcase Exploded View
18-23 ft. lbs. 18-23 ft. lbs.

(24-31 Nm) (24-31 Nm)
7
1 Screw (5/16-18 x 1.0) 15 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 Bushing 1
5 Cover, Output 1 20 Pinion, 10T 1
6 Shim 1 21 Gear, 26T Output 1
7 Bearing, Ball 1 22 Bearing, Ball 1
8 Gear, Ring 37T 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 O-Ring 1 27 N/A -
13 Pipe, Knock 4 28 N/A -
14 Seal, Triple Lip 1 29 N/A -
15 Ring, Retaining 2 30 Ring, Hog 2
7.37
FINAL DRIVE
DRIVE SHAFT SERVICE 2. Remove the large end of the boot from the CV joint and
slide the boot down the shaft.
Drive Shaft / CV Joint Handling Tips
Care should be exercised during drive shaft removal or when
servicing CV joints. Drive shaft components are precision parts.
Cleanliness and following these instructions is very important to

ensure proper shaft function and a normal service life.
The complete drive shaft and joint should be handled by

getting hold of the interconnecting shaft to avoid
disassembly or potential damage to the drive shaft
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 3. Clean the grease from the face of the joint.
protected during handling to avoid damage.
4. Place the drive shaft in a soft-jawed vise.
Do not allow boots to come into contact with sharp
edges or hot engine and exhaust components. 5. Using a soft-faced hammer, or brass drift, strike the inner
race of the joint to drive the joint off the drive shaft. Be sure
The drive shaft is not to be used as a lever arm to to tap evenly around the joint to avoid binding.
position other suspension components.
Brass Drift Shown
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.
Outer CV Joint / Boot Replacement

1. Using a side cutters, cut away and discard the boot clamps.
IMPORTANT: Tap on inner race only!

6. Make sure the circlip is on the shaft and not left in the joint.
Circlip
7.38
FINAL DRIVE
7. Remove the CV boot from the shaft. 13. Grease the joint with the special CV joint grease provided
in the boot replacement kit. Fill the cavity behind the balls
and the splined hole in the joints inner race. Pack the ball
CAUTION tracks and outer face flush with grease. Place any remaining
grease into the boot.
Complete disassembly of the CV joint is NOT
recommended. The internal components are a
precision fit and develop their own characteristic CAUTION
wear patterns. Intermixing the internal
components could result in looseness, binding, The grease provided in the replacement kit is
and/or premature failure of the joint. specially formulated for wear resistance and
durability. DO NOT use substitutes
IMPORTANT: If the grease in the joint is obviously or mix with other lubricants.
contaminated with water and/or dirt, the joint should
be replaced. NOTE: The amount of grease thats provided is pre-
measured, so use all the grease.
Boot Replacement Grease Requirements:
Grease Only Service Kits

PN 1350059 - 20g / PN 1350046 - 30g / PN 1350047 - 50g
Outer CV Joint Capacity:

Front - 74g / Rear - 90g
14. Slide the joint onto the drive shaft splines and align the
circlip with the lead-in chamfer on the inner race of the
joint.
8. Thoroughly clean the joint with an appropriate solvent and
dry the joint to prevent any residual solvent from being left
7
in the joint upon reassembly.
9. Visually inspect the joint by tilting the inner race to one side
to expose each ball. Severe pitting, galling, play between
the ball and its cage window, any cracking or damage to the
cage, pitting or galling or chips in raceways call for joint
replacement.
NOTE: Shiny areas in ball tracks and on the cage

spheres are normal. Do not replace CV joints
because parts have polished surfaces. Replace CV
joint only if components are cracked, broken, worn
or otherwise unserviceable.
10. Clean the splines on the end of the shaft and apply a light 15. Use a soft-faced hammer to tap the joint onto the drive shaft
coat of grease prior to reassembly. until it locks into place.
11. Slide the small boot clamp and boot (small end first) onto 16. Pull on the joint to make sure it is securely locked in place.
the drive shaft and position the boot in its groove machined
in the shaft. 17. Remove excess grease from the CV joint's external surfaces
and place the excess grease in the boot.
12. Install a NEW circlip on the end of the shaft.
18. Pull the boot over the joint and position the boot lips into
the grooves on the joint housing and shaft. Make sure the
boot is not dimpled or collapsed.
7.39
FINAL DRIVE
19. Install and tighten the large clamp using the Axle Boot Inner Plunging Joint / Boot Replacement
Clamp Tool (PU-48951).
1. Using a side cutters, cut away and discard the boot clamps.
Axle Boot Clamp Tool 2. Remove the large end of the boot from the plunging joint
PU-48951 and slide the boot down the shaft.
20. 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 shaft.
21. Install and tighten the small clamp on the boot using the
Axle Boot Clamp Tool (PU-48951).
3. Clean the grease from the face of the joint.

4. Place the drive shaft in a soft-jawed vise.
5. Using a soft-faced hammer, or brass drift, strike the inner
race of the joint to drive the joint off the drive shaft. Be sure
to tap evenly around the joint to avoid binding.
Brass Drift Shown
Axle Boot Clamp Tool

PU-48951
7.40
FINAL DRIVE
IMPORTANT: Tap on inner race only! 11. Slide the small boot clamp and boot (small end first) onto
the drive shaft and position the boot in its groove machined
6. Make sure the circlip is still on the shaft and not left in the
in the shaft.
joint.
12. Install a NEW circlip on the end of the shaft.
Circlip
13. Grease the joint with the special CV joint grease provided
in the boot replacement kit. Fill the cavity behind the balls
and the splined hole in the joints inner race. Pack the ball
tracks and outer face flush with grease. Place any remaining
grease into the boot.
CAUTION
The grease provided in the replacement kit is

specially formulated for wear resistance and
durability. DO NOT use substitutes
or mix with other lubricants.
7. Remove the boot from the shaft.
NOTE: The amount of grease thats provided is pre-
measured, so use all the grease.
CAUTION
Boot Replacement Grease Requirements:
Complete disassembly of the plunging joint is
NOT recommended. The internal components
Grease Only Service Kits
are a precision fit and develop their own
characteristic wear patterns. Intermixing the PN 1350059 - 20g / PN 1350046 - 30g / PN 1350047 - 50g
internal components could result in looseness,
binding, and/or premature failure of the joint. Inner Plunging Joint Capacity:
IMPORTANT: If the grease in the joint is obviously
Front - 60g / Rear - 100g
7
contaminated with water and/or dirt, the joint should
be replaced. 14. Fully compress the joint and push the drive shaft firmly into
the inner race.
15. Align the circlip with the lead-in chamfer.
8. Thoroughly clean the joint with an appropriate solvent and

dry the joint to prevent any residual solvent from being left
in the joint upon reassembly.
16. Use a soft-faced hammer to tap the joint onto the drive shaft
9. Visually inspect the joint for damage. Replace if needed. until you reach the end of the splines and the joint locks in
place.
10. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
7.41
FINAL DRIVE
17. Pull on the joint to test that the circlip is seated and that the Drive Shaft Exploded View
joint is securely fastened to the shaft.
FRONT SHAFT
18. Remove excess grease from the plunging joints external
surfaces and place the excess grease in the boot. Spring Ring
19. Pull the boot over the joint and position the boot lips into
the grooves on the joint housing and shaft. Make sure the Plunging
Joint
boot is not dimpled or collapsed.
20. Install and tighten the small clamp using the Axle Boot
Clamp Tool (PU-48951). Gear Side
Boot Kit
Grease Capacity
60 Grams
Grease Capacity
74 Grams
Wheel Side
Boot Kit
CV Joint
Axle Boot Clamp Tool
PU-48951 REAR SHAFT
Rear 4x4 Shown
21. Pull out on the drive shaft to center the joint in the housing. Spring Ring
Slide a straight O-ring pick or a small slotted screw driver
between the large end of the boot and the joint housing and
Plunging
lift up to equalize the air pressure in the boot. Joint
22. Position the boot lip in its groove. Install and tighten the
large clamp using the Axle Boot Clamp Tool (PU-48951).
Gear Side
Grease Capacity Boot Kit
100 Grams
Grease Capacity
90 Grams
Wheel Side
Boot Kit
Axle Boot Clamp Tool CV Joint
PU-48951
7.42
FINAL DRIVE
REAR PROPSHAFT (6X6) Installation
1. Install the rear propshaft onto the rear gearcase input shaft.
Removal
1. Drive the roll pin from the rear propshaft yoke located at 2. Align the rear propshaft pin hole with the pin hole on the
the mid gearcase. mid gearcase rear output shaft.
3. Slide the rear propshaft forward onto the mid gearcase rear
output shaft and drive a NEW roll pin into the propshaft
yoke.
4. Install the parking brake caliper assembly. Tighten the two

Roll Pin
Removal Tool
18 ft. lbs.
(24 Nm)
2. Remove the parking brake caliper assembly from the

back on the rear gearcase input shaft.
=T
Parking Brake Caliper - Mounting Bolts: 7
18 ft. lbs. (24 Nm)
Remove
3. Slide the rear propshaft back on the rear gearcase input

shaft, remove the propshaft from the mid gearcase and
remove the propshaft from the vehicle.
7.43
FINAL DRIVE
REAR GEARCASE (6X6)
Differential - Unlock
General Operation
Clutch Gear
The RANGER rear gearcase has three traction operational
modes: AWD, Differential Lock, and Differential Unlock. Shift Yoke
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.
AWD
When Differential-Lock is selected on the switch, power is
removed from the electrical solenoid allowing the solenoid
Differential - Lock plunger to retract. Spring tension moves the shift yoke back into
place and engages the clutch gear into the engagement dogs that
are attached to the differential gear assembly, locking the rear
Differential - Unlock differential as a solid rear axle.
When switch position is set

to Lock, power is removed
from the solenoid and spring
tension retracts the
When Differential-Unlock is selected on the switch, the rear plunger to engage
differential becomes unlocked for tighter turns. An electrical the clutch gear
solenoid mounted in the rear gearcase housing actuates the shift and lock the
yoke. The solenoid plunger extends out to move the shift yoke differential.
and slides the clutch gear away from the engagement dogs that
are attached to the differential gear assembly. This unlocks the
rear differential.

to Unlock, the solenoid is
powered and the Differential - Lock
plunger extends
to disengage the Clutch Gear
clutch gear and
unlock the Shift Yoke
differential.
7.44
FINAL DRIVE
When the clutch gear is unlocked the rear drive shafts are Gearcase Removal
dependent on the differential allowing tighter turns. When its
locked it becomes a solid rear axle increasing traction. 1. Follow the MID / REAR DRIVE SHAFT - Removal
procedure to remove the rear drive shafts from each side of
the rear gearcase.
Differential
2. Disconnect the differential solenoid 2-wire harness.
3. Completely drain the lubricant from the rear gearcase.
Clutch Gear
Drain Plug
Locked Mode
4. Remove the (4) bolts that secure the rear gearcase to the
Clutch Gear frame.
Locked
Axle Shaft Axle Shaft
Remove the (2)

fasteners from
Unlocked Mode each side.
Clutch Gear 5. Remove the (3) fasteners retaining the parking brake
IRS Axle caliper bracket to the rear gearcase and carefully pull the
rear gear case assembly from the frame. Allow the rear
Unlocked
propshaft to slide off of the rear gearcase shaft.
Axle Shaft Axle Shaft
Bracket
(3)
Propshaft
7.45
FINAL DRIVE
Gearcase Disassembly 3. Remove the differential assembly from the housing.
IMPORTANT: The pinion gear assembly is NOT

intended to be disassembled from the case, as it
requires special OEM tooling in order to properly
reassemble. If there is any damage to the pinion gear,
bearings or case, the assembly must be replaced.
Pinion and ring gear shimming information is NOT
provided due to OEM manufacturing requirements.
1. Remove the differential solenoid from the gearcase cover

if servicing the solenoid, shift lever, shift lever spring, or
shift yoke. If none of these items are being serviced, the
solenoid can remain installed in the gearcase cover.
4. Inspect the bevel gear teeth for chipped, worn, or broken

teeth.
Inspect Teeth
2. Remove the (7) bolts that secure the cover to the housing.
Remove Cover Bolts
5. Remove the small bearing from the differential assembly.

Inspect the bearing for smoothness and wear.
7.46
FINAL DRIVE
6. Remove the shims from the differential assembly. Be sure 9. If the solenoid was removed for servicing, inspect the tip
to keep the shims together for reassembly. of the solenoid for wear. If the tip of the solenoid is flattened
the solenoid must be replaced.
7. Remove the large bearing from the differential assembly. 10. Remove the clutch gear from the gearcase cover.
Inspect the bearing for smoothness and wear.
7
11. Inspect the shift lever (A), shift lever spring (B), shift return
8. Remove the shims from the differential assembly. Be sure springs (C), and shift yoke (D) for excessive wear or
to keep the shims together for reassembly. damage. If disassembly is required proceed to the next step.
If no disassembly is required proceed to Rear Gearcase
Assembly.
C
D
B A
7.47
FINAL DRIVE
12. Loosen the lock assembly pin. 15. Inspect the shift lever (A), shift lever spring (B), shift return
springs (C), shift yoke (D), and lock pin bushing (E).
Inspect the components for excessive wear or damage and
replace as needed.
C
13. Remove the pin from the gearcase cover. E B
Rear Gearcase Assembly

NOTE: Grease all seals and O-rings with Polaris All
Season Grease (PN 2871322) upon assembly.
1. Remove the pinion shaft oil seal using a seal puller and
replace with a new seal.
14. Carefully remove the shift yoke assembly from the

gearcase cover.
NOTE: The pinion gear assembly is NOT intended to

be disassembled from the case, as it requires
special OEM tooling in order to properly reassemble.
If there is any damage to the pinion gear, bearings or
case, the assembly must be replaced.
7.48
FINAL DRIVE
4. Install the original shims (A) onto the differential assembly
(B) on both sides. Install the bearings (C), replace with new
bearings if needed.
Do Not Disassemble.
Replace as an assembly
if damaged or worn.
C
2. Replace the drive shaft oil seals located in the main B

gearcase and gearcase cover
A
7
5. Install the differential assembly into the carrier housing.
3. Replace all worn components.
7.49
FINAL DRIVE
6. If previously removed; assembly the shift lever (A), shift 9. Install the new lightly greased O-ring onto the carrier cover.
lever spring (B), shift return springs (C), shift yoke (D), and
lock pin bushing (E). O-Ring
C
E B
10. Assemble the gearcase halves and install the (7) bolts that
secure the cover to the housing. Torque the bolts in a criss
7. Carefully install the shift yoke assembly into the gearcase cross pattern to 25-35 ft. lbs. (34-48 Nm).
cover.
25-35 ft. lbs.
(34-48 Nm)
11. If previously removed, install the differential solenoid into

8. Install the lock assembly pin and tighten. the carrier cover. Torque solenoid to 30-40 ft. lbs. (41-54
Nm).
30-40 ft. lbs.

(41-54 Nm)
7.50
FINAL DRIVE
Rear Gearcase Installation
1. Place the rear gearcase assembly into the frame. Slide the
rear propshaft onto the rear gearcase input shaft.
2. Install the (4) gearcase mounting fasteners and torque the

fasteners to 40 ft. lbs. (54 Nm).
3. Install the parking brake caliper bracket fasteners and

torque the fasteners to 17 ft. lbs. (23 Nm).
Bracket
17 ft. lbs.
23 (Nm)
Propshaft
40 ft. lbs.
(54 Nm)
4. Connect the differential solenoid 2-wire harness.
5. Follow the MID / REAR DRIVE SHAFT - Installation

procedure to reinstall the rear drive shafts.
6. Add Polaris ATV Angle Drive Fluid (PN 2876160) to rear

carrier. Refer to maintenance information in Chapter 2 for
7
more details. Torque drain plug to 30-45 in. lbs. (3-5 Nm).
Torque fill plug to 40-50 ft. lbs. (54-68 Nm).
Fill Plug Drain Plug

40-50 ft. lbs. 30-45 in. lbs.
(54-68 Nm) (3-5 Nm)
Rear Gearcase Lubricant / Capacity:

ATV Angle Drive Fluid / 18 fl. oz. (532 ml)
7.51
FINAL DRIVE
Rear Gearcase Exploded View
40-50 ft. lbs.

(54-68 Nm)
30-45 in. lbs.

(3-5 Nm)
70-90 ft. lbs.
(95-122 Nm)
25-35 ft. lbs.

(34-48 Nm)
30-40 ft. lbs.

(41-54 Nm)
REF# DESCRIPTION QTY REF# DESCRIPTION QTY REF# DESCRIPTION QTY

1 Hypoid Gear Assembly 1 15 Bearing Cone - Diff 1 29 Pinion Nut 1
2 Carrier Housing Half 1 16 Bearing Cup - Diff 1 30 Oil Seal - Pinion 1
3 Carrier Cover Half 1 17 Bearing - Roller 1 31 Pinion Thrust-Washer AR
4 Diff Case Half 1 18 Bearing - Cup 1 32 Lock Pin Bushing 1
5 Diff Case Cover Half 1 19 Bearing Assembly - Collar 1 33 Shift Return Spring 2
6 Diff Side Gear 2 20 Clutch Gear 1 34 Drain Plug 1
7 Diff Pinion Mate Gear 2 21 O-Ring - Housing Halves 1 35 Oil Seal - Shaft 2
8 Pinion Mate Thrust-Washer 2 22 Lock Assembly Pin 1 36 Fill Plug 1
9 Diff Cross Pin 1 23 Vent Tube 1 37 Shift Yoke 1
10 Diff Roll Pin 1 24 Flanged Hex Bolt - Housing 7 38 Shift Lever 1
11 Hex Bolt - Ring Gear 8 25 Diff Solenoid 1 39 Shift Lever Spring 1
12 Diff Case Thrust-Washer AR 26 Spacer - Kit AR 40 Pinion Spacer 1
13 Side Gear Thrust-Washer 1 27 Bearing Cup - Pinion 2
14 Diff Case Thrust-Washer AR 28 Bearing Cone - Pinion 2
7.52
TRANSMISSION (4X4)
CHAPTER 8
TRANSMISSION (4X4)
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
SHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
SNORKEL / OUTPUT GEAR BACKLASH PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 8.16
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.23
TRANSMISSION EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
RANGER XP/HD 800 (PN 1332812); RANGER CREW 800 (PN 1332818) . . . . . . . . . 8.25
8.3
TRANSMISSION (4X4)
SPECIFICATIONS Lubrication
Torque Specifications
=
ITEM TORQUE VALUE
10-14 ft. lbs. Recommended Transmission Lubricant:
Drain / Fill Plug Premium Synthetic AGL (PN 2873602) (Quart)
(14-19 Nm)
25-30 ft. lbs. Capacity: 33.8 oz. (1000 ml)
Case Bolts
(34-41 Nm)
12-18 ft. lbs.
Bell Crank Nut
(16-24 Nm) SHIFT LEVER
8-12 ft. lbs.
Gear Sector Cover Removal
(11-16 Nm)
23-27 ft. lbs. 1. Remove the (2) push rivets retaining the dash panel and
Differential Solenoid remove the panel from the dash to access the shift lever.
(31-37 Nm)
Output Gear Assembly 8-12 ft. lbs. 2. Remove the shift knob cover, retaining screw and shift
Retaining Screws (11-16 Nm) knob from the shift lever.
8-12 ft. lbs.

Snorkel Tube Locking Screw
(11-16 Nm)
8-12 ft. lbs.
Shift Fork Retaining Screws
(11-16 Nm)
20-30 in. lbs.
Oil Deflector Shield Screws
(2.3-3.4 Nm)
Differential Cover 23-27 ft. lbs.
Assembly Bolts (31-37 Nm)
Transmission Mounting Bolts 20 ft. lbs.
Front 5/16 Bolts (27 Nm)
Transmission Mounting Bolts 37 ft. lbs.
Lower / Rear 3/8 Bolts (50 Nm)
Special Tools
PART NUMBER TOOL DESCRIPTION
PA-50231 Snorkel Tool
Rear Output
2871698 (Part of 2871702 Kit) 3. Remove the grommet around the shift lever from the dash.
Seal Driver
Rear Driveshaft 4. Remove the clip and washer retaining the shift cable to the
2871699 (Part of 2871702 Kit) shift lever and disconnect the cable end from the lever.
Seal Guide
Bearing Seal Driver 5. Remove the retaining ring, outer washer, and both bushings
2871282 from the shift lever.
(50 mm)
6. Slide the shift lever off the mounting bracket and out from
the frame.
Installation
1. Repeat the steps in reverse order to install the gear shift
lever.
8.4
TRANSMISSION (4X4)
SHIFT CABLE 3. With two open-end wrenches, loosen the outside jam nut
counterclockwise. Turn the outside jam nut 1 1/2 turns.
Inspection
Shift cable adjustment is necessary when symptoms include: Inside Jam Nut
Noise on deceleration
Excessive gear clash (noise)
Gear selector is moving out of desired range
Inspect shift cable, clevis pins, and pivot bushings and replace
if worn or damaged.
Outside Jam Nut
Adjustment
adjustment point located near the transmission. If 4. After turning the outside jam nut 1 1/2 turns. Hold the
adjustment is needed beyond that, remove the dash outside jam nut with a wrench and tighten the inside jam
panel to access the shift cable adjustment point nut clockwise, until it is tight against the bracket.
1. Place gear selector in neutral. Make sure the transmission made to the shift cable.
cable as needed.
Adjustment
Point
8
Neutral Position
2. Locate the shift cable adjustment point at the engine-to-

transmission mount bracket.
8.5
TRANSMISSION (4X4)
TRANSMISSION SERVICE
General Operation
The RANGER 4x4 transmission has two traction operational Unlocked
modes: 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.
AWD
Differential - Lock
When Differential-Lock is selected on the switch, power is

Differential - Unlock removed from the electrical solenoid allowing the solenoid
plunger to retract. Spring tension moves the shift fork back into
place and engages the engagement dog to the side gear that is
part of the planetary differential assembly. This locks the rear
differential as a solid rear axle, increasing traction.
When Differential-Unlock is selected on the switch, the rear When switch position is set
differential becomes unlocked for tighter turns. An electrical to Lock, power is removed
solenoid mounted in the rear portion of the transmission actuates from the solenoid and
the shift fork. The solenoid plunger extends out to move the shift the plunger retracts
fork and slides the engagement dog away from the side gear that to engage the
is part of the planetary differential assembly. This unlocks the clutch gear
rear differential. The rear drive shafts are now dependent on the and lock the
differential allowing for tighter turns. differential.

to Unlock, the solenoid is
powered and the
plunger extends
to disengage the
clutch gear and
unlock the
differential. Locked
8.6
TRANSMISSION (4X4)
Transmission Removal 9. Using a Phillips screwdriver, remove the (3) screws
retaining the inner PVT cover to the engine. Using a 3/8
1. Place vehicle on a level surface and block the front wheels. socket and ratchet, remove the (5) screws retaining the
inner PVT cover to the transmission and remove the cover.
2. Elevate the rear of the vehicle and safely support the vehicle
under the rear frame area.
CAUTION

procedure. Always wear eye protection.
3. Remove the wheel nuts and washers from both rear wheels.
Remove the rear wheels and set them off to the side.
4. If internal transmission repair is required, drain the

transmission lubricant.
5. Remove the seat and side storage container to access the 10. Using a 15mm socket, ratchet and wrench, remove the
PVT system. upper fastener from the rear shock on each side.
6. Disconnect the brake switch harness located below the

outer PVT cover.
7. Using a 3/8 socket, extension and ratchet, remove the (9)

screws retaining the outer PVT cover. Remove the cover
from the vehicle.
8. Remove the drive belt, drive clutch and driven clutch (see
Chapter 6 Clutching).
8
11. Remove the rear brake lines from the rear upper A-arm
retainers.
8.7
TRANSMISSION (4X4)
12. Using a 15mm socket, ratchet and wrench, remove the 15. Remove the shift cable from the transmission bell crank and
through-bolt retaining the rear upper A-arm to the bearing disconnect the gear selector switch.
carrier on each side.
Remove
Disconnect
16. Using a 3/4 open-end wrench, loosen the lower jam nut on
13. Remove the rear drive shafts from each side of the the shift cable and remove the shift cable from the mount
transmission by pulling out sharply on each shaft. bracket.
Mount
Bracket
Loosen
14. Remove the exhaust springs retaining the exhaust silencer 17. Disconnect the rear differential solenoid.
and remove the silencer from the vehicle.
Solenoid
8.8
TRANSMISSION (4X4)
18. Remove the (3) fasteners retaining the parking brake mount 21. Remove the engine-to-transmission mount bracket from
bracket and remove the parking brake caliper as an the vehicle.
assembly.
Mount Mount
Bracket Bracket
22. Remove the lower transmission through-bolt.

19. Remove the (2) through-bolts and (2) lower engine mount
nuts from the engine-to-transmission mount bracket.
Mount
Bracket
23. Remove the rear transmission through-bolt.

8
20. Remove the (2) rubber engine mounts from the engine.
Engine
Mounts
8.9
TRANSMISSION (4X4)
24. Retain each rear drive shaft to the lower A-arm to keep them 27. Tie the exhaust pipe to the airbox to hold it up during
out of the way during transmission removal. transmission removal. Remove the airbox lid and air filter.
Tie Strap
Tie Strap
25. Using a 15mm socket and ratchet, remove the retaining nut 28. Remove the lower clip and pin from the cargo box shock.
from the upper portion of the stabilizer bar linkage bushing Tie the shock out of the way or completely remove it.
on each side of the vehicle.
29. With the help of an assistant, lift up on the transmission and
shift it over to the side to clear the vertical frame support.
26. Using a 1/2 socket and ratchet, remove the two fasteners
that secure the stabilizer bar to the main frame on each side.
Remove the stabilizer bar from the vehicle. NOTE: The propshaft will slide off during removal.
30. With the help of an assistant, lift up on the transmission and

carefully move it towards the rear of the vehicle.
Remove
8.10
TRANSMISSION (4X4)
31. Close the cargo box. With the help of an assistant, remove NOTE: Removal can be aided by using your thumbs
the transmission from the rear of the vehicle as shown. to press down on the shafts while pulling up the
cover with your fingers.
Transmission Disassembly 7. Remove the compression spring (G).
NOTE: Refer to the exploded view at the end of this

chapter as a reference.
1. Place the transmission in Reverse before disassembly.
2. Drain and properly dispose of the transmission lubricant

(see Chapter 2).
3. Remove the shift cable from the bellcrank (B).
4. Remove the bellcrank nut (A) and bellcrank (B).
8
8. Remove the detent star (H). Note how the detent star fits
onto the splined shaft with the raised edge facing outward
for reassembly.
9. Remove the lockout disc (I). Note the raised edge facing
outward for reassembly.
10. Remove the shift shaft (J), detent pawl (K) and the shift
gears (L and M).
IMPORTANT: Note the timing marks on the shift gears

(L and M) for reassembly purposes.
5. Remove the E-clip (C) that retains the gear selector switch
(D) and remove the switch.
6. Remove the sector cover bolts (E) and remove the sector
cover (F).
8.11
TRANSMISSION (4X4)
11. Remove the bolt retaining the brake disc assembly to the 14. Remove the cam chain tensioner spring (O). Slide the cam
transmission and remove the disc. chain tensioner shoe (P), pins (Q) and cam chain tensioner
cam (N) from the assembly.
12. Remove all the transmission cover bolts. Using suitable pry
bars, remove the cover using the designated pry points
(indicated by the black arrows in the illustration below).
Tap cover with soft face hammer to remove.
N O
P Q Q
15. Remove the differential gear (R) and chain by gently prying
underneath or tapping the differential gear from the
opposite side until it tips toward the output gear (S). The
differential gear is connected to the shift fork and must slide
backwards to clear the fork arms once the chain is removed.
CAUTION
Do not pry on case sealing surfaces.

Use only the designated pry points
on the transmission.
13. Note location of chain tensioner cam (N). If fully extended,

chain is worn beyond service limit and should be replaced
along with the chain tensioner shoe.
R
S
16. Using a T20 Torx driver, remove the screws that secure the
N oil deflector (T).
8.12
TRANSMISSION (4X4)
17. Using a T27 Torx driver, remove the screws that secure the 20. Place the gear cluster assembly on a clean surface for
output gear (U). inspection.
18. Remove the shift drum (V) from the gearcase by moving Gear Cluster Disassembly
the drum up and to the right to clear the shift shaft.
21. Remove the bearing from the reverse shaft using a bearing
puller. Slide the engagement dog off of the reverse shaft
V (see Figure 8-1).
19. Remove the output gear (U) and gear cluster assembly from
the gearcase by pulling both assemblies straight up. 8
Figure 8-1
8.13
TRANSMISSION (4X4)
22. Remove the retaining ring and washer from the reverse 30. To disassemble the shift fork rail remove the snap ring (W)
shaft (see Figure 8-1). from the end of the shift rail on either side.
23. Remove the bearing from the input shaft using a bearing W
puller (see Figure 8-1).
24. Remove the 33T gear and needle bearing from the reverse
shaft (see Figure 8-1).
25. The reverse shaft should slide out of the silent chain to
separate the assembly. W
CAUTION
Use caution when disassembling the shift rail.
The compressed springs on the shift rail may
pop off causing eye or face injury.
Snorkel Shaft Removal / Disassembly

31. Using a T27 Torx driver, remove the snorkel tube locking
screw located inside the gearcase.
26. Remove the rest of the ball bearings from each shaft.
27. Disassemble the other end of the reverse shaft. Remove the
retaining ring, washer, gear and needle bearing from the
reverse shaft (see Figure 8-2).
Locking Screw
32. Remove the seal from the snorkel shaft to access the snorkel
tube for removal.
Figure 8-2
28. Remove the washer, retaining ring and engagement dog

from the reverse shaft (see Figure 8-2).
29. Remove the retaining ring, washer, 38T sprocket and Seal Removed
needle bearing from the reverse shaft (see Figure 8-2).
8.14
TRANSMISSION (4X4)
33. Using the Snorkel Tool (PA-50231), loosen and remove the 36. Remove the snap ring and shim retaining the bearing in the
snorkel tube and shaft assembly. snorkel tube.
Shim
PA-50231 Snap Ring
37. Lightly tap on the bearing from the opposite side to remove
it from the snorkel tube.
34. Remove the snap ring and shim from the snorkel shaft.
Snap Ring
38. To remove the remaining bearing on the snorkel shaft, 8
remove the retaining ring and press the bearing off.
Shim
35. Use an arbor press to remove the snorkel tube from the
snorkel shaft.
39. Remove all seals from the gearcase halves and clean the
cases in preparation for assembly.
8.15
TRANSMISSION (4X4)
Snorkel / Output Gear Backlash Procedure 3. Install the snorkel shaft into the gearcase. Using the Snorkel
Tool (PA-50231), tighten the snorkel tube about 10 full
1. Reassemble the snorkel shaft assembly by reversing the rotations. Do not completely tighten the snorkel tube.
disassembly procedure (see Transmission Snorkel Shaft
Removal / Disassembly in previous section).
PA-50231
4. Inspect the output gear assembly and replace bearings if

needed. Inspect each gear for damage, chips or abnormal
worn teeth.
2. Apply a small amount of white lithium grease on the threads

of the snorkel tube.
Grease Threads
5. Install the output gear assembly. Be sure to properly mesh

the snorkel shaft bevel gear with the output bevel gear.
6. Install the 4 torx screws (A) that secure the output gear
assembly. Torque the screws to specification.
8.16
TRANSMISSION (4X4)
11. Once the backlash is set, apply Loctite 242 to the threads
and install the locking screw to secure the snorkel tube.
=T
Output Gear Retaining Screws:
8-12 ft. lbs. (11-16 Nm)
7. Tighten the snorkel tube until it is lightly seated using the

snorkel tool (PA-50231). Turn the output shaft to prevent
binding while tightening the snorkel tube. Make sure the
snorkel shaft gear and output bevel gear have zero lash.
NOTE: It is important to have zero lash between the

output gear and the snorkel shaft gear. If there is
binding or excess lash, tighten or loosen the snorkel
shaft until there is zero lash.
IMPORTANT: Do not overtighten the snorkel tube.

Gears should rotate freely without binding. 12. Torque the locking screw to specification.
8. Look down into the gearcase at the snorkel locking screw

hole opening to reference your starting point.
9. Slowly rotate the snorkel tube counterclockwise while

counting the number of notches passing through the hole
opening as you rotate the tube. Rotate the snorkel tube to
the 7th notch from the seated position obtained in step 7.
Count 7 notches through

the locking screw hole
8-12 ft. lbs.
(11-16 Nm)
=T 8
Snorkel Locking Screw:
8-12 ft. lbs. (11-16 Nm)
13. With the snorkel shaft assembly properly installed, remove

the (4) Torx screws and remove the output shaft assembly.
10. Check the output shaft gear backlash again by feel. If the
output shaft lash appears to be too tight, rotate the snorkel
shaft counterclockwise to the next notch.
8.17
TRANSMISSION (4X4)
Transmission Assembly 2. Inspect the shift drum for any damage or wear. Inspect the
splines of the shift drum. Replace the O-ring on the end of
1. Assemble the reverse shaft assembly and input shaft the shift drum and lubricate it before assembly.
assembly if previously disassembled (see illustrations).
3. Stretch the silent chain on a flat surface and measure the

length of 8 pitches in a minimum of three places on the
chain. Replace the chain if the measurement is longer than
the service limit.
= In. / mm.
Silent Chain Service Limit (8 pitch):

3.090 (7.849 cm)
4. The shift drum, reverse shaft, input shaft, shift fork rail and
output gear assembly must be installed at the same time to
properly align all components.
Input Shaft Shift Fork Rail
Reverse Shaft
8.18
TRANSMISSION (4X4)
NOTE: To ease assembly use a plastic tie strap to 6. With all the components in the correct position, install the
hold the shift forks and the shift drum together (4) output gear assembly retaining screws. Apply Loctite
during assembly. 242 to the threads of the screws. Torque the screws to
specification.
Tie Strap
NOTE: If the transmission is in gear, place the
transmission in Neutral.
5. With the gearcase on its side, hold the gear cluster

assembly and output assembly together. Carefully install
each shaft into their respective recess in the gearcase.
=T
Output Gear Retaining Screws:
8-12 ft. lbs. (11-16 Nm)
7. Install the oil deflector shield into the gearcase. Apply

Loctite 242 to the threads of the screws. Torque the screws
to specification.
=T
Oil Deflector Retaining Screws:
20-30 in. lbs. (2.3-3.4 Nm)
8.19
TRANSMISSION (4X4)
8. Install the rear drive differential and drive chain, following Place the spring over the front pin and hook the spring
these precautions: leg under the cam.
The case half rear output seal should be removed prior View From Left Side of Transmission
to installation of the differential, as seal damage can
occur with seal installed due to the angle of entry.
Forward
Install the differential sliding geardog onto the shift
fork arms at the same time the silent chain is installed.
The differential gear bearing may be lightly tapped into
place. The output seal can be installed once the
assembly is in place.
Lift Spring Over Rear

Hook Spring Leg Under Cam Mounting Pin
Lift the end of the spring up and over the rear pin. The
tensioner cam will lift the shoe to provide chain tension.
9. Tensioner Installation:
NOTE: Case-halve mating may be difficult due to

tensioner pressure on the silent chain during
installation. Release tension at the ratcheting cam to
aid case half installation. Release the tensioner
spring after the case halves are mated but not yet
touching.
Assemble the tensioner cam and tensioner shoe and 10. Apply a continuous bead of Crankcase 3 Bond Sealant
place them into the transmission. (PN 2871557) to the LH gearcase mating surface and install
the cover. Install and tighten the 20 screws in an even criss-
Insert the front pin through the tensioner cam and the cross pattern to evenly secure the cover. Torque the screws
rear pin through the tensioner shoe. to specification.
Spring Leg
=T
Forward Gearcase Cover Bolts:

25-30 ft. lbs. (34-41 Nm)
Top View
Tensioner Cam
8.20
TRANSMISSION (4X4)
11. Install all new seals into the gearcases. Use the Rear Output 13. Install the sector gear (16T) onto the shift drum shaft. Install
Seal Driver (PN 2871698) and Rear Driveshaft Seal Guide the shift shaft assembly and sector gear (11T) into the
(PN 2871699) to install the seals into the gearcase halves bushing pocket on the left side. Align the timing marks on
(refer to the following illustration to identify the seals the gears as shown.
needing replacement).
2871698
Timing Marks
2871699
Reverse Gear Shown
14. Install the lockout disc onto the shift drum shaft. Be sure to
install the lockout disc with the raised edge facing outward.
Lockout Disc
8
15. Install the detent star onto the shift drum shaft. Be sure to
install the detent star with the raised edge facing outward.
12. Thoroughly clean the shift shaft housing. Be sure the

transmission is in Reverse prior to reassembly.
Detent Star
8.21
TRANSMISSION (4X4)
16. Install the detent pawl onto the shift shaft and carefully 20. Install the shift cable onto the bellcrank end (if removed)
install the compression spring. and secure with the outer washer and clip.
Bellcrank Nut
Spring
Retaining Ring
Washer Clip
Detent Pawl
17. Install a new O-ring on each shift shaft. Apply a small 21. Install the transmission gear selector switch and secure the
amount of white lithium grease on the O-rings, shift shafts switch with the retaining ring.
and component contact surfaces prior to installing the
sector cover. 22. Install the brake disc assembly onto the output shaft. Apply
Loctite 262 or 2760 to the mounting bolt threads and
torque the bolt to specification.
O-Rings
18. Apply Crankcase Sealant (3-Bond) (PN 2871557) onto the

cover and transmission case mating surface. Install the
sector cover and torque the bolts to specification.
=T
=T Park Brake Disc Mounting Bolt:

15-18 ft. lbs. (20-24 Nm)
Sector Cover Bolts:
8-12 ft. lbs. (11-16 Nm)
19. Install the bellcrank onto the shift shaft. Note the key
splined on the bellcrank and shift shaft. Install the nut
and torque to specification.
=T
Bellcrank Nut:
12-18 ft. lbs. (16-24 Nm)
8.22
TRANSMISSION (4X4)
Transmission Installation
1. If transmission lubricant was drained, fill the transmission
=T
with the specified amount of Premium Synthetic ATV
Transmission Mounting Fastener Torque:
Gearcase Lubricant (AGL) prior to installation.
Front 5/16 Bolts: 20 ft. lbs. (27 Nm)
Lower / Rear 3/8 Bolts: 37 ft. lbs. (50 Nm)
=
9. Install the parking brake caliper assembly and torque the
Recommended Transmission Lubricant: mount bracket fasteners to specification.
Premium Synthetic AGL (PN 2873602) (Quart)

=T
Parking Brake Caliper to Mount Bracket:
2. Apply Polaris Premium All Season Grease (PN 2871423)
18 ft. lbs. (24 Nm)
to splines of front output shaft.
Mount Bracket to Transmission:
3. With the help of an assistant, position the transmission into 40 ft. lbs. (54 Nm)
the frame from the rear of the vehicle. Align the output shaft
and propshaft splines while positioning the transmission to 10. Connect the electrical harnesses to the rear differential
allow the shafts to slide together. solenoid and the gear selector switch.
4. Install the engine-to-transmission mount bracket. 11. Remove the tie straps retaining each drive shaft and the one
retaining the exhaust pipe to the airbox. Reinstall the air
5. Install the (2) rubber engine mounts into the engine filter and airbox lid.
crankcase.
12. Properly route the transmission vent line. Be sure vent line
6. Position the engine-to-transmission mount bracket and is not kinked or pinched.
install the (2) through-bolts and (2) lower engine mount
nuts loosely. 13. Install the rear cargo box shock.
14. Install the stabilizer bar to the frame and to each stabilizer
7. Install the lower and rear transmission through-bolts.
linkage. Torque fasteners to specification.
IMPORTANT: Be sure the brake line is clear of the
lower through-bolt upon installation. =T
Lower
8
Stabilizer Bar Retaining Bolts:
Through-Bolt Stabilizer Linkage Rubber Bushing Nuts:
17 ft. lbs. (24 Nm)
15. Apply anti-seize to the splines of each rear drive shaft and
insert them into the transmission.
8. Torque all transmission mount fasteners to specification.
Apply Anti-Seize
8.23
TRANSMISSION (4X4)
16. Attach the rear upper A-arms to the bearing carrier on each TROUBLESHOOTING
side and torque the fasteners to specification.
Troubleshooting Checklist
=T Check the following items when shifting difficulty is
encountered.
Rear Upper A-Arm to Bearing Carrier Bolts:
30 ft. lbs. (41 Nm) Shift cable adjustment/condition
17. Place the rear brake line into the retainer located on each Idle speed (throttle cable routing)
rear upper A-arm. PVT clutch alignment
Transmission lubricant type/quality
Drive belt deflection (where applicable)
Loose fasteners on sector gear cover
Worn rod ends, clevis pins, or pivot arm bushings
Shift selector rail travel
Worn, broken or damaged internal transmission
components
NOTE: To determine if shifting difficulty or problem

is caused by an internal transmission problem,
isolate the transmission by disconnecting the shift
cable end from the transmission bellcrank. Manually
18. Attach the rear shocks to the frame and torque the upper select each gear range at the transmission bellcrank,
fasteners to specification. and test ride vehicle. If it functions properly, the
problem is outside the transmission.
=T If transmission problem remains, disassemble

transmission and inspect all gear dogs for wear
Rear Upper Shock Bolts: 30 ft. lbs. (41 Nm) (rounding) or damage. Inspect all bearings, circlips,
thrust washers and shafts for wear.
19. Install the shift cable onto the mount bracket and reinstall
the shift cable onto the transmission bell crank.
20. If both adjustment jam nuts were moved, adjust the shift
cable (see Shift Cable - Adjustment).
21. Install the exhaust silencer and (2) retaining springs.
22. Install the inner PVT cover and torque the (8) screws to
specification (see Chapter 6).
23. Install the drive clutch, driven clutch and drive belt. Torque
the clutch retaining bolts to specification (see Chapter 6).
NOTE: Align clutches as outlined in Chapter 6.
24. Install the outer PVT cover and (9) screws. Torque the
screws to specification (see Chapter 6).
25. Install the brake switch harness below the outer PVT cover.
26. Install the rear wheels, washers and wheel nuts. Torque the
wheel nuts to specification (see Chapter 2).
27. Carefully lower the vehicle to the ground and reinstall the
side storage container and seat.
8.24
TRANSMISSION (4X4)
TRANSMISSION EXPLODED VIEW
RANGER XP/HD 800 (PN 1332812); RANGER CREW 800 (PN 1332818)
23-27 ft. lbs. 25-30 ft. lbs.
(31-37 Nm) (34-41 Nm)
242
15-18 ft. lbs.

(20-24 Nm)
262
20-30 in. lbs.

(2.3-3.4 Nm)
242
8-12 ft. lbs.
(11-16 Nm)
242
23-27 ft. lbs. 8-12 ft. lbs.

(11-16 Nm)
(31-37 Nm) 242
10-14 ft. lbs.

(14-19 Nm)
8
8-12 ft. lbs.

(11-16 Nm) 242
8-12 ft. lbs.

(11-16 Nm)
242
FOR REASSEMBLY
Apply White Lithium
Based Grease.
8-12 ft. lbs.
(11-16 Nm)
Apply Polaris
Crankcase Sealant.
12-18 ft. lbs.
(16-24 Nm)
Apply Loctite to
the bolt threads.
8.25
TRANSMISSION (4X4)
Exploded View, Continued
Ref. Qty. Description Ref. Qty. Description
1. 20 Screw, Self Tapping Hex 50. 1 Detent Pawl
2. 2 Seal, Triple Lip 51. 1 Compression Spring, Detent
3. 1 Cover, LH 52. 1 Cover, Sector
4. 2 Bearing, Ball 53. 1 Bellcrank, Shift Drum
5. 1 Silent Chain 54. 1 Lock Nut
6. 1 Case, RH 55. 1 Switch, Rotary
7. 1 Bearing, Ball 56. 1 Retaining Ring
8. 1 Sprocket, 19T 57. 1 Gear, Sector 16T
9. 1 Oil Deflector 58. 1 Drain Plug, Magnetic
10. 2 Screw, Self Tapping Torx 59. 1 Detent Star
11. 1 Output Gear, 91T 60. 1 O-Ring
12. 1 Retaining Ring 61. 1 Gear, 13T Snorkel
13. 6 Screw, Self Tapping Hex 62. 1 Bearing, Ball
14. 1 Bearing Cover, Center Drive 63. 1 Retaining Ring
15. 2 Retaining Ring 64. 1 Snorkel Tube
16. 1 Shim 65. 7 Screw, Torx
17. 1 Bearing, Ball 66. 1 Shim
18. 1 Pinion, 13T Center Drive 67. 2 Retaining Ring
19. 1 Retaining Ring 68. 1 Seal, Triple Lip
20. 1 Thrust Washer 69. 1 Seal, Triple Lip
21. 1 Gear, 36T Spur (XP/HD); Gear, 41T Spur (CREW) 71. 2 Dowel Pin
22. 1 Bearing, Needle 72. 1 Fill Plug
23. 1 Washer 73. 2 Compression Spring
25. 2 Engagement Dog, 6-Face 74. 2 Retaining Ring
26. 2 Retaining Ring 75. 2 Washer, Cup
27. 2 Thrust Washer 76. 1 Retaining Ring
28. 1 Sprocket, 38T 6-Face 77. 1 Shim
29. 1 Reverse Shaft, 26T 78. 1 Engagement Dog
30. 1 Gear, 33T 6-Face 79. 1 Torsion Spring
31. 1 Shift Collar 80. 1 Shift Fork
33. 2 Bearing, Ball 81. 1 Side Gear, 36T
34. 1 Seal, Triple Lip 82. 1 Carrier Assembly
35. 3 Bearing, Ball 83. 1 Side Gear, 36T, Disconnect
36. 1 Input Shaft, 35T (XP/HD); Input Shaft, 31T (CREW) 84. 6 Gear Assembly
37. 1 Silent Chain 85. 6 Dowel Pin
38. 1 Compression Spring 86. 1 Cover
39. 2 Shift Fork 87. 6 Screw
40. 2 Compression Spring 88. 1 Solenoid
41. 1 Rail, Shift Shaft 89. 2 Washer, Fender
42. 2 Pin 93. 2 Bearing, Needle
43. 1 Torsion Spring 94. 1 Lockout Disc
44. 1 Cam, Chain Tensioner 99 1 Plug, Speed Sensor
45. 1 Shoe, Chain Tensioner 100. 1 O-Ring
46. 1 Shift Drum 101. 1 Brake Disc/Hub Assembly
47. 1 Gear, Sector 31T 102. 1 Washer, Fender
48. 1 Shift Shaft 103. 1 Screw
49. 1 O-Ring 104. 1 Vent Tube
8.26
TRANSMISSION (6X6)
CHAPTER 8
TRANSMISSION (6X6)
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.28
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.28
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.28
SHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.28
INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.28
TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.29
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.29
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.31
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.36
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40
TRANSMISSION EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.42
RANGER 6X6 800 (PN 1332702). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.42
8.27
TRANSMISSION (6X6)
TORQUE SPECIFICATIONS 5. Remove the retaining ring, outer washer, and both bushings
from the shift lever.
ITEM TORQUE VALUE 6. Slide the shift lever off the mounting bracket and out from
Transmission 10-14 ft. lbs. the frame.
Fill Plug (14-19 Nm)
Installation
Transmission 10-14 ft. lbs.
Drain Plug (14-19 Nm) 1. Repeat the steps in reverse order to install the gear shift
lever.
Transmission 27-34 ft. lbs.
Case Bolts (37-46 Nm)
Transmission 40 ft. lbs. SHIFT CABLE
Mounting Bolts (54 Nm)
12-18 ft. lbs. Inspection
Bell Crank Nut
(16-24 Nm)
Shift cable adjustment is necessary when symptoms include:
7-9 ft. lbs.
Bell Crank Gear Cover Noise on deceleration
(10-12 Nm)
SHIFT LEVER Excessive gear clash (noise)
Removal Gear selector is moving out of desired range
1. Remove the (2) push rivets retaining the dash panel and Inspect shift cable, clevis pins, and pivot bushings and replace
remove the panel from the dash to access the shift lever. if worn or damaged.
2. Remove the shift knob cover, retaining screw and shift Adjustment
knob from the shift lever.
adjustment is needed beyond that, remove the dash

Adjustment
Point
Neutral Position
3. Remove the grommet around the shift lever from the dash. 2. Locate the shift cable adjustment point attached to the
frame in front of the transmission.
4. Remove the clip and washer retaining the shift cable to the
shift lever and disconnect the cable end from the lever.
8.28
TRANSMISSION (6X6)
3. With two open-end wrenches loosen the outside jam nut 2. Drive the roll pin from the rear propshaft yoke located at
counterclockwise. Turn the outside jam nut 1 1/2 turns. the mid gearcase.
Outside Jam Nut
Roll Pin
Inside Jam Nut Removal Tool
4. After turning the outside jam nut 1 1/2 turns. Hold the 3. Remove the parking brake caliper assembly from the
outside jam nut with a wrench and tighten the inside jam caliper mount bracket to allow the rear propshaft to slide
nut clockwise, until it is tight against the bracket. back on the rear gearcase input shaft during removal.

made for the transmission cable.

cable as needed.
Remove
TRANSMISSION SERVICE
Transmission Removal
1. Drive the roll pin from the mid propshaft yoke located at
the transmission.
8
Roll Pin 4. Slide the rear propshaft back on the rear gearcase input shaft
Removal Tool and remove the propshaft from the mid gearcase.
5. Loosen the (4) bolts retaining the mid gearcase to the frame.
NOTE: The front propshaft yolk slides off during the

transmission removal.
8.29
TRANSMISSION (6X6)
6. Slide the mid gearcase forward. Lift up on the gearcase to 9. Loosen the transmission shift cable jam nuts. Remove the
clear the frame and slide the gearcase towards the rear of cable from the mounting bracket.
the vehicle to remove the mid propshaft from the
transmission.
Rear Propshaft
Jam Nuts
Mid Gearcase
10. Remove the PVT system from the left side of the
transmission (see Chapter 6 Clutching).
7. Remove the air intake hose from the air box and air intake
baffle. Remove vent line from the top of transmission. 11. Remove the transmission to frame bolts (A).
12. Remove the rear transmission mount bolt (B) and remove
the rear transmission mount bracket bolts (C).
13. Remove the front transmission-to-engine mount bolts (D).
8. Disconnect the transmission switch and remove the pin clip

from the shift cable end. Remove the washer and shift cable
from the bellcrank.
Disconnect
14. Remove transmission from right side of frame.
Remove
8.30
TRANSMISSION (6X6)
Transmission Disassembly 5. Mark the detent gear with a white pen. Remove the detent
gear from the case.
NOTE: Refer to the exploded view at the end of this
chapter. NOTE: It may be helpful to place a mark just above
the keyed spline.
1. Remove the retaining ring and transmission switch.
Detent Gear
2. Remove the nut, and washer that secure the bell crank and
remove the bellcrank.
6. Mark the lockout disc, this will indicate which side of the
disc faces outward during assembly. Remove the disc.
NOTE: It may be helpful to place a mark just above

the keyed spline. Note the raised edge on the detent.
3. Remove the five bolts that secure the cover and remove the Lockout Disc
cover from the transmission.
4. Remove the detent spring.
7. Remove the shift shaft and detent lever.
8. Note the transmission gear position and mark the two shift
gears before removing them to aid with reassembly.
Remove the shift gears from the case.
Spring
8.31
TRANSMISSION (6X6)
NOTE: Depending on what gear the transmission is 12. Remove the upper gear cluster and shift forks. You may
in upon disassembly, the stamped timing marks may need to move the assembly back and forth to aid in removal
not be lined up. To avoid confusion, mark the two
gears as described in Step 8.
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.
14. Remove the shift forks from the assembly. Note the correct
position of each fork.
Shift Fork
11. Remove the shift drum.
NOTE: You may have to tap the shift drum from the
backside of the case to aid in removal.
NOTE: The picture above depicts a transmission

with a Park engagement dog on the end of the
shaft instead of a regular engagement dog. The
transmission will have a regular engagement dog in
the location indicated by the arrow in the photo.
8.32
TRANSMISSION (6X6)
15. Remove the bearing from the reverse shaft with a puller. 18. Remove the snap ring and washer from the reverse shaft.
16. Remove the engagement dog. Remove the wave spring and 19. Remove low gear (33T) and the needle bearing.
reverse engagement dog.
Engagement
Dogs
20. Remove the reverse gear shaft.

17. Remove the bearing from the input shaft with a puller.
21. Remove the rest of the bearings from the shafts.
8.33
TRANSMISSION (6X6)
22. Use a press to remove the gear from the shaft. 25. Slide off the shift dogs and wave springs.
23. Make note of the direction of the gear and hub location. 26. Remove the snap ring, washer, gear, and split bearing.
24. Remove the gear, split bearing, and washer from the reverse 27. Remove bearing and the helical gear.
shaft.
8.34
TRANSMISSION (6X6)
28. Remove the pinion shaft retainer plate and the pinion shaft. 31. Remove the shafts as an assembly.
29. Remove the front housing cover screws. 32. Remove the silent chain from the assembly for shaft
inspection.
33. Clean all components in a parts washer and inspect for

wear.
34. Inspect engagement dogs of gears and replace if edges are

rounded.
35. Inspect gear teeth for wear, cracks, chips or broken teeth.
Note the location of the hubs on the gear.
Note Location of Hubs
30. Remove the front housing cover, shim, thrust button, and
thrust button shim.
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.
8.35
TRANSMISSION (6X6)
Transmission Assembly 3. Before installing the cover make sure the sealing surfaces
are clean and dry, and shafts are fully seated in the
1. Reinstall the chain onto the front output shaft and rear transmission case. Apply Polaris Crankcase Sealant to the
output shaft. mating surfaces.
2. Install front and rear output shafts into the case.

Crankcase Sealant
(PN 2871557)
4. Reinstall the thrust button shim, thrust button, and other

shims into the cover. Reinstall cover and torque bolts in a
criss-cross pattern in 3 steps to 27-34 ft. lbs. (37-46 Nm).
NOTE: Make sure that the case locating pins (knock
pipes) are in place.
=T
Front Cover Bolts:
27-34 ft. lbs. (37-46 Nm)
5. 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.
6. Install pinion shaft with bearing.
8.36
TRANSMISSION (6X6)
7. Install retainer plate with flat side toward bearing. 11. Slide the reverse shaft assembly through the silent chain.
8. Apply Loctite 262 (Red) (PN 2871951) to screw threads

and torque screws to 6-12 ft. lbs. (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.
13. Install the engagement dogs, wave springs, and bearing.
=T 14. Install the ball bearing onto the end of the input shaft.
Pinion Retainer Plate Bolts:

6-12 ft. lbs. (8-16 Nm)
9. Install a new needle bearing, the 38T 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 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 8
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.
8.37
TRANSMISSION (6X6)
16. Carefully install the shaft assembly and gear cluster as a 20. Lift the shift rail slightly and rotate the rail/fork assembly
unit into their respective bearing case recesses. Tap with a so it meshes with the tracks on the shift drum. Be sure the
soft face hammer to seat shaft assemblies. wave springs are properly in place and that the shift rail is
seated into the pocket on the backside of the case.
17. Position the shift forks up and so the pins point toward the
9 oclock position, before installing the shift drum 21. Install the helical gear and bearing onto the pinion shaft.
assembly.
22. Clean the mating surfaces of the case and cover. Apply
Crankcase Sealant (PN 2871557) to the mating surfaces. Be
sure the locating pins (knock pipes) are in place. Reinstall
cover and torque bolts in a criss-cross pattern in 3 steps to
27-34 ft. lbs. (37-46 Nm).
23. Reinstall the lower left-hand mount bracket if previously

removed.
18. Replace and grease the O-rings on the shift drum before
installation.
=T
Front Cover Bolts:
27-34 ft. lbs. (37-46 Nm)
24. 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
19. Install the shift drum into the case. shaft seal.
NOTE: Make sure shift shaft pins are properly

positioned in the slot on selector arms.
8.38
TRANSMISSION (6X6)
25. Install drain plug with a new sealing washer. Torque to 28. Install the lockout disc with the raised edge facing outward.
specification. Use the white mars that was previously applied for
reference.
Lockout Disc
29. Install the detent gear with the raised edge facing outward.
Note the keyed spline on the end of the shaft.
30. Install the detent lever spring. Install a new O-ring onto the
shift shaft after the detent lever is assembled to the shaft.
Place a small amount of grease on the small O-ring on the
=T shift shaft and on the detent gear. Grease the O-ring on the
end of the shift drum.
Drain Plug:
Detent Gear
10-14 ft. lbs. (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.
Detent Lever 8
Spring
31. 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. lbs. (10-12 Nm). This helps to align the cover
and shaft to ensure smoother shifting.
7-9 ft. lbs.
(10-12 Nm)
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.
Tighten This Bolt First
8.39
TRANSMISSION (6X6)
32. Torque the remaining bolts to 7-9 ft. lbs. (10-12 Nm). Transmission Installation
1. Install transmission from right side of vehicle.
=T
2. Align the front output shaft to the front propshaft yoke on
Cover Bolts: the vehicle and install the propshaft.
7-9 ft. lbs. (10-12 Nm)
3. Install the mid propshaft onto the transmission output shaft
33. Install a new bellcrank onto the shift shaft. Note the keyed and align the roll pin holes. Drive a NEW roll pin into the
spline on the bellcrank and shaft. Install the washer and nut. propshaft yoke.
Torque the bellcrank nut to 12-18 ft. lbs. (16-24 Nm).
4. Slide the mid gearcase forward in the frame. Install the mid
Keyed Spline 5. Position transmission in frame.
6. Loosely install the front transmission to frame bolts.
7. Loosely install the rear transmission to frame bolt.
8. Loosely install the three bottom transmission to frame

bolts.
9. Tighten mounting fasteners in order A-D as shown.
=T
Bellcrank Nut:
12-18 ft. lbs. (16-24 Nm)
34. Install the transmission and add Polaris AGL Gearcase

Lubricant (PN 2873602). Torque fill plug to specification.
=T
Transmission Mounting Bolts: B, C, D
40 ft. lbs. (54 Nm)
NOTE: Be sure to tighten the lower transmission

bolts first, this ensures that the transmission is tight
= against the lower frame and helps to properly align
the transmission.
10. Reinstall the transmission switch, shift cable, the air intake
AGL Gearcase Lube
hose and the vent hose on top of the transmission.
43.6 oz. (1290 ml)
8.40
TRANSMISSION (6X6)
11. Reinstall the PVT system (see Chapter 6 Clutching for TROUBLESHOOTING
assembly procedure).
Troubleshooting Checklist
NOTE: Align clutches as outlined in Chapter 6.
Check the following items when shifting difficulty is
12. Position the mid gearcase and install the (4) mounting bolts. encountered.
Shift cable adjustment/condition
Idle speed (throttle cable routing)
PVT alignment
Transmission lubricant type/quality
Drive belt deflection (where applicable)
Loose fasteners on rod ends
Loose fasteners on sector gear cover
Worn rod ends, clevis pins, or pivot arm bushings
30-36 ft. lbs. Linkage rod adjustment and rod end positioning
(41-49 Nm)
Shift selector rail travel
*Worn, broken or damaged internal transmission
=T components
Mid Gearcase - Mounting Bolts: NOTE: To determine if shifting difficulty or problem

30-36 ft. lbs. (41-49 Nm) is caused by an internal transmission problem,
isolate the transmission by disconnecting linkage
13. Install the rear propshaft onto the mid gearcase and drive a rod from transmission bellcrank. Manually select
NEW roll pin into the propshaft yoke. each gear range at the transmission bellcrank, and
test ride vehicle. If it functions properly, the problem
14. Install the parking brake caliper assembly. Tighten the two is outside the transmission.
If transmission problem remains, disassemble
transmission and inspect all gear dogs for wear
(rounding), damage. Inspect all bearings, circlips, 8
thrust washers and shafts for wear.
18 ft. lbs.
(24 Nm)
=T
18 ft. lbs. (24 Nm)
8.41
TRANSMISSION (6X6)
TRANSMISSION EXPLODED VIEW
RANGER 6x6 800 (PN 1332702)
27-34 ft. lbs.

(37-46 Nm)
6-12 ft. lbs.

(8-16 Nm)
10-14 ft. lbs.

(14-19 Nm)
GREASE
27-34 ft. lbs.

(37-46 Nm)
7-9 ft. lbs.

(10-12 Nm)
15-19 ft. lbs.
(20-26 Nm)
10-14 ft. lbs.

(14-19 Nm)
12-18 ft. lbs.

(16-24 Nm) FOR REASSEMBLY
Apply White Lithium
Based Grease.
Apply Polaris
Crankcase Sealant.
Apply LoctiteTM 262 to

the bolt threads.
8.42
TRANSMISSION (6X6)
Exploded View, Continued
Ref. Qty. Description Ref. Qty. Description
1. 1 Plug, Fill 36. 1 Sprocket, 22T
2. 1 Plug, Drain, Magnetic 37. 1 Lockout Disc
3. 5 Screw, Self-Tapping 1/4-20 38. 1 Detent Pawl
4. 2 Screw, 5/16-18 39. 1 Detent Star
5. 4 Screw, 1/4-20 40. 1 Bellcrank, Shift Drum
6. 15 Screws, Self-Tapping 5/16-18 41. 1 Output Shaft, Front Main
7. 1 Nut, Nylon Lock 42. 1 Trust Button
8. 2 Nut, Nylon Lock 43. 1 Rail, Shift Shaft
9. 1 Washer 44. 1 Shift Shaft
10. 1 Washer 45. 1 Output Shaft, Rear Main
11. 1 Washer 46. 1 Gear, 33T
12. 4 Dowel Pin 47. 1 Sprocket, 19T
13. 1 Retaining Ring, External 48. 4 Engagement Dog, 6 Face
14. 1 Retaining Ring, External 49. 1 Reverse Shaft
15. 2 Retaining Ring, External 50. 1 Gear, Mid-Output, 47T
16. 1 Spacer 51. 1 Gear, Mid-Output, 60T
17. 1 Thrust Washer 52. 1 Vent Tube
18. 1 Shim 53. 1 Sprocket, 38T
19. 1 Shim 54. 1 Gear, 36T
20. 1 Needle Bearing 55. 1 Gear Set, 10T/31T
21. 4 Ball Bearing 56. 2 Shift Fork w/Pin
22. 4 Ball Bearing 57. 1 Input Shaft, 37/19/15
23. 1 Needle Bearing 58. 1 Cover, Center Drive Bearing
24. 1 Plain Bearing 59. - N/A 8
25. 1 Needle Bearing 60. 1 Silent Chain, 11W/40P
26. 1 Ball Bearing 61. 1 Chain
27. 1 Spring, Compression 62. 1 Switch, 6-Pin Rotary
28. 2 Spring, Wave 63. 1 Seal, Dual Lip
29. 1 Cover, Sector Gear 64. 2 Seal, Triple Lip
30. 1 Cover, LH Input 65. 1 O-Ring
31. 1 Gearcase, Main 66. 1 O-Ring
32. 1 Shift Drum 67. 1 O-Ring
33. 1 Cover, Output 68. - N/A
34. 1 Sector Gear, 16T 69. 1 Bracket, Transmission Mount
35. 1 Sector Gear, 31T
8.43
TRANSMISSION (6X6)
NOTES
8.44
BRAKES
CHAPTER 9
BRAKES
GENERAL SPECIFICATIONS / TORQUE SPECIFICATIONS / SPECIAL TOOLS . . . . . 9.2
BRAKE SYSTEM SERVICE NOTES / BRAKE NOISE TROUBLESHOOTING . . . . . . . . 9.3
HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
BRAKE SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
FOOT BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
EXPLODED VIEW (XP / HD / CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
EXPLODED VIEW (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
INSPECTION / CABLE TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
PARKING BRAKE CALIPER SERVICE (4X4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
NEW BRAKE PAD / CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
PARKING BRAKE CALIPER SERVICE (6X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
NEW BRAKE PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
PARKING BRAKE DISC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
PAD REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
PAD ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
REAR BRAKE PADS (XP / HD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
PAD INSPECTION / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
REAR BRAKE PADS (CREW / 6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
PAD REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9
PAD ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
REAR CALIPER SERVICE (XP / HD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
CALIPER ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31
REAR CALIPER SERVICE (CREW / 6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33
CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.34
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36
9.1
BRAKES
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 .188" ( 4.78 mm) .170" (3.56 mm)
Front Brake Disc Runout - .010" (.254 mm)
REAR BRAKE SYSTEM

Rear Brake Pad Thickness .298 .007"/ 7.56 .178 mm .180" (4.6 mm)
Rear Brake Disc Thickness .188" (4.78 mm) .170" (4.32 mm)
Rear Brake Disc Runout - .010" (.254 mm)
PARK BRAKE SYSTEM

Inboard - .304 (7.72 mm) .240" (6.1 mm)
Park Brake Pad Thickness
Outboard - .360 (9.14 mm) .310 (7.87 mm)
Park Brake Disc Thickness 0.164 - 0.173 (4.17 - 4.39 mm) .140" (3.56 mm)
TORQUE SPECIFICATIONS SPECIAL TOOLS

Torque Torque Part Number Tool Description
Item
ft. lbs. Nm
2870975 Mity Vac Pressure Test Tool
Front Caliper Mounting Bolts 30 41
Rear Caliper Mounting Bolts 30 41
Park Brake Assembly Bolts 25 34
Park Brake Caliper to Mount
18 24
Bracket Bolts
Park Brake Mount Bracket to
40 54
Transmission Bolts (4x4)
Park Brake Mount Bracket to
18 24
Rear Gearcase Bolts (6x6)
Park Brake Lever Mount Bolts 13 18
Brake Line Flare Fittings 12-15 16-20
Brake Line Banjo Bolts (All) 15 20
Front Brake Disc to Hub Bolts 18 24
Rear Brake Disc to Hub Bolts 28 38
Park Brake Disc Mounting Bolt 18 24
Brake Switch 12-15 16-20
Master Cylinder Mount Bolts 15 20
9.2
BRAKES
BRAKE SYSTEM SERVICE NOTES
Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will 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.
Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment.
Do not over-fill the master cylinder fluid reservoir.
Make sure the brake pedal returns freely and completely.
Adjust stop pin on front caliper after pad service.
Check and adjust master cylinder reservoir fluid level after pad service.
Make sure atmospheric vent on reservoir is unobstructed.
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
products.
BRAKE NOISE TROUBLESHOOTING

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

Possible Cause Remedy
Spray disc and pads with CRC Brakeleen or an equivalent
Dirt, dust, or imbedded material on pads or disc 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) because Adjust pad stop (front calipers)
of improper adjustment
Master cylinder reservoir overfilled
Master cylinder compensating port restricted
Set to proper level
Clean compensating port
9
Master cylinder piston not returning completely Inspect. Repair as necessary
Caliper piston(s) not returning Clean piston(s) seal
Operator error (riding the brake) 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
If noise does not change when brake is applied check other
Noise is from other source (axle, hub, disc or wheel)
sources. Inspect and repair as necessary
Wrong pad for conditions Change to a softer or harder pad
9.3
BRAKES
HYDRAULIC BRAKE SYSTEM OPERATION
The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines,
brake calipers, brake pads, and brake discs, which are secured to the drive line.
When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master cylinder
piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure within the brake
system. As the pressure within the system is increased, the pistons located in the brake calipers move outward and apply pressure
to the moveable brake pads. These pads contact the brake discs and move the calipers in their floating bracket, pulling the stationary
side pads into the brake discs. The resulting friction reduces brake disc and vehicle speed.
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 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 which is opened and closed by the master cylinder piston assembly. As
the temperature within the hydraulic system changes, this port compensates for fluid expansion or contraction. Due to the high
temperatures created within the system during heavy braking, it is very important that the master cylinder reservoir have adequate
space to allow for fluid expansion. Never overfill the reservoir! Do not fill the reservoir beyond the MAX LEVEL line!
When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). 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
BRAKES
BRAKE SYSTEM EXPLODED VIEW
XP / HD Brake System LH Front Caliper

2
LH Front
Cross Fitting Brake Line
LH Rear Line
Master Cylinder Top View
3 1
RH Front
2 Brake Line
1 LH Rear Caliper 3 MC Rear
Brake Line 1 RH Front Caliper
Brake 2
2 1 Switch
1
RH Rear Caliper
RH Rear Line Caliper Banjo Style Fittings:

Master Cylinder 1
15 ft. lbs. (20 Nm).
Side View
All Caliper Bleed Screws:
1 2 47 in. lbs. (5.3 Nm)
All Flare Style Fittings:
3 12-15 ft. lbs. (16-20 Nm)
CREW / 6x6 Brake System LH Front Caliper

2
LH Front
Cross Fitting Brake Line
LH Rear Line
Master Cylinder Top View
3 1
3
2
RH Front
1
LH Rear Caliper
3 MC Rear
1
Brake Line 9
Brake Line RH Front Caliper
2
2 1 Brake
Switch
1
RH Rear Caliper
Caliper Banjo Style Fittings:
1 15 ft. lbs. (20 Nm).
All Caliper Bleed Screws:
RH Rear Line Master Cylinder 2 47 in. lbs. (5.3 Nm)
Side View
All Flare Style Fittings:
1 3 12-15 ft. lbs. (16-20 Nm)
9.5
BRAKES
MASTER CYLINDER FOOT BRAKE PEDAL
Removal Pedal Removal
1. Remove the retaining clip (A) from the clevis pin (B) that 1. Remove the E-clip from the end of the brake pedal mount
attaches the master cylinder to the brake pedal lever. bracket.
2. Remove LH wheel well panel to access master cylinder. Master Brake Pedal
Cylinder Mount Bracket
C
Clevis Pin
B Clip
Bushing
E-Clip
15 ft. lbs. Bushing
(20 Nm) A
Brake Pedal
2. Remove the retaining clip and clevis pin from the master
cylinder to free it from the brake pedal.
15 ft. lbs. 3. Slide the brake pedal and bushings off the mount bracket.
(20 Nm) D
Pedal Installation
3. Remove the two mounting bolts (C) that secure the master 1. Reverse Steps 1-3 for foot brake installation.
cylinder to the frame.
2. Use a new E-clip upon installation.
4. Remove master cylinder and place a fluid catch container
under the master cylinder brake line banjo bolts (D).
CAUTION
Brake fluid will damage finished surfaces.

Do not allow brake fluid to come in contact
with finished surfaces.
5. Loosen the brake line banjo bolts (D) and allow the fluid
to drain.
NOTE: Make note of front and rear brake line

orientation on the master cylinder.
6. Dispose of brake fluid properly and do not re-use.
Installation
1. Reverse Steps 1-5 for master cylinder installation.
Refer to the torque specifications in the illustration.
9.6
BRAKES
BRAKE BLEEDING / FLUID CHANGE
NOTE: When bleeding the brakes or replacing the
fluid always start with the furthest caliper from the Bleeder
master cylinder. Screw
CAUTION
Always wear safety glasses.
CAUTION
Brake fluid will damage finished surfaces. Do not

8. Place a small amount of fresh brake fluid into a small, clear
allow brake fluid to come in contact with finished
container and place the other end of bleeder hose into the
surfaces. This procedure should be used to
container.
change fluid or bleed brakes during
regular maintenance. 9. Have an assistant slowly pump the brake pedal until
pressure builds and then hold.
1. Locate master cylinder reservoir in the front LH wheel
well area (Figure 1-6). Clean reservoir cover thoroughly. 10. Quickly open and close the bleed screw while holding
pressure on the brake pedal.
2. Remove cover from reservoir.
NOTE: Do not release brake pedal before bleeder
3. If changing fluid, remove old fluid from reservoir with a screw is tight or air may be drawn into master
Mity Vac pump or similar tool. cylinder.
11. Release brake pedal pressure. Check level of fluid in
Mity Vac (PN 2870975) reservoir and add if necessary (Figure 1-6).
12. Repeat Steps 9, 10, and 11 until brake pedal is firm and no
4. Add brake fluid to the indicated MAX level of reservoir
air can be seen moving through the clear hose. Add fluid
(Figure 1-6).
as necessary to maintain level in reservoir.
Add Fluid Master Cylinder Fluid Level

HERE
Between the MIN and MAX line.
CAUTION
9
Maintain at least 1/2"(1.27 cm) of brake fluid in
the reservoir to prevent air from
Level Indicator entering the master cylinder.
Figure 1-6
13. Tighten bleeder screw and remove bleeder hose. Torque
bleeder screw to 47 in. lbs. (5.3 Nm).
Polaris DOT 4 Brake Fluid 14. Repeat Steps 9 - 13 for the remaining brake calipers.
(P/N 2872189) 15. Install master cylinder reservoir cover.
5. Begin bleeding procedure with caliper furthest from master 16. Field test machine at low speed before putting into service.
cylinder. Check for proper braking action and pedal reserve. With
pedal firmly applied, pedal reserve should be no less than
6. Install a box-end wrench on caliper bleeder screw. 1/2"(1.3 cm).
7. Attach a tight-fitting, clear hose to the bleeder fitting. 17. Check brake system for fluid leaks.
9.7
BRAKES
PARKING BRAKE
Exploded View (XP / HD / CREW)
Parking Brake
Lever
Clevis
Pin
Clevis
Pin
Bolts
14 ft. lbs.
(19 Nm)
Nuts
13 ft. lbs.
(18 Nm)
Clip Clip
Parking Brake
Caliper
Cable 18 ft. lbs.

Nuts (24 Nm)
Tie Strap
Mount Bracket
Bolt
40 ft. lbs.
(54 Nm)
Transmission
Parking Brake Disc
Bolts
40 ft. lbs.
(54 Nm)
9.8
BRAKES
Exploded View (6x6)
Parking Brake
Lever
Bolts
14 ft. lbs.
(19 Nm)
Clevis
Pin
13 ft. lbs.
Nuts
(18 Nm)
Parking Brake
Caliper
Clevis
Pin Screw 18 ft. lbs.
Nut
(24 Nm)
Clip Clip
Washer
Bolt
Mount Bracket
Cable
18 ft. lbs.
Nut
(24 Nm)
Rear Propshaft Bolts

w/Parking Brake Disc
Rear Gearcase
9.9
BRAKES
Inspection 1. Pull back on the parking brake lever (located in the dash).
1. Inspect the parking brake cable and brake pads on the 2. After 3 clicks the (P) brake light should illuminate on the
caliper assembly. Refer to the appropriate Parking instrument cluster and the wheels of the vehicle should not
Brake Caliper Service procedure for brake pad rotate when turning by hand. After 8 full clicks of lever
replacement information. travel, the vehicle should not roll while parked.
3. If the vehicle moves, adjustment is necessary.

Inboard Pad
Outboard Pad 4. Adjust the parking brake cable where the cable attaches to
the caliper mount bracket. The mount bracket is located on
the left-hand side of the transmission behind the outer PVT
cover (4x4) or on the rear gearcase (6x6).
Adjustment Procedure
1. Place the vehicle in neutral on a flat level surface.
2. Carefully lift the rear of the vehicle off the ground and
stabilize on jack stands.
Transmission 4x4
3. Locate the parking brake cable adjustment area where the
cable attaches to the caliper mount bracket.
Inboard Pad
Outboard Pad 4x4
Propshaft 6x6 Parking Brake

Cable Adjustment
Cable Tension Adjustment

6x6
When the parking brake is fully engaged and the parking brake
indicator is illuminated, engine speed is limited to 1300 RPM in
all gears, including neutral. If throttle is applied, this limiting
feature prevents operation, which protects the parking brake
pads from excessive wear.
NOTE: Inspect the parking brake cable tension after

the first 25 hours of operation and every 100 hours Parking Brake
of operation afterwards to ensure proper cable Cable Adjustment
tension.
Loss of tension in the parking brake cable will cause

illumination of the parking brake light and activation of the
limiting feature. If this occurs, inspect and adjust parking brake
cable tension. If performing this service is difficult due to
conditions or location, open the hood and temporarily
disconnect the parking brake connector. Reconnect the parking
brake connector as soon as it is practical and adjust the parking
brake cable to proper tension.
9.10
BRAKES
4. Use two open-end wrenches and loosen the outer jam nut
(D). Back out the outer jam nut (D) 1 1/2 turns.
To Parking
Mount Bracket
Brake Caliper
C D
4x4
To Parking
Brake Caliper
C D
6x6 Mount Bracket
5. Now hold the outer jam nut (D) and turn in the inner jam
nut (C) clockwise, until the jam nut is tight against the
bracket.

obtained for the parking brake.
NOTE: See Chapter 10 for more information on the

9
parking brake switch.
9.11
BRAKES
PARKING BRAKE CALIPER SERVICE (4X4)
Exploded View
18 ft. lbs. Pad & Holder Stationary Actuator

(24 Nm) Thrust Washer Nut
Hex Head Hex Nut
Mount Bolt Lever
Plain
Sleeve Washer
Shim Pack
Asm. Bolt (5 Shims)
25 ft. lbs. Spring Pin
(34 Nm) Spring Steel Balls (3) Nut Figure 9.12
Caliper Removal
NOTE: Do not get oil, grease, or fluid on the parking 2. Disconnect the rear differential solenoid harness.
brake pads. Damage to or contamination of the pads
may cause the pads to function improperly.
1. Remove the clip pin and pin (A) from the parking brake
cable.
Disconnect
NOTE: Be sure the parking brake is not engaged.
9.12
BRAKES
3. Loosen the (2) bolts that retain the caliper to the mount Caliper Disassembly / Inspection
bracket.
NOTE: Refer to the Electronic Parts Catalog for
parking brake caliper replacement information.
1. Remove the two caliper assembly bolts (C).
4. Remove the (3) fasteners retaining the parking brake mount

bracket and remove the parking brake caliper as an
assembly. NOTE: The image shown below has the PVT
system removed for picture clarity. 2. Slide the brake pads and springs from the assembly.
NOTE: Retain the lever and ball bearings for
Mount reassembly.
Bracket
3. Inspect brake pads for excessive wear. Replace as needed.
4. Check the three steel balls for any signs of cracking.
Replace as needed.
5. Check ball seats in lever and stationary actuator. If
excessively worn, replace parts as needed.
6. Measure the thickness of the rear caliper parking brake
pads. Replace assembly or pads as needed. See illustration
below for proper readings.
Inboard Inboard Pad
Pad New .304 (7.72 mm)
Limit: 0.24 (6.1 mm)
5. Lift the parking brake caliper and mount bracket off the
brake disc. Remove the (2) caliper mounting bolts and Outboard
remove the caliper from the mount bracket. Pad
Outboard Pad
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) 4x4
9.13
BRAKES
New Brake Pad Installation Caliper Installation
NOTE: Parking Brake Pads can be replaced by 1. Attach the parking brake caliper to the mount bracket and
ordering one of the following kits: finger tighten the (2) mounting bolts.
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. 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 .203 - .193 (5.16 - 4.90
mm). For shim location, see Figure 9.12 on page 12.
Add shims until gap

measures .203-.193
(5.16-4.90 mm)
2. Place the parking brake assembly into place. Install and
tighten the (3) mount bracket fasteners to specification.
=T
Parking Brake Caliper - Mount Bracket Bolts:
40 ft. lbs. (54 Nm)
3. Tighten the (2) parking brake caliper mounting bolts to

specification.
2. Once you have determined the correct amount of shims to

use, install the assembly bolts through the sleeves. Install 18 ft. lbs.
the nuts and the correct amount of shims, the inner brake
(24 Nm)
pad, springs, and outer brake pad. Torque the assembly nuts
to 25 ft. lbs. (34 Nm).
=T
Parking Brake Caliper - Assembly Bolts:
25 ft. lbs. (34 Nm)
3. Ensure the parking brake assembly functions properly by

actuating the lever before reinstallation.
=T
18 ft. lbs. (24 Nm)
4. Connect the rear differential solenoid harness.
5. Install the cable, pin and clip pin. Test the park brake for
proper function.
9.14
BRAKES
PARKING BRAKE CALIPER SERVICE (6X6)
Exploded View
Hex Nut
Pad & Holder
Pad & Holder Plain Washer
18 ft. lbs.
(24 Nm)
Sleeve Thrust Washer
Hex Head
Mount Bolt
Shim Pack Lever

Nut (4 Shims)
Asm. Bolt
25 ft. lbs.
(34 Nm)
Stationary Actuator
Spring Pin
Compression Spring Steel Balls (3) Figure 9.15
Caliper Removal
NOTE: Do not get oil, grease, or fluid on the parking 2. If replacing the brake pads, slightly loosen the caliper
brake pads. Damage to or contamination of the pads assembly bolts before removing the complete caliper
may cause the pads to function improperly. assembly. This will ease the caliper disassembly procedure
later.
1. Remove the clip pin and pin (A) from the parking brake
cable.
NOTE: Be sure the parking brake is not engaged.
9.15
BRAKES
3. Loosen the two brake caliper mounting bolts (B) in equal 6. Measure the thickness of the rear caliper parking brake
increments. pads. Replace assembly or pads as needed. See illustration
below for proper readings.
B Inboard Pad
New .304 (7.72 mm)
Limit: 0.24 (6.1 mm)
Outboard
Inboard Pad
Pad
Outboard Pad
New 0.360 (9.14 mm)
Limit: 0.31 (7.87 mm)
Installed Disc to Park Brake

4. Remove the mounting bolts from the mount bracket and lift 0.375 (0.953 cm)
the parking brake caliper assembly out of the vehicle.
New Rotor Disc Thickness

Caliper Disassembly / Inspection 0.150 - 0.164
(3.81 - 4.16 mm)
NOTE: Refer to the Electronic Parts Catalog for
parking brake caliper replacement information.
6x6
1. Remove the two caliper assembly nuts (C) that were
previously loosened during Step 2 of Caliper Removal.
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
C 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. 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 .203 - .193 (5.16 - 4.90
2. Slide the brake pads and springs from the assembly. mm). For shim location, see Figure 9.15 on page 15.
NOTE: Retain the lever and ball bearings for Add shims until gap
reassembly. measures .203 - .193
(5.16 - 4.90 mm)
3. Inspect brake pads for excessive wear. Replace as needed.
4. Check the three steel balls for any signs of cracking.

Replace as needed.
5. Check ball seats in lever and stationary actuator. If

excessively worn, replace parts as needed.
9.16
BRAKES
2. Once you have determined the correct amount of shims to PARKING BRAKE DISC SERVICE
use, install the assembly bolts through the sleeves. Install
the nuts and the correct amount of shims, the inner brake Disc Inspection / Removal (4x4)
pad, springs, and outer brake pad. Torque the assembly nuts
1. Measure the brake disc with a micrometer. If the thickness
to 25 ft. lbs. (34 Nm).
of the disc is less than specified, replace the disc assembly.
2. Remove the outer PVT cover, belt, drive clutch, driven
=T clutch and inner PVT cover (see Chapter 6) .
3. Using a 1/2 socket and ratchet, remove the brake disc
Parking Brake Caliper - Assembly Bolts: retaining bolt and remove the disc from the transmission.
25 ft. lbs. (34 Nm)
3. Ensure the parking brake assembly functions properly by New Disc:

actuating the lever before reinstallation. 0.164 - 0.173 Service Limit:
(4.17 - 4.39 mm) .140 (3.56 mm)
Apply
LoctiteTM 262
Remove
Bolt
Caliper Installation
1. Install the parking brake assembly into place. Tighten the
two mounting bolts in increments for proper installation. 4. Reverse this procedure to reinstall the brake disc. Torque
the disc mounting bolt to 15-18 ft. lbs. (20-24 Nm).
18 ft. lbs.
(24 Nm) Disc Inspection / Removal (6x6)
1. Measure the brake disc with a micrometer. If the thickness
of the disc is less than specified, replace the rear propshaft
assembly.
2. Follow the rear prop shaft removal procedure listed in
Chapter 7 to remove the rear propshaft assembly.
New Disc: 0.164 - 0.173 (4.17 - 4.39 mm)
9
Disc Service Limit: 0.140 (3.56 mm)
Remove Bolts
2. Torque the two mounting bolts to 18 ft. lbs. (24 Nm).
=T
18 ft. lbs. (24 Nm)
3. Install the cable, pin, and clip pin. Test the park brake for
proper function. 3. Refer to Chapter 7 to reinstall the rear propshaft assembly.
9.17
BRAKES
FRONT BRAKE PADS 5. Push the mounting bracket inward and the slip outer brake
pad out between the bracket and caliper body.
Pad Removal
1. Elevate and support front of vehicle.
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 wheel nuts, washers and front wheel. Loosen

pad adjuster screw.
6. Remove the inner pad from the bracket and caliper.
Pad
Pad Inspection
Adjuster 1. Measure the thickness of the pad material. Replace pads if
worn beyond the service limit.
3. Remove the upper and lower caliper mounting bolts and

remove the caliper from the front hub.
NOTE: When removing caliper, use care not to
damage brake line. Support caliper so to avoid
kinking or bending brake line.
4. Push caliper piston into caliper bore slowly using a
C-clamp or locking pliers with pads installed.
Measure
Thickness
NOTE: Brake fluid will be forced through Front Brake Pad Thickness
compensating port into master cylinder fluid New: .298 .007 (7.56 .178 mm)
reservoir when piston is pushed back into caliper. Service Limit: .180 (4.6 mm)
Remove excess fluid from reservoir as required.
9.18
BRAKES
Pad Assembly / Installation 5. Install the pad adjuster set screw and turn clockwise until
stationary pad contacts disc, then back off 1/2 turn
1. Lubricate mounting bracket pins with a light film of (counterclockwise).
Polaris Premium All Season Grease (PN 2871423), and
install rubber dust boots.
1/2 Turn
Apply Grease to Each

Bracket Pin
Pad
Adjuster
6. Verify fluid level in reservoir is up to MAX line inside

reservoir and install reservoir cap.
2. Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
other.
Master Cylinder Fluid
Up to MAX line inside reservoir
WARNING
If brake pads are contaminated with grease, oil, Chapter 2 - Maintenance).
or liquid soaked do not use the pads.
Use only new, clean pads.
Brake Burnishing Procedure
3. Install caliper onto front hub and torque mounting bolts.
It is required that a burnishing procedure be performed after
installation of new brake pads to extend service life and reduce
noise.
Start machine and slowly increase speed to 30 mph. Gradually
apply brakes to stop machine. Allow pads and disc to cool
sufficiently during the procedure. Do not allow pads or disc to
become hot or warping may result. Repeat this procedure 10
times.
30 ft. lbs.
(41 Nm)
9
=T
Front Caliper Mounting Bolts:
30 ft. lbs. (41 Nm)
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.
9.19
BRAKES
FRONT CALIPER SERVICE
Caliper Exploded View
Apply Polaris DOT 4 Brake Fluid

C
to Components 47 in. lbs.
B
(5.3 Nm)
Apply Polaris All Purpose
Grease D A
E D
F
G
A. Socket Set Screw

B. Bleeder Screw
H
C. Caliper Assy.
D. Boots
E. Square O-rings I
F. Pistons
G. Caliper Mount
H. Brake Pads J
I. Brake Scraper
J. Bolts
Caliper Removal
1. Elevate and safely support the front of the vehicle. 5. Loosen brake pad adjustment set screw to allow brake pad
2. Remove the (4) wheel nuts and the front wheel. removal after the caliper is removed.
CAUTION
Use care when supporting vehicle so that it does not

tip or fall. Severe injury may occur.
3. Clean caliper area before removal. Pad

Adjuster
4. Place a container below the caliper to catch brake fluid
when removing the line. Remove brake line from caliper.
Remove
Brake Line
9.20
BRAKES
6. Remove the two caliper mounting bolts and the caliper. IMPORTANT: Do not remove the caliper pistons with
a standard pliers. The piston sealing surfaces will
become damaged if a standard pliers is used.
4. Once the pistons are removed, use a pick to carefully

remove the square O-rings from the caliper. O-rings should
be replaced during caliper service.
Remove
Caliper Disassembly
1. Remove both brake pads from the caliper (see FRONT
BRAKE PADS - Pad Removal).
2. Remove the mount bracket assembly and the dust boots 5. Clean the caliper body, piston, and retaining bracket with
from caliper. Thoroughly clean the caliper before brake cleaner or alcohol.
disassembly and prepare a clean work area for disassembly.
Clean
Components
IMPORTANT: Be sure to clean the seal grooves in

3. Use a commercially available caliper piston pliers to extract
the pistons from the caliper.
caliper body. 9
9.21
BRAKES
Caliper Inspection Caliper Assembly
1. Inspect caliper body for nicks, scratches, pitting or wear. 1. Install new O-rings in the caliper body. Be sure the
Measure bore size and compare to specifications. Replace grooves are clean and free of residue or brakes may drag
if damaged or worn beyond service limit. upon assembly.
Seal
Grooves
New
O-Rings
2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install

= In. / mm. pistons with a twisting motion while pushing inward.
Piston should slide in and out of bore smoothly, with light
resistance.
Caliper Piston Bore I.D.:
Std: 1.373 (34.87 mm) 3. Lubricate the mounting bracket pins with Polaris Premium
Service Limit: 1.375 (34.93 mm) All Season Grease (PN 2871423), and install the rubber
dust seal boots.
2. Inspect piston for nicks, scratches, pitting or wear. Measure
piston diameter and replace if damaged or worn beyond
service limit. Apply Grease to Each
Bracket Pin
4. Compress the mounting bracket and make sure the dust seal
boots are fully seated. Install the brake pads. Clean the disc
and pads with brake parts cleaner or denatured alcohol to
= In. / mm. remove any dirt, oil or grease.
Caliper Piston O.D.:

Std: 1.370 (34.80 mm)
Service Limit: 1.368 (34.75 mm)
3. Inspect the brake disc and pads as outlined in this chapter.
9.22
BRAKES
Caliper Installation 3. Install the pad adjustment screw and turn until stationary
pad contacts disc, then back off 1/2 turn.
1. Install caliper and torque mounting bolts to specification.
IMPORTANT: If brake disc scraper was removed, be 1/2 Turn

sure to reinstall it upon caliper installation.
Disc
Scraper
Pad
Adjuster
30 ft. lbs.
(41 Nm)
4. Perform brake bleeding procedure as outlined earlier in this

chapter.

=T Chapter 2).
6. Field test unit for proper braking action before putting into
Front Caliper Mounting Bolts:
service. Inspect for fluid leaks and firm brakes. Make sure
30 ft. lbs. (41 Nm)
the brake is not dragging when pedal is released. If the brake
drags, re-check assembly and installation.
2. Install brake line and torque the banjo bolt to the proper
torque specification. NOTE: If new brake pads are installed, brake
burnishing is recommended (see FRONT BRAKE
PADS - Brake Burnishing Procedure).
15 ft. lbs.
(20 Nm)
9
9.23
BRAKES
FRONT BRAKE DISC
Brake Disc Thickness
Disc Runout New .188 (4.78 mm)
1. Mount dial indicator as shown to measure disc runout. Service Limit .170 (4.32 mm)
Slowly rotate the disc and read total runout on the dial
indicator. Replace the disc if runout exceeds specification.
Brake Disc Thickness Variance
difference between measurements
Disc Removal / Replacement

1. Remove front brake caliper (see Front Caliper Service).
2. Remove cotter pin, castle nut and washers.
3. Remove the wheel hub assembly from the vehicle and

remove the (4) bolts retaining the disc to the hub.
(4) Bolts
Brake Disc Runout

Washers
Service Limit .010 (.254 mm) Nut
Cotter Pin
Disc Inspection
1. Visually inspect disc for scoring, scratches, or gouges.
4. Clean the wheel hub mating surface and install new disc on
Replace the disc if any deep scratches are evident.
wheel hub. Torque new bolts to 18 ft. lbs. (24 Nm).
2. Use a 0-1 micrometer and measure the disc thickness at
18 ft. lbs.
eight different points around the pad contact surface.
(24 Nm)
Replace disc if worn beyond service limit.
Measure
Thickness
Front
Disc
80 ft. lbs.
(108 Nm)
9.24
BRAKES
REAR BRAKE PADS (XP / HD)
CAUTION
Pad Removal
Always use new brake disc mounting bolts. The 1. Elevate and support rear of machine.
bolts have a pre-applied locking agent which is
destroyed upon removal.
CAUTION
5. Install wheel hub assembly, washers, and castle nut. Torque
castle nut to 80 ft. lbs. (108 Nm) and install a new cotter pin.
Use care when supporting vehicle so that it does
6. Install front brake caliper (see Front Caliper Service). not tip or fall. Severe injury may occur
Follow bleeding procedure outlined earlier in this chapter. if machine tips or falls.
7. Field test unit for proper braking action before putting into 2. Remove the rear wheel. Loosen pad adjuster screw 2-3
service. Inspect for fluid leaks and firm brakes. Make sure turns.
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.
Remove Caliper Bolts
5. Push caliper piston into caliper bore slowly with pads

installed.
9.25
BRAKES
NOTE: Brake fluid will be forced through Pad Installation
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper. 1. Install new pads in caliper body.
6. Remove the brake pads.
2. Install caliper and torque mounting bolts.
Pad Inspection
1. Clean the caliper with brake cleaner or alcohol.
2. Measure the thickness of the pad material. Replace pads if 30 ft. lbs.
worn beyond the service limit. (41 Nm)
=T
Rear Brake Caliper Mounting Bolts:
30 ft. lbs. (41 Nm)
Measure 3. Turn adjuster screw back in finger tight using a hex wrench.
Thickness
up. Maintain at least 1/2"(12.7 mm) of brake fluid in the
Rear Brake Pad Thickness reservoir to prevent air from entering the master cylinder.
New .298 + .007 (7.56 + .178 mm)
Service Limit .180 (4.6 mm)
noise.
become hot or warping may result. Repeat this procedure 10
times.
9.26
BRAKES
REAR BRAKE PADS (CREW / 6X6) 5. Push the mounting bracket inward and the slip outer brake
pad out between the bracket and caliper body.
Pad Removal
1. Elevate and support rear of vehicle.
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 wheel nuts, washers and rear wheel. Loosen

pad adjuster screw.
6. Remove the inner pad from the bracket and caliper.
Pad Inspection
Pad 1. Measure the thickness of the pad material. Replace pads if
Adjuster worn beyond the service limit.
3. Remove the upper and lower caliper mounting bolts and

remove the caliper from the front hub.
NOTE: When removing caliper, use care not to
damage brake line. Support caliper so to avoid
kinking or bending brake line.
4. Push caliper piston into caliper bore slowly using a
C-clamp or locking pliers with pads installed.
Measure
Thickness
Front Brake Pad Thickness

NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
New: .298 .007 (7.56 .178 mm)
reservoir when piston is pushed back into caliper. Service Limit: .180 (4.6 mm)
9.27
BRAKES
Pad Assembly / Installation 5. Install the pad adjuster set screw and turn clockwise until
stationary pad contacts disc, then back off 1/2 turn
1. Lubricate mounting bracket pins with a light film of (counterclockwise).
Polaris Premium All Season Grease (PN 2871423), and
install rubber dust boots.
1/2 Turn
Apply Grease to Each
Bracket Pin
Pad
Adjuster
6. Verify fluid level in reservoir is up to MAX line inside

reservoir and install reservoir cap.
2. Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
other.
Master Cylinder Fluid
Up to MAX line inside reservoir
WARNING
If brake pads are contaminated with grease, oil, Chapter 2 - Maintenance).
or liquid soaked do not use the pads.
Use only new, clean pads.
3. Install caliper onto rear hub and torque mounting bolts.
noise.
30 ft. lbs. become hot or warping may result. Repeat this procedure 10
(41 Nm) times.
=T
Rear Caliper Mount Bolt Torque:
30 ft. lbs. (41 Nm)
up. Maintain at least 1/2, (12.7 mm) of brake fluid in the
reservoir to prevent air from entering the brake system.
9.28
BRAKES
REAR CALIPER SERVICE (XP / HD)
Rear Caliper Exploded View
Apply Polaris DOT 4 Brake Fluid G

to Component

Grease
E F
D
H
A. Socket Set Screw B E

B. Bleeder Screw 47 in. lbs.
C. Caliper Assy. (5.3 Nm)
D. Boot
E. Square O-rings
F. Piston
G. Caliper Mount
H. Brake Pads C
Caliper Removal
1. Safely support the rear of the machine. 3. After the fluid has drained 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.
2. Use a wrench to remove the brake line. Place a container

9
to catch brake fluid draining from brake lines.
4. Clean disc, caliper body, and pistons with brake cleaner or

alcohol.
9.29
BRAKES
Caliper Disassembly Caliper Inspection
1. Remove brake pad adjuster screw (A). 1. Inspect caliper body for nicks, scratches or wear. Measure
bore size and compare to specifications. Replace if damage
2. Push upper pad retainer pin inward and slip brake pads past is evident or if worn beyond service limit.
edge, if pads are still installed.
3. Remove mounting bracket (B) and dust boot (C).

B Pads
C
F D
A = In. / mm.
4. Remove piston (D) and square O-rings (E) from the caliper
body (F). Caliper Piston Bore I.D.:
Std: 1.505 (38.23 mm)
2. Inspect piston for nicks, scratches, wear or damage.

Measure diameter and replace if damaged or worn beyond
service limit.
5. Clean the caliper body, piston, and retaining bracket with

brake cleaner or alcohol.
NOTE: Be sure to clean seal grooves in caliper

body.
= In. / mm.

Std: 1.500 (38.10 mm)
3. Inspect the brake disc and pads as outlined for brake pad
replacement in this chapter.
9.30
BRAKES
Caliper Assembly Caliper Installation
1. Install new square O-rings (A) in the caliper body. Be sure 1. Install the rear caliper onto the mounting bolts. Torque
that the grooves are clean and free of residue or brakes may mounting bolts to 30 ft. lbs. (41 Nm).
drag.
2. Install brake line banjo bolt. Torque banjo bolt to 15 ft. lbs.
(21 Nm).
A
30 ft. lbs.
(41 Nm)
15 ft. lbs.
(21 Nm)
2. Coat the piston with clean DOT 4 Brake Fluid
(PN 2872189). Install piston (B) with a twisting motion
while pushing inward. Piston should slide in and out of bore 3. Install the rear wheel and wheel nuts. Carefully lower the
smoothly, with light resistance. vehicle.
3. Lubricate the mounting bracket pins with Polaris Premium 4. Field test unit for proper braking action before putting into
All Season Grease, and install the rubber dust seal boots. service. Inspect for fluid leaks and firm brakes. Make sure
NOTE: If new brake pads are installed, brake

burnishing is recommended (see REAR BRAKE
9
Polaris Premium All Season Grease
(PN 2871423)
4. Compress the mounting bracket and make sure the dust

seals are fully seated. Install the brake pads. Clean the disc
remove any dirt, oil or grease.
9.31
BRAKES
REAR CALIPER SERVICE (CREW / 6X6)
Rear Caliper Exploded View
Apply Polaris DOT 4 Brake Fluid 47 in. lbs. B

to Component (5.3 Nm)
A
E
Grease F
H
D
I
A. Socket Set Screw

B. Bleeder Screw
C. Caliper Assy.
D. Boot
E. Square O-rings (large)
F. Square O-rings (small)
G. Piston
H. Caliper Mount
I. Brake Pads
Caliper Removal
1. Elevate and safely support the rear of the vehicle. 5. Loosen brake pad adjustment set screw to allow brake pad
2. Remove the (4) wheel nuts, (4) washers and rear wheel. removal after the caliper is removed.
CAUTION
Use care when supporting vehicle so that it does not

tip or fall. Severe injury may occur.
3. Clean caliper area before removal. Pad

Adjuster
4. Place a container below the caliper to catch brake fluid
when removing the line. Remove brake line from caliper.
Remove
Brake Line
9.32
BRAKES
6. Remove the two caliper mounting bolts and the caliper. IMPORTANT: Do not remove the caliper pistons with
a standard pliers. The piston sealing surfaces will
become damaged if a standard pliers is used.
4. Once the pistons are removed, use a pick to carefully

remove the square O-rings from the caliper. O-rings should
be replaced during caliper service.
Remove
Caliper Disassembly
1. Remove both brake pads from the caliper. Refer to REAR
BRAKE PADS (CREW / 6X6).
2. Remove the mount bracket assembly and the dust boots 5. Clean the caliper body, piston, and retaining bracket with
from caliper. Thoroughly clean the caliper before brake cleaner or alcohol.
disassembly and prepare a clean work area for disassembly.
Clean
Components
3. Use a commercially available caliper piston pliers to extract

the pistons from the caliper.
IMPORTANT: Be sure to clean the seal grooves in
caliper body.
9
9.33
BRAKES
Caliper Inspection Caliper Assembly
1. Inspect caliper body for nicks, scratches, pitting or wear. 1. Install new O-rings in the caliper body. Be sure the
Measure bore size and compare to specifications. Replace grooves are clean and free of residue or brakes may drag
if damaged or worn beyond service limit. upon assembly.
Seal
Grooves
New
O-Rings
2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install

= In. / mm. pistons with a twisting motion while pushing inward.
Piston should slide in and out of bore smoothly, with light
resistance.
Caliper Piston Bore I.D.:
Std: 1.192 (30.28 mm) 3. Lubricate the mounting bracket pins with Polaris Premium
Service Limit: 1.194 (34.33 mm) All Season Grease (PN 2871423), and install the rubber
dust seal boots.
2. Inspect piston for nicks, scratches, pitting or wear. Measure
piston diameter and replace if damaged or worn beyond
service limit. Apply Grease to Each
Bracket Pin
4. Compress the mounting bracket and make sure the dust seal
boots are fully seated. Install the brake pads. Clean the disc
= In. / mm. remove any dirt, oil or grease.

Std: 1.186 (30.12 mm)
3. Inspect the brake disc and pads as outlined in this chapter.
9.34
BRAKES
Caliper Installation 4. Perform brake bleeding procedure as outlined earlier in this
chapter.
1. Install caliper and torque mounting bolts to specification.
Chapter 2).
6. Field test unit for proper braking action before putting into
service. Inspect for fluid leaks and firm brakes. Make sure
30 ft. lbs.
(41 Nm) NOTE: If new brake pads are installed, brake
burnishing is recommended (see REAR BRAKE
=T
Rear Caliper Mount Bolt Torque:
30 ft. lbs. (41 Nm)
2. Install brake line and torque the banjo bolt to the proper
torque specification.
15 ft. lbs.
(20 Nm)
3. Install the pad adjustment screw and turn until stationary

pad contacts disc, then back off 1/2 turn.
9
1/2 Turn
Pad
Adjuster
9.35
BRAKES
REAR BRAKE DISC
Brake Disc Thickness
Disc Runout New .188 (4.78 mm)
1. Mount a dial indicator and measure disc runout. Slowly Service Limit .170 (4.32 mm)
rotate the disc and read total runout on the dial indicator.
Replace the disc if runout exceeds specification.
Brake Disc Thickness Variance
Service Limit .002 (.051 mm)

difference between measurements
Disc Removal / Replacement

1. Remove rear brake caliper (see Rear Caliper Service).
2. Remove cotter pin, castle nut and washers.
3. Remove the wheel hub assembly from the vehicle and

remove the (4) bolts retaining the disc to the hub.
(4) Bolts
Brake Disc Runout

Washers
Service Limit .010 (.254 mm)
Nut
Cotter
Pin
Disc Inspection
4. Clean the wheel hub mating surface and install new disc on
1. Visually inspect disc for scoring, scratches, or gouges.
wheel hub.
Replace the disc if any deep scratches are evident.
2. Use a 0-1" micrometer and measure disc thickness at 8 5. Install new bolts and torque to 28 ft. lbs. (38 Nm).
different points around perimeter of disc. Replace disc if 28 ft. lbs.
worn beyond service limit. (38 Nm)
Rear
Disc
110 ft. lbs.

(150 Nm)
Measure
Thickness
9.36
BRAKES
TROUBLESHOOTING
CAUTION
Brakes Squeal / Poor Brake Performance
Always use new brake disc mounting bolts. The Air in system
bolts have a pre-applied locking agent which is
destroyed upon removal. Water in system (brake fluid contaminated)
6. Install wheel hub assembly, washers, and castle nut. Torque Caliper/disc misaligned
castle nut to 110 ft. lbs. (150 Nm) and install a new cotter Caliper dirty or damaged
pin.
Brake line damaged or lining ruptured
7. Install rear brake caliper (see REAR CALIPER
Worn disc and/or friction pads
SERVICE). Follow the bleeding procedure outlined
earlier in this chapter. Incorrectly adjusted stationary pad
8. Field test unit for proper braking action before putting into Worn or damaged master cylinder or components
service. Inspect for fluid leaks and firm brakes. Make sure Damaged break pad noise insulator
drags, re-check assembly and installation. 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 9
Improper assembly of brake system components
9.37
BRAKES
NOTES
9.38
ELECTRICAL
CHAPTER 10
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
HEADLIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
AWD / 2WD / TURF SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
DIFFERENTIAL SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
STANDARD DISPLAY MODES / DIAGNOSTIC DISPLAY MODE . . . . . . . . . . . . . . . . 10.8
VIEWING DIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
INSTRUMENT CLUSTER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 10.11
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . . . . . . . 10.12
TEST 1 - NO ALL WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
TEST 2 - NO DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
TEST 3 - WHEEL SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
TEST 4 - NO AWD HUB SAFETY LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
GEAR POSITION INDICATOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
HEADLIGHT ADJUSTMENT / BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 10.17
HEADLIGHT HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
HEADLIGHT HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
TAIL LIGHT / BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
LED LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
FAN CONTROL CIRCUIT OPERATION / BYPASS TEST. . . . . . . . . . . . . . . . . . . . . . 10.21
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
EFI DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
FUSES / CIRCUIT BREAKER / RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
CHARGING SYSTEM BREAK EVEN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
CHARGING SYSTEM ALTERNATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
REGULATOR / RECTIFIER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
10
BATTERY TERMINALS / BOLTS / TERMINAL BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 10.28
BATTERY ACTIVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
BATTERY INSPECTION / REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 10.29
CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
OCV - OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
SPECIFIC GRAVITY TEST / LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
CHARGING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
10.1
ELECTRICAL
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
STARTER MOTOR REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
BRUSH INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
ARMATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
STARTER REASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
STARTER SOLENOID BENCH TEST / OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
STARTER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
STARTING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
ELECTRONIC POWER STEERING (EPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
EPS SYSTEM BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
EPS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
EPS 8-WAY WIRE HARNESS CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
EPS MALFUNCTION INDICATOR LIGHT (MIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
PROPER EPS SYSTEM DIAGNOSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
EPS TROUBLESHOOTING (NON-FUNCTIONAL WITH EPS MIL ON) . . . . . . . . . . . 10.40
EPS TROUBLESHOOTING (NON-FUNCTIONAL WITH EPS MIL OFF) . . . . . . . . . . 10.41
EPS TROUBLESHOOTING (FUNCTIONAL WITH EPS MIL ON) . . . . . . . . . . . . . . . . 10.42
ELECTRIC BOX LIFT ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43
10.2
ELECTRICAL
GENERAL INFORMATION Components Under Hood
The following components can be accessed under the hood.
Special Tools
Voltage Regulator (in front of radiator)
Part Number Tool Description
Battery
PV-43568 Fluke 77 Digital Multimeter
Battery Cables
PV-43526 Connector Test Kit
Terminal Block
2870630 Timing Light
Starter Solenoid
2870836 Battery Hydrometer
Relays
2460761 Hall Sensor Probe Harness
2871745 Static Timing Light Harness Fuses
PU-47063 Digital Wrench Diagnostic Software Digital Wrench Diagnostic Connector
PU-47471 Digital Wrench SmartLink Module Kit

Components Behind Dash Panel
The following components can be accessed with the dash panel
Electrical Service Notes
removed (see Chapter 5 for removal).
Keep the following notes in mind when diagnosing an electrical
problem: Speedometer
Speedometer Mode Switch
Refer to wiring diagram for stator and electrical
component resistance specifications. AWD/2WD/TURF Switch
When measuring resistance of a component that has a Headlight Switch

resistance value under 10 Ohms, remember to subtract
12 VDC Accessory Power Points
meter lead resistance from the reading. Connect the
leads together and record the resistance. The resistance Ignition Switch
of the component is equal to tested value minus the lead
resistance. Parking Brake Switch
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 Owners Manual included with your meter for more
information.
Voltage, amperage, and resistance values included in

this manual are obtained with a Fluke 77 Digital
Multimeter (PV-43568). This meter is used when
diagnosing electrical problems. Readings obtained with
other meters may differ.
10
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.
10.3
ELECTRICAL
SWITCHES / CONTROLS When the switch is in position #3 (TURF), there should
be continuity between terminals 4 (White/Green) and 5
Headlight Switch (Brown).
1. Remove the dash panel from the dash (see Chapter 5).
2. Disconnect the headlight switch harness (Brown, Green,

and Yellow), by depressing the connector lock and pulling
on the connector. Do not pull on the wiring.
3. Inspect the switch connections and test the switch for

continuity.
When the headlight switch is turned on, there should be

continuity between terminals 2 (Yellow) and 3 (Green).
Differential Solenoid
The differential solenoid is located on the right side of the
transmission (4x4) or on the rear gear case (6x6). The solenoid
actuates an engagement dog, which locks and unlocks the rear
differential. Refer to Chapter 8 (4x4) or Chapter 7 (6x6) for
more information on the rear differential mechanical operation.
AWD / 2WD / TURF Switch

2. Disconnect the switch harness (Gray, Orange/White,

Brown, White/Green), by depressing the connector lock
and pulling on the connector. Do not pull on the wiring.
3. Inspect the switch connections and test the switch for

continuity.
When the switch is in position #1 (AWD), there should

be continuity between terminals 2 (Orange/White) and
3 (Gray).
10.4
ELECTRICAL
Differential Solenoid Circuit Operation If the rear differential fails to switch from operational modes:
The Rear Diff Solenoid Relay is located on the frame under the Check the solenoid and relay connectors. Look for
rear cargo box. loose wires or bad connections.
When the switch is pushed to activate TURF mode, a ground Check for power from the relay connector, to ensure the
signal is provided to the ECU from the AWD / 2WD / TURF solenoid has power to be activated.
Switch.
Check the AWD / 2WD / TURF Switch wires for loose
Depending on engine speed, gear position criteria and parking connections.
brake input, the ECU energizes the Rear Diff Solenoid Relay
Remove solenoid from rear differential and ensure the
allowing it to enable the differential solenoid. NOTE: The rear
solenoid plunger is actuating.
differential will not unlock if the parking brake is set.
CAUTION
Do not power the solenoid with 12 Volts for more

than 1 second, or damage may occur to solenoid.
Brake Light Switch

The brake light switch is located on the frame under the rear
portion of the PVT cover. The brake pressure switch is installed
into a junction block.
1. Disconnect the wire harness from the brake switch.
Brake Switch
2. Connect an ohmmeter across switch contacts. Reading

should be infinite (OL).
3. Apply foot brake and check for continuity between switch

10
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 The Parking Brake Switch
The parking brake switch is located within the parking brake 1. Disconnect the harness connector at the parking brake
lever. Follow the parking brake lever under the dash to locate the switch (Orange/Red and Red/White wires).
internally mounted switch.
2. Place the ohmmeter leads onto the switch terminals. The
reading should be infinite (OL).
3. Apply the parking brake. Continuity should now exist

between the switch terminals. If no continuity exists when
the parking brake is applied, try to clean the switch
terminals and re-test. Replace switch if necessary.
Park Brake
Indicator
The switch remains in the open position when the park brake
lever is not applied.
When the parking brake lever is applied, the switch makes

contact and sends voltage to the ECU and Instrument Cluster to
illuminate the Park Brake Indicator - (P) near the top-center of
the instrument cluster.
NOTE: If the parking brake is applied the ECU will

rev limit the engine at 1300 RPM until the parking
brake is released. This feature has been added to
prevent drive-away with the parking brake applied.
If trying to perform an engine diagnostic running test

with the parking brake applied, disconnect the
switch harness connector to allow the engine to rev
higher than 1300 RPMs.
10.6
ELECTRICAL
INSTRUMENT CLUSTER Rider Information Display
The rider information display is located in the instrument
Overview
cluster. All segments will light up for 2.5 seconds at start-up.
The RANGER instrument cluster senses vehicle speed from the
NOTE: If the instrument cluster fails to illuminate, a
right front wheel. The instrument cluster measures distance in
battery over-voltage may have occurred and the
miles as well as time, hours of operation and engine RPM.
instrument cluster may have shut off to protect the
electronic speedometer.
Park Brake 3 4 5 6
Indicator 7
Speedometer
8
Speedometer
Needle
1. Gear Indicator - This indicator displays gear shifter

position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
Rider
Information
Display 2. AWD Indicator - This indicator illuminates when the
AWD switch is in the AWD position.
3. Engine Hour Display Indicator

NOTE: In addition to showing vehicle speed, the
speedometer needle flashes when a low fuel 4. Service Interval / Diagnostic Mode Indicator
condition exists.
5. Low Battery and Over Voltage - This warning usually
NOTE: Use the Mode Button shown below to indicates that the vehicle is operating at an RPM too low to
toggle between Instrument Cluster display screens. 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
7. Fuel Gauge - The segments of the fuel gauge show the level
of fuel in the fuel tank. When the last segment clears, a low
fuel warning is activated. All segments will flash, FUEL 10
will display in the LCD, and the speedometer needle will
blink. Refuel immediately.
Key Mode Instrument 8. Check Engine Warning Indicator - This indicator serves
Switch Button Cluster 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 Battery Voltage Screen
Use the yellow mode button located under the speedometer to View this screen to check battery voltage level.
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 or kilometers 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 display reads 0.
NOTE: In the Rider Information Display, the trip

meter display contains a decimal point, but the Tachometer Screen
odometer displays without a decimal point. View the tachometer to check engine speed.
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.
Diagnostic Display Mode AWD Diagnostic Screen

The wrench icon will display when the gauge is in the diagnostic The gauge indicates whether or not current is flowing through
mode. To exit the diagnostic mode, turn the key switch off and the AWD coil.
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
activated.
5. Use the mode button to toggle through the diagnostic

screens.
10.8
ELECTRICAL
Gear Circuit Diagnostic Screen Programmable Service Interval
This screen displays the resistance value (in ohms) being read at When the hours of engine operation equal the programmed
the gear switch input of the gauge. service interval setting, the wrench icon will flash for 5 seconds
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 to 50

hours at the factory.
To enable or disable the service interval:

1. 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:

1. Enter the diagnostic mode. 10
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
NOTE: A 10 - 20% variance from these readings is
advance the hours quickly.
within normal parameters.
10.9
ELECTRICAL
NOTE: If you scroll past the intended number, press Viewing Diagnostic Codes
and hold the button until the hours cycle back to
zero. Use the following procedure to view diagnostic blink codes
(failure codes) from the EFI module:
5. When the desired setting is displayed, wait until the wrench
icon stops flashing. The new service interval is now NOTE: Refer to Chapter 4 Electronic Fuel Injection
programmed. for a complete list of Diagnostic Blink Codes.
Miles / Kilometers Toggle 1. Engage the parking brake.

2. Stop the engine.
The display in the tripmeter and odometer can be changed to
display either standard or metric units of measurement. 3. Turn the key switch to the ON position.
4. Turn the key switch off and on three times in less than five
1. Enter the diagnostic mode.
seconds, then leave the switch on. The word Wait will
2. Toggle to the screen that displays either kilometers (KM) appear on the screen along with a flashing Check Engine
or miles (MP). light.
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.
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.
10.10
ELECTRICAL
Instrument Cluster Removal Instrument Cluster Installation
NOTE: Do not allow alcohol or petroleum products 1. Spray a soap and water mixture onto the outer surface area
to come in contact with the instrument cluster lens. of the instrument cluster. This will help the instrument
cluster slide into the rubber mount more easily.
2. Disconnect the wire connectors from the back side of the

instrument cluster.
2. Be sure the rubber mount inside the dash panel 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

3. Push the instrument cluster out from the back side of the
cluster into the dash panel. Twist the instrument cluster
dash panel, while securely holding the panel and rubber
gently in a clockwise motion to properly seat the instrument
mount.
cluster. Apply pressure on the bezel while pressing down
on the instrument cluster.
NOTE: Do not remove the rubber mount from the

dash panel. Only remove the rubber mount if
necessary. 10
10.11
ELECTRICAL
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS
Test 1 - No All Wheel Drive
10.12
ELECTRICAL
TEST 2 - No Display
TEST 3 - Wheel Speed Sensor
10
10.13
ELECTRICAL
TEST 4 - No AWD Hub Safety Limiter
10.14
ELECTRICAL
TEST 5 - Fuel Gauge Display Not Working
TEST 6 - Shift Indicator Not Working (Transmission Switch)
10
10.15
ELECTRICAL
ALL WHEEL DRIVE (AWD) COIL GEAR POSITION INDICATOR SWITCH
Operation Overview Test Diagram
When the AWD switch is ON, 12 VDC power is NOTE: Also see INSTRUMENT CLUSTER
present at the hub coil. TROUBLESHOOTING for switch circuit.
If the criteria is met, the instrument cluster provides a TRANSMISSION SWITCH
ground path at pin #16 (Brown/White wire). When this
High / Low / Neutral / Reverse
occurs the AWD icon should display in the instrument
cluster.
The AWD system must be grounded to operate.
Diagnosing System Failures

Verify the AWD switch is functional and that a
minimum of 11 volts is present at the hub coil. High Range
Low Range
Verify the AWD hub coil is functional. Test the AWD Neutral
hub coil using an ohm meter. See specifications below: Reverse
Green/White Brown/Red
Violet White/Blue
Blue/Red
7HVW5HVLVWDQFH
5HDGLQJVVKRXOGEH
*<WR%1:+a2KPV
*<WR*URXQG1R&RQQHFWLRQ
AWD Hub Coil Resistance:

24 5%
Verify the wiring harness, wiring, connectors, connector

pins and grounds are undamaged, clean and connected
properly.
Verify continuity of wire connections with a 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.
80% of all electrical issues are caused by bad/failed
connections and grounds.
10.16
ELECTRICAL
HEADLIGHTS 6. Once the beam is set to the position, tighten the adjustment
screw. Repeat the procedure to adjust the other headlight.
Headlight Adjustment
The RANGER headlights are adjustable. WARNING
1. Place the vehicle on a level surface with the headlight
Due to the nature of light utility vehicles and
approximately 25 ft. (7.6 m) from a wall.
where they are operated, headlight lenses
become dirty. Frequent washing is necessary to
maintain lighting quality. Riding with poor
25 ft. (7.6 m) lighting can result in severe injury or death.
X1 X2
8 in. (20 cm)
Headlight Bulb Replacement

1. Open the hood.
2. Locate the bulb on the back side of headlight.
2. Measure the distance from the floor to the center of the

headlight (X1) and make a mark on the wall at the same
height (X2). Bulb
3. With the machine in Neutral and parking brake applied,

start the engine and turn the headlight switch on.
4. The 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. Locate the T25 Torx-head adjustment screw through the 3. Turn the bulb counterclockwise to remove it.
wheel well (see illustration). Adjust the beam to the desired
position by loosening the adjustment screw and moving the
lamp to the appropriate height.
10
10.17
ELECTRICAL
4. Unplug the headlight bulb from the wiring harness. Be sure 3. Carefully pull the fascia out far enough to access the
to pull on the connector, not on the wiring. headlight housing.
Wire Harness Headlight

Housing
Bulb
5. Install the wire harness into the new headlight bulb. 4. Remove the bulb from the headlight housing (see
Headlight Bulb Replacement).
6. Install the bulb into the housing and rotate it clockwise 90
to lock it in place. 5. Remove the O-rings (A) from each side of the headlight
housing. Remove the adjustment screw (B) and pull the
NOTE: Make sure the tab on the bulb locates headlight from the brackets.
properly in the housing.
Headlight Housing Removal A

1. Open the hood.
2. Remove the front facia to access the headlight housing.
10.18
ELECTRICAL
Headlight Housing Installation TAIL LIGHT / BRAKE LIGHT
1. Install the headlight housing by pressing the headlight tabs
LED Lamp Replacement
back into the brackets.
1. From the rear of the LED lamp, remove the (2) T20 Torx-
2. Secure the headlight housing with the rubber O-rings on head screws retaining the lamp assembly.
each side (A). Install the adjustment screw (B).
NOTE: Be sure to twist the O-rings upon installation

as shown below.
A T20 Screws
B
2. Remove the lamp from the cargo box and disconnect the tail
light / brake light wire harness.
NOTE: Before replacing the LED lamp assembly,

3. Reinstall the bulb into the housing and rotate it clockwise use a digital multi-meter to test the harness to
90 to lock it in place. ensure the lamp is receiving 12 volts and that a
ground path is present.
4. Reinstall the front fascia and securely tighten all fasteners.
3. If the LED still does not work, replace the LED lamp
assembly with the recommended lamp. Apply dielectric
grease (PN 2871329) to the new lamp connector terminals.
4. Reinstall the assembly by reversing this procedure.
5. Test the tail light / brake light after installation to verify

proper function.
Install
10
5. Adjust headlights using the Headlight Adjustment
procedure.
10.19
ELECTRICAL
COOLING SYSTEM
Cooling System Break-Out Diagram
10.20
ELECTRICAL
Fan Control Circuit Operation EFI DIAGNOSTICS
Power is supplied to the fan via the Orange/Black wire when the
EFI Component Testing
relay is energized. The Brown wire provides the ground path for
the fan motor. Refer to RELAYS later in this chapter for more All EFI component information and diagnostic testing
information on fan functions. procedures are located in Chapter 4.
Refer to Chapter 4 Electronic Fuel Injection System (EFI)

CAUTION when diagnosing an EFI System.
Keep hands away from fan blades during FUEL SENDER

operation. Serious personal injury could result.
Testing
NOTE: The fan may not function or operation may
be delayed if coolant level is low or if air is trapped in 1. Drain the fuel tank and remove it from the chassis.
the cooling system. Be sure cooling system is full 2. Set the fuel tank on a flat surface.
and purged of air. Refer to Chapter 2 Maintenance
for cooling system information. 3. Attach an ohm meter to the fuel sender harness Violet/
White wire (B) and Brown wire (C).
Fan Control Circuit Bypass Test 4. Allow the sender float to sit in the empty position and
compare to specification.
1. Disconnect harness from coolant temperature sensor on
engine.
Fuel Sender - Empty: 5 5%
2. With the parking brake applied, turn the ignition key ON.
The fan should start running.
5. Slowly tilt the tank so that gravity moves the sender float
3. If the fan does not run or runs slowly, check the fan motor to the full position and compare to specification.
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 Fuel Sender
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.
Empty: 5 5%
1. With the engine and temperature sensor at room
temperature (68F = 20C), disconnect the harness Half: 57 5%
connector. Full: 90 5%
2. With the meter in the ohms mode, place the meter leads
onto the sensor contacts.
Fuel Sender - Full: 90 5%
3. Use the following table to determine if the sensor needs to
be replaced. 10
6. If the readings are not to specification, or if the reading is
erratic or LCD display sticks, check the following before
TEMPERATURE F (C) RESISTANCE replacing the fuel pump assembly.
68 F (20 C) 2.5 k 6% Loose float
212 F (100 C) 0.186 2% Float contact with tank
Bent Float Rod
NOTE: If the coolant temperature sensor or circuit
malfunctions the radiator fan will default ON. If none of the conditions exists, the sender assembly is faulty.
Fuel pump/tank assembly replacement is required.
10.21
ELECTRICAL
RELAYS FAN RELAY
NOTE: Refer to the Electronic Power Steering (EPS) COLOR FUNCTION

section in this chapter for information on EPS relays. Orange / Black Relay switched 12V power to the fan motor.
Operation Key-On 12V power supply, provides power to

Red / White
operate the relay.
The relays assist with fan, EFI, brake light and rear differential 15 Amp circuit breaker protected, 12V relay
operation. Red
power supply.
The Fan Relay, controlled by the ECM and Engine Coolant ECM ground input to connect the relay 15 Amp
Yellow / Black
Temp Sensor, operates the fan motor. 12V power to the fan motor.
The EFI Relay, controlled by the ECM and key switch, powers EFI RELAY
the EFI components such as the fuel pump, injectors and ignition
coil. COLOR FUNCTION
Relay switched 12V power to the EFI

The Brake Light Relay, controlled by the brake pressure switch Red / Black
components.
and key switch, powers the brake lights.
Key-On 12V power supply, provides power to
Red / White
The Rear Diff Solenoid Relay, controlled by the AWD/2WD/ operate the relay.
TURF switch and ECM, operates the differential solenoid.
Orange 15 Amp fuse protected, 12V relay power supply.
ECM ground input to connect the relay 15 Amp
Gray / White
12V power to the EFI components.
BRAKE LIGHT RELAY
COLOR FUNCTION
Orange Relay switched 12V power to the brake lights.

Key-On 12V power supply, provides the relay
Red / White
power supply and voltage to operate the relay.
Brake switch ground input to connect the relay
Brown / Yellow 12V power supply to the brake lights when the
brake pedal is applied.
REAR DIFF SOLENOID RELAY
COLOR FUNCTION
Key-On 12V power supply, provides the relay

Red / White
power supply and voltage to operate the relay.
ECM ground input to connect the relay power
Green / White
supply to the rear diff solenoid.
Brown Ground input to energize the rear diff solenoid.
Red Relay switched power to the rear diff solenoid.
Blue Ground input to energize the rear diff solenoid.
10.22
ELECTRICAL
FUSES / CIRCUIT BREAKER / RESISTOR
Operation
The fuses, located in the relay/fuse box under the hood, provide current protection for components such as the ECM, EFI system,
main harness, lights, accessories and power steering (EPS Models Only).
A 15 Amp circuit breaker, located under the hood near the relay/fuse box, protects the fan motor circuit.
A 120 resistor, located in the relay/fuse box, is used for Electronic Power Steering (EPS) operation (EPS Models Only).
10
10.23
ELECTRICAL
CHARGING SYSTEM Charging System Break Even Test
Current Draw - Key Off

CAUTION
CAUTION Do not allow the battery cables to become

disconnected with the engine running. Follow the
Do not connect or disconnect the battery cable steps below as outlined to reduce the chance of
or ammeter with the engine running. Damage will damage to electrical components.
occur to electrical components.
The break even point of the charging system is the point at
Connect an ammeter in series with the negative battery cable. which the alternator overcomes all system loads (lights, etc.)
Check for current draw with the key off. If the draw is excessive, and begins to charge the battery. Depending on battery condition
loads should be disconnected from the system one by one until and system load, the break even point may vary slightly. The
the draw is eliminated. Check component wiring as well as the battery should be fully charged before performing this test.
component for partial shorts to ground to eliminate the draw.
Current Draw Inspection WARNING

Key Off
Never start the engine with an ammeter
connected in series. Damage to the meter or
meter fuse will result.
Do not run test for extended period of time.
Do not run test with high amperage accessories.
1. Using an inductive amperage metering device, (set to DC

30 Amp amps) connect to the negative battery cable.
2. With engine off, and the key switch and lights in the ON
position, the ammeter should read negative amps (battery
discharge). Reverse meter lead if a positive reading is
indicated.
Current Draw - Key Off: 3. Shift transmission into neutral with the parking brake
Maximum of .01 DCA (10 mA) applied and start the engine. With the engine running at idle,
observe meter readings.
4. Increase engine RPM while observing ammeter and

tachometer.
5. Note RPM at which the battery starts to charge (ammeter

indication is positive).
6. With lights and other electrical loads off, the break even
point should occur at approximately 1500 RPM or lower.
7. With the engine running, turn the lights on and engage

parking brake to keep brake light on.
8. Repeat test, observing ammeter and tachometer. With

lights on, charging should occur at or below 2000 RPM.
10.24
ELECTRICAL
Charging System Alternator Tests TEST 3: Measure AC Voltage Output of Each Stator Leg at
Charging RPM
Three tests can be performed using a multi-meter to determine
the condition of the stator (alternator). 1. Set the selector dial to measure AC Voltage.
2. Start the engine and let it idle.
3. While holding the engine at a specified RPM, separately

Y1 measure the voltage across each leg of the stator by
Y2 connecting the meter leads to the wires leading from the
alternator (Y1 to Y2, Y1 to Y3, Y2 to Y3).
4. Refer to the following table for approximate AC Voltage

Y3 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.
Perform tests at
Stator / Regulator connector 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.
TEST 1: Resistance Value of Each Stator Leg
1. Measure the resistance value of each of the three stator RPM Reading AC Voltage (VAC) Reading
legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3.
Each test should measure: 0.19 15% 1300 18 VAC 25 %
3000 42 VAC 25 %
Connect Meter 5000 64 VAC 25 %
Test Ohms Reading
Leads To:
Battery Charge Coil Y1 to Y2 0.19 15%

NOTE: If there are any significant variations in ohm

readings between the three legs it is an indication
that one of the three stator legs maybe weak or
failed.
TEST 2: Resistance Value of Each Stator Leg to Ground

1. Measure the resistance value of each of the stator legs to
ground: Y1 to Ground, Y2 to Ground, Y3 to Ground.
Each test should measure: Open Line (OL)
10
Connect Meter
Test Ohms Reading
Leads To:
Y1, Y2, or Y3 Open Line

Battery Charge Coil
to Ground (Infinity)
NOTE: Any measurement other than Infinity (open)

will indicate a failed or shorted stator leg.
10.25
ELECTRICAL
Regulator / Rectifier Test
Remove the regulator / rectifier from the vehicle. NOTE: Unit must be cool for accurate testing.
Use DIODE CHECK function on the Fluke 77 DMM
Perform all tests described in test table below. Test results describe a properly functioning component.
NOTE: If the temperature of the regulator / rectifier exceeds

194 F (90C), the unit will turn itself off to cool down. The
unit will turn on at approximately 167F (75C). If it turns off,
verify the housing cooling fins are clean, free from debris
and that adequate airflow is present.
Regulator / Rectifier Test Table - Set DMM to DIODE CHECK Function

DMM RED LEAD DMM BLACK LEAD RESULT
AC - 1 (3-wire connector) AC - 2 (3-wire connector) Open Circuit

RED Battery + (2-wire connector) BLACK Ground (2-wire connector) Open Circuit
BLACK Ground (2-wire connector) RED Battery + (2-wire connector) 2300mV to 2400mV
BLACK Ground (2-wire connector) Regulator / Rectifier Case Closed Circuit (continuity)
BLACK Ground (2-wire connector) Any Phase Open Circuit
AC - 1 (3-wire connector) BLACK Ground (2-wire connector) Open Circuit
AC - 2 (3-wire connector) BLACK Ground (2-wire connector) 2200mV to 2300mV
AC - 3 (3-wire connector) BLACK Ground (2-wire connector) Open Circuit
RED Battery + (2-wire connector) Any Phase Open Circuit
AC - 1 (3-wire connector) RED Battery + (2-wire connector) 400mV to 500mV
10.26
ELECTRICAL
Charging System Testing Flow Chart
Whenever charging system problems are suspected, 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 No 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 Yes Check Key off Current Draw.
multitester. Readings should increase to
between 13.0 and 14.6 V D.C. Do they?
No
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. 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, Inspect the wiring harness between
continue with alternator output test.
the panel and the stator for
Meter Setting: AC Volts
damage. If no damage is found,
Disconnect the Yellow wires from the regulator /
rectifier. Using a multitester, perform an Alternator No remove the recoil and flywheel.
Output test. See test procedure on Page 10.25. Inspect the flywheel magnets, stator
coils and stator wires for damage.
Does output meet specification? Repair or replace any damaged
components.
Yes
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. No wire connections and wire condition.
Is voltage present? Repair or replace faulty wiring or 10
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.
10.27
ELECTRICAL
BATTERY SERVICE Battery Activation
Battery Terminals / Bolts

WARNING
Use Polaris corrosion resistant Nyogel grease (PN 2871329)
on battery terminal bolts. Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Antidote:
Apply External: Flush with water.

Nyogel
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 batteries.
KEEP OUT OF REACH OF CHILDREN.
Battery Terminal Block WARNING

The terminal block is located under the hood next to the battery
The gases given off by a battery are explosive.
and fuse box. The terminal block provides easy hookup for
accessories. 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
Terminal
with battery acid, wash the affected area with
Block
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 batterys full potential.
To activate a new battery:

=T
1. Remove all the filling plugs.
Terminal Block Nuts:
2. Remove the sealing tube (red cap) from vent fitting.
20-25 in. lbs. (2.3-2.8 Nm)
3. Place battery on a level surface. Fill battery with electrolyte
to upper level marks on the battery case.
NOTE: Never activate a battery on the vehicle.

Electrolyte spillage can cause damage.
10.28
ELECTRICAL
4. Set battery aside to allow for acid absorption and 11. Make sure the battery top is clean and dry. A dirty battery
stabilization for 30 minutes. actually discharges across the grime on top of the case. Use
a soft brush and a baking soda solution. Make sure plugs
5. Add electrolyte to bring the level back to the upper level are finger tight so cleaning solution doesnt get into the cells
mark on the battery case. and neutralize the acid.
6. Charge battery for 3 - 5 hours 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).
7. Check during initial charging to see if electrolyte level has

fallen, and if so, fill with acid to the upper level. After
adding, charge for another hour at the same rate.
NOTE: This is the last time that electrolyte should

be added. If the level becomes low after this point,
add only distilled water.
8. When charging is complete, install the filling plugs firmly.
IMPORTANT: Do not apply excessive pressure. 12. Inspect the battery terminals, screws and cables for
Finger tighten only. Do not over-tighten. breakage, corrosion or loose connections. Clean the
terminals and cable ends with a wire brush and coat
9. Wash off spilled acid with water and baking soda solution,
terminals with Nyogel.
paying particular attention that any acid is washed off the
terminals. Dry the battery case. 13. Check the electrolyte level and add distilled water if
necessary.
Battery Inspection
The battery is located under the hood.
Battery
IMPORTANT: Dont add acid, use distilled water only! 10

10. Inspect the battery case for obvious damage such as cracks 14. Check the vent tube. Make sure its not kinked, pinched or
or leaks. Look for discoloration, warping or raised top, otherwise obstructed.
which may indicate the battery has overheated or been
overcharged.
Battery Removal / Installation
See Chapter 2 Maintenance for battery service procedures.
10.29
ELECTRICAL
Conventional Battery Testing Specific Gravity Test
Whenever a service complaint is related to either the starting or A tool such as a Battery Hydrometer (PN 2870836) can be used
charging systems, the battery should be checked first. to measure electrolyte strength or specific gravity. As the battery
goes through the charge/discharge cycle, the electrolyte goes
Following are three tests which can easily be made on a battery from a heavy (more acidic) state at full charge to a light (more
to determine its condition: OCV Test, Specific Gravity Test and water) state when discharged. The hydrometer can measure
Load Test. state of charge and differences between cells in a multi-cell
battery. Readings of 1.270 or greater should be observed in a
OCV - Open Circuit Voltage Test fully charged battery. Differences of more than .025 between the
lowest and highest cell readings indicate a need to replace the
Battery voltage should be checked with a digital multimeter. battery.
Readings of 12.6 volts or less require further battery testing and
charging. See the following chart.
Battery Hydrometer
(PN 2870836)
SPECIFIC GRAVITY
NOTE: Lead-acid batteries should be kept at or near
State of Charge* YuMicron Type
a full charge as possible. Electrolyte level should be
kept between the low and full marks. If the battery is 100% Charged 1.275
stored or used in a partially charged condition, or
75% Charged 1.225
with low electrolyte levels, hard crystal sulfation will
form on the plates, reducing the efficiency and 50% Charged 1.175
service life of the battery.
25% Charged 1.135
OPEN CIRCUIT VOLTAGE 0% Charged 1.115 or less
State of Charge YuMicron Type * At 80 F. NOTE: Subtract .01 from the specific
gravity reading at 40 F.
100% Charged 12.70 V
75% Charged 12.50 V Load Test
50% Charged 12.20 V A battery may indicate a full charge condition in the OCV test
25% Charged 12.0 V and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system.
0% Charged 11.9 V or less For this reason, a battery capacity or load test should be
conducted whenever poor battery performance is encountered.
This is the best test of battery condition under starting load. Use
a load testing device that has an adjustable load. Apply a load of
three times the ampere-hour rating.
At 14 seconds into the test, check battery voltage. A good 12V

battery will have at least 10.5 Volts. If the reading is low, charge
the battery and retest.
10.30
ELECTRICAL
Charging Procedure STARTER SYSTEM
1. Remove the battery to prevent damage from leaking or
Troubleshooting
spilled acid during charging.
Starter Motor Does Not Run
2. Charge the battery with a charging output no larger than 1/
10 of the batterys amp/hr rating. Charge as needed to raise Battery discharged - Low specific gravity
the specific gravity to 1.270 or greater. Loose or faulty battery cables or corroded connections
(see Voltage Drop Tests)
3. Install battery in vehicle. Coat threads of battery bolt with
a corrosion resistant dielectric grease. Related wiring loose, disconnected, or corroded
Poor ground connections at battery cable, starter motor
Dielectric Grease
or starter solenoid (see Voltage Drop Tests)
(PN 2871329) Faulty key switch
4. Connect battery cables. Faulty starter solenoid or starter motor

Engine problem - seized or binding (can engine be
rotated easily)
WARNING
Starter Motor Turns Over Slowly
To avoid the possibility of explosion, connect
positive (+) cable first and negative (-) cable last. Battery discharged - low specific gravity
Excessive circuit resistance - poor connections (see
5. After connecting the battery cables, install the cover on the Voltage Drop Test)
battery and attach the hold down strap.
Engine problem - seized or binding (can engine be
6. Install clear battery vent tube from vehicle to battery vent. rotated easily)
WARNING: Vent tube must be free from obstructions and
kinks and securely installed. If not, battery gases could Faulty or worn brushes in starter motor
accumulate and cause an explosion. Vent should be routed Starter Motor Turns - Engine Does Not Rotate
away from frame and body to prevent contact with
electrolyte. Avoid skin contact with electrolyte, as severe Faulty starter drive
burns could result. If electrolyte contacts the vehicle frame, Faulty starter drive gears or starter motor gear
corrosion will occur.
Faulty flywheel gear or loose flywheel
7. Route cables so they are tucked away in front and behind
battery.
Off Season Storage

See Chapter 2 Maintenance for battery service procedures.
10
10.31
ELECTRICAL
Voltage Drop Test NOTE: Note the alignment marks on both ends of
the starter motor casing. These marks must align
The Voltage Drop Test is used to test for bad connections. When during reassembly.
performing the test, you are testing the amount of voltage drop
through the connection. A poor or corroded connection will 3. Remove the front bracket assembly and the rear bracket
appear as a high voltage reading. Voltage shown on the meter assembly. Remove the shims from the armature shaft and
when testing connections should not exceed .1 VDC per inspect the O-rings located on the armature housing.
connection or component. O-Rings
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 in the Starter System Testing Flow Chart.
Voltage should not exceed

.1 DC volts per connection
Starter Motor Removal / Disassembly Shims
NOTE: Use electrical contact cleaner to clean starter

motor parts. Some solvents may leave a residue or NOTE: The shims will be replaced during
damage internal parts and insulation. reassembly.
1. Remove the starter from the engine.
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.
2. Remove the two bolts, washers, and sealing O-Rings.

Inspect O-Rings and replace if damaged.
10.32
ELECTRICAL
2. Measure resistance between insulated brush and starter Brush Replacement
housing. Reading should be infinite (OL). Inspect
1. Remove terminal nut with lock washer, flat washer, large
insulation on brush wires for damage and repair or replace
phenolic washer, the small phenolic spacers, and sealing
as necessary.
O-ring. Inspect O-ring and replace if damaged.
2. Slide positive brush springs to the side, pull brushes out of

their guides and remove brush plate.
3. Slide positive brush springs to the side, pull brushes out of CAUTION
their guides and remove brush plate. Slide brush end frame
off end of starter.
Some cleaning solvents may damage the
NOTE: The electrical input post must stay with the insulation in the starter. Care should be
field coil housing. exercised when selecting an appropriate
solvent. If the commutator needs cleaning use
4. Measure resistance between ground brush and brush plate. only electrical contact cleaner.
Resistance should be .3 ohms or less.
Armature Testing
1. Remove armature from starter casing. Note order of shims
on drive end for reassembly.
Brush Inspection
1. Measure length of each carbon brush. Replace brush
assembly when worn to 5/16 (8 mm) or less. The brushes 10
must slide freely in their holders.
2. Inspect surface of commutator. Replace if excessively
Brush Length
worn or damaged.
3. Using a digital multitester, measure the resistance between

each of the commutator segments. The reading should be
.3 ohms or less.
Limit 5/16 (8 mm)
10.33
ELECTRICAL
4. Measure the resistance between each commutator segment 2. Install O-ring, two small phenolic spacers, large phenolic
and the armature shaft. The reading should be infinite (no washer, flat washer, lock washer, and terminal nut.
continuity).
3. While holding brush springs away from brushes, push
brushes back and hold in place.
4. Slide armature into field magnet housing. Release brushes.
5. Lightly grease the drive roller bearing and reinstall drive

end frame on armature. Inspect seal for wear or damage.
Replace drive end cap if necessary.
Roller Bearing
Seal
5. Check commutator bars for discoloration. Bars discolored

in pairs indicate shorted coils, requiring replacement of the
starter motor.
6. 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. 6. Be sure wire insulation is in place around positive brush
wire and pushed completely into slot on phenolic plate.
CAUTION 7. Using Dielectric Grease (PN 2871329), lubricate brush end

bushing and install shims.
Use care when handling starter housing. 8. Align brush plate and install cover and screws.
Do not drop or strike the housing as
magnet damage is possible. 9. Lightly grease pinion shaft and install pinion, spring
If magnets are damaged, starter must be replaced. stopper, and snap ring.
Starter Reassembly / Installation

1. Install brush plate to field magnet housing aligning index
tab.
Set Bolt Torque: 35-52 in. lbs. (3.9-5.9 Nm)
10. Completely assemble starter motor and torque set bolts to

35 - 52 in. lbs. (3.9 - 5.9 Nm).
11. Install the starter onto the engine case. Hand tighten each
bolt. Torque the bottom bolt first to 9 ft. lbs. (12 Nm).
Then torque the top bolt to the same specification.
10.34
ELECTRICAL
NOTE: It is important to tighten the bottom starter 2. Remove the retaining ring, thrust washer, spring retainers
bolt first (circle), as the bottom hole acts as a pilot and clutch return spring. Screw the overrun clutch off the
hole to properly align the starter drive (bendix) with end of the pinion shaft. Remove the old spring and install
the flywheel. This helps to prevent binding and a new one. Lightly grease the pinion shaft and reinstall the
starter damage. clutch, spring, retainers, end washer and lock ring in the
reverse order. Make sure the end washer is positioned
properly so that it will hold the lock ring in its groove.
Starter Solenoid Bench Test

Test the start solenoid by powering the solenoid using battery
voltage for a maximum of 5 seconds. With the solenoid
energized, there should be continuity between terminals (A) and
(B). If there is no continuity or high resistance, replace the
starter solenoid.
Starter Solenoid Operation

To energize the starter solenoid the following must occur:
Starter Drive The brake must be applied to provide a ground path via
If the garter spring is damaged, the overrun clutch may fail to the Brown / Yellow wire.
return properly. Use either of the following methods to remove The key switch must be turned to the start position to
and install a new garter spring: provide 12V power via the White / Red wire.
Once the pull-in coil is energized, the solenoid provides
a current path for 12V power to reach the starter motor.
H
G
A F
D
A. Gear Assembly
E Closed when brake
B. Thrust Washer C pedal is applied
C. Busing
D. Retaining Ring
E. Thrust Washer
F. Stopper
G. Cover
H. Spring
10
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.
10.35
ELECTRICAL
Starter Exploded View
* Indicates - Do not reuse. 1. Rubber Ring* 10. Gear Assembly

Replace with new parts. 2. Brush Spring 11. Through Bolt
3. Thrust Washer 12. Cover
4. Gear Assembly 13. Stopper
5. O-Ring* 14. Snap Ring
6. Brush Complete 15. Washer
7. O-Ring* 16. Flange Bolt
8. Thrust Washer 17. Thrust Washer
9. Shaft Complete 18. Flange Bushing
10.36
ELECTRICAL
STARTING SYSTEM TESTING FLOW CHART
Condition: Starter fails to turn over the engine.
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
Disconnect 2-wire connector at the solenoid. Check for voltage at the chassis 20 Amp fuse
Using a multi-meter, connect the black meter lead and then check for voltage entering the
to the Orange/Green harness wire and the red No ignition switch. Battery voltage should be
meter lead to the White/Red harness wire. Apply present. If battery voltage is present at the
the brake and turn ignition switch to the start ignition switch, but not the solenoid, replace
position. Meter should read battery voltage. the switch. NOTE: The brake MUST be
applied when performing these tests.
Test the start solenoid by powering the solenoid via the 2-wire connection.
Yes With the solenoid energized, resistance should read about 0.5 10%
between the two terminals. If resistance measurement is out of specification,
Voltage Drop replace the starter solenoid (see Starter Solenoid Bench Test)
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 or replace the cable.
end of the battery-to-solenoid wire. Turn the ignition
key to the start position. Reading should be less
than .1 V D.C.
Yes
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. Turn Replace the starter solenoid.
the ignition key to the start position. Reading
should be less than .1 V D.C.
Yes
Connect the black tester lead to the solenoid end of

the solenoid-to-starter cable. Connect the red Clean the solenoid-to-starter cable ends or
tester lead to the starter end of the same cable. Turn No
replace the cable. 10
the ignition key to the start position. 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.
10.37
ELECTRICAL
ELECTRONIC POWER STEERING (EPS)
EPS System Breakout
10.38
ELECTRICAL
EPS Operation EPS 8-Way Wire Harness Connector
The EPS module is an intelligent electronic power steering
system that operates off of the vehicles 12V electrical system. CAUTION
It calculates steering assist by sensing the difference between
the input torque of the steering post and the output torque The EPS 8-way wire harness connector can
required to turn the wheels, and then provides assist by cause severe damage if connected
energizing an electric motor. The process provides a smooth, in the wrong orientation.
seamless assist.
The system is continuously running diagnostic checks and The 8-way connector, two rows of four pins, does not have a
monitoring factors such as battery voltage, ground speed and channeled lock on both sides, allowing it to be installed 180
engine speed. In the event an internal or external issue that from its intended position. The connector will not positively
affects the EPS system is detected, the system will illuminate a engage or snap into place while in the wrong position, but can
fault indicator and transition to a normal mechanically coupled still be installed. If the connector is not installed correctly,
steering system. The system is Polaris Digital Wrench damage will occur if the engine is started. At this point the MIL
compatible for simplified diagnostics and system will illuminate, with no power steering operation and Digital
troubleshooting through the vehicles diagnostic port. Wrench will not initialize communication.
With the engine off and the key on, the power steering unit will NOTE: Damage can occur to the fault lamp driver
operate for up to five minutes. After the five minutes, you will circuit if the connector is installed 180 off from its
need to either cycle the key switch or start the engine to regain intended position.
power steering operation.
This occurs because the AC stator signal is then fed directly into
The Power Steering 30A Fuse. the fault lamp driver. This situation can be avoided by paying
close attention when installing the 8-way connector and by
If the fuse fails, the Power Steering MIL on the dash performing an ignition key on test before starting the engine.
panel will not illuminate. During this time, the vehicle If the 8-way is connected properly, the vehicle should have assist
will have no power steering operation and Digital with the key on, but engine off. The fault lamp should come on
Wrench will not initialize communication. for 1.5 seconds and then turn off as well.
120 CAN Termination Resistor.

This resistor is located in the fuse box and is required EPS Malfunction Indicator Light (MIL)
for Digital Wrench use. The Power Steering Unit uses several different inputs to control
the amount of torque assist provided. If the engine is run in
The Power Steering EPS Relay and Fault Relay. neutral above 2400 RPM for longer then 25 seconds, it will turn
These two relays are currently interchangeable. on the Power Steering MIL.
The fault lamp relay is used to drive the EPS fault lamp NOTE: This is considered normal operation and
on the vehicles dash. The relay is normally closed, requires no troubleshooting.
meaning the EPS unit must turn the relay on to turn off
the fault lamp. If this occurs, you will need to turn the ignition key off in order
for the MIL to turn off. You should also erase the historic code
NOTE: DO NOT SPLICE OR CUT INTO THE CAN in the system using Digital Wrench.
CIRCUITS.
10
NOTE: See Chapter 5 Body/Steering/Suspension Proper EPS System Diagnosing
for power steering unit removal and installation
procedures. READ BEFORE YOU REPLACE THE EPS UNIT!
IMPORTANT: Try to reflash the EPS unit before
WARNING attempting to replace it. A simple reflash may be all
that is needed to repair the EPS problem. Always
reflash the EPS unit as the first step in diagnosing an
Electronic Power Steering (EPS) units are not EPS problem.
interchangeable between ATV and RANGER
product lines.
10.39
ELECTRICAL
EPS Troubleshooting (Power Steering Non-Functional with EPS MIL ON)
10.40
ELECTRICAL
EPS Troubleshooting (Power Steering Non-Functional with EPS MIL OFF)
10
10.41
ELECTRICAL
EPS Troubleshooting (Power Steering Functional with EPS MIL ON)
10.42
ELECTRICAL
ELECTRIC BOX LIFT ACTUATOR
DIAGNOSIS (if equipped)
1. Disconnect the wiring harness to the

box lift actuator. Disconnect Harness
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.
NO
YES
(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.
NO YES
10
(Not 12 Volts between wires) (12 Volts between wires)
Test the accessory and wiring circuit Test wiring between the main
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.
10.43
ELECTRICAL
NOTES
10.44

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2010 Ranger 800 XP HD 6X6 Service Manual

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GENERAL INFORMATION

Machine Model Number Identification

Engine Designation Number

Vehicle and Engine Serial Number Locations

Figure 1-1 Figure 1-2

VIN Engine Serial Number

NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from

Series# Part Number

Main Headlights 50 Watt / Halogen x 2 Brake System 4 Wheel Hydraulic Disc

Tail Lights 0.3 Watts / L.E.D. x 2 Brake Fluid DOT 4

Starting System Electric Start CLUTCH CHART

MODEL NUMBER: R10TY76AN Transmission Type Polaris Automatic PVT 1

Engine Transmission Gear Ratio:

Compression Ratio 9.78:1 Drive Belt 3211133

Engine Idle Speed 1200 100 RPM Steering / Suspension

Oil Requirements PS-4 PLUS Front Suspension Dual A-arm

Fuel System Wheels / Brakes

Fuel Pressure 39 psi Front Tire

Engine Transmission Gear Ratio:

Compression Ratio 9.78:1 Drive Belt 3211133

Engine Idle Speed 1200 100 RPM Steering / Suspension

Oil Requirements PS-4 PLUS Front Suspension Dual A-arm

Coolant Capacity 3.25 qts. (3.08 L) Rear Suspension Independent (IRS)

Exhaust System 2 to 1 Canister Style Shock Preload Adjustment Cam Adjustment

Fuel System Wheels / Brakes

Fuel System Type Bosch EFI 12 x 6 / Steel

MODEL NUMBER: R10HR76AG, AR Transmission Type Polaris Automatic PVT 1

Engine Transmission Gear Reduction:

MISC. SPECIFICATIONS AND CHARTS

C to F: 9/5(C + 32) = F F to C: 5/9(F - 32) = C

Metric Tap / Drill Sizes

Severe Use Definition

Maintenance Chart Key

= SEVERE USE ITEM: See information provided above.

E = Emission Control System Service (California).

 Transmission Lubricant 25 H Monthly 250 (400) Inspect level; change yearly

 General Lubrication 50 H 3M 500 (800)

 Rear Suspension 50 H 6M 500 (800) Lubricate (if applicable)

Grease Lubrication Points

Item Recommended Lube Method Frequency

Part No. Description Part No. Description

Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc. 2

Demand Drive Plus 2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)

III. # Item Lube Rec. Method Frequency*

III. # Item Lube Rec. Method Frequency*

GENERAL VEHICLE INSPECTION Shift Cable Adjustment (XP / HD / CREW)

All brakes - check operation, fluid level and adjustment

Headlight/Taillight/Brakelight - check operation of all

Ignition switch - check for proper function

Wheels - check for tightness of wheel nuts and axle

Air cleaner element - check for dirt; clean or replace

Check all suspension components for wear or damage

Frame, Nuts, Bolts, and Fasteners

2. Locate the shift cable adjustment point attached to the

3. With two open-end wrenches loosen the outside jam nut

Outside Jam Nut

Inside Jam Nut

5. Repeat Step 3 and Step 4 until the proper adjustment is

6. Use this procedure to loosen or tighten the shift linkage

FUEL SYSTEM AND AIR INTAKE Throttle Pedal Inspection

Check the throttle pedal play periodically in accordance with the

3. If the filter element is dirty, clean it with a high flash point

3. If the filter element is dirty, clean it with a high flash point

A smooth idle generally indicates good compression. Low

= SEVERE USE ITEM: See information provided above.

Transmission Lubricant 25 H Monthly 250 (400) Inspect level; change yearly

General Lubrication 50 H 3M 500 (800)

Rear Suspension 50 H 6M 500 (800) Lubricate (if applicable)